Partnership, Energy Strategy Transforms WI Paper Mill

Founded in 1896 along the Wisconsin River, the Biron Mill has long been part of one of the world’s most respected papermaking regions. Since becoming part of ND Paper in 2018, the facility has continued to modernize while maintaining its important role in the local community.

As energy costs rose, ND Paper looked for practical ways to reduce energy use without slowing production or hurting performance. Focus on Energy helped the ND Paper team identify opportunities, confirm savings, and move high-impact projects forward.

“With the help of Focus on Energy, ND Paper’s Biron Division has become a safer, more energy-efficient, and profitable mill, bringing back more than 100 jobs and generating millions of dollars of economic impact for the community. Our energy demand and environmental footprint have been reduced because of our close partnership and teamwork with Focus on Energy.” 
—Steve Demyon

Uncovering Inefficiencies with their Energy Advisor

For a large industrial facility, energy projects must make sense in daily operations. They need to fit capital plans, compete for resources, and deliver results leaders can trust.

ND Paper’s work with Focus on Energy began with comprehensive water and energy assessments focused on process water use, reuse, and waste. The audit showed where water and heat could be captured, reused, or repurposed to save energy.  

“Focus on Energy combines deep subject-matter expertise with substantial incentives to help industry improve performance.” 
—Steve Demyon

That support mattered. Focus on Energy helped validate designs, analyze savings, and document the business case needed to move projects from discussion to action.

From Audit Findings to Action

With a clearer roadmap, ND Paper focused on projects that could deliver both near-term and long-term value.  

One major opportunity involved recovering heat from hood exhaust and using it to warm process water. Instead of letting that heat leave the system, the mill could reuse it to heat fresh water previously heated by natural gas.

ND Paper also enhanced its save-all performance and added filtration capabilities. These upgrades allow more process water to be reused in chemical injections and low-pressure showers. Other improvements include upgrading the filtered water system, integrating heat recovery from multiple sources, and installing new refiners in the plant to significantly reduce pumping energy needs.

Together, these projects help the mill reduce waste, reuse resources, and lower energy demand in ways that support operations.

Delivering Measurable Results

After the assessment, ND Paper completed two high-impact projects: enhancing internal electrical generation and reducing freshwater heating energy use. Focus on Energy experts modeled and validated the expected benefits, while incentives helped offset costs from planning through execution.

The partnership continued through preparation, installation, commissioning, and validation. One major result was the successful commissioning of the internal electrical generation project. By using recovered heat to offset energy demand, the project increased energy output. Now, the mill's turbines will generate enough additional energy to match the needs of more than 1,800 homes.

Making Energy Performance Part of the Culture

“The partnership with Focus on Energy has been instrumental in advancing the mill’s operational and energy performance. I only wish other states had such expertise and programs like this.” 
—Joel Pike, Vice President of Operational Excellence and Energy, ND Paper

The impact at the mill goes beyond individual upgrades. Over time, the partnership has helped make energy performance part of how the mill operates.

The ND Paper team utilizes several Focus on Energy resources, like Strategic Energy Management, energy team support, and incentives to offset the costs associated with assessing and completing energy-saving projects. Energy Teams track performance, review energy metrics, and look for ways to sustain gains instead of treating efficiency as a one-time effort.

Steve Demyon credits the strength of the partnership not only to the program, but also to the people involved.

“Gary Hegewald and others are experts in energy savings and are relentless in supporting and driving results.” 
—Steve Demyon

Looking Ahead

Four additional energy efficiency projects are currently underway at the mill, each designed to further reduce consumption while improving operational performance.

“I’ve worked in the paper industry for three decades, much of that time spent at the Biron Mill. I know how challenging it can be to think creatively about improving efficiency in this work. Having recently stepped into the general manager role, I’m grateful to benefit from the partnership we’ve built with Focus on Energy. Their team has challenged us to think differently and supported us as we implement impactful projects. I’m excited to champion these initiatives as we continue moving the mill forward.” 
—Steve Raczek, Vice President and General Manager, Biron Mill

This work also reinforces the mill’s role in the local economy. Improved efficiency supports profitability and continued investment, helping sustain jobs and economic activity in the community.

With Focus on Energy providing technical expertise, financial support, and practical guidance, ND Paper’s Biron Mill is positioned to continue strengthening its future and the future of the community and all of Wisconsin.