Irving Wallboard completes major facility upgrade with Project Rolling Rock
Irving Wallboard has successfully completed Project Rolling Rock, a major facility upgrade focused on modernizing critical infrastructure, removing production bottlenecks and increasing capacity to better meet Canada’s growing wallboard and housing needs.
The project was completed with the successful commissioning of a new stucco cooler, bringing all major components of the project online. The new cooler improves the processing of gypsum, supports increased production capacity and replaces aging infrastructure that had become a limitation for the business.
Broken into three phases, each Project Rolling Rock upgrade was designed to work together to strengthen the manufacturing process. Early phases included infeed hopper upgrades and the installation of a new roller mill. Together, the hopper upgrades, roller mill and stucco cooler addressed different constraints within the manufacturing process, creating a stronger, more reliable and higher-capacity operation.
"Project Rolling Rock was about investing in the future of Irving Wallboard," said Peter MacNeill, General Manager. "By modernizing critical infrastructure, increasing capacity and improving reliability, we're building a stronger foundation for our employees, our customers and the long-term success of the business."
The project was delivered through the collaboration of team members spanning operations, maintenance, engineering, project management, automation, electrical, safety, supply chain, suppliers, affiliates and contractor partners. Safety remained the foundation of every decision throughout the shutdown and commissioning work.
"What I'm most proud of isn't the equipment itself. It's the teamwork that made it happen," said MacNeill. "The planning, communication and commitment to safety shown by everyone involved allowed us to complete a complex project safely, on schedule and successfully."
For customers, the investment means a stronger and more reliable manufacturing operation. For employees, it provides improved tools and systems that help the plant run more consistently and efficiently. For Irving Wallboard, it creates greater flexibility for future growth while helping ensure the business can continue meeting customer needs safely and effectively.
The completion of Project Rolling Rock represents one of the largest improvement projects undertaken at Irving Wallboard in recent years and demonstrates what can be achieved when employees, contractors, suppliers and JDI teams work together toward a common goal. With key constraints now removed, the focus turns to optimizing operations, increasing production rates and identifying future investment opportunities that support safe, reliable and sustainable growth.
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