In 1979, Johnson moved to Wisconsin with his wife Jane, and both started working for PACUR, a custom sheet extruder company, with his wife's brother, Patrick Curler, for whom the company was named. PACUR had been created, a few months before Johnson arrived in Wisconsin, with funding from Patrick and from Jane's father, Howard Curler. PACUR's sole customer for the first several years of the company's existence was a company called Bemis, which was run by Howard Curler.
For nearly a year, Johnson worked as the accountant and as a machine operator, trading 12-hour shifts with his brother-in-law, with whom he also shared a small cot. The company later expanded into the area of medical device packaging, which involved hiring salespeople and exporting products to other countries. In the mid-80s Pat Curler left PACUR and Johnson became CEO. In 1987, the Curler family sold PACUR to Bowater Industries for $18 million. Bowater kept Johnson on as the company's CEO. In 1997, Johnson purchased PACUR from Bowater; he remained as the company's CEO until he was elected to the U.S. Senate in 2010.