Board Converting News, December 14, 2020

BoardConverting Serving the North American Corrugated and Folding Carton Industries for 36 years December 14, 2020 VOL. 36, NO. 50

DS Smith Expands U.S. Footprint With IN Plant BY JACKIE SCHULTZ

ISM: Manufacturing Continues To Expand

Manufacturing continued to expand in the lat- est data, even while signs of slowing persist in many markets and with activity remaining below pre-pandemic levels, according to the Institute for Supply Management (ISM). The organization reported that manufac- turing activity in November pulled back from October, which had recorded the fastest pace since September 2018. The index noted de- celerating—but still solid—expansions for new orders and production. Demand and output in the sector expand- ed for the sixth straight month, bouncing back from steep declines from COVID-19 in the spring. Yet, supply chain disruptions contin- ued to challenge many firms. After expanding in October at the fastest pace in two years, the Dallas Federal Reserve said that manufacturing grew at a slower rate in November, mirroring other regional sur- veys. Activity expanded in Texas for the fourth consecutive month, with respondents upbeat in their outlook moving forward. New orders for manufactured goods rose 1.0 percent in October, increasing for the sixth straight month. Despite notable gains since

Just three years after entering the U.S. corrugated market, DS Smith, an international packaging business headquartered in London, has strengthened its foothold with the opening of a 550,000-square-foot facility in Lebanon, Indiana. Located about 30 miles northwest of India- napolis, the plant was started up in January.

It was designed to model three DS Smith locations in Europe that are highly automated, customer-centric plants which can accept and process high-volume orders with short lead times – many with same- day turnaround. The plant produces flexo (up to four colors), digital or pre-printed corrugated packaging primarily for the FMCG (fast-moving consumer goods) sector. The top markets include food, beverage, pet care and beauty products. Its location and proximity to major interstate highways is ideal for serving customers and brands with distribution centers primarily in the Chicago, Columbus, Cincinnati, St. Louis and Nashville markets. Currently, there are 108 employees working two shifts, with plans to expand to 180 employees and three shifts, according to David Mc- Cracken, Business Unit General Manager of Box Plants & PrePrint. Mc- Cracken joined DS Smith about two and a half years ago and is respon- sible for four plants. He has 37 years of industry experience working for both independent and integrated plants. CONTINUED ON PAGE 24 DS Smith opened a new facility in Lebanon, Indiana, in January 2020. The plant was designed to model DS Smith facilities in Europe.


WHAT’S INSIDE 6 Get Ready For BCN Supplier Reports, Converter Outlooks 14 Atlantic Packaging Launches Recyclable Can Carrier System 16 Packaging 101 Boot Camp Now Available Through TAPPI 20 PPEC’s Mullinder: A Different Approach To Recycled Content


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December 14, 2020

C u r r e n t O p e r a t o r E x p e r i e n c e

S T E P 1

M a c h i n e t y p e G o a l s / E x p e c t a t i o n s

I s s u e s


P l a n 2 d a y s w i t h i n y o u r s c h e d u l e

S T E P 2

1 d a y c l a s s r o o m a n d 1 d a y a t m a c h i n e


1 - B o x S e t u p C a l i b r a t i o n T o o l i n g

S T E P 3


T r o u b l e s h o o t i n g

ISM: Manufacturing (CONT’D FROM PAGE 1 )

the spring, the pace of new orders remains 3.2 percent below the pre-pandemic pace. New orders for core capital goods—a proxy for capital spending in the U.S. economy—rose 0.8 percent to $70.1 billion in October, a new record. Encouragingly, core capi- tal goods orders have risen a very robust 5.9 percent over the past 12 months. Manufacturing added 27,000 workers in November, rising for the seventh straight month. Employment in the sector remains well below its pre-COVID-19 pace, down by 599,000 in November relative to the level in February. The current outlook is for 12,250,000 employees in the manufacturing sector at year’s end. Outside of manufacturing, overall job growth eased in November. However, the unemployment rate dropped to 6.7 percent, as labor force participation declined once again. Overall, the labor market remains challenged with millions of Americans out of work. The so-called “real unemployment rate”—a term that refers to those marginally attached to the workforce, in- cluding discouraged workers and the underemployed— declined from 12.1 percent to 12.0 percent. The percentage of the unemployed suggesting that they lost their job permanently ticked up from 3,684,000 in October to 3,743,000 in November, just shy of Septem- ber’s pace (3,756,000), the highest since May 2013.

The Price is Right More readers rely on Board Converting News’ containerboard pricing to negotiate their contracts. SUBSCRIBE TODAY.

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December 14, 2020

AVERAGE CONTAINERBOARD PRICES The average prices reported are tabulated from prices PAID by various sources throughout the United States the week previous to issue. Prices in some areas of the country may be higher or lower than the tabulated average. The prices tabulated here are intended only for purposes of reference. They do not connote any commitment to sell any material at the indi- cated average. Transactions may be completed at any time at a price agreed upon by seller and purchaser.

REGION E. Coast Midwest Southeast Southwest

42# Kraft liner $885.00-890.00 $900.00-910.00 $900.00-910.00 $900.00-910.00 $930.00-940.00 $903.00-912.00

26# Semi-Chem. Medium

Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del.

$820.00-850.00 $835.00-855.00 $835.00-855.00 $835.00-855.00 $865.00-875.00 $838.00-858.00

West Coast U.S. Average

SHEET PRICES BY REGION (AVERAGE) Per 1MSF, local delivery included, 50MSF single item order, truckload delivery. Sheets

E. Coast Midwest South-SW S. CA N.CA/WA-OR US Aver.

200# 275#



$62.69 $82.80

$85.35 119.54

$73.13 101.29













107.46 118.45

114.69 129.32

116.54 137.25 117.82 145.56





CANADIAN SHEET PRICES (AVERAGE) In Canadian Dollars, per 1MSF, local delivery included, under 50MSF single item order, truckload delivery. 200# 275# Oyster UC 275#DW 350#DW $78.56 $99.18 $9.00 $96.32 $105.83 CANADIAN LINERBOARD & MEDIUM The average prices reported are tabulated from prices PAID by various sources throughout Canada. Prices may be higher or lower in various areas of the country. The prices tabulated here are intended only for purposes of reference. They do not connote any commitment to sell any material at the indicated average. Transactions may be completed at any time at a price agreed upon by seller and purchaser. Prices are Canadian $ and per metric ton.

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42# Kraft Liner 26#

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East West

$920.00 $965.00

$910.00 $945.00


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Decemebr 14, 2020

Get Ready For BCN Supplier Reports, Converter Outlooks For 2021 Board Converting News ( BCN) is now scheduling the con- tent for two of its annual features, Supplier Reports and Converter Reports. The year 2021 is expected to be an innovative and productive one as both suppliers and con- verters continue to grapple with the challenges created by COVID-19, which is projected to grow throughout and beyond the holiday season. An e-mail requesting a Supplier Report will be sent this week to all active BCN advertisers asking for information on what products or services they will be marketing and selling in 2021 and what business has been like as the in- dustry adapts to a “new normal,” that is, without industry meetings or trade shows. As in past years, there is “no charge” for having your Supplier Report in an issue of Board Converting News . It is essentially FREE advertising; a supplier has between 500-750 words to explain their product or service. It’s just another way that BCN thanks its advertisers and sponsors for their support. Supplier Reports will enjoy additional ex- posure as BCN continues to build its presence online at . Converter Outlooks for 2021 also promise to be infor- mative and enlightening.Converters who choose to par- CONTINUED ON PAGE 8

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December 14, 2020

40 ft of paper travel from preheater to hot plates 3 seconds of heat, glue and bonding 1 chance to get it right! the ZONE

Design & Production

Chicago Electric offers 10 technology solutions to control ‘the Zone’ CORRUGATOR Sectoral preheating plate

Our sectoral preheating plates provide direct heat by means of a double steam circuit, allowing for efficient heating in hard-to-access locations, as well as to act as a steam shower to open the paper’s fibre, making it receptive to absorbing the heat and the glue.

This translates into increased speed and improved quality of the cardboard sheet finish.

The system’s main advantages are as follows:

• The plate may only be used to heat, only to humidify, or both options at the same time. • The plate is sectored, which allows for applying humidity to the sections. • It provides temperature in previously inaccessible locations and near the location needed. • It compensates the loss of temperature dissipated due to distance, speed or limitations of the exiting preheaters. • Quick transferring of heat to the paper. • The combination of the hot plate and steam shower allows for providing heat even to the hardest papers to heat. • Does not dry out the paper. • Possibility of operating as a humidifier and pre-conditioner. • Maintains and improves the fibre’s elasticity. • Acts according to the operator’s needs. • Facilitates the paper’s hygroscopy to absorb the glue and improve rubberising.


1. Wrap Arm - Position & Temperature 2. Preheater Direct Drive


3. Steam Plate 4. Contact Roll 5. Glue Machine Direct Drive Touch Productivity Issue—Glue Unit Many glue units run with a rider roll or a guiding bar system. The rider roll with paper gap allows a precise glue application, but requires frequent Contact Roll


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calibrations and settings. Bar systems avoid this, but compensate this with the risk of exces- sive glue application. The system contains many wearing parts. Solution The contact roll combines the ad antage of both systems and ensures minimum contact between board and applicator roll. The system uses small pneumatic cylinders in order to achieve a “soft touch.”

6. Gap Control 7. Curved Plate 8. Roller Shoe Press When it comes to a short-term increas of web tension, spring loaded systems with shoes or airpressure activated system have problems in compensating these. The system is lifted for a short time. This may result in de-lamination and in the ‘double kiss’ effect. Solution For a defined and exact bonding point of the web fiv weight rollers will be installed usually over the first flat hotplate of the heating section. The rolls are mounted into a frame, which is actuated by means of two pneumatic cylinders. P oductivity Issu —Double Kiss Bonding




Roller Shoe


9. Thin Wall Hot Plates 10. Pressure System Benefits —Exact glue application due to defined contact of applicator roll to web. Web is in contact to less flute tips compared to bar systems. • High precision glue application • Less moisture applied to web —No wear of shoes and springs —No adjustment of shoes or paper gap —Uniform glue application over entire working width for all flutes by use of pneumatic cylinders instead of springs — Less contamination by paper dust and glue remains —No jam of board because of web breaks caused by splice joints going through 630-784-0800 Benefits —Rollers secure exact defined first point of contact of liner and single-faced board - No double kiss —Frame design avoids unintended lifting of roller shoe (compared to spring or air loaded systems) - No double kiss —Pressure can be increased or released for special grades or products 490 Tower Blvd., Carol Stream, IL Contact Chicago Electric to GET IT RIGHT 630-784-0800 Solution The ProPress system ensures an optimum heat transfer to the board. It offers a wide range of set- tings. The loadi g pressure can be varied, the number of shoes can be lifted in accordance t the line speed. The outer shoes can be lifted in accordance to the paper width. The shoe bars will be delivered pre-assembled for a short installation time. —Liftable for easy paper infeed and for cleaning of the machine —Position adjustable in paper direction to avoid grooves in hotplate Press Productivity Issue—Poor Heat Transfer Rollers are usually limiting the heat transfer, since they often have contact mainly on the edges of the plates due to wear or bent plates. They also cause often loss of caliper and bearing need to be replaced frequently. Airpressure actuated systems can only supply a limited pressure and have com- pared to shoe systems a closed surface. Pressure Shoe

Plate vity Issue—Poor Heat Control l hotplates are slow to react to pressure due to high steam volume and massive y also have high heat radiation and heat profile. Worn plates can damage crease edge crush.

Thin-Wall Hot Plates

t by peripheral drilled hot plates. anufactured out of special wear and nt steel, through which a continuous is drilled, with one inlet and one outlet. ecured by a massive steel frame.

ance from steam to paper surface results in fast heat flow

Get Ready For BCN (CONT’D FROM PAGE 6)

Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month October 2020

ticipate have up to 1,000 words to share their thoughts on the state of the industry, new products and innovations, strategies for building sales and relationships, and even, as some have expressed in the past, their opinions on the political landscape. We are asking, however, that any polit- ical opinions be expressed in the context of how it impacts the corrugated and folding carton industries. As always, BCN seeks to have a diverse representation of independent converters from all regions of North Amer- ica. From smaller family-owned box makers to multi- sheet plant operations to “super plants,” all converter outlooks are welcome. Many “outlooks” also provide the foundation for a coveted BCN feature story, in which converters have even more space to tell their story and include photos of the people and the machinery that enable them to be suc- cessful. Again, emails will be sent requesting participation during the week, but suppliers and converters can send their reports and outlooks now to Editor-in-Chief, Len Pra- zych, at Questions are al- ways welcome, as are suggestions on how to make our publication as valuable as possible for our growing num- ber of readers, sponsors and advertisers, whose help will allow BCN , for the 37th year in 2021, to be the only week- ly publication – in print AND online – serving the North American Corrugated and Folding Carton Industries!



Percent Change Avg Week Percent Change

2020 2019

37.396 35.888


8.499 7.802


Industry Total

Year-to Date

October 2020



Percent Change Avg Week Percent Change

2020 2019

337.942 330.090


7.933 7.785


Industry Total

Containerboard Consumption (Thousands of Tons)



Percent Change Year-to-Date Percent Change

2020 2019

3.0635 2.9470


27.6535 27.1498


Container Board Inventory - Corrugator Plants (Thousands of Tons)

Corrugator Plants Only


Percent Change Weeks of Supply

Percent Change


1.8156 1.9511


2.6 2.9



Shipping Days




2020 2019

22 23

213 212

SOURCE: Fibre Box Association


December 14, 2020



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USDA Appoints P+PB 2021 Members, Directors

• Kingsley Shannon, SVP, Segment President - Fine Pa- per & Packaging Division, Neenah, Inc. • Steven C. Voorhees, CEO, WestRock • Pete Watson, President and CEO, Greif, Inc. Visit . to see the current roster and to learn more. Great Northern StrataGraph Earns G7 Targeted Qualification Appleton, Wisconsin based Great Northern StrataGraph has announced its requalification as a G7 Master Facility, along with a G7 Targeted designation for its off-set print press. This qualification verifies that Great Northern’s off-set press meets G7 Targeted color specifications for grayscale colors, as well as primary and secondary colors (CMYK and RGB). Great Northern’s Twin Cities location is also a G7 Master Facility. “A brand’s color is one of its most important and recog- nizable attributes,” said Bruce Kehler, VP Sales Develop- ment at Great Northern StrataGraph. “When color is print- ed consistently on consumer packaging, it reinforces the brand’s visual identity and can affect consumer perception and purchasing behavior within seconds. The G7 Target- ed qualification provides assurance to our customers that their packaging will have a high-quality, consistent print color for each project across all G7 certified devices.”

The Paper and Packaging Board (P+PB) has announced the appointment of James Harrell, Sonoco; Pete Watson, Greif; and Rob Melton, Domtar, by USDA Secretary Sonny Perdue for a 3-year board term beginning January 2021. Three seats were open on the board, including a South seat, filled by Harrell, and a seat representing the rest of the U.S.,filled by Watson. Melton fills the Importer seat. A nine-member Board of Directors representing the four grades of paper funding the Paper & Packaging – How Life Unfolds campaign oversees the paper and pack- aging sectors’ national promotion program. For 2021, offi- cers and board members include: • Chair, Scott Light, Executive Vice President, Packaging & Cellulose, Georgia-Pacific LLC • Vice-Chair, Jonathan Kraft, President, The Kraft Group • Secretary/Treasurer, Fred Towler, Chief Diversity Offi- cer & Vice President Global Talent Management, Inter- national Paper Co. • Michael P. Doss, President and CEO, Graphic Packag- ing International, Inc. • James Harrell, Vice President and General Manager Paper, NA, Sonoco • Rob Melton, Vice President and General Manager, Pa- per, Domtar

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December 14, 2020

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Bay Cities Donates To Christmas Toy Drive

As such, we launched into gear by not only providing toys for the drive but also by designing a display system. Bay Cities designs, manufacturers and packs out point of purchase displays going into retail stores across the coun- try. At the end of every year there is a base of left-over toys and goods that are too small or costly to return and we donate these to various charities. The display system includes visual merchandising blocks to focus on the specialty dump bin branded for this specific occasion. As there aren’t many venues to park do- nation bins, by complementing the donation of toys with something special like the blocks, this should generate traffic and drive extra donations. The toy drive did launch new “drive through” donation events as the same traffic at our great retailers may be a bit slow due to the virus. Bay Cities has been supporting Pico Rivera’s holiday events for many years. The Pico Rivera Chamber of Com- merce had to adjust their approach a bit this year. The Chamber decided to sponsor two non-profit organiza- tions, Casa Santa Fe and AltaMed Families. 25 Families from each individual organization will receive toys and food. Bay Cities donated toys through the Chamber for each of the children of these families. “Bay Cities is happy to support the toy drives of Pico Rivera, Manhattan Beach and Hermosa Beach,” said Greg Tucker, CEO. “We are glad that, especially during these times, we are able to make a difference for children with our contributions during the holiday season.”

Pico Rivera, California based Bay Cities has partnered with the Pico Rivera Chamber of Commerce and the Beach Cit- ies Toy Drive for their Annual Toy Drives. For the last few years, Bay Cities Packaging and Design has been help- ing Peter Tucker gather toys for the toy drive in Hermosa

Beach and Manhattan Beach. This drive normally begins when the annual Hermosa Christmas Tree Lighting Cere- mony takes place, by bringing folks together for a memo- rable night of fun and entertainment on the pier in Hermo- sa Beach. This year, that event was unfortunately canceled due to COVID-19.


December 14, 2020

Atlantic Packaging Launches Fishbone Recyclable Can Carrier System

Wilmington, Delaware based Atlantic Packaging has announced the launch of a recyclable can carrier system, Fishbone, to replace plastic ring handles. The Fishbone beverage carrier is a curbside recyclable, biodegradable, and performance tested product that will eliminate sin- gle use plastic from beverage packaging.

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Single use plastics are a known threat to our environment, generat- ing millions of tons of unnecessary waste every year that makes its way into our waters and breaks up into microplastics. These microplastics disrupt entire ecosystems and cause great harm to turtles, wildlife, sea birds, and the marine life that ingests them. Fishbone replaces single use plastics with paper-based can carriers that use significantly less material than full overwrap paperboard car- tons. Fishbone carriers are available for standard cans as well as Alu- mi-Tek bottles in both 4-pack and 6-pack formats and are sealed with a recyclable, compostable water-based barrier coating for moisture re- sistance. Fishbone can carriers come in a variety of options designed to complement any brand and to communicate the brand’s commitment to sustainability. Custom printing and graphics are also an option for unique branding opportunities on the carrier. The comprehensive Fishbone system also features semi-automat- ic and fully automatic equipment engineered specifically to apply the Fishbone carriers to a 6-pack of 12-ounce cans and to a 4-pack of ei- ther 12-ounce or 16-ounce cans. The BCF10 tabletop model runs up to 60 cans per minute and is available for a monthly user fee. The BCF40 high-speed model runs up to 240 cans per minute and is available for purchase. Bringing this system to market has been a collaboration between Fishbone Packaging, the innovators of the Fishbone carrier design, and Atlantic Packaging, the exclusive licensee of Fishbone Packaging. At- lantic will handle all aspects of the customer experience, from product ordering and delivery, to equipment sales and support. During a time when businesses are facing increasing pressure from environmental groups, consumers, and now governments to eliminate single use plastics, the Fishbone system is readily available for craft brewers and beverage producers who want to make the switch to a sustainable packaging option.

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Get Answers-Be Proactive. • There’s a board increase or decrease? • My volume goes up or down? • I lost my largest customer? • My MIX changed ? • I bought a new machine? • I sold more sheets? • My labor costs go up 5%? • I added OT or another shift?

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Atlantic Packaging Launches (CONT’D FROM PAGE 14)

application technologies to a wider market. We have a long-standing and successful working relationship with At- lantic Packaging and this alliance has been developed to better serve and to grow sustainable, impactful and con- sumer-friendly packaging with our shared values.” Fishbone can carriers and application equipment are available for purchase online at . Packaging 101 Boot Camp Now Available Through TAPPI TAPPI and The Packaging School (TPS), the exclusive licensee of a professional packaging curriculum devel- oped at Clemson University, have announced the addition of Packaging 101 Boot Camp to TPS’s online offerings. Packaging 101 Boot Camp will serve as an introduction to the packaging industry and provide the fundamental

“As an industry, we have to acknowledge that sin- gle-use, consumer destined plastic packaging creates en- vironmental pollution that isn’t sustainable for our planet,” said Atlantic Packaging President, Wes Carter. “For these reasons, polyethylene plastic beverage rings have been problematic packaging since their introduction decades ago. Atlantic and Fishbone have collaborated to bring the first ever 100 percent curbside recyclable paperboard beverage carrier to the marketplace. This sustainable Fish- bone solution addresses all environmental concerns, and also is highly marketable for our customers. We are proud to introduce this transformative technology to packaging.” Kevin L’Heureux, Fishbone Packaging Inc. President, and Keith Elliott, Co-Founder, remarked: “Fishbone Pack- aging is thrilled to partner with Atlantic Packaging to bring our innovative, plastic-free packaging products and

knowledge necessary to get attendees up to speed. Packaging 101 BootCamp runs over 20 work days, with an investment of less than 20 minutes per day. With eight hours of edu- cational content, activities, and cheat sheets, participants will exit with a solid foundation in packaging basics. Departments such as marketing, sales, procurement, legal, distribution, quality con- trol, manufacturing and warehousing all have unique demands on the packaging. After completing this course, attendees will have an understanding of the thought process required of a successful stakeholder in the packaging development process. This course was created for everyone that wants a broad understanding of the packag- ing industry whether just starting one’s ca- reer or if they are a seasoned professional. Packaging 101 Boot Camp will provide the vo- cabulary needed to communicate with stake- holders across the value packaging chain. The course includes a printable 182-page reference manual designed to help apply the course content and develop a better under- standing of the materials so attendees can begin using their new-found knowledge right away. Completing the reference manual will also help build a customized packaging re- source that can be used long after the course has ended. TPS is a global platform where attendees can learn skills on a variety of topics, such as polymers, packaging machinery, consumer packaged goods branding, distribution test- ing, supply chain optimization, sustainable packaging, contract manufacturing, process- ing, design software, and more. Visit .

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ARC International Promotes Heflin To Plant Manager In Las Vegas Charlotte, North Carolina based ARC International has an- nounced the promotion of Troy Heflin to Plant Manager at

The Perfect Couple Get Peak Performance From Paired Sets Of Ink Chambers And Anilox Rollers

the company’s Las Vegas, Neva- da, facility. Throughout his 33-year tenure with ARC, Heflin has per- formed with excellence in nearly every aspect of crafting high quali- ty flexographic press components. From machining and inspecting to drawing and AutoCAD engineer- ing rollers as well as providing

Troy Heflin

technical guidance he has learned exactly what’s needed to prescribe exact product specifications for each roller application. “Troy’s hands-on experience with manufacturing and inspecting ARC products, coupled with his many years of specifying, managing and assisting with customer services makes him more than qualified to lead our ARC West divi- sion,” noted ARC International President, CEO, and Found- er, Micheal Foran. “We are confident that he can maintain the high standards that have become the hallmark of our firm. He’s been an important part of the company since our early years!”. Heflin can be reached at theflin@arcinterna-

There’s nothing quite like a couple made for each other. That’s why state-of-the-art anilox rollers and carbon ber ink chambers fromARC International

are a match made in heaven. Each precision engineered, crafted, and engraved roller is paired with a rigid, durable, 100% carbon ber chamber—a combo that gives you more output, accuracy, and density control than you ever thought possible. Get the press speeds and print quality you need to ll your most demanding orders. ARC engineers do all they can to see your exo folder gluers and die-cutters perform to their best. If your job is printing, coating, cutting, or moving board, The ARChitects of Flexo should be your partners.

Huston Patterson Appoints Mixell Director Of Finance

Decatur, Illinois based Huston Patterson has appoint- ed Merle Mixell as Director of Finance. He will lead all

accounting and IT functions for both Huston Patterson and Sigma Graphics.

“Merle brings a vast amount of experience and expertise to Hus- ton Patterson,” said Huston Pat- terson President Tonya Kowa-Mo- relli. “His sound and diverse background as an accounting pro- fessional is a critical asset for us as we continue to grow and evolve within our industry.” Mixell holds a Bachelor of Science in Business Admin- istration from the University of Illinois-Chicago, as well as an MBA from Loyola University Chicago and has exten- sive experience in variance analysis, finance, accounting, financial reporting and strategic planning. “It is an honor to represent Huston Patterson and Sig- ma Graphics,” says Merle Mixell. “Their reputation in the corrugated packaging industry as a leader, yet one with such deep roots is very exciting to be a part of. I look for- ward to the opportunity of helping Huston Patterson build on that success.” Merle Mixell

Contact ARC today to learn how this ideal couple can help you achieve a more perfect union of production and prots. 800-526-4569 The ARChitects of exo


December 14, 2020

A Different Approach To Recycled Content And The Circular Economy BY JOHN MULLINDER Recycled content is the key component in the creation of a circular economy. It keeps raw materials flowing with-


in the economy longer, reduces the pressure to extract more vir- gin materials from the earth, and delays their eventual disposal as waste. Recovering more materials for further use also creates jobs. A circular economy is something that companies and governments say they want to encourage.

John Mullinder

Voluntary And Mandatory Approaches The strategies to encourage recycled content range from voluntary approaches through to government man- dated minimums and the threat of banning product sales if those minimums are not met. With a voluntary strategy, the government adopts a hands-off approach, allowing the marketplace to deter- mine what happens. In the Canadian province of Ontario, the paper packaging industry has gone from below 50 percent recycled content to all but one mill today produc- ing 100 percent recycled content boxes and cartons. This is presumably the type of ‘’circular economy” that Ontario wants. The “problem” is that the approach is slow. It took some 25 years to get there. The mandatory approach, on the other hand, is where the government regulates or legislates a framework of minimum recycled content targets, with fines or penalties or sales bans for non-achievement. One of the problems with government mandates, however, is that they apply only to that government’s ju- risdiction. For example, an Ontario mandate would not apply to other provinces. There may also be international trade implications for material being shipped into Ontar- io. Another complication is that most design decisions on recycled content are not made in Ontario but rather at company head office (in the U.S. or Europe) with packag- ing design undertaken at global not local (Ontario) scale. Also, the last thing industry wants is provinces or states leapfrogging over themselves to set successive- ly higher (and perhaps public relations inspired) targets for industry to achieve in different jurisdictions. A federal mandate would be preferable, but that would mean get- ting all provinces/states to agree, which may prove diffi- cult and time-consuming. Mixed Approaches Some governments have chosen to mix voluntary and mandatory approaches to increasing recycled content. They have done this by including incentives within regulat- ed programs. The choice is voluntary and at a company’s own pace.

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December 14, 2020

THE NEW RD115/135S

The NEW KOLBUS Hycorr RD115/135S Flexo Rotary Die Cutter represents years of investment by the KOLBUS engineering team in Rahden, Germany and the Hycorr technical team in Kalamazoo, Michigan. This cooperation, combined with the input from our customers, has resulted in the ultimate blend of quality, performance, and value. Designed with all corrugated markets in mind, the RD115/135S is well equipped for high throughput, quick make-ready, and high graphics print production. With a complement of new features and benefits to accompany.

KOLBUS America Inc. | 216-931-5100 |


Esko shares learnings about impact of pandemic on packaging industry in new free e-book COVID-19: From Impact to Action in the Packaging Industry. The book examines how to sustain agility and profitability in the packaging value chain in the new normal. Esko has launched a new e-book which examines the impact of the coronavirus (COVID-19) crisis on the packaging industry and provides advice to help businesses negotiate the challenges presented by the pandemic. “COVID-19: From Impact to Action in the Packaging Industry” features insights from customers all over the globe gathered by Esko leaders. It takes a hard look at the impacts of the crisis on the packaging industry and offers lessons to drive agility and profitability. “The Covid-19 pandemic is having a devas¬tating effect on people, businesses and economies around the world,” said Mattias Byström, Esko Group President, Packaging & Color Businesses, in his introduction and opening article of the e-book. “Fundamental cultural shifts are occurring in the way we live and work. From remote working to online shopping, ensuring new hygiene and safety protocols are observed across society has created changes in the way businesses operate in what is becoming known as the ‘new normal’.

MATTIAS BYSTRÖM Esko Group President Packaging & Color Businesses

“But what has this meant for the packaging industry? How does it need to respond to remain successful as the world changes? As the en- tire packaging supply chain comes under increasing pressure to adapt and deliver, we’ve gathered a range of insights from our customers around the world to compile in the articles contained in this e-book. We hope by doing this we are investing in the future of our industry to help us all move forward together.” To download your free Esko e-book, click here: https://www.esko. com/en/lp/ebooks/covid-19



December 14, 2020

Productivity Tool for Corrugated.


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DS Smith Expands (CONT’D FROM PAGE 1 )

300,000 Boxes An Hour DS Smith entered the U.S. market in 2017 with the ac- quisition of Interstate Resources. The purchase gave DS Smith 19 production sites in the United States. Since then it has acquired Corrugated Container Corp. and The Dis- play Connection, and last year the company announced the relocation of its U.S. headquarters from Arlington, Va. to Atlanta, Ga. Lebanon was the first operation in the U.S. that was not an acquisition. “It’s unique because we built it as a green- field,” McCracken says. “We’re transitioning the other plants, but they still have that hybrid look of the previous owner. Lebanon is all DS Smith. It is the largest of our fa- cilities, and it is the most automated and most advanced of any DS facility because it is the newest. It’s amazing the level of automation. We could literally never touch the box. It could go from corrugator all the way to shipping without ever being touched by human hands.” There are eight machine lines with plans to add two more within the next six to nine months. Robotic board han- dling systems on both ends of the converting machines, along with a fully conveyorized Ducker material handling system with smart cars, streamlines material transport. The plant is capable of producing 300,000 boxes an hour and 2 billion square feet of recyclable packaging a year. CONTINUED ON PAGE 26

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GapChek™, the latest corrugated vision system from Valco Melton’s ClearVision division, moves the measurement point to the bundle so that the lead and trail gaps are measured on finished boxes. GapChek displays live measurements of each gap and per-bundle averages with statistical process control charts on-screen Users can look at per-job and per-box gap data and analyze historical trends for certain box designs or customers.

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December 14, 2020

COMMIT THIS TO MEMORY The J Press 750S brings profitable short runs.

Few segments show better growth opportunities and stronger margins than the short-run folding carton market. The J Press 750S doesn’t just open new packaging doors for you—it brings in the profit.

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DS Smith Expands (CONT’D FROM PAGE 24)

Under Roof Separators... ...Made Simple

For proprietary reasons, McCracken could not share details about the actual lines. While there is some redun- dancy with the other DS Smith facilities, he says there are some “unique” machines as well The plant has a 110-inch S/Line Fosber corrugator that is able to run 1500 ft per minute. The line features a Link M3

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December 14, 2020

Do you print in Mullchannel? Do you wanna save up to 30% Ink?

Our pre-press manager myself and our lead operator were shocked to see how well the profile is prinnng and we saw an ink savings anywhere from 20 to 50%. What a great way to drive margin back into our businesses without sacrificing print quality.

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DS Smith Expands (CONT’D FROM PAGE 26)

Another feature, common in Europe, is a sound enclo- sure. Fosber designed and installed the Lebanon plant’s enclosure. When the machine is running full speed, the sound level outside the enclosure is 85 decibels, which is quite low for a corrugator and more corresponding to the sounds of a power lawnmower or a window air conditioner. The plant uses Kiwiplan’s Corrugator Scheduling sys- tem as well as the full suite of Kiwiplan manufacturing soft-

The corrugator has a Link M3 roll loading system.

ware, including the QMS (Quality Management System) module. McCracken says there were several features of the Fosber corrugator that were especially important for the new plant, including infusion plates on both webs and the automatic roll stands, which, according to Fosber, are the most automated splicer/roll stands in the industry. “Mostly the things that were important to us with Fosber was the reliable high speed corrugator. It is flexible and has inte- grated well into different process and control systems,” he says. “We’re very happy with the performance of the machine.” Lebanon is DS Smith’s first plant in the U.S. to install a Fosber corrugator. It products B-, C-, E- and R-flute and doublewall combinations. R-flute is similar to B-flute, but slightly lower in caliper and stronger. It is widely used in Europe for retail-ready packaging, consumer packaging and e-commerce. Lebanon is the only North American plant that is producing it. “The other plants have a car- tridge system so as we grow the demand, we’ll get the corrugating rolls to be able to run it at the other sites,” Mc- Cracken says. He says installation and start-up of the corrugator went quite well. With the Fosber maintenance program a techni- cian is onsite for two years. “With any new machine there are going to be issues that you battle. With the tech onsite those issues will be resolved very quickly. There were very few to begin with, but the tech takes care of all that and it makes for a very smooth running machine.”



December 14, 2020

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