BoardConverting Serving the North American Corrugated and Folding Carton Industries for 37 years March 8, 2021 VOL. 37, NO. 10
The BoxMaker Leads In Diversified Success BY REBECCA RENDON
Landaal Packaging Systems Acquires Westcott Displays Burton, Michigan based Landaal Packaging Systems, a third-generation family-owned and operated multi-site corrugated packaging company, has acquired Westcott Displays lo- cated in Detroit, Michigan. Terms of the trans- action were not disclosed. Westcott Displays is a manufacturer of point of purchase displays, offering corrugat- ed and folding carton boxes, as well as custom Point of Purchase Displays and innovative de- sign services. Westcott Displays’ dedication to quality, high-level of customer service, and flexibility align perfectly with Landaal Packag- ing Systems’ core businesses and customer service model. “We are excited that Landaal will be ser- vicing our valued customer list,” said Greg Campbell, Westcott CEO. “We have worked with them over the past 10 years, so we know from experience that they are an innovative, forward-thinking company with an emphasis on uncompromising customer service.” The acquisition allows for Westcott Dis- plays customers to enjoy the scale of Landaal Packaging Systems national service mod- el and full range of packaging printing and
AICC, The Independent Packaging Association, recently hosted its sec- ond Virtual Plant Tour at The BoxMaker’s manufacturing headquarters and High Graphics Center, located outside of Seattle, Washington. Richard Brown, President and co-owner of The BoxMaker, walked attendees through the facilities that handle all of the manufacturing of custom designed packaging, brown boxes and labels. This virtual plant
tour was part of an ongoing, free series of plant tours hosted by AICC, and streamed live via Zoom. The BoxMaker has considered themselves a leader in packaging innovation since 1981, serving customers in the Pacific Northwest and beyond, with offices and distribution centers located in Washington and Oregon. Brown began the tour at the traditional box plant that has histori- cally produced plain and flexo printed brown boxes, trays, pads and shipping containers. This corrugated sheet plant sources the majority of its sheets from a local corrugator nearby, utilizing suppliers that are Sustainable Forestry Initiative Certified. Due to the large order volume, The BoxMaker is turning over their sheet inventory in less than 36 hours and brings in a minimum of six truck loads per day to keep up with production. Their Pit Stock area stores standard sized sheets for the most commonly used machines CONTINUED ON PAGE 16 An early adopter of digital printing, The BoxMaker invested in an HP Page- Wide C500 press to help diversify its product offerings.
CONTINUED ON PAGE 6
WHAT’S INSIDE 5 Michael Brunton, Publisher, Industry Icon, Dies At 73 12 WestRock’s Voorhees Steps Down, Sewell Elected To Role 14 DS Smith Introduces Greentote, Recyclable Option To Plastic 26 Supplier Reports: Part 6
T H A C K E R I N D U S T R I A L S E R V I C E C O M P A N Y
O P E R A T O R T R A I N I N G T A I L O R E D T O Y O U R G O A L S Before any training star ts, we need to know your goals. We’ l l help you identi f y them, customize them, measure them and help achieve the expectations set by your team. Our intensive training wi l l encompass two ful l days at your faci l ity for al l par ticipants, during the week or on a weekend. Al l you need is a room for training your group and the machine you want to train on.
O U R T E A M
Our Training team consists of three corrugated industry exper ts with nearly 100 years of combined experience. Their backgrounds are in both integrated and independent companies with roles ranging from Machine Operator to Director of Operations. Making them more than qual i f ied to tackle any machine and training issue. Cal l today to learn how your team can benef it from the industry ’s premier training program.
www. thacker i ndus t r i a l . com (682) 552 5852 For more Information:
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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
Q U E S T I O N N A I R E
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
S C H E D U L 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 A I N I N G
T r o u b l e s h o o t i n g
Calling Profero Systems just another equipment supplier is like calling the Tour just a bike ride. Profero Systems
Proven unsurpassed customer service over the long run, commitment to our customers is second to none!
Add value to your Corrugating Process, be the go-to Company for your customers.
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704-923-0990
PO BOX 950 DALLAS, NC 28034
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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 indicated 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 $955.00-960.00 $970.00-980.00 $970.00-980.00 $970.00-980.00 $1000.00-1010.00 $973.00-982.00
26# Semi-Chem. Medium
Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del.
$890.00-940.00 $905.00-925.00 $905.00-925.00 $905.00-925.00 $925.00-945.00 $908.00-928.00
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#
$62.26
$72.05
$62.69 $82.80
$85.35 119.54
$73.13 101.29
97.32
99.89
90.86
113.65
OYSTER UP-CHARGE 8.34
8.34
8.34
8.34
8.34
8.34
275# DBL-WALL 350# DBL-WALL
107.46 118.45
114.69 129.32
116.54 137.25 117.82 145.56
141.08 148.46
122.76 131.80
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.
42# Kraft Liner 26#
Semi-Chem Medium
East West
$970.00
$960.00 $995.00
$1,015.00
Michael Brunton, Publisher, Industry Icon, Dies At 73
Michael Brunton, former Managing Director of Brunton Business Publications Ltd and global corrugated indus- try icon for more than four decades, passed away in a UK
hospital on the evening of Wednesday, March 3, from complications due to a stroke. He was 73. Brunton and the late Ted Vilardi, founder and owner of NV Business Publications, co-founded Corrugated Today, sis- ter publication of Board Converting News , in 2005. Brunton is survived by his wife, Fiona, and sons, Benjamin and Dan- iel, who is joint Presi-
dent/Publisher of Brunton Business Publications Ltd. A full obituary will appear in the March 15 issue of Board Converting News and on the websites boardcon- vertingnews.com and thepackagingportal.com as soon as it becomes available. Michael Brunton
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Landaal Packaging (CONT’D FROM PAGE 1 )
converting capabilities. “POP display is one of our core businesses, and with the acquisition of Westcott Displays’ assets Landaal is poised for even greater growth in this important segment,” said Robert B. Landaal, President. To ensure a smooth transition and seamless client ser- vice, Westcott Displays Executive Vice President George Chirillo will join the Landaal team. He said, “We will be able to produce our programs more efficiently and be more competitive. I look forward to a smooth transition between the two companies, and providing the high-level of service our Westcott Displays customers expect.” The Westcott Displays team will continue to service their customers under the Westcott Displays name, and will be integrated into the Landaal Packaging Systems’ ser- vice model. “Westcott Displays customers will now have access to a wider range of value-add services, printing, and finishing capabilities to meet the ever-changing needs for nationwide and regional POP program execution,” said Mark C. Landaal, Vice President of Sales & Marketing. Since 1959, Landaal Packaging has been helping cus- tomers solve their packaging problems with innovative ideas, uncompromising product quality and on-time deliv- ery. For over three generations as a family-owned busi- ness, the Landaal Packaging team prides itself on a tradi- tion of consistent, reliable service to our many customers. Visit landaal.com for more information.
Boring? If we didn't paint it this way, it wouldn't get noticed.
When it comes to a baler that takes care of business, boring reliability is the holy grail. But right-sized automation that makes the baler an operator-friendly and low-maintenance part of your operation is no less important. The Balemaster brand of balers delivers both. (Paint job is extra.)
More than a source. A resource.
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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.
CONTROLLABILITY
1. Wrap Arm - Position & Temperature 2. Preheater Direct Drive
DOUBLEBACKER IMPROVEMENT
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
PRODUCTIVITY
C/ Orfeó Català 13-15 · 08440 Cardedeu (Barcelona) telf: +34 93 846 01 06 · comercial@al-gar.com WWW.AL-GAR.COM
DOUBLEBACKER IMPROVEMENT
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
PRODUCTIVITY
PRODUCTIVITY
DOUBLEBACKER IMPROVEMENT
Roller Shoe
DOUBLEBACKER IMPROVEMENT
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 info@chicagoelectric.com chicagoelectric.com 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.
CORR24usa.com
ance from steam to paper surface results in fast heat flow
AICC Requesting Data For 2021 Sales Compensation Survey AICC, The Independent Packaging Association, has begun collecting data from independent converters for the 2021 Sales Compensation Survey. This survey, conducted every two years, represents the most compressive data of key sales employees’ salaries and benefits in the U.S. The final report is a tool that can be used to measure a company’s compensation package against independents regionally and nationwide. The survey is managed by an independent research firm, Association Research, Inc., located in Gaithersburg, Maryland. The company collects the confidential data us- ing an online survey. The deadline for submission is Friday, March 19th. AICC encourages all US converter members to partici- pate. The greater the response, the stronger the data. Par- ticipants will receive a complimentary electronic copy of the final report. AICC general members (independent converters) were emailed a link to the survey on February 24th and mailed survey instructions the week of March 1st. Any company that has not received the survey and that wants to participate, can contact Maria Frustaci, Director of Administration, at (703) 836-2422 x 1382 or mfrustaci@ aiccbox.org for instructions.
Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month December 2020
Year
Actual
Percent Change Avg Week Percent Change
2020 2019
34.916 31.332
11.4
8.729 7.833
11.4
Industry Total
Year-to Date
December 2020
Year
Actual
Percent Change Avg Week Percent Change
2020 2019
406.776 393.483
3.4
8.071 7.838
3.0
Industry Total
Containerboard Consumption (Thousands of Tons)
Year
Month
Percent Change Year-to-Date Percent Change
2020 2019
2.7727 2.5660
8.1
33.0739 32.3005
2.4
Container Board Inventory - Corrugator Plants (Thousands of Tons)
Corrugator Plants Only
Date
Percent Change Weeks of Supply
Percent Change
Dec. Nov.
1.8921 1.7912
5.6
2.7 2.5
8.0
Shipping Days
Year
Month
Year-to-Date
2020 2019
20 20
252 251
SOURCE: Fibre Box Association
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TAKE CONTROL OF YOUR ENTIRE SYSTEM
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PCA Plans $440M Conversion In AL
State of Alabama, the Alabama Department of Commerce, the City of Jackson and Clarke County to help us continue providing quality jobs and a positive economic impact in the Jackson community,” Kowlzan said. Governor Kay Ivey said the project represents a pos- itive development for the Jackson mill, a major industrial employer with more than 500 workers. “Packaging Corp. of America’s reinvestment in its Jack- son manufacturing facility will solidify the plant’s future by enhancing its competitiveness,” Governor Ivey said. “This decision underlines the company’s confidence in its Ala- bama operation while also preserving jobs and safeguard- ing local education tax dollars. It’s a win for the company, the community and the state.” Greg Canfield, Secretary of the Alabama Department of Commerce, said PCA’s project will provide a long-term economic boost to Jackson, a city with a population of around 5,300. “We’re committed to helping existing busi- nesses grow and thrive in Alabama, and the impact of a major investment is always magnified when in happens in rural communities,” Secretary Canfield said. “With this proj- ect, PCA is positioning its Jackson mill for the future, which will benefit the city and the region for years to come.” PCA’s Packaging segment includes six container- board mills and 90 converting operations. In 2019, PCA produced about 4.2 million tons of containerboard and shipped about 59.4 billion square-feet (BSF) of corrugated products.
Lake Forest, Illinois based Packaging Corp. of America (PCA) has announced plans to launch a three-year, $440 million project to permanently convert a paper machine at its mill in Clarke County, Alabama, to produce linerboard used for corrugated packaging. PCA announced that it discontinued the production of uncoated freesheet, used for copy paper and other appli- cations, on its No. 3 paper machine at the Jackson mill in late 2020. After a temporary switch to produce linerboard, PCA is nowmaking preparations to convert the mill’s paper machine into a 700,000-ton-per-year high-performance, virgin kraft linerboard machine in a phased approach over the next 36 months. PCA said key elements in the conversion project in- clude the installation of an OCC plant for recycling old corrugated containers and various pulp mill modifications. In addition, modifications and upgrades will be made to critical sections of the paper machine. PCA Chairman and CEO Mark Kowlzan said the project will enable the company to meet strong packaging de- mand and to optimize the Alabama mill’s profitability and viability. The capital cost of the conversion is expected to be approximately $440 million. “We are appreciative of the continued support from the
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WestRock’s Voorhees Steps Down, Sewell Elected President And CEO Norcross, Georgia based WestRock Company announced last week that Steven C. Voorhees has decided to step down from his position as President and CEO and a di-
sition, John A. Luke, Jr., Chairman of WestRock’s Board of Directors, stated, “Our decision to elect David as CEO is the result of a robust succession planning process, and he is the right choice to lead our company into the future. He is a proven executive with a strong record of driving prof- itable growth, both organic and acquisitive, and building organizational capability that develops and nurtures excel- lent leadership and talent while driving a culture of equity and inclusion. “It is an honor to have the opportunity to serve as the company’s CEO, and I thank the Board for its confidence in me,” said Sewell. “I am excited about joining WestRock and look forward to working with this talented leadership team and outstanding organization to build on the compa- ny’s success and together realize the opportunities ahead for our customers, team members and stockholders.” “It has been an honor to lead and to serve with such an incredible team of people,” said Voorhees. “Thanks to the hard work and dedication of a team that is second to none, WestRock is better positioned than ever to support its customers and achieve its goals, and I am proud to have been part of what we have built together. I am happy and comfortable to be leaving WestRock in good capable hands. I look forward to addressing my immediate health needs and investing more time with my family and person- al interests. I have every confidence in David, WestRock’s leadership team, our teammates and the Board to contin- ue creating value for all of our stakeholders.”
rector of the company for health reasons, effective March 15, 2021. In addition, the company’s Board of Di- rectors announced that it has elect- ed David B. Sewell to succeed Voor- hees as WestRock’s President and Chief Executive Officer. Sewell has been appointed to the Board of Di-
David Sewell
rectors, effective as of when he assumes his new role, and Voorhees will be available to support a smooth transition. Sewell, 52, brings with him more than 25 years of com- mercial, marketing, and general management experience. He joins WestRock from The Sherwin-Williams Company, where he most recently served as President and Chief Op- erating Officer responsible for global operating segments that generated $18.4 billion in sales and are supported by 60,000 team members. Prior to joining Sherwin-Williams, Sewell spent 15 years at General Electric Company. He holds a bachelor’s degree in economics from the Universi- ty of Southern California. Commenting on the appointment of Sewell to the po- BCN(US)202002(o)(出血5mm).pdf 1 2021/2/6 上午 09:19:31
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DS Smith Introduces Greentote, The First 100% Recyclable Option To Plastic Bags As more states, counties and cities ban plastic bags, Atlanta, Georgia based DS Smith, a leading supplier of sustainable packaging solutions, is now offering grocery stores and consumers Greentote, the first re- usable, moisture-resistant, modular, 100 percent recyclable container made from renewable resources. The company’s development of the Greentote alternative arrives as stores and supermarkets respond to the pandemic-driven jump in
online fulfilment sales, BOPIS (buy online, pick up in-store) and third-party grocery deliv- ery services. That potentially has translated into more plastic bags ending up their customers’ homes and eventually landfills, or worse - waterways. Recent surveys have indi- cated that many shoppers say they’d likely continue online buying if items were delivered
Cosmo DeNicola Chairman, Amtech Software
with less packaging or used more sustainable material. They’d also pre- fer items delivered in more recyclable packaging. Greentote offers retail grocery chains and their customers what they’re demanding: an envi- ronmentally friendly, recyclable, reusable and food contact-safe solution for transporting groceries and merchandise. “Greentote is about convenience and sustainability,” said Melanie Galloway, Vice President of Sales, Marketing and Innovation for DS Smith North America Packaging. “From staging orders to curbside pick- up or delivery, our sustainable, renewable, fiber-based tote is sturdier than paper, keeps perishable and other grocery items organized and safe, and is reusable.” “Corrugated is the safest medium for transporting goods in our glob- al supply chain, and Greentote takes that confidence one step further by being USDA food-contact safe,” she said. Eighteen states already have enacted legislation to ban plastic bags, and major retailers including Walmart, CVS Health, Albertsons, Dollar General and Dick’s Sporting Goods have joined “The Beyond the Bag Initiative,” a group seeking to reinvent the single-use plastic retail bag. The goal: identify, test and implement viable design solutions and mod- els that more sustainably serve the purpose of the current retail bag. Made of cardboard and available in two sizes, Greentote can hold more than three times the number of groceries than plastic bags and can interlock with each other, ensuring safety and convenience when transporting. Additionally, Greentote is coated with DS Smith’s propri- etary Greencoat, which revolutionized the wax-coated shipping industry for poultry, produce, and seafood with its sustainable, moisture-resistant capabilities and durability in demanding supply chains. “Boxes in our Greencoat line are designed and manufactured to sur- vive harsh wholesale environments while being fully recyclable,” Gal- loway said. “That means that the grocer who’s packing and stacking a Greentote will appreciate the modular functionality and ease of use. Customers and delivery services will love the ability to create a tidy trunk or backseat without worrying about groceries sliding out of bags and being damaged.”
Packaging ERP Algorithmic Scheduling Web-Based Access Online Customer Portals
Paperless Workflows Mobile Sales Systems Digital Signage Production Monitoring Mobile Logistics Management Analytics & Reporting Cloud Hosting IT Management Services Cyber Security Management
600 + Plants 60,000 Users North America Latin America
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STOP GUESSING.
WE KNOW THE ANSWERS TO THESE QUESTIONS...
WHAT IF?
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?
With Amtech’s NEW AUTOMATED PERFORMANCE COSTING To Learn More or Schedule a Demo Darren Artillio: dartillio@amtechsoftware.com 215.639.9540 www.amtechsoftware.com/accurate-costing
The BoxMaker (CONT’D FROM PAGE 1 )
for quality. The BoxMaker’s McKinley flexo folder gluer is similar to the Ward but handles smaller sized sheets. It produc- es up to 300 boxes per minute and prints two colors. It’s equipped with a full die-cut section which adds to their specialty offering and provides customers with shelf-ready options like tear away, vent holes and snap-lock bottoms. The Bobst Eterna Maxcut automatic platen die-cutter is ideal for delicate handling of their digitally printed sheets without damaging the high graphics. The Eterna includes a stripping section to automatically remove waste and trim. This die-cutter is the ideal solution for the digitally printed projects coming from the HP PageWide C500 press. Lower volume jobs and some digitally printed orders run through the Marumatsu platen die-cutter, which can be a less expensive option due to the dies that it uses. Units move down the line to be palletized and are con- veyed to a Samuel strapper. After that, they are transport- ed to a distribution warehouse located two miles away. Sustainability And Waste Reduction Sustainability and waste reducing initiatives are men- tioned throughout the tour, as the company places a heavy emphasis on keeping their plant as efficient as possible with a reported two percent average waste. “A specialized Machines Centers team tracks KPIs and is continuously looking to improve efficiency by reducing waste and im- proving safety,” said Brown.
and is used to produce samples, short runs and rush or- ders, allowing them to be agile to customer needs. Inside The Box Plant Brown took attendees through the life cycle of a box in the plant, starting at the Ward flexo folder gluer. Installed in 2007, the Ward prints in two colors, die-cuts, folds and glues in one pass, while producing up to 180 boxes per
minute. Waste falls on to a scrap conveyor and is baled for recycling while loads pass through a counter ejector and automatic bundler then on to a quality check station where operators randomly inspect glue joints and the box The Bobst Eterna Maxcut diecutter handles digitally printed sheets without damaging the high graphic surfaces.
CONTINUED ON PAGE 18
We’ve got our customers covered… …with our fiberglass backed, boltless, full double-wide blankets and an extensive inventory of corrugated parts needed by virtually every box plant in the country. The innovator of the original fiberglass-backed knuckle locking anvil cover, Stafford is the industry’s go-to source for everything corrugated. TM
www.go2stafford.com 800-282-5787 IS THE MANUFACTURER OF STAFFORD ANVIL COVERS ®
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The BoxMaker (CONT’D FROM PAGE 16)
AIR CONVEYING CORPORATION is a recognized leader in the industry of Pneumatic Conveying Systems and has been in business since 1968. As an equipment manufacturer rather than simply a sales organization, we have complete control over the quality of material and products which make up your proposed system. Our equipment is found in Printing, Folding Carton and Corrugated plants throughout the country and the world.
A portion of The BoxMaker’s business comes from cus- tomers needing solutions for large appliances, televisions and mattresses. With a stitcher/gluer/taper, they are able to handle stitched joints, staples and gluing large two- piece boxes or tape joints. The jumbo rotary die-cutter is an original machine, dat- ing back to 1981, and maintains its purpose. It slots, scores and prints in one color per pass, with the capability to han- dle the largest sheet sizes, used for mattress or appliance boxes. The Bobst specialty folder gluer brings more options with five glue heads and two tape heads. The specialty glue and tape options provide more complex solutions like auto-bottom and in-line trays. High Graphics Center The next stop on the tour was the High Graphics Cen- ter. In 2011, the original investment into digital printing provided solutions for rapid prototyping and short run, low-volume orders. As an early adopter of digital print, The BoxMaker can be considered one of the industry experts in corrugated digital printing. In the past 10 years, their dig- ital business has grown and technology has advanced ex- ponentially in speed, capacity and quality. Brown reported that nearly half of their revenue comes from digital print, while flexo printed products account for higher volume.
AIR CONVEYING CORPORATION PH: 901-454-5016 FAX: 901-324-7979 e-mail: sales@accfilter.com • www.accfilter.com
CONTINUED ON PAGE 20
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The BoxMaker (CONT’D FROM PAGE 18)
pounds and require no additional barriers to meet interna- tional food packaging regulations. They are also compliant with Swiss Ordinance and Nestlé Guidance. “The special- ized ink and print quality are what sets the C500 apart,” says Brown. WSA-USA supplied all of the infeed and discharge con- veyor for the C500, as well as a stack inverter.
“Brands can now use corrugated packaging to convey messages that would otherwise have been reflected on folding carton packages or flexible packaging, with a simi- lar level of quality and no impact on brand integrity.” The Boxmaker’s High Graphics Center houses two dig- ital corrugated printing presses, both of which are G7 cer- tified for optimal printing and color matching. The first of the two presses is the Scitex 17000 wide-for- mat digital press which delivers four-color process print in several passes and features UV and LED curing. The Scitex low-odor UV cured inks are designed primarily for printing on paperboard to reduce cracking and are AgBB and UL Greenguard certified. The company’s design team utilizes the Esko WebCen- ter to load production ready files. They utilize automation software to generate a PDF proof. Once approved by the customer, an optimized sheet layout is generated to en- sure efficiency in printing and cutting. The file is sent to the press where the sheet is picked up by suction cups and pulled onto the bed. The bed flows back and forth to lay the image in multiple passes. The second digital press is the HP PageWide C500 single pass digital press, which was installed in 2018. It delivers the latest advancements in digital print technolo- gies and primarily produces food-safe packaging with its water-based inks. The inks are free of UV reactive com-
Once printed, product produced on the digital printers is cut on a Zund cutting table or is die-cut at the box plant. “Today our continued investments are bearing fruit and we are able to deliver beautiful, full-color, digitally printed boxes, retail-ready displays and labels,” said Brown. “The C500 offers offset quality print comparable to litho labels or 125 line screen HP flexo printing.”
CONTINUED ON PAGE 22
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The BoxMaker (CONT’D FROM PAGE 20)
to deliver faster and more efficiently. As with many box plants, business initially dropped in the teens for a couple of months into the 2020 pandemic, but with much of their business coming from customers dealing in medical products, pharmaceuticals and ventila- tors, they saw an uptick. In Q3 and Q4, the company expe- rienced a tidal wave of business in every direction which has continued into 2021.
Like with many of the digital printers, The BoxMaker is realizing the benefits of digital print: minimal set-up times, the absence of print plates, low order quantities, less waste and variable data customization such as barcoding and serialization. The digital presses are capable of pro- ducing up to 10-million square-feet of product per month, with digital orders shipping within 10 days or less. Also housed in the High Graphics Center, the Lamina Specialty folder gluer applies tape for e-commerce pack- aging. Orders flow directly to a fulfillment center where teams handle everything from simple display assembly, to packing displays or boxes with products that can be drop shipped to retail locations or directly to consumers. “Think of our fulfillment center as a flexible labor pool that can enhance your existing operations without the overhead or The BoxMaker has made significant investments in la- bels and other narrow web projects with its two HP Indigo web presses. Since 1992, it diversified with its foam con- verting and packaging supplies distribution business. Fantastapack is another area in which the company has branched out and diversified, with the help of digital print. Fantastapack is a web-to-print online retailer, selling dig- ital boxes and displays to the US and Canada. This new offering enables them to leverage ecommerce platforms management,” said Brown. Additional Diversification
Brown reports that the company will expand the 14,000 square-foot Tangopress facility, located in Arkansas, and will add another C500 press, WSA-USA conveyor and Zund cutting tables. “We are pushing new limits and that certainly requires support from really great business part- ners,” said Brown. Fantastapak is The BoxMaker’s web-to-print online retail oper- ation that sells it products within the U.S. and Canada.
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Leverage your message to your customers and potential customers with the power and credibility of Board Converting News behind it. Sponsor a weekly Monday issue or we’ll send out an eblast any day of the week to our full online circulation. You provide the copy, images and/or link to a video or website and we’ll do the rest. Give your digital marketing campaign a boost! Robyn Smith President/NV Publications 910-553-4055 rsmith@nvpublications.com
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AF&PA Releases Guide To Advance Paper Recycling Design Guidance Building on the sustainability success of paper based packaging and recycling, the American Forest & Paper As- sociation (AF&PA) has released a new tool, “The Design Guidance for Recyclability,” a data-driven resource to aid packaging designers and brands in the design and manu- facture of packaging to meet recyclability goals. The guide provides data on how certain non-fiber el- ements, such as coatings and additives, impact the recy- clability of paper-based packaging. “Paper recycling is a circular economy success story. Increasingly, consumers are seeking more sustainable packaging, and as a result, brands are challenged to add more recyclable packaging to their portfolio,” said Heidi Brock, AF&PA President and CEO. “Combining our indus- try’s track record on paper recycling – meeting or exceed- ing a 63 percent recycling rate since 2009 – along with AF&PA’s industry data and statistics, this guide will be a true asset to those seeking to innovate around sustainable packaging. I am confident that a deeper understanding, as to the complexities brands and packaging designers face in balancing design and performance with recyclability, will further advance paper recycling innovation,” The findings in the report are the result of an AF&PA member survey of company mills in a range of sectors in the United States and Canada. The survey had a 75 per- cent response rate. In total, data for 86 mills was reported. The study included corrugated packaging, bleached and unbleached paperboard cartons, carrier stock cartons, Kraft paper bags, multiwall shipping sacks and molded fi- ber containers. The study examined numerous non-fiber elements including inks and dyes, adhesives, tapes and labels, coatings and barriers, metals and plastics, foils, wet strength, and non-tree fibers. Key findings include: • Non-fiber elements may present a recycling “chal- lenge” when they slow down the mill’s pulping process, plug screening systems or leave residue on finished paper or paperboard. • Being a “challenge” does not mean “not recyclable.” Each non-fiber element applied to each kind of pack- aging was rated by some mills as not a “challenge.” “This technical guidance is not meant to be mandatory or a standard for the packaging industry. Rather, it is an information tool to help individuals and organizations that specify and design packaging to better meet a customer’s recycling needs,” said Brian Hawkinson, AF&PA’s Execu- tive Director of Recovered Fiber. In addition to data about the impact non-fiber elements have on packaging recyclability, the report includes re- sources about the recycling process, standards and in- sights from mills on specific non-fiber elements. “The Design Guidance for Recyclability” is free. Download it at afandpa.org/sustainability/design-guidance .
BCN
says,
to the sponsors of our 2021 calendar!
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Please visit www.nvpublications.com to view the 2021 industry events and links to our sponsors’ websites where you can learn more about their products and services.
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SUPPLIER REPORTS 2021 (PART 6) ABSOLUTE Huddersfield, UK: Antony Whiteside reports, “I don’t think it’s a surprise to any of BCN’s readers to say that 2020
shrink the footprint of InkSave to make it compatible with a wider range of equipment. This was really successful, and resulted in a 25 percent size reduction, which makes InkSave applicable to ‘mini’ machines such as Bobst 618’s, EMBA 170 and 175’s and any other equipment where space around the ink station is at a premium, such as a Bobst Transline. “This immediately produced a P.O. from a major Inte- grated who is a longstanding customer for Absolute. It also attracted attention from several OEM customers, who have now started purchasing InkSave technology for their new equipment offerings. By the end of Q1 sales of Ink- Save exceeded sales for the whole of 2019. That feels like an opportunity we grabbed with both hands…
didn’t really progress in the way the Absolute Team anticipated, however as with all change, it presented both issues and opportunities. Innovation is the norm at Absolute, and 2020 was no different. Reacting to our Industry’s focus on continuous im- provement of Green Credentials, we
Antony Whiteside
have continued to evolve InkSave, our ink-loss minimiz- ing ink circuit washup system. We completed a project to
“One of the strengths of Absolute is our ability to install and service our equipment worldwide using only our own Specialist Technicians. It’s a resource that is expensive to build and expensive to maintain, however it ensures our customers have access to a high degree of technical ability in Absolute’s range of products, and knowledge of flexography. “During 2020 this resource really came to the fore in The Americas. Regardless of the issues with COVID, our team continued to support customers across the continent. This service went from live streaming of the mea- sure up process, where our Technicians were at the machine, working alongside a Design Specialist at Absolute HQ, who was reviewing the video while comparing it to our 10,000 in- stallation archive of 3D projects. This partner- ship allowed us to complete designs without interruption, before manufacturing the com- ponents in-house and then installing at the customers plant. Other customers who need- ed support in regions like Canada and Mexi- co also had this resource at their disposal, as did existing customers who needed technical service support or just additional training for new recruits. “Of course, the core product of Absolute remains our original woven carbon fiber ink- ing beams. UniBlade single blade systems remain hugely popular within The Americas, however customers are increasingly specify- ing our dual blade chambers. We believe this is because there are increasing numbers of aging Bobst and Gopfert equipment that was originally supplied with a dual blade system, and that now requires upgrading to an ink re- pelling material with a tool-free, quick-change
Once recycled, corrugated box fibers are used 7-10 times to make new boxes and other paper products. And, more corrugated packaging is recovered for recycling than any other packaging material. Corrugated attracts eco-conscious customers who prefer to choose sustainably packaged products. Environmentally Responsible. Recyclable. Compostable. Extraordinary.
Learn more at boxesareextraordinary.com
CONTINUED ON PAGE 28
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Supplier Reports, Part 6 (CONT’D FROM PAGE 26)
blade and seal system. Having supplied systems in The Americas for over 20 years, we have a track record in com- pleting these upgrades reliably, and supporting them over the long term, after all they come with a 15 year warranty! “So if you have a tired ink circuit on your post printer that doesn’t optimize ink loss and washup, or maybe you are buying new equipment and want the inker to be class leading, its worth discussing! If its an existing line, there’s a 99% chance we already have it in our archive, and if its new, we may well be supplying your prospective OEM al- ready! Let’s talk.” Email aw@absolute-eng.com. BOBST Roseland, New Jersey: Brian Kentopp reports, “BOBST, as a leading supplier of printing and converting equipment
1030 S. Edgewood Ave. Urbana, Ohio 43078
in the packaging industry, found 2020 to be one with many chal- lenging changes. Workdays in the office were altered to working from home. Those of us that historically traveled weekly, went from frequent flier miles to Zoom memberships. Yet through the changes, and the list is
Brian Kentopp
long, BOBST reflects on a very successful year in both the folding carton and corrugated segments of the business.
CONTINUED ON PAGE 30
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