BoardConverting Serving the North American Corrugated and Folding Carton Industries for 40 years June 17, 2024 VOL. 40, NO. 25
Rand-Whitney Adds Boylston Jewel To NE Boxmaking Crown BY LEN PRAZYCH The word “greenfield” evokes images of open land, a clean slate, a fresh start, and the incredible opportunities it often presents. As it pertains to business, a greenfield project is one that lacks constraints imposed by prior work on a particular site, that is, development on an entirely
Green Bay Packaging Acquires SMC Packaging Green Bay, Wisconsin based Green Bay Pack- aging Inc. (GBP) announced the acquisition of SMC Packaging Group based in Springfield, Missouri. The transaction, which took place on May 31, marks a significant milestone for both companies. GBP said that SMC Packaging Group, founded in 1972 by co-founders Ross Aus- burn and Charles Bachus, has garnered an outstanding reputation for its innovative cor- rugated packaging solutions. With over 50 years of growth, expansion, and technologi- cal advancement, SMC Packaging Group op- erates across multiple locations in Missouri, Arkansas, and Oklahoma. The company’s Midwest roots instill a strong work ethic, a commitment to safety, and a focus on delivering quality products, customized solutions, and exceptional cus- tomer satisfaction, GBP said. “We are excited to unite two well-estab- lished, family-run businesses,” said Will Kress, Chairman and CEO of Green Bay Packaging. “We look forward to the continued growth and success of both SMC Packaging Group and Green Bay Packaging.” CONTINUED ON PAGE 3
WHAT’S INSIDE SupplyOne Acquires Columbia Corrugated Box Co. TAPPI/AICC Box Manufacturing Olympics Deadline Set June 28 PPC Makes Tour Stops At Drupa 2024 Trade Fair
6 x x 8 x x 12 x x 26 x x
vacant site and completely from scratch, as opposed to a “brownfield” project, which does carry constraints related to the site’s current state. As it pertains to the corrugated industry, “greenfield” represents the foundational philosophy behind the construction and opening last year of Rand-Whitney’s newest 384,000-square-foot showpiece of a box CONTINUED ON PAGE 24 Rand-Whitney’s President/CEO, Nick Smith, left, and Adam Tominsky, the company’s General Manager, led the initiative that brought Rand-Whitney’s greenfield facility in Boylston, MA to fruition.
20 Berkley Acquires Sisco Corporation
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GBP Acquires (CONT’D FROM PAGE 1)
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.
Said Kevin Ausburn, SMC Packaging Group’s Chairman and CEO: “For over five decades, our employee-owners have diligently provided quality products in a timely man- ner to our customers. Simultaneously, we have fostered a profitable and successful company deeply rooted in com- munity values.
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 $973.00-983.00
26# Semi-Chem. Medium
Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del.
$ 890 .00-9 4 0.00 $9 0 5.00-9 2 5.00 $9 0 5.00-9 2 5.00 $9 0 5.00-9 2 5.00 $9 2 5.00-9 4 5.00 $9 0 8.00-9 2 8.00
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.
“As SMC Packaging Group expands beyond our found- er’s vision, we are ready to embark on the next chapter by joining Green Bay Packaging. Their shared commitment to employee well-being and community pride aligns perfect- ly with our philosophy.” GBP Executive Vice President Bryan Hollenbach add- ed: “We are thrilled to have SMC join the GBP family. SMC is known for the service and quality it provides its custom-
42# Kraft Liner 26#
Semi-Chem Medium
East West
$9 2 0.00 $ 96 5.00
$9 1 0.00 $9 4 5.00
CONTINUED ON PAGE 4
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GBP Acquires (CONT’D FROM PAGE 3)
Core Competency
ers. SMC has a strong group of leaders who understand the value of Safety, Quality, Service and treating their employees with respect and dignity. SMC expands GBP’s geographic reach while being a perfect cultural fit. We are looking forward to working together to build our business.” SMC Packaging Group will continue to operate as a corporation, 100 percent owned by Green Bay Packaging. Mark McNay, previously Vice President and General Man- ager of SMC, will become President of SMC Packaging Group, reporting to Bryan Hollenbach. “We couldn’t be more excited about joining forces with the team from Green Bay Packaging,” said McNay. “The opportunities are boundless as SMC sets our sights on the next 50 years of growth. Green Bay is the perfect fit — in that they complement the customer service, product quality, strategic vision, and culture that have pro- vided the foundation for SMC’s success over the years.” The strategic integration of SMC Packaging Group into Green Bay Packaging, Inc. establishes a strong presence in the Missouri, Arkansas, Kansas, and Oklahoma markets. Started in 1933, GBP is a vertically integrated company consisting of corrugated container plants, a folding car- ton facility, recycled and virgin containerboard mills, pres- sure-sensitive label roll stock plants, timberlands, a paper slitting operation, and a sawmill facility. It operates 41 facili- ties in 16 states. For more information, visit gbp.com .
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SupplyOne Acquires Columbia Corrugated Box Company
Newtown Square, Pennsylvania based SupplyOne, Inc., one of the largest independent suppliers of corrugated and value-added packaging products, equipment, and services in North America, announced that it has expand- ed its footprint to the West Coast with the acquisition of Columbia Corrugated Box Company, Inc (CCB). CCB man- ufactures custom corrugated solutions, protective packag- ing, and high-resolution printed packaging solutions in the Pacific Northwest. Founded in 1967, CCB is comprised of two divisions, Columbia Corrugated Box and Packaging Resources Com- pany (PRC). The company primarily operates within Wash- ington, Oregon and Northern California, with facilities in
the Portland and Seattle metro areas as well as Medford, Oregon and Eugene, Oregon. In addition to offering tra- ditional corrugated packaging solutions, CCB offers spe- cialty custom corrugated services, retail point-of-purchase displays, and high color graphics through litho lamination and digital printing capabilities. The PRC division primar-
ily operates in the protective packaging solution field. Products provided consist of items such as custom cushioned crates, thermoformed pick-and-place build pal- lets, and value-added foam products. “Adding a SupplyOne presence to the West Coast further enhances our ability to service customers nationwide, in addition to ongoing expansion of our North Amer- ican coverage,” said Todd Renehan, Pres- ident and CEO of SupplyOne. “From our first conversations with CCB, we aligned strongly on approaching each customer with custom solutions and superior ser- vice.” “As a family-owned business for over 50 years, it was extremely important to find the right partner that continues our legacy of fast, high quality packaging solu- tions, embraces a customer-first attitude, and treats employees like family. Supply- One fit the bill on all fronts while offering an expansive North American footprint to serve our customers even more broadly,” said Steve Tanner, Owner of CCB. “The management team and loyal em- ployees of CCB have built one of the best corrugated and protective packaging busi- nesses in the country over the last 50+ years, of which we are very proud. As part of SupplyOne, we are looking forward to taking the business to the next level with international scale, while maintaining the high-touch service our customers expect. We are very excited for the future growth this partnership will help drive,” said Roggy Pflug, COO of CCB. This acquisition represents the 41st ad- dition to the SupplyOne portfolio in its 25 years in business.
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TAPPI/AICC Box Manufacturing Olympics Deadline Is June 28 Are you ready to showcase your organization’s creativity and technical prowess? TAPPI and AICC invites corrugated, rigid box and fold- ing carton makers and their suppliers worldwide to par- ticipate in the prestigious Box Manufacturing Olympics during SuperCorrExpo 2024 slated September 8-12 in Orlando, Florida. The deadline to compete is June 28. This exciting competition combines TAPPI’s CorrPak Competition and AICC’s Design Competition into one unified event, where global packaging leaders come to- gether to exhibit their greatest innovations. Why participate? Showcase Your Innovations: Gain recognition for your team’s hard work and creative designs. It’s more than just a competition; it’s a chance to shine among the best in the industry. Be Featured at the Olympic Village of Innovation: Your entry will be displayed in a dedicated area where all entries are showcased, offering a unique opportunity to see the best in the industry and draw inspiration. More- over, attendees will have the opportunity to vote for their favorite entries, adding an exciting interactive element to the showcase. CONTINUED ON PAGE 10
Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month December 2023
Year
Actual
Percent Change Avg Week Percent Change
2023 2022
29.711 30.124
-1.4
7.819 7.927
-1.4
Industry Total
Year-to Date
December 2023
Year
Actual
Percent Change Avg Week Percent Change
2023 2022
380.555 400.520
-5.0
7.611 7.979
-4.6
Industry Total
Containerboard Consumption (Thousands of Tons)
Year
Month
Percent Change Year-to-Date Percent Change
2023 2022
2.4080 2.4260
-0.7
30.9333 32.5461
-5.0
Container Board Inventory - Corrugator Plants (Thousands of Tons)
Corrugator Plants Only
Date
Percent Change Weeks of Supply
Percent Change
Dec. Nov.
2.1892 2.1071
3.9
3.5 3.5
6.1
Shipping Days
Year
Month
Year-to-Date
2023 2022
19 19
250 251
SOURCE: Fibre Box Association
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Ciao bellA!
Say hello to Italian innovative excellence with the Encore FD 821 flexo folder gluer. From prefeed through palletizing, there’s beauty cooked into the process.
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Box Manufacturing Olympics (CONT’D FROM PAGE 8)
ries and requirements. All entries must be composed of at least 50 percent paper or corrugated paper (unless other- wise noted in category criteria). All entries must be die cut, except pre-print liner category. Judges will evaluate entries on a number of levels,
This not only enhances visibility for your work but also engages potential clients and partners in a direct and meaningful way.
including design, quality, graphic excellence, tech- nical difficulty, and inno- vative application, among others. Details on all 41 cate- gories can be found in the brochure. All entries will be prominently displayed during SuperCorrExpo and winners will be announced each day preceding the opening session, with the Best of Industry winners
Utah PaperBox won Best of In- dustry Folding Carton in 2021.
and Attendee’s Choice being announced on the last day. Winners will be featured on the SuperCorrExpo, TAPPI and AICC websites, and will also be announced in various industry publications. To enter and download the brochure, visit https://my.re- viewr.com/s2/site/BoxManufacturingOlympics_2024 . For more information, contact Laura Mihalick, AICC Se- nior Meeting Manager, at LMihalick@aiccbox.org or call (877) 836-2422.
Gain Global Recognition: Attract attention from indus- try leaders and potential clients from around the world. This is an opportunity to promote your brand on a global scale and discover new growth opportunities. Packaging schools and universities are also invited to participate in the competition and have their own catego- Vanguard Packaging won the Best of Industry, Corrugated Structure, award in 2021.
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Paperboard Packaging Council Reflects On Drupa 2024 International Trade Fair Ben (PPC President Ben Markens) and I are incredibly grateful for the opportunity to travel to Düsseldorf, Germany, to attend drupa 2024, the first trade fair since the COVID-19 pandemic. It was a transformative ex-
Customer Care Portal
Quality Management
perience to walk over 100,000 steps at the event. We were thrilled to reconnect with our international friends and colleagues, and it was fantastic to see so many people from the United States making the trip across the pond.
drupa is considered the Olympics of the printing and packaging world. I wasn’t sure what to expect when we arrived in Germany, but all our expecta- tions were exceeded. During our time there, we no- ticed three key themes everywhere we looked: sustainability and auto- mation, innovations and digitalization, and data integration. Emily Leonczyk
TopGun
ScrapTrakker
Sign & Drive Visual Analytics
Advanced Planning Board
ScoreKeeper
Corrugator Scheduling
Automated Performance Costing
Our drupa tour stop at BOBST featured a presentation on their lead- ing innovations to increase productivity, connectivity, digitalization, auto- mation, and sustainability. Thank you, Harold Leete and team, for having us at your booth! We were so pleased to meet with Graphic Packaging International, LLC Packaging International CEO, Michael Doss. Thank you for taking the
Partner Integrations:
time to celebrate our Associate Members’ innovation and tech- nology advancement. We stopped by the BW Pa- persystems booth where Max Rawson featured their innova- tive Mercury project. The new generation of web-fed platen die cutter can get up to 2.5 times the output of traditional flatbed die cutters, producing up to 25,500 boxes per hour!
At the Valco Melton booth, they are addressing the need to support skilled workforce challenges by showcasing their camera inspection CONTINUED ON PAGE 14
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PPC Reflects (CONT’D FROM PAGE 12)
The Perfect Combo Get Peak Performance From Your Equipment with Matched Component Sets
solutions, a growing demand in the folding carton industry. Thank you, Scott Lydell, for highlighting how the camera uniquely inspects the top of braille—a Valco Metlon exclu- sive technology.
We entered Koenig & Bauer (US)/(CA)’s expansive booth at drupa – no. 1 for printing technologies. Eric Frank high- lighted their three core pillars: digitalization, modularity, and sustainability. As a 207-year-old family-managed com- pany, they offer a wide range of products custom-made in Europe for your exact needs. We were inspired to visit our friends at Baumer hhs GmbH and see firsthand their solutions to implement sus- tainability in everything they do at drupa – no. 1 for printing technologies. How do they do it? By continuously ques- tioning everything they do!
Nothing’s more rewarding than a couple made for each other.
That’s why the engineers at ARC International have focused their skills and talents on crafting perfect matches between the components that must work in tandem on your flexo folder gluers and die-cutters: • Anilox Rollers and Ink Chambers • Anilox and Wiper Rollers • Feed and Pull Rollers • Glue and Meter Rollers You can achieve the press speeds and print quality you need to fill your most demanding orders by pairing your team with The ARChitects of Flexo . Contact ARC today to learn how these engineered matches of flexo folder gluer and die-cutter components (new or reconditioned) can help you achieve a more perfect union of production and profits.
We enjoyed a fascinating demonstration from eProduc- tivity Software at drupa – no. 1 for printing technologies. Alex Zlatic and Steve Green highlighted their transforma- tional technology dedicated to print and packaging! Their state-of-the-art packaging software creates one “source of truth” where all relevant data resides. It allows for real-time, high-quality collection and has the tools to turn data into “information” with automated and actionable insights. Leveraging cloud-based systems, AI, gamification, and automated cost forensics, eProductivity Software is lead-
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CONTINUED ON PAGE 16
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PPC Reflects (CONT’D FROM PAGE 14)
proach to optimizing carton recyclability by using only as much adhesive as the packaging function requires and nothing more. At a time when sustainability is an indis- pensable standard, we were happy to learn about their technology, which exceeds waste regulation requirements and optimizes CO2 balance in folding carton production. Thanks to our friends for an excellent excursion and fan- tastic hot and cold glue solutions. Harold Leete and the team at BOBST delivered on their promise to prioritize sustainability throughout the value chain. The drupa – no. 1 for printing technologies booth featured its leading innovations to increase productivity, connectivity, digitalization, automation, and sustainability. Their vision of sustainable end-to-end solutions is revolu- tionary. This foresight was well demonstrated throughout the pavilion. Well done, and kudos to the visionary Jean-Pas- cal Bobst, CEO of the Bobst Group. We joined Eric Frank at Koenig & Bauer (US)/(CA)to see their latest technology and equipment displayed at drupa – no. 1 for printing technologies! Koenig & Bauer is focused on tailor-made solutions for folding carton producers. Eric highlighted their Europe- an-manufactured equipment and software, including ana- log and digital offset presses, rotary and platen diecutting, a blazing fast gluer, and connected packaging—all inte- grated into a singular system! CONTINUED ON PAGE 18
ing packaging producers into the future with transforma- tional tech. We were delighted to connect with Jeff Besnick and his McLean Packaging Corporation team at the Gietz AG- booth at drupa – no. 1 for printing technologies.
Gietz showcased their digital workflow and innovative software, “Illucode,” to save material, straighten hot foil stamping workflow, and increase performance by calculat- ing foil and machine costs using only PDF data. Our visit to the Baumer hhs GmbH factory in Krefeld was well worth the journey. We saw firsthand their ap-
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PPC Reflects (CONT’D FROM PAGE 16)
Ben said, “That gluer is running so fast it looks like it’s going backwards!” as it hit over 120,000 cartons per hour and almost 2000 feet per minute. We’re thankful for Eric’s commitment to serving our in- dustry as a PPC Board Member, industry champion, men- tor to all, and thoughtful friend!
We visited eProductivity Software to learn more about their leading ERP system for packaging. Steve Green high- lighted some of his favorite features, including individual- ized “workbenches” to provide essential information daily, automated PrintFlow scheduling to optimize on-time de- livery and efficiency, and their Automator solution that can
CONTINUED ON PAGE 20
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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No Lights. No Camera. All Action.
Make a stronger, lighter and more sustainable corrugated blank using less glue by implementing a “brick” style pattern developed by Baumer hhs. This pattern creates a stronger bond using less glue. Our new all-electric PX 1000 applicators with over a billion cycle life can easily apply the pattern with clean cutoff and accurate placement. The PGD 1000 sensor is there to show your customer that every box was properly glued so you’ll never end up on some gag reel. You can be the star with The CorrBox solution from Baumer hhs.
PGD 1000 Monitoring Sensor • Measure the glue proximity to the edge of the tab and avoid squeeze-out so you deliver an accurately glued box every time. • The printing on the carton does not effect the hybrid sensor’s ability to read the bead. Black, white, plaid or polka dot, the sensor is not bothered, so neither are you. • No UV additives needed for detection saves you money, time and effort.
PX 1000 Cold Glue Applicator • Extremely fast and powerful closing force means no drips or tailing so your first box is a good box. • Strong armature activation easily handles viscosity fluctuations and will work with a large variety of adhesives. • Fast action coil means you can now stitch your beads at higher running speeds lowering adhesive consumption up to 70% and improving board output.
GLUE SAVINGS Activation Aktiv
Find more information on CorrBox at URL below or use the QR Code: https://shorturl.at/sACE0 Or contact us at: 937-886-3160 or email sales.usa@baumerhhs.com Baumer hhs 10570 Success Lane, Dayton, Ohio 45458
Savings
70%
Max Gap 4 mm
Berkley Acquires Sisco Corporation
PPC Reflects (CONT’D FROM PAGE 18)
trigger events, messages, and actions from any point in the system. He gave a few great examples of the Automator in ac- tion, including: • An automatic email trigger to notify the customer that a delivery has left the building; • An automatic reminder for your salesperson when it’s time to complete expenses; and • An automatic notification when a high-value sales or- der has just come in, and a senior director needs fore- warning. This impressive software solution is tailored to folding cartons with interfaces to all the major OEMs. We were so happy to connect with Hilda Murray and learn about the innovation from drupa – no. 1 for printing technologies she and her team plan to bring back to TPC Packaging. Celebrating 100 years in business, Hilda has big plans to keep their company focused on growth by leveraging leading technology in packaging. Hilda is a very engaged and dedicated PPC member, and we’re thankful for the guidance, support, and leadership she provides our asso- ciation and our industry! Thank you for following along and we are excited to see you in four years! This article was an excerpt from a column by Emily Leon- czyk, COO and Executive Vice President of PPC.
Lakewood, California based Berkley has confirmed it has completed the acquisition of Sisco Corporation (also known as Sisco Box and Sisco Container), a family-owned business based in Nashville, Illinois. “This acquisition marks a significant milestone in Berk- ley’s continued growth and commitment to serving our customers’ needs with enhanced capabilities,” said Berk- ley CEO Eric Berkley.
Established 50 years ago, Sisco Corp has built a strong reputation for manufacturing high-quality corrugated box- es and displays. “By integrating Sisco’s manufacturing equipment and CONTINUED ON PAGE 22 Sisco Corp. in Nashville, Illinois.
A FULL LINE OF INNOVATION
CONTACT US TO DISCUSS YOUR PRODUCTIVITY GOALS!
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Max Speed: 10,000 s/h
Available Sizes (max sheet): 2,100 / 82” (82 x 62.99”) 2,400 / 94” (94.5 x 62.99”) 2,800 / 110” (110.24 x 62.99”)
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Available Sizes (max sheet): 2,100 / 82” (82 x 62.99”) 2,400 / 94” (94.5 x 62.99”) 2,800 / 110” (110.24 x 62.99”) Features: • 3 minute auto job change • Setup while running • Preset print • Inside/Outside Print • Print and die cut inspection • Anilox Roll Changing System (Automatic: 2+1)
Max Sheet Width: 110.24 “ Max Sheet Length: 60.24” Min/Max Caliper: .039/.354” Features: • 3 minute auto job change • Setup while running • Preset print and die cut
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Berkley Acquires (CONT’D FROM PAGE 20)
“We are thrilled to welcome Sisco Corp. onto the Berk- ley team. Their dedication to quality and community mir- rors our own values, making this a natural and exciting fit. We look forward to leveraging their expertise and equip- ment to better serve our customers and continue our his- tory of growth.” Haire Group Welcomes Wood As East Coast Account Manager
expertise into Berkley, we are significantly expanding our in-house production capabilities, enabling us to better meet the diverse needs of our customers,” Berkley said. Berkley was founded in 2012 by Eric Berkley and his fa- ther Jeff Berkley. With sales offices in Lakewood, a design center in Rogers, Arkansas, and a warehouse in Lowell, Ar- kansas, they have been steadily expanding their footprint across the country. “The addition of Sisco’s manufacturing capabilities en- hances our ability to provide top-tier packaging solutions more efficiently. “This acquisition not only strengthens our product of- ferings but also ensures we continue to deliver the excep- tional service our customers have come to expect,” Berk- ley said.
Merrillville, Indiana based Haire Group announced its newest mem- ber to the team, Marshall Wood, as an Account Manager. A well-established player in the corrugated industry, Marshall comes to Haire Group with extensive industry
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knowledge and ex- perience. Through- out his 30-year career in sales, Marshall has demonstrated his sales acumen. He has excelled in the footwear and steel industries, and his transition to the corrugated industry was seamless. Before joining the Haire Group team, Marshall served as a Regional Sales Man- ager of the Southwest/West Coast Territo- ry for a leading corrugated conveyor sys- tems company. In this role, he not only streamlined plant output but also achieved a remark- able sales increase every year from 2019- 2022. Marshall’s sales success is a testament to his dedication to serving his customers and providing them with the best solutions available, making him an excellent addition to the Haire Group sales team. “We are excited to welcome Marshall Wood to the Haire Group team. Customer service is extremely important to the Haire Group, and we believe that adding Mar- shall to our team will give our East Coast customers even better service and access to our organization than ever before,” said Danny Lopez, Director of New Machinery Sales of Haire Group. “With Marshall’s experience in the in- dustry and his desire to improve the lives of our customers, we believe he is a per- fect addition to an already very strong Haire sales team.” Haire Group is continuing to build its team of experts. For more information, call (219) 947-4545 or visit hairegroup.com . Marshall Wood
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June 17, 2024
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Rand-Whitney (CONT’D FROM PAGE 1)
be built to replace the infrastructure and product and ser- vice offerings of its nearby sister plant, but one would be mistaken. A Dream Come True “What we’re doing here in Boylston is a full comple- ment to what we’ve been doing in Worcester,” says Adam Tominsky, General Manager of Rand-Whitney. “We haven’t had to shut down any operations in this location or any others in the Northeast and in fact, we’ve leveraged our
plant in Boylston, Massachusetts, almost 40 miles west of Boston. Rand-Whitney is an independent company owned by The Kraft Group, the Foxborough, Massachusetts based business and entertainment dynasty that according Forbes, ranks in the top 90 of America’s largest private- ly-owned businesses and employs more than 9,500 peo-
ple worldwide. In the paper, packaging, and forestry indus- tries – the Group also owns mills, thus ensuring its paper supply in perpetuity and is considered an independent-in- tegrated company. Its Boylston facility is Rand-Whitney’s fifth in the Northeast and was built a mere 12 miles and 15 minutes from its Worcester facility, where the company’s roots date back to 1938. One might think that the new facility in Boylston would
personnel, maintenance, and labor in Worcester to get us up to speed and producing at a high level here in our greenfield operation where everything – every piece of machinery in this building – from the ground up is brand new, which is a dream come true.” Who could argue with having such an enviable place in the industry and in the marketplace? CONTINUED ON PAGE 26
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June 17, 2024
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Rand-Whitney (CONT’D FROM PAGE 24)
Nick Smith, President/CEO at Rand-Whitney, applauds The Kraft Group and its managers for the opportunity. “The Krafts have given us the funds to build the new- est and fastest car in the neighborhood and we’re begin- ning to see just how fast and far we can drive it,” he says. “We’ll be running over two billion square feet annually and we’ll be doing it with fewer than 60 people. We’re striving for complete efficiency and having the newest and best equipment definitely helps.” Like kids in a candy store, Smith and Tominsky began filling the new facility to their heart’s desire. They began with an MHI Evol 115 Flexo Folder Gluer and a BW Paper- systems/Ward Graphics G Rotary Die Cutter before “drop- ping in” a BHS 110-inch single wall/double wall corrugator. They purchased a second Evol 115 and outfitted both iden-
tically with Alliance Prefeeders, BW Papersystems Twin Box Slitters, and Alliance Robotic Load Formers. The final piece of the machine family was a Jumbo flexo A brand new BHS 110-inch corrugator is the “beast of a ma- chine” whose output feeds Rand-Whitney’s converting lines, including their Engico Jumbo Flexo Folder Gluer.
folder gluer by the Italian manufacturer Engico – represented by Merrilville, Indi- ana based Haire Group – which has been taking the North American corrugated in- dustry by storm. The reason, according to Tominsky, is that the Engico has dual-cyl- inder capability, a true 99-inches through the machine both for printing and for die cutting, which is unique. The machine is completely servo driven, so it provides a lot of flexibility in terms of what you're printing what you’re cutting; it has the abil- ity to run side slots and as well as slotted trays without a cutting die. It also offers the ability to glue and stitch in a single pass. “Engico packaged several different ma- chines into one, which was really intriguing and exciting to us because we don’t have to handle orders multiple times in multiple passes,” he says. “The other big thing that I like about the Engico is the innovation be- hind it. I think in our industry you don’t see a lot of innovation quickly. It takes time, usually 5 to 10 years, before something re- ally new arrives to the market and to me, discovering the Engico was one of those innovative moments.” Adds Smith, “We really haven’t been di- rectly involved in the jumbo business for about 10 years and we feel that the market has come a long way and we’re seeing a lot of opportunity out there. We’ve always had our hands in the jumbo business but we were outsourcing it. Having the Engico gives us a great reason to bring that busi- ness back in-house.” News of the Engico Jumbo Flexo Fold- er Gluer came to Rand-Whitney’s attention not too far into the design of its new build-
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CONTINUED ON PAGE 28
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June 17, 2024
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Rand-Whitney (CONT’D FROM PAGE 26)
relatively quickly, Rand-Whitney’s management team did its due diligence. They visited Lawrence Paper Company in Lawrence, Kansas, already running their third Engico before making the commitment with Haire Group on their own machine for Boylston. “The reputation of this group was enough validation for me to justify our investment in the Engico,” says Tominsky.
ing about three years ago through Haire Group’s Keith Umlauf. “Keith intrigued us very quickly with the machine, its capabilities and the successes other converters were hav- ing with it. It was only a few months before we made the
The Engico has dual cylinder capability, a ‘true’ 99-inches through the machine both for printing and die cutting.
“Now we have people from other plants reaching out to us wanting to see it in operation.” It wasn't until the machine was just about ready to be broken down and be shipped from Engico’s manufacturing facility in Lissone, Italy, near Milan, that Tominsky traveled to personally witness the performance testing and demos. CONTINUED ON PAGE 30
decision to buy one ourselves,” says Tominsky. “Since we had a greenfield site and the machine was a great com- plement to the rest of our plans, we decided to design the rest of the plant around it. We would be able to handle everything from small twin-box work all the way up to the biggest jumbo boxes.” While the decision to invest in the Engico was made
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Rand-Whitney (CONT’D FROM PAGE 28)
He describes the experience: “We assigned five different jobs and we chose the specs while Engico built the tooling and ordered the board. We set some speed factors and determined our quality criteria and everything checked out perfectly. I think it was probably one of the shortest demos I’ve ever done. The Engico team was gracious, pro- fessional, and transparent throughout.” After four weeks for installation and six weeks of training by Engico’s staff, the machine began running in Rand-Whitney’s Boylston facility in February of this year.
According to Smith, startup went great and Rand-Whit- ney in Boylston is already staffing for a second shift. There have been virtually no operational challenges. “Even though it’s got the one color on the 99-inch cyl- inder and two colors on the 66-inch cylinder, you can run it as a three-color machine. You're not going to get the full 99-inch graphics on all three colors but you can use the two downs to create the effect of a second 99-inch cylinder.” Others considering a similar growth initiative with a large-format machine would do well to heed Smith’s wis- dom. “We now have a Jumbo in our system and we’ve tethered it to a ‘beast of a corrugator’ in a massive facility, so unless you're willing to make that kind of investment, it may not the right strategic decision for you,” he says. “Once we laid the groundwork and put our plan in mo- tion, we knew we were going to have mid-size flexos and Rand-Whitney’s operators achieve maximum efficiency on their Engico Jumbo.
CONTINUED ON PAGE 32
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Rand-Whitney (CONT’D FROM PAGE 30)
more opportunities to invest in even more machinery. Smith again mentioned Haire Group and their relationship with Dong Fang and its innovative EDF material handling equipment off the Engico. “If you're going to remain competitive in our industry, you've got to be investing,” says Smith. “If you’re not in- vesting, it’s just a question of time before your competitor
die cutters but we definitely knew we wanted a world- class Jumbo. We found it in the Engico.” As one would expect with Rand-Whitney’s jumbo-sized undertaking in Boylston, the material handling WIP system is fully automated and boasts three autonomous trans-
is and some point you’re at a disadvantage. We’re very proud of what we’ve done here, what we’re continuing to do and we’re happy to have our competitors visit so they can see for themselves what’s possible. This plant is not only a show plant for Engico, but also for all the other ven- dors that helped us pull this together.” A BW Papersystems Twin Box Slitter conveys product to an EAM Mosca Max-Q.
An Alliance robotic load former off the MHIA Evol.
fer cars; after board comes off the corrugator – full-plan scheduling and interface is through Kiwiplan – there is no human contact with material until it arrives at the convert- ing lines, all of which are operated by two-person crews. With a sales force leveraging existing relationships with long-term customers, having the Engico has created more opportunities for new business, and with it, of course,
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