BoardConverting Serving the North American Corrugated and Folding Carton Industries for 40 years September 9, 2024 VOL. 40, NO. 37
Packaging Express Celebrates 25 Years Of ‘Playing In The Niches’ BY LEN PRAZYCH Family and fun are two words that don’t often go together when you’re having a conversation about the corrugated box business. Matt Davis, owner and president (and AICC Chairman for the past year) of Colora- do Springs, Colorado based Packaging Express, however, seems com- pelled to change the conversation. The perpetually smiling Davis is at the helm of a thriving independent box making company located near the Garden of the Gods and the gateway to the Rocky Mountains that apparently, “everyone wants to work for” and “no one wants to leave.”
Menasha Packaging Invests In Preprint Hub
Neenah, Wisconsin based Menasha Packag- ing, a provider of innovative packaging solu- tions, announced an investment in its North American preprint capabilities. With a commit- ment of over $50 million, Menasha says it is poised to revolutionize the preprinted graphic packaging space. Here are the key highlights: Strategic investment in new assets, auto- mation and robotics will create a North Amer- ican Preprint Hub: Menasha’s major preprint expansion initiative includes substantial in- vestments in cutting-edge equipment and automation. The organization will add a NEW 8-color + varnish press to its existing fleet of assets, complemented by NEW facility auto- mation and robotics focused on addressing the industries need for a wide range of run quantities, and quick changeovers.
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WHAT’S INSIDE 5 AICC Announces New Guest 7 StandFast Packaging Invests In SUN Automation, PARA 10 TAPPI YP, AICC EL Network At 2024 SuperCorrExpo 12 MRP Invests In Koenig & Bauer Rapida 164 Press 16 Roundtable CEO Group Celebrates 25 Years 20 Advanced Equipment Sales Going Strong For 35 Years 30 G.F. Puhl Partners With Sonoco Hosts For Breaking Down Boxes
Davis, who is 48, says “Once an employee is hired, we have a his- tory of keeping that employee for the long term. We have experienced little to no turnover as we have grown with an average tenure in the double digits.” Packaging Express was founded in 1998, when his father, Jim Davis, after a 30+ year career at Deline Box in Denver, opened a “comple- mentary” sheet plant in Colorado Springs when he realized there was a niche that needed filling. The elder Davis opened his doors and be- gan serving one of his new company’s first large customers, that being Columbia House – remember Columbia House, the company that sold six compact disks for a penny and they all came in small corrugated one-piece folders – and from there slowly began filling niches in the late 1990s, when his son Matt began a five-year agreement of buying From left, Andrew Bell, Senior Account Executive; Kirby Heck, CFO; Dan Pocrnick, Sales Account Executive; and Matt Davis, president and owner of Colorado Springs, Colorado based Packaging Express.
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AICC Announces Four New Guest Hosts For Breaking Down Boxes AICC, The Independent Packaging Association, an- nounced the latest episode of its popular podcast, Break- ing Down Boxes, featuring a special introduction of four
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 42# Kraft liner 26# Semi-Chem. Medium $ 900.00-925. 00 $ 825. 00 -$850.00 U.S. Average 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 $970.00 $960.00 West $1,015.00 $995.00 REGION
new guest hosts. This episode marks a significant moment as the podcast transitions to fresh voic- es while continuing its tradition of sharing compelling and relatable stories from the independent pack- aging sector. In this episode, Virginia Hum- phrey, AICC’s podcast producer,
Menasha Packaging (CONT’D FROM PAGE 1)
Mike Schaefer
introduces the new guest hosts: Mike Schaefer, President of Tavens Packaging & Display; Jeff Pallini, President of Fosber America; Simona Georgescu, Founder of Adduco Communications; and George Perreira, Vice President of Moyy.
The company said these investments are set to double its North American preprint capacity, reinforcing its posi- tion as an industry leader in preprinted graphic packaging solutions. This investment complements recent invest- ments in Menasha’s suite of graphic packaging technolo- gy, to include: digital flexo (short and long run), digital off- set, litho laminate, and direct print for both corrugated and folding carton. With the new press, combined with Menasha’s already existing fleet of preprint presses, pre-press capabilities, and in-house platemaking, Menasha is set to meet the evolving needs of its customers. Jeff Krepline, Executive Vice President at Menasha says, “These investments are going to drive improvements in both quality and safety, while delivering incremental capacity and significant re- ductions in make ready and set up times. This Preprint hub will support a North American corrugated and packout network that not only converts the preprint into graphic packaging boxes, but also fulfills a significant portion of the boxes with customer product when required.” Job Creation and Community Impact: Menasha’s com- mitment will create 25-30 new jobs in the Fox Valley area in Wisconsin. Roles span from press operators to second- ary operators, plate mounters, utility, and shipping and re- ceiving team members. Mike Riegsecker, President of Menasha Packaging, emphasizes the company’s excitement: “We’re committed to being the leader in North American preprinted graphic packaging solutions. We see these investments as some- thing that underscores our unwavering commitment to our customers, to innovation, and community growth.” Menasha’s Preprint will be produced locally in Neenah and converted across the Menasha North American net- work, and final graphic packaging solutions will ship to all 50 states, Canada, and Mexico. “I am excited about the stability this investment brings locally here in Wisconsin as we add new positions, but the rolls of printed liner will also support hundreds of positions across multiple states providing an exciting future for our employees,” says Krepline.
Each new host shares their jour- ney into the packaging industry, providing listeners with a deep- er understanding of their back- grounds, expertise, and the motiva- tions that drive them. From George Perreira’s transition from the minis- try to sales at Moyy, to Mike Schae- path led him from the tissue indus- try in Italy to getting Fosber Amer- ica up and running, and Simona Georgescu, who has made a signif- icant impact in the packaging and graphic arts space with her com- munications firm. Each host brings a unique approach to storytelling, promising to offer fresh insights months. The new hosts are com- mitted to continuing the legacy of Breaking Down Boxes by delving into the personal and professional stories that make the independent packaging sector so vibrant.
Jeff Pallini
fer’s unplanned but rewarding entry into the box business, the episode is filled with stories that resonate with the challenges and triumphs of the independent sector. Listeners will also hear from Jeff Pallini, whose career
Simona Georgescu
and dynamic discussions in future episodes. The September episode is just the beginning, with more engaging conversations set to air in the coming
“AICC is fortunate to have such a deep bench that we find multiple hosts that can continue to bring the world compelling stories straight from our great mem- bers,” said AICC President Mike D’Angelo. Tune in at AICCbox.org/Boxes . George Perreira
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Machinery and Handling for the Corrugated Board Industry
StandFast Packaging Invests In SUN Automation, PARA Eleva Palletizer Carol Stream, Illinois based StandFast Packaging, a pro- vider of corrugated packaging and retail displays, an- nounced a mission they undertook recently to optimize their production line. StandFast was determined to find a solution that aligned with their commitment to efficiency and innovation. Founded in 1967, StandFast Packaging continues to op- erate as a family-owned business with Midwestern values. With a network of manufacturing plants and sales offices throughout the United States and Canada, StandFast pro- vides a full range of customized solutions and services that reinforce brands, drive retail purchasing, manage in- ventory and streamline costs and processes. To meet growing demand, StandFast has invested in some of the most advanced machinery, technology and software available. However, as with any growing box plant, there are always opportunities and challenges. “We put a bundle breaker behind our rotary die cut- ter as we were looking to get away from nicked bundle breaks. We were also aiming for higher throughput and efficiency of the line. However, once we installed the bun- dle breaker, we still faced the issue of hand stacking at the back of the machine,” said Jay Carman, President and CEO for StandFast Packaging.
The StandFast team needed a space-efficient solu- tion that could fit around their existing line and electrical box. “Essentially, every solution we tried was too large or
wouldn’t fit because of where our electrical box is located,” Carman noted. This is where SUN Automation Group and their distribution partner, Corrugated Solutions, stepped in. Since 2021, SUN Automation has been the exclusive sales representative and service provider for all PARA ma- CONTINUED ON PAGE 8
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StandFast Packaging (CONT’D FROM PAGE 7)
terial handling systems in the United States, Canada, Mex- ico, the United Kingdom, and Ireland. As a result, Corrugat- ed Solutions had a new line of equipment in their arsenal and recommended the PARA Eleva Palletizer through SUN Automation. “PARA has over 20 plant installations in the USA, with over a dozen systems sold through SUN, and over 15,000 worldwide,” said Michael Klear, President for Corrugated Solutions. “Their proven track record made the Eleva Pal- letizer an ideal solution for StandFast.” With over 15,000 PARA installations globally and SUN Automation Group handling install and service, Standfast was confident moving forward. “Once we mapped it out, we knew it would fit and we needed to give it a try,” said Carman. The Eleva Palletizer is a high-speed, fully automated load former capable of forming almost any combination of patterns and layers without operator intervention. It inserts bottom sheets, tie sheets, and even pallets. With the ad- dition of the patented Satellite system, the Eleva Palletizer can form automated chimney stacks without slowing down high-speed FFG operations. It requires no pits, foundation work, or hydraulics, making it a quick and easy installation. The installation of the Eleva Palletizer took place in ear- ly spring and went smoothly, thanks to the collaborative ef-
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TAPPI Young Professionals, AICC Emerging Leaders Join Forces At SCE TAPPI’s Young Professionals and AI’s Emerging Leaders are joining forces with two SuperCorrExpo events in Or- lando, Florida this week. Following a networking event at the Hyatt Coral Springs before the Opening Night Reception, they will have a training program presented by Ron Sessions of Carolina Container Monday evening (September 9) at the Orange County Convention Center. AICC’s Emerging Leader Program is an exclusive series of training, networking, and leadership opportunities for ambitious professionals (35 and under) in the paper-pack- aging industry. With the opportunities and information available in the program, participants have the chance to grow into proven, reliable future leaders in their company and industry.
StandFast Packaging (CONT’D FROM PAGE 8)
forts of SUN Automation, PARA, and other vendors in the production line. “Everyone collaborated really well, and the SUN and PARA team did a great job,” Carman noted. In fact, Corrugated Solutions also worked with StandFast to integrate a stretch wrapper behind the palletizer. This critical addition was necessary for moving product down the mainline after stacking off the bundle breaker. Since its installation, the Eleva Palletizer has been operational and delivering significant benefits. Carman highlights, “The result was it allowed us to get completely stripped units that we could stack in our whip area. We can now stack six orders in the same area we could only previously stack two. In addition, it cut our labor from three to four people needed to only one person controlling the line.”
DESIGNS THAT INCREASE PRODUCTION
There are typically three Emerging Lead- ers national training/networking events per year, along with various regional and virtual Emerging Leader events. The group cur- rently has 155 members.
The TAPPI Young Professional (YP) Divi- sion is where undergraduate and graduate students, recent graduates, and early ca- reer professionals come together to devel- op their leadership and technical skills, and to build relationships with peers and expe- rienced industry professionals from across the pulp, paper, packaging, tissue, and re- lated industries. They are the gateway to all that TAPPI has to offer as an industry association and a launchpad for young professionals across the industry. Early career professionals in the paper and packaging industry are en- couraged to replay the orientation event to hear from keynote speakers in the industry. For more information about becoming a member of TAPPI Young Professionals or AICC Emerging Leaders, visit yp.tappi.org and aiccbox.org/leader . AICC’s Emerging Leaders networked during the Spring Meeting in Palm Springs, California earlier this year.
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MRP Invests In Koenig & Bauer Rapida 164 UV Press
utation as a premier partner in delivering superior brand experiences through innovative packaging designs. The new press brings additional critical capabilities to help meet customer demands for the highest quality and consistent color. MRP has chosen a full suite of specific
New York, New York based Mill Rock Packaging (MRP) an- nounced a new investment in a Koenig & Bauer Rapida 164 eight-color UV large-format press. The new press will be installed at MRP’s Renton, Washington, facility, which employs close to 200 people. “When we launched Mill Rock Packaging, our goal was to invest in growth-oriented companies with advanced service and product capabilities in the consumer packag- ing industry,” says Allen Ennis, Mill Rock’s Chief Executive Officer. “Koenig & Bauer has been a steadfast partner in our remarkable growth, providing us with the most techno- logically advanced printing presses. Our Renton site has been operating Koenig & Bauer presses since 1990, and we continue to invest in the Koenig & Bauer brand due to the high print quality and fast run speeds. With our latest large-format press on its way, our team members are ex- cited about this new technology and how it supports our commitment to providing quality products in a competitive market.” The company said that the new investment will be a vital asset for both single face laminate (SFL) and folding carton production, the company said. Equipped with the latest automation, monitoring, measuring, and inline color control systems, the Rapida press will bolster MRP’s rep-
color control features, including the industry leading Koe- nig & Bauer QualiTronic inline color management system ensuring consistent color across all production. By integrating the state-of-the-art press, MRP said it is poised to enhance its production capabilities, maintain its leading market position, and continue building a tradition of innovation and excellence in the packaging industry. But, says Ennis, one of the most significant features of the new Koenig & Bauer 164 press is its larger size, en- hancing efficiency for high-volume production of large boxes and increasing overall capacity in the pressroom.
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Superior boxes require precise printing and cutting.
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MHIA Celebrates Global Success Of EVOL Flexo Folder Gluer Hunt Valley, Maryland based Mitsubishi Heavy Indus- tries America (MHIA) Corrugating Machinery Division an- nounced the celebration of global milestones achieved by its EVOL Flexo Folder Gluer. With over 235 units sold in North America and more than 670 worldwide, the EVOL has established itself as a gold standard. The General Manager of Rand Whitney said, “We could have bought any machine we wanted, but it was EVOL all the way.” The Vice President of Operations at President Container added, “I’ve never in my life, on the converting side, had such a good experience.” The EVOL comes in various models, including the 84/400, 100/350, 100/400, and 115/330. It features robust construction to ensure durability and longevity. Its design minimizes waste, making it an environmentally friendly choice. A user-friendly interface simplifies operation and maintenance with less downtime. The EVOL 100/400 DSL model boasts the ability to produce 24,000 boxes per hour (bph), and up to 48,000 bph with the Dual Slotter. It has the capability to switch between jobs in just two minutes. The EVOL features a transfer conveyor with a one-piece vacuum belt and in- dependent drives on each printing cylinder, ensuring the highest quality printing. Mitsubishi’s Lead Edge Feeder
with overlapping wheels in a zigzag arrangement provides accurate feed for any corrugated board. The patented design of the EVOL includes gauging rollers, forming belts with speed control, and automatically adjusted folding guides. These features yield precise fold- ing accuracy, ensuring the production of high-quality box- es. The expanded EVOL AR Library includes a collection of augmented reality-enhanced procedures for the EVOL
100 with step-by-step guidance for machine maintenance. Future developments include tailored procedures for the EVOL 115, ensuring up-to-date instructions for all users. The integration of EVOL Digital Services with Maintenance Agreement Visits (MAVs) provides seamless access to both the EVOL AR and EVOL CBT programs. “We are honored to work closely with our customers and want to ensure they have the best chance at success,” said Christine Little, Director of Sales for MHIA Corrugating Machinery Division. MHIA also offers the Production Improvement Program designed to help maintain EVOL machines to original equipment manufacturer (OEM) specifications.
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Roundtable CEO Group Celebrates 25th Anniversary
When independent converters gather in the same room, the camarade- rie, learning opportunities and sparks of inspiration and ideas have no limits. That’s why some of the brightest minds in the industry decided to make that kind of experience official with the launch of Roundtable CEO Group in 1999. Joseph R. Palmeri of Jamestown Container, who was one of the original members, said that they were all on the same page. They want- ed to benchmark against each other to improve their processes. This was an advantage the integrated companies had the ability to do with
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their many plant locations. Now the independents could lean on each other for support and gain answers to any questions or problems they were having. “We discussed future equipment purchases and who in the group may have had any experience with a piece of equipment that was being considered for purchase. Being in a small group you can get into much more details,” Palmeri said. In addition to Palmeri, the first group included Jay Wertheimer of Wertheimer Box; Brian Buckley of Brian Thomas Industries; Tom Skin- ner of Phoenix Packaging; Roy Allen of Buckeye Containers; Mike Sime of Creative Carton; Tim Alter of Illinois Valley Container; Brad McCros- key of Triple A Container; and CPA Mitch Klingher of Klingher Nadler, who facilitated the group with his late partner, Mort Akerman of M.S. Ackerman & Co. The inaugural meeting took place at the Plaza Hotel in New York City with industry giant Dennis Mehiel, the former CEO and principal The Roundtable CEO Group met at Swing 46 in New York City in July this year to celebrate their 25th anniversary. From left, are Taylor Mooter, Kim Schleich, Elyse Klingher, Dianna Palmeri, Michelle Cabanilla, Joe M. Palmeri, Tony Schleich, Mitch Klingher, Justin Mooter, and Larry Grossbard.
Partner Integrations:
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Roundtable CEO Group (CONT’D FROM PAGE 16)
The Perfect Combo Get Peak Performance From Your Equipment with Matched Component Sets
shareholder of Box USA, as the guest speaker. Palmeri said that it helped that the facilitators were CPAs so they could better understand the numbers. “This group ushered in an era of CEO group forma- tion that is continuing to this day, and while the members changed over time due to deaths, retirements and compa- ny acquisitions, it is still a vibrant entity that gives its mem- bers a powerful tool for collaboration amongst a group of talented converters who do not compete with one anoth- er,” Klingher said. Fast forward 25 years and Klingher still facilitates the group, and though the mission has not changed over the
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.
years, the membership has. The Roundtable CEO Group celebrated their silver anniversary milestone in style in the Big Apple in July. The event included dinner and dancing at Swing 46 on New York’s famous Restaurant Row, “Hell’s Kitchen,” a Broadway show, dinner at Wolfgang’s Steak- house, a tour of President Container in Middletown, New York, and a meeting at the Sofitel Hotel. “It is an excellent collection of successful operators and terrific people, and I am proud to have been able to keep it operating and thriving 25 years later,” Klingher said. Today’s nine-member group, which includes four sec- ond-generation members, includes: Larry Grossbard of President Container Group; Justin Mooter of Viking Paper; Joe M. Palmeri of Jamestown Container; Jenise Harris Cox of Harris Packaging; Jay Alter of Illinois Valley Container; Bob Landaal of Landaal Packaging; Tony Schleich of Law- rence Paper; Andrew Akers of Akers Packaging; and Sahar Mehrabzadeh of Bay Cities. There have been several independent converter CEO groups over the years. Klingher said that eight are still in operation and that he facilitates four of them. The Round- table CEO group generally meets twice a year. Joseph M. Palmeri said that he started attending in place of his father two years ago. “The value is the benchmarking, the information shar- ing, the industry knowledge sharing, and, most important- ly, the friendships,” he said. “The same reasons why the group started 25 years ago.”
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Advanced Equipment Sales: 35 Years And Going Strong
“It’s almost like origami the way they cut and fold, and they have little chips of disposal. We gather them from up to 50 to 70 Packsize machines at a time and then convey that away from the process. So that’s no touching of the scrap, no noise, and no dust,” Jeff said.
Souderton, Pennsylvania based AES, now 35 years in the making, continues to gain traction in the world of scrap col- lection, baling and dust control. As more and more manu- facturers rely on them for critical fire safety and air quality requirements, AES products also help their clients’ opera- tions be more profitable, productive, and sustainable. Their exponential growth, in terms of products, tech- nologies and its people, says it all about the bright future that lies ahead. “Tenfold easily,” said Jeff Dietterich, who founded the company in 1989 with his wife, Jill Dietterich. “We’re ex- panding the AirShark product line, adding new compo- nents and broadening our reach within the packaging in- dustry and outside the packaging industry.” The AES AirShark is a rotary material separator that of- fers high air handling capacity in a compact footprint for in- door and outdoor applications. It is hailed as an alternative to traditional screen separators and bulky cyclones that can eliminate the need for dust collectors. AES has found strong applications for the AirShark with Packsize machines and “Right-sized Packaging on De- mand” solutions used in robotic warehouses. AES piloted a system recently in New Jersey, and the first full-scale in- stallations will happen in California in November.
The AirShark is a vast visual improvement as well. One customer was happy to have old rusty cyclones removed from their roof and replaced with AES’s streamlined air handling equipment with dust flowing only upwards through the collector. At AES, they are always moving forward and that in- CONTINUED ON PAGE 22 Jeff and Jill Dietterich
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FOR IMMEDIATE RELEASE Contact: Thomas Brettschneider VP of Operations (770) 425-3353 thomas@cstsystems.net CST Systems is proud to introduce four new products to our North American partners in the corrugating and converting industries. CST is leading the way for customers to Build a Better Box. Kennesaw, GA – August 19th, 2024: CST Systems invites you to visit booth #1943 at this year’s SuperCorrExpo in Orlando, Florida, from September 8th through September 12th. See the industry’s future as CST Systems introduces four groundbreaking new products to our North American partners. An industry leader in roll pushers, brakes, chucks, and converting knives, CST Systems now has your entire plant covered with the introduction of four products designed to increase line speeds, eliminate warp issues, improve cuts and quality, and, most importantly, save you time and money. Nebula – Moisture Control Technology: The world’s most sophisticated and advanced moisture control system. Nebula’s advanced closed-loop technology utilizes specialized scanners that read the corrugated board’s moisture levels, temperature, and planarity. Nebula reacts to the readings in real-time and automatically corrects any moisture variations using its patented leak-proof moisture control system. This exact, accurate, real-time scanning, combined with targeted zone-by-zone moisture control – spraying only where moisture is needed – ensures reduced starch consumption, flatter board, and increased output by eliminating waste. Revolution – Advanced Hybrid Braking System: Our patented braking system replaces pneumatic energy and recovers and redirects typically wasted energy back into your power grid. This revolutionary technology eliminates heat and dust, ensuring a more sustainable and efficient operation. Beyond its energy-saving capabilities, Revolution offers a wide range of income-generating and plant-efficiency benefits. Consistent web tension and zero maintenance requirements enhance product quality and increase safety. Seamless splicing with up to 25% faster line speeds can generate production increases, ranging up to millions of linear feet annually.
Royal Cut Anvil Covers: CST Systems has partnered with a top European manufacturer of anvil covers – bringing over 40 years of production experience to the table. We are pleased to offer a full line of premium anvil covers for all rotary die cutters and flexos. Our formulation technology has allowed us to maximize and increase the life of covers by improving the material durability, thus optimizing the quality of your die cuts and ensuring proper blade penetration throughout the life of the anvil covers. Surely No-Crush Wheels: Engineered for maximum life and performance, our wheels are designed with specially formulated polyurethane. They provide maximum grip power to drive the corrugated board yet are soft enough to avoid marking the paper. Born from decades of continuous research, exhaustive testing, and development, our manufacturer has developed a product that is heat resistant to your highest corrugating line temperatures and resistant to hits, abrasion, and wear. About CST Systems: For nearly 25 years, CST Systems has partnered with some of the best manufacturers in the world to bring next-generation products to the converting and corrugated industries. CST is the exclusive distributor in North and Central America (except Mexico) for all Renova products and continues to build a strong portfolio of premium and OEM quality products. Since the first inception of CST, exceptional customer service and quick response times have been the cornerstones of CST’s business model as they work to solve customer issues and make the industry stronger, safer, and more profitable. To learn more, please visit https://cstsystems.net .
Advanced Equipment Sales (CONT’D FROM PAGE 20)
to the plant and we capture and put the dust to beneficial secondary uses,” he said. “That is what makes most mod- ern manufacturing operations tick.”
cludes industries outside of box converting and printing that are utilizing next-generation technologies. Currently they are working on a specialized material separator that will support one of the largest electric vehicle battery man- ufacturers in the world. To fully appreciate the origins of AES, it’s necessary to look at Jeff’s background. His career started in the direct marketing printing industry in the 1980s where his talents soon flowed from operations to engineering, helping de- sign in-house printing and converting equipment, electri- cal controls and eventually a scrap conveyance system. With his growing expertise in scrap systems, Jeff soon found himself in demand. At night, it wasn’t unusual for him to be in the shop or even his spare bedroom building panels and working on UL certifications to ensure that his electrical industrial power panels met the standards for safety and proper construction. All his hard work laid the groundwork for developing a product that integrated all the fans, shredders, balers, and dust collector processes into a seamless system that could be sold and manufac- tured. By 1989, Jeff and Jill were well-positioned to start their own company, AES (Advanced Equipment Sales). Several years ago, Jeff said they decided to make one of the integral pieces, the air material separator that sepa- rates the scrap, dust, and air, resulting in a clean, efficient baling operation. “We have clean fresh air flowing back
Box manufacturers see the value of grade segregation as scrap is being generated more and more quickly, he said. “When you have grade segregation, you can manage your return on investment by creating higher value scrap bales to sell. Some of our customers are really dialed in CONTINUED ON PAGE 24 AES Staff, from left, Ben Rudolph, Sales Engineer; Eric Conery, Project Engineer; and William Luong, Draftsperson.
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Advanced Equipment Sales (CONT’D FROM PAGE 22)
on that and run three or four balers just for the purpose of great segregation when they have a particularly high value of material they want to recover.” Jeff said that TAVO Packaging, which produces three grades of paper bales sold to recyclers, is a good example of great segregation. “Fiber prices go up and down, but if you handle it right, you’re always going to come out on the plus side with it,” Jill said. “And having that automation in place, having clean run- ning systems in place, that’s where we help our customers complete that piece of their production because they real- ly can’t run without dealing with the scrap. If you can turn that scrap into a valuable commodity — all the better. Extra revenue in your pocket.”
From left, Jeff Dietterich, President, and Jeffrey Burnley, Vice President of Operations.
AES gets to know its customers extreme- ly well; that’s because their relationship is ongoing. They provide preventive mainte- nance services to keep balers up and run- ning and they operate a 24/7 emergency hotline so that resources can be deployed to them as soon as possible if something goes wrong. “That’s really a big part of our business — supporting that customer from the time we do that installation and throughout the service life of the equipment,” Jill said. “We really pride ourselves on having that holistic relationship with that customer. We want them for life, and we want to take care of them. Our sales engineers keep in con- tact with that customer to make sure that we can help and support them throughout. They have questions, they call us.” Each box company is unique and that’s how AES treats them. “Every one of them is different. They’re all customized, their equipment and their production and their products and those nuances are important to get right,” she said. Jill’s role at the company spans multiple departments from marketing director and process improvements to insurance and contracts. Jeff said that one of Jill’s most im- portant contributions in the past five years has been integrating Salesforce customer management software into their operations and automated accounting software for better real-time information to gauge com- pany performance in the field. “We need to be able to react in real-time to control costs and to catch potential prob- lems early in the process. We’re big on
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Advanced Equipment Sales (CONT’D FROM PAGE 24)
cess inventory here. We have our shop which is constant- ly funneling through baler rebuilds that we do and some sheet metal fabrication, but we’re a little bit limited until we grow our footprints,” Jeff said.
controls and managing proactively as opposed to reac- tively and Jill has helped us build the tools in-house so that we’re nimbler, we’re more able to respond to different situations so that little problems don’t become big prob- lems,” Jeff said. The Dietterichs say they are bursting at the seams with activity at their plant. They have staff in project manage- ment, engineering, accounting and are fortunate to be in a financial position that allows them to attract and hire the best people. “We’ve got a great team in the field,” Jeff said. “We de- cided to do more with our own installation crews and de- velop that talent in-house so we’re less reliant on outside crews. We can improve our margins and improve our qual- ity by doing that. That was one of our goals for this past year is to reinvest in people.” Originally, AES operated in Langhorne, Pennsylvania, then nearby Skippack before building a facility in Souder- ton, Pennsylvania, 34 miles north of Philadelphia, in 2001. Jill said the area has changed over the years to their ad- vantage in terms of land values and major highway access, which fuels the number of distribution center warehouses in the region. “We’re really stretched to the max; we do some of our manufacturing offsite. We have a lot of storage offsite be- cause we don’t have the space to store our work-in-pro-
An AirSHARK unit completed and ready for delivery.
Situated on three acres in a 10,000-square-foot facility, the Dietterichs already have plans drawn when the time is right to expand their headquarters. Though the Dietterich’s offspring are not in the busi- ness, AES has a multi-generational family feel with sec-
CONTINUED ON PAGE 28
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Advanced Equipment Sales (CONT’D FROM PAGE 26)
ond-generation employees in the management ranks. “We know that pedigree and we want to develop that next generation,” Jeff said. He loves to see their enthu- siasm for the capabilities of their product, their compet- itiveness, and the ultimate excitement when a customer selects their equipment. Additionally, there are employees in their twenties with mechanical aptitudes who are inter- ested in learning from the ground up. “We have some very talented young people here and we’re looking to get younger, intentionally. We need smart young talent and that’s what we’re trying to attract,” he said. At AES, they are always moving forward and that in- cludes industries outside of box converting and printing that are utilizing next-generation technologies. Currently they are working on a specialized material separator that will support one of the largest electric vehicle battery man- ufacturers in the world. For more information about AES, visit advancedequipmentsales.com . Rusken Announces New Warehouse Facility In Portland, Tennessee Cullman, Alabama based Rusken Packaging announced continued expansion with a new warehouse site in Port- land, Tennessee. The new facility supports Rusken’s con- tinuous commitment to invest in resources to support its
customers’ needs and is dedicated to further serve Port- land with Just-in-Time (JIT) delivery and Inventory Man- agement. “We are extremely excited to expand our service area to include the I 65 corridor. While the immediate need was to provide daily service to a new client, we now have the ability to capitalize on other new opportunities in the area,” said Rusken Regional General Manager Jim Baker. Managing the new Portland warehouse acquisition will be tenured Clarksville, Tennessee employees Charles and Stephanie Yates. Rusken is a integrated packaging company operating 19 facilities in 10 states serving multiple industries includ- ing E-commerce, automotive, agriculture, food and bever- age, and general manufacturing. For more information, visit rusken.com .
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G.F. Puhl Partners With Sonoco On Scrap Handling System
cart and conveyor while the baler was in production. With careful planning, skilled engineering, and close collaboration, G.F. Puhl and Sonoco completed the instal-
lation with minimal downtime. The benefits were immedi- ate. The G.F. Puhl system re- duced energy consumption and cost Vs a conventional air conveyed system by utilizing a sequential system opening the vacuum at the collection points only on an as-needed basis while maintaining con- veying velocity and pressure balancing throughout the sys- tem. This innovative design reduced total system size and CFM by approximately 60 percent. The whole-can sequen- tial system was designed by G.F. Puhl’s engineering team
G.F. Puhl Company and Sonoco recently teamed up to solve a challenging scrap handling dilemma: How do you design, install, and commission a scrap handling sys- tem for a production line that supplies food can products throughout the western hemisphere – and almost never shuts down?
The result is a custom designed one-of-a-kind scrap handling system that evacuates whole paper-based food cans ejected from multiple production lines and multiple pickup points on each line. Cans range in size from ap- proximately 4 inches to 12 inches in length. During the can master tube production process, the G.F. Puhl scrap col- lection system also picks up trim rings at multiple pickup points. In total, the system collects materials at more than 40 scrap collection points. As a condition of purchase, this system had to be in- stalled while the plant was in full production. But that
and tested in G.F. Puhl’s fabrication shop. Approximately 30,000 cans were conveyed through the test system and observed by Sonoco engineers for their input and approv- al prior to system fabrication. Because the product is critical to Sonoco’s operation and very minimal downtime is acceptable, the G.F. Puhl design features a backup system that automatically en- gages when the main system is on maintenance. In addi- tion, all the conveying air is filtered through two filters and returned to the facility at near hospital grade particulate levels.
wasn’t the only requirement. In the existing system, each collection point was serviced by bins on wheels that were manually pushed to a bin dumper loading into a baler. Sonoco wanted the collection hoppers on the new G.F. Puhl system to maintain the same or smaller footprint com- pared to the existing rolling bins. The new collection hoppers had to be easily switchable back to the old system in the event of a breakdown. In ad- dition, the G.F. Puhl system had to deliver the scrap cans and trim rings to the same baler that was using the dump
The Sonoco system includes PLC controls and a remote production floor control panel to facilitate operations. Sys- tem controls monitor when the cans are being ejected to eliminate any jamming issues during the sequential valve cycling process. In a complex scrap collection scenario like this one where so much is at stake, collaboration is key. G.F. Puhl partnered with Sonoco every step of the way. Thanks to an unwavering commitment to teamwork by both parties, this project achieved all its goals.
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