BoardConverting Serving the North American Corrugated and Folding Carton Industries for 38 years October 24, 2022 VOL. 38, NO. 43
Packaging Fulfillment Achieves 30th Anniversary Milestone BY SUSAN RILEY It may be “just a small little family-owned business,” but that has not stopped Middle Tennessee’s only integrated distributor from securing some top-tier clients. Mark Mondelli, Owner and President of LaVergne, Tennessee based Packaging Fulfillment Co., Inc. was working for someone else when he started his career in the packaging industry as a sales representative, mainly in resale and stocking distribution. But Mondelli had more entre- preneurial notions in mind.
Atlas Holdings Acquires Crown Paper Group
Greenwich, Connecticut based Atlas Hold- ings announced that it has completed the acquisition of Crown Paper Group, including Port Townsend Paper Corporation and Crown Corrugated Company, an integrated mill and containerboard operation with a strategic presence in the growing markets of the Pacif- ic Northwest and Western Canada. Terms of the transaction were not disclosed. Port Townsend Paper Corporation is a leading provider of high-quality recycled and virgin kraft containerboard, kraft pulp and specialty products in Port Townsend, Wash- ington. The two converting facilities, known as Crown Packaging and Boxmaster, operate with extensive customer reach and distribu- tion capabilities throughout British Columbia and Alberta. Atlas also announced the appointment of paper and packaging industry executive Ran- dy Nebel as chairman of the Crown board of directors. Nebel has extensive experience in the sector, previously serving as President and CEO of Verso Corporation, a North American producer of graphic, specialty and packaging
“I just knew if you wanted to stay relevant in the distribution or pack- aging industry, you had to start making things,” he said. He started in a 2,000-square-foot warehouse in 1992 selling basic commodities, consumables, stretch film, carton sealing tape, stock box- es, and bags. As the business evolved, his customers began wanting more and Mondelli would need to invest in paper converting equip- ment to do that, not to mention larger real estate. That, however, was never something he shied away from if the price was right. This forward-thinking philosophy has everything to do with where Packaging Fulfillment is today as the company celebrates its 30th an- niversary serving the packaging and shipping needs of manufactur- ers across the state and surrounding area. Among its clients are top tier automotive suppliers. Nissan just dropped an order, and they have CONTINUED ON PAGE 24 Mark Mondelli, Owner and President of Packaging Fulfillment and his son, Jacob Mondelli, Designer and Sales Representative.
CONTINUED ON PAGE 4
WHAT’S INSIDE
6 x x 8 x x 12 x x 26 x x
Enrollment Open For AICC Emerging Leader Program 6 Georgia-Pacific To Close WI Packaging Plant
Manufacturers Unite To Protect Intellectual Property Rights
34 Explain Forest Certification Basics to Your Customers
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.
V I RTUAL
REGION E. Coast Midwest Southeast Southwest
42# Kraft liner
26# Semi-Chem. Medium
$1005.00-1010.00 $1020.00-1030.00 $1020.00-1030.00 $1020.00-1030.00 $1050.00-1060.00 $1023.00-1032.00
Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del.
$940.00-990.00 $955.00-975.00 $955.00-975.00 $955.00-975.00 $975.00-995.00 $958.00-978.00
West Coast U.S. Average
SHEET PRICES BY REGION (AVERAGE) Per 1MSF, local delivery included, 50MSF single item order, truckload delivery. Sheets
From making paper to customer delivery and all “folding carton” points and processes in between, this comprehensive program is everything you wanted to know about folding cartons. BOOT CAMP
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.
November 14-17 paperbox.org/bootcamp
42# Kraft Liner 26#
Semi-Chem Medium
East West
$970.00
$960.00 $995.00
$1,015.00
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October 24, 2022
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Atlas Holdings Acquires (CONT’D FROM PAGE 1)
Core Competency
paper and market pulp, and President of Longview Paper & Packaging, a manufacturer of high-quality container- board, corrugated products, and other specialty papers. "It's always an exciting day when we can welcome a great paper and packaging company to the Atlas Family of manufacturing, distribution and logistics businesses," said Atlas co-founder and managing partner Tim Fazio. "Atlas planted its roots in paper when we were founded with the purchase of a single corrugated medium mill in Indiana, preserving jobs and transforming operations to lay a strong foundation for future growth. Now, more than two decades later, paper, packaging and allied industries remain an important and growing sector for Atlas. We're thrilled to welcome the Crown team and excited to get to work in building an even stronger company." "I have proudly spent my professional life strengthening and growing paper and packaging businesses and could not be more excited to take on this new role as Chairman of Crown Paper," Nebel said. "Our goal is simple; we will be a superb employer, a trusted steward of our communities and a valued partner for our customers and suppliers." Atlas Holdings and its affiliates are a group of 26 man- ufacturing and distribution businesses in the automotive, building materials, business services, construction, ener- gy, food and beverage, industrial services, metals, packag- ing, printing, pulp, paper, and logistics industries.
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© Blower Application Company, Inc., Germantown, WI 2020
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Enrollment Open For AICC Emerging Leader Program
leadership opportunities within AICC, including participa- tion in industry committees like government relations, pa- perboard supply and regulation, and industry education; short and long-term mentorship programs with veteran industry experts; meaningful group presence on the AICC Board of Directors; and creating and executing education- al content for the industry. Companies who support their young professionals in the Emerging Leader Program get the benefit of increas- ingly knowledgeable employees who are developing their soft skills and have an interest in contributing to the health of their company on a high level. Their ELs have a strong network of peers, access to mentorship and advice the industry has available and are establishing the necessary skills to take on leadership roles within the company. AICC Member companies can retain young talent by encourag- ing their employees to participate in the career develop- ment opportunities offered by the EL Program.
AICC, The Independent Packaging Association, has more than 100 Emerging Leaders representing 82 AICC mem- ber companies. The AICC Emerging Leader (EL) Program is an exclusive series of training, networking, and leader- ship opportunities for ambitious young professionals (35 and under) in the paper and packaging industry. With the opportunities and information available in the EL Program, young professionals who are ready to commit to their pro- fessional development will have the chance to grow into reliable future leaders in their company and industry. Emerging Leaders have access to customized training and networking opportunities, both regionally and nation- ally, like on-site workshops, education-intensive field trips, and executive roundtables. They also get direct access to
Applications are welcome from AICC General (boxmaker) and Associate (sup- plier) Members. There is no fee to join the Program, but some events have registra- tion fees. Learn more at www.AICCbox.org/ Leader . Questions can be directed to Taryn Pyle, Director of Education & Leadership De- velopment, tpyle@aiccbox.org/Leader. Georgia-Pacific To Close WI Packaging Plant Atlanta, Georgia based Georgia-Pacific gave notice to the state of Wisconsin last week that it has closed its Oshkosh packaging facil- ity, effective immediately. According to local media reports, the company sent a notice to the Wisconsin Department of Workforce De- velopment on October 17, saying all positions were being eliminated and layoffs are effec- tive on that date but did not give a reason for permanently closing the plant. Some workers will stay on longer to help shut down the plant and operations. Geor- gia-Pacific said it was giving all workers at least 60 days’ pay with benefits in accor- dance with state requirements, including the Worker Adjustment and Retraining Noti- fication (WARN) Act and Wisconsin Business Closing and Mass Layoff Law (WBCML). Georgia-Pacific Oshkosh facility manufac- tured corrugated packaging with a focus on post-consumer recycled material. It operates 45 corrugated facilities in the U.S., including one in Sheboygan, Wisconsin. The compa- ny's website says it has six facilities in Wis- consin, directly employing 2,030 people and indirectly contributing to 5,210 more jobs.
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Southern Champion Tray Makes Leadership Changes
had the experience and skills needed for this succession. “Brad’s background, passion, and commitment to our culture will serve the team well,” says Simpson. “It has been a pleasure watching him positively impact our busi- ness, and no doubt the team will flourish under his leader- ship. Brad is one example of the many blessings that have been bestowed on SCT Mansfield during my tenure.” Greif Signs First Sustainable Financing Agreement Delaware, Ohio based Greif, a global manufacturer of industrial packaging products and services, recently com- pleted its debut sustainable finance transaction as part of its sustainability journey. From the $2.4 million financing package, the $1.8 mil- lion Secured RCF and Term Loan A-1 had the pricing of the loans tied to Greif's sustainability performance, captured via an EcoVadis ESG score. Greif worked with ING Capital LLC, its sustainability structuring agent, to include an innovative feature to the facility which is the option to switch to internally set Key Performance Indicators (KPI) at a later stage, providing ad- ditional flexibility as Greif makes continuous progress on its sustainability targets. "We see the sustainability linked loan (SLL) as a great
Southern Champion Tray has confirmed the retirement of John Simpson, General Manager of its Mansfield, Texas,
facility, effective January 31, 2023. In the past eight years, the Mansfield team has seen tremendous growth, including a major expansion and ren- ovation project and expanded capa- bilities with the introduction of digital print technology and the installation of an HP Indigo 30000 digital press. “John builds deep relationships, leads with humility, positively influ- ences others, and embodies an ex- cellent spirit for our business," said Roy Hibbs, COO. The company has also confirmed that Brad Haralson will be SCT Man- sfield’s newest General Manager, ef-
John Simpson
Under Simpson’s leadership, the Mansfield team has grown from 70 people to 150 team members, expanded capacity with the addition of a third shift, and has more than doubled its sales growth.
Brad Haralson
fective October 1, 2022. He joined SCT in August 2018 as Sales Manager. It was evident from the beginning that he
CONTINUED ON PAGE 10
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Greif Signs (CONT’D FROM PAGE 8)
Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month June 2022
example of 'The Greif Way' in action. It is Greif's commit- ment to sustainability values and standards directly con- nected to finance," said Ana Carolina Oliveira, ING Amer- ica's Head of Sustainable Finance. "What makes this SLL particularly special is the ability to switch the structure to customized sustainability targets later on. As Greif is con- tinually pushing for greater sustainability performance, the structure allows the loans to evolve and track with that am- bition." "We are pleased that ING supported us in securing this innovative finance agreement, demonstrating confidence in our continued commitment to reducing the environmen- tal impact of our products and operations, and contribut- ing towards a more circular economy," added Tony Kra- bill, Treasurer at Greif. "Earlier this year we published our 13th consecutive annual sustainability report and will be announcing our new sustainability targets for 2030 soon." The EcoVadis ESG score examines the performance of a company across four themes: Environment, Ethics, La- bor and Human Rights and Sustainable Procurement. Greif has been awarded Gold Rating by EcoVadis since 2018 and ranks in the top four percent of companies assessed worldwide. Greif has also recently received its new MSCI ESG rat- ing of AA, which is used to measure a company's manage- ment of financially relevant ESG risks and opportunities.
Year
Actual
Percent Change Avg Week Percent Change
2022 2021
34.771 35.948
-3.3
7.903 8.170
-3.3
Industry Total
Year-to Date
June 2022
Year
Actual
Percent Change Avg Week Percent Change
2022 2021
205.855 208.569
-1.3
8.019 8.170
-2.1
Industry Total
Containerboard Consumption (Thousands of Tons)
Year
Month
Percent Change Year-to-Date Percent Change
2022 2021
2.8451 2.9436
-3.0
16.8851 17.0466
-0.9
Container Board Inventory - Corrugator Plants (Thousands of Tons)
Corrugator Plants Only
Date
Percent Change Weeks of Supply
Percent Change
Jun. May
2.4415 2.3469
4.0
3.8 3.6
5.6
Shipping Days
Year
Month
Year-to-Date
2022 2021
22 22
127 126
SOURCE: Fibre Box Association
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KOLBUS RD 115S Fl e x o Rotary Die Cutter Ex cellence in M otion "We have been thoroughly impressed with the machine quality. Simply put – the machine is an engineering marvel . From the 4” thick cast iron side frames, print quality, on-time installation with exceptional training, and after installation support, we couldn’t be more pleased with our investment in the Kolbus RD115S. It’s allowed us to print jobs immediately, that took us years to perfect.” - Steve MacDonald Production Manager, New England Wooden Ware
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Manufacturers Unite To Protect Intellectual Property Rights
Manufacturing associations across almost 40 states joined with the Na- tional Association of Manufacturers (NAM) in calling on the White House to safeguard intellectual property at the World Trade Organization (WTO). The WTO is considering waiving IP rights for COVID-19-related vaccines and treatments—an action that would harm American manufacturers that have led the fight against COVID-19.
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The NAM has previously pushed back aggressively on the proposal, and alongside manufacturers nationwide, it is stepping up its work. In a letter addressed to Secretary of State Antony Blinken, United States Trade Representative Katherine Tai and other senior Biden administration offi- cials, the NAM joined nearly 40 state manufacturing organizations in argu- ing that waiving these IP rights will negatively affect American manufactur- ing—as well as the overall fight against COVID-19. According to NAM, “This proposal would weaken critical global rules for IP protections that support innovation in a range of manufacturing sec- tors by including not only broad new categories of COVID-19 products, but also their upstream supply chains. Furthermore, an expanded waiver allows commercial rivals like China to unfairly seize American innovation to benefit their domestic economies.” Those manufacturing associations argue that IP gives an incentive for manufacturers to broaden research and development and a reason to in- vest in expanding industries. American manufacturers are concerned that the IP waivers would expose them to unfair competition from foreign rivals and would take away employment opportunities from Americans. “Our organizations strongly urge the Biden administration and Con- gress to stand with manufacturers and workers to firmly oppose an ex- panded IP waiver at the WTO," said NAM in a press release. "We stand ready to work with you and your agencies in support of real solutions to the pandemic and future health crises—and to advance U.S. leadership in manufacturing and innovation.” Today, the NAM is still innovating and disrupting an ever-changing na- tional landscape in order to build our industry, create progress and ad- vance the values that make our nation exceptional: free enterprise, com- petitiveness, individual liberty and equal opportunity. We are the one-stop shop for manufacturers, delivering expertise in advocacy, workforce de- velopment, legal action and operational excellence. Visit nam.org .
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Kraft Family Foundation Donates $50M To Massachusetts General Massachusetts General Hospital, a founding member of Mass General Brigham, announced the gifting of $50 million from Robert K. Kraft and The Kraft Family Foun-
more than doubles the previous commitments of the Kraft family to ensure that the highest quality equitable health care is available in all the communities served by Mass General. “On behalf of the hospital, I would like to express our pro- found gratitude to the Kraft family for this transformative and inspirational act of philanthropy, which is not only the largest of its kind in our history, but also the latest highlight of their al- ready lengthy history of support for Mass General,” said David F. M. Brown, MD, president of Mass General. The Kraft family’s gift will support a permanent Robert K. Kraft Endowed Chair in Diversity, Equity and Inclusion ad- dressing health disparities in clinical care at Mass General and can be replicated beyond hospital walls. The chair will be held by the medical director of the Com- prehensive Sickle Cell Disease Treatment Center at Mass General. Research into sickle cell disease (SCD), a serious ge- netic blood disorder primarily impacting African Americans (as well as Latinos of Caribbean ancestry, and people of Middle Eastern or Indian Subcontinent descent), is historically under- funded, leading to inequitable access to appropriate care for this debilitating, painful disease. “With this gift, it is not only our intention to grow and expand the scale of the Kraft Center, but to also help bring increased visibility to the equity issues that exist in therapy treatment and development,” said Robert Kraft, Chairman and CEO of the Kraft Group, which is a group of privately held companies in the professional sports, manufacturing, and real estate de- velopment industries doing business in 90 countries.
dation that will address health care disparities caused by race, ethnicity, geography and economic status. The gift is the largest in support of community health and health equity in the history of Mass General and Robert Kraft, Chairman and CEO of the Kraft Group.
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J.S. McCarthy Invests In Bobst To Earn Folding Carton Excellence Augusta, Maine based J.S. McCarthy, a folding carton printer, is one of the oldest and largest sheetfed printers in the state. Established in 1947, the business is 100 per- cent employee-owned and has a reputation for exemplary service, world-class owner-operators and leading-edge technology. When combined, the result is a high-quality finished product. Established in the high-end commercial print and finish- ing market, the business has expanded to serve the needs of the growing folding carton market, with an emphasis on the food, pharmaceutical, and cosmetic industries. The company attributes this growth to strong direct mill rela- tionships and strategic and continuous investment in tech- nology such as a sheeter, two 41-inch eight-color presses
and a range of BOBST equipment. The business operates from an expansive 150,000 square-foot facility, employing 160 individuals operating 24/7. Jon Tardiff, President of J.S. McCarthy, right, with his talented team of Bobst equipment operators.
DESIGNS THAT INCREASE PRODUCTION
J.S. McCarthy recognizes that, across the folding carton sector, there are a handful of key pressure points for which its experience in commercial printing brings key advantag- es. These include accessing and processing feedstock, reducing lead times, and exceed- ing service levels in challenging market con- ditions. The business uses multiple Bobst solutions, including two SP104-BM machines, which of- fer both die cutting and hot foil stamping ca- pabilities, designed to meet the needs of the folding carton market. With this technology in place, the business is able to die cut and strip in a simple, straightforward workflow. Since purchasing the SP104-BMs, J.S. Mc- Carthy further invested in Bobst solutions, in- cluding two EXPERTFOLD 110 folder gluers, a VISIONFOLD 110 folder gluer, and an EXPERT- CUT 106 PER flatbed die cutter with a second on order, scheduled to be online in late 2023. EXPERTCUT 106 PER provides the produc- tivity that packaging converters need. Along- side effortless precision and perfect stripping, waste removal and batch alignment for blank- ing, EXPERTCUT features a highly productive workflow, enabling job changeovers in under eight minutes. Hailed as the ‘ultimate all-rounder’ in fold- ing-gluing, the VISIONFOLD 110 line delivers consistent quality and handles an impressive- ly diverse range of box styles. The machine processes multi-fold packaging with a choice of left, right or simultaneous folding. With ex- ceptional stability and precise folding, VISION- FOLD is a durable, cost-efficient, and high- speed solution for the folding carton market.
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CONTINUED ON PAGE 18
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J.S. McCarthy Invests (CONT’D FROM PAGE 16)
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Jon Tardiff, President at J.S. McCarthy, said they first expanded into the folding carton market around 17 years ago, and it now accounts for between 60 to 70 percent of their business. “Our goal is clear: we aim to not just meet the printing needs of our customers, but exceed expecta- tions in quality and speed, time and again. To do that, we invest in market-leading technology. “We work closely with BOBST, particularly on our VI- SIONFOLD. At the time it was the only one in the world with a scoring shaft – and it may still be. We use it for a lot of our high-volume greeting cards and self-mailers where we are scoring and plow folding in line.” The company is currently operating three Bobst fold- er-gluers, with plans to add a fourth in the future. “Ultimately, we have a reputation for stellar customer service, and that’s something we’ve worked on over many years. We bring a commercial print mindset to the packag- ing world, and with investments in our technology, we can consistently elevate our service level even further,” Tardiff said. “One of the biggest benefits Bobst offers to the busi- ness is productivity.” Tardiff said they saw a huge leap forward in how much they were able to accomplish in the same timeframe when they switched from their previous machines to Bobst. “We’re talking 30-50 percent improvements in a lot of cases. The IT and digital integration are also a big jump forward for us from a productivity standpoint,” he said. The training available on Bobst die cutters and fold- er-gluers was also impressive. “There is a huge amount of market knowledge, and if a machine can run at 9,000 sheets per hour, they will train you to run it at 9,000 sheets per hour,” Tardiff said. “With a constant point of contact and regular site visits, they’re constantly pushing productivity.” Also impressive was the durability of Bobst equipment. “The machines are built to last and perform at a top lev- el, so the lifetime value is fantastic and that’s quality that you can rely on,” Tardiff said. “Our blanker runs for close to four shifts now, and it’s just made to do it.” The productivity advantages became even clear- er during the pandemic. "As COVID-19 brought a labor crunch, we struggled to find people for the hand stripping of blanks,” Tardiff said. “Bobst EXPERTCUT technology al- lowed us to remain productive and profitable with fewer people. For example, we’d need up to 20 people air-chis- eling and removing waste to keep up with our plant. In- stead, we’re doing it with a blanker. “Bobst is built to last and to perform every single day. You get what you pay for and, with BOBST, that’s produc- tivity and throughput. It performs as advertised, and to be honest, I think it does even more than that.” J.S. McCarthy is a 100 percent employee-owned com- pany, where each member of its team has a vested inter- est in customer success because it directly relates to their success as business owners. Visit jsmccarthy.com .
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Chicago TAPPI’s ‘What’s New’ Program Slated For November 1 Chicago TAPPI invites all suppliers and converters to at- tend its “What’s New” program, which includes dinner, a social hour and a way to connect one-to-one with industry leaders at 5:00 p.m. on Tuesday, November 1 at the Marri- ott Oak Brook in Oak Brook, Illinois. Moderated by Jeff Pallini and Dennis Kaiser, the pro- gram provides information about new technologies, prod- ucts or new and emerging services in the corrugated in- dustry, including:
• Sun Automation: Michael Prassel • Global Boxmachine: Penny Field • Haire Group: Tim Wilson • Fosber America: Tony Battaglia • Bobst: Brian Foley • JB Machinery: Dave Burgess • Digital Print Inc.: Stu Brownell • Kadant Johnson: Ron Buckhold
Each presentation is no more than eight minutes in length and provides important and timely information about what’s new in the industry. The event fee is $100/person for suppliers and $75/ person for converters; dinner is included for all attendees. For hotel information and advance registration, visit the Chicago TAPPI page at tappi.org .
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Truck. Loads. More.
Corrugated printing has gone from basic to beautiful in 10 years. With the explosion of packaging demands and shorter print runs, speed has become the #1 capacity driver.
One of our customers tells us automated complete plate cleaning in < 4 minutes adds 25% capacity in a working week with FlexoCleanerBrush™
He calls it ‘Truckloads More Capacity’. You can do your own math.
AI Expert Richard Boyd To Explore Impacts Of Machine Learning Richard Boyd, CEO and co-founder of Tanjo AI, an award-winning machine learning (ML) company, will join
gence to Drive Manufacturing Insights,” Boyd will join Gil- len Young, Chief Architect for IIOT Solutions at AT&T; and Bryce Austin, CEO of TCE Strategy in offering insights for manufacturing and fabricating decision-makers. Boyd will share his expertise and experience in help- ing companies leverage machine learning and optimize processes across supply and value chains. Specifically, machine learning can be used to continuously ingest and organize all the digital content in supply chain processes to gain key competitive advantages. “In this era of accelerating complexity, prior methods are proving quickly to be insufficient. Fortunately, new tools like AI and Machine Learning are emerging as pow- erful aids to augment our past methods and help automate some of these daunting tasks,” said Boyd. “From preven- tative maintenance and operator training to plant process automation, AI and Machine Learning can impact every process in manufacturing.” Boyd will also address methods for combining AI and Machine Learning technologies with sources of data, na- tive knowledge, and expertise to amplify business intelli- gence to ultimately drive value in manufacturing process- es. “It’s an exciting time for manufacturers of all types,” said Boyd. “I’m looking forward to working with my fellow pan- elists and getting to reconnect with exhibitors and attend- ees at FABtech.” Visit fabtechexpo.com for more information.
an all-star keynote panel to discuss the impact and uses of Artificial In- telligence (AI) and machine learning at FABTECH as part of its FABx Tech Talks on Wednesday, November 9, from noon to 1:30 p.m., at Georgia World Congress Center in Atlanta, Georgia.
Richard Boyd
Boyd was a keynote presenter at TAPPI/AICC Super- CorrExpo in 2021. FABTECH is North America’s largest metal forming, fabricating, welding and finishing event. Boyd is a serial entrepreneur, tech consultant, cele- brated author and sought-after speaker on virtual worlds, computer gaming, machine learning and human/computer interfaces. Boyd is also the co-founder and CEO of Ultisim Inc., a simulation learning company that utilizes gaming technology and AI. Boyd and his teams work with a wide array of industries outside of manufacturing – including energy, healthcare, defense, education and motion pic- tures. Tanjo is a recent XPRIZE semifinalist for its Commu- nity Confidence COVID-19 machine learning dashboard. Entitled “Don’t Get Left Behind: Using Artificial Intelli-
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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Packaging Fulfillment (CONT’D FROM PAGE 1)
been making the boxes for Ford’s glass windshields for several years now. “Our client mix has evolved from small distributors and mom and pop shops when I first started to more corporate customers, some of the big guys,” Mondelli said. And like the big guys — integrated companies like West Rock and Georgia Pacific – Mondelli considers his compa- ny an integrated distributor as well. “We do four things, and we do them pretty well,” he said. "Corrugated Sheet Plant, Slit/Rewind and Sheet Pa- per, Packaging Supplies and Fulfillment Services." Mondelli first bought equipment with sheeting and re- winding capabilities. Then in 2006, he bought the com- pany’s first corrugated piece of equipment. Considered a small sheet plant at this point, the company moved into the integrated world after opening a packaging fulfillment
center. They were no longer limited to just making boxes and selling them as a contract packager, they would also be devoted to fulfilling the needs of large auto- motive components. The 'monster' of the machine lineup at Packaging Fulfillment is the Emba 240 flexo folder gluer.
By doing this, the large boxes are nailed to a skid, filled with the specific dunnage required, capped and shipped to their customers ready to go. Packaging Fulfillment’s dunnage capabil- ities make it unique. Often the packing material is die cut and glued together to make the build- up. To cut correctly, they determine how each product is situated in a box, where the flanges are located, and the distancing requirements between the box and the flange. “No two boxes are the same — everything inside it is different,” Mondelli said. Passing The Shake Test Many of Packaging Fulfillment’s clients are Original Equipment Manufacturers (OEM). In addition to Ford Glass, they box Tesla’s drive components, Nissan’s electric batteries, and Mercedes-Benz and BMW components. Often before OEMs agree to order, they conduct a box trial in which testing — including a shake test and a visual test — is performed to ensure the integrity of boxes. A lot rides on protecting the cargo. For Mondelli, the proof is in the boxes. Consider a Ford-150 windshield. It’s curved, considerably weighty, and susceptible to damage, but Pack- aging Fulfillment has a process. They sandwich the windshield between two pieces of dun- nage that meets together in a perfect marriage of sorts around the product. Then instead of skids, they use corrugated runners that are glued to the bottom of the tray. “It’s not a skid, we eliminated their skid and we’re putting corrugated runners under the bottom of this tray,” he said. “The tray is kind of like a shoebox with a top and a bottom, and
CONTINUED ON PAGE 26
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Packaging Fulfillment (CONT’D FROM PAGE 24)
we notch the runner. We have a little machine that we built so that the customer can slide the strapping under the box through the notches that we made and come back over the top of the box and band the windshield in place.” Equipment & Facilities Over the years, Packaging Fulfillment has grown into bigger and bigger spaces. In 1994, they moved into an 8,000-square-foot warehouse, and in 1997 a 16,000- square-foot warehouse. In 2001, they purchased a 32,000-square-foot warehouse in LaVergne, and he added another 10,000-square-feet in 2006 and another 10,000-square- feet in 2013. Also in 2006, he purchased a 60,000-square-foot warehouse in Portland, Tennessee, where the fulfillment center operates, as well as a scrap removal system. This year, they purchased a 10,000-square-foot build- ing in Madisonville, Kentucky, and next month, they are getting ready to add another 15,000-square-feet to their LaVergne facility. Among his first equipment purchases was a 72-inch bandsaw, a Langston 72-inch rewinder, a Beck 42-inch sheeter, and a Miehle 6/0 flat-bed die cutter. There is also an EMBA 240 43x94 Flexo Folder Gluer, a Koppers rotary die cutter, and two Acme two-headed stitchers that allows them to stitch big boxes twice in opposite corners.
SPECIALTY FOLDER GLUERS • OPERATOR TRAINING • REBUILDS & RELOCATIONS • RECONDITIONING in Kenosha • PARTS & MACHINE REVIEWS • GUARANTEED IMPROVEMENT TOROSIAN TECH SERVICES INC. Training and Reconditioning Center 930 Tenth Street • Racine, WI 53403 (800) 555-5876 (U.S. only) Phone: (262) 633-5133 • Fax: (262) 633-5176
CONTINUED ON PAGE 28
Do you need printed sheets? We have your answer.. Introducing Heartland’s ColorCorr. This is “flexo-printing in the round”. On our corrugator we can print up to 109” wide. The advantage is that we can print the equivalent of ½ roll at a time and not be required to keep several rolls of very expensive preprinted paper on the floor. Much less waste and risk. In continual print mode, we use either laser-engraved rubber rolls or solid rubber rolls to print a “flood coat” or a repeating pattern. If we are printing a repeating pattern, we can run a two-color design on the paper. Customers have found that running sheets we print can allow them to run a lighter-grade due to reduced caliper loss, and in some cases eliminate one or more machine passes.
For more information contact: Charlie Freeman | 816-500-8889 | cfreeman@heartlandsheets.com Tim Kramer | 816-841-8317 | color@heartlandsheets.com
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Packaging Fulfillment (CONT’D FROM PAGE 26)
“It advances the board through the machine, and it stitches the top two panels together and it stitches the two bottom panels together for one pass. You just have to send it through the machine one time,” he said. The two-headed stitcher complements the company’s 60x140 Hooper letter press which starts the product. Af- ter it comes out of the letter press, the product is glued or stitched. Back in the 1960s, when the letter press was built, flexo folder gluers didn’t exist so they had to have a way to join the corner of a box to manufacture a joint, Mondelli said: “It’s a beast, it runs great, and it’s almost 60 years old.” Other equipment includes an 84-inch Hamblett sheeter, a 72-inch slitter rewinder, two 42-inch BECK sheeters, and two General gluers.
Work Smarter, Not Harder
Along the way, Mondelli and his team have found ways to work better and more efficiently. They created their own Roll Edge Protector machine which was sparked by cus- tomers who made products with curved or round edges that are susceptible to damage such as medical filter pa- per, air filters and fuel filters. “The big boys already have it, they’re making it them- selves, but we had to figure out our own may to make it and we did and now I have two customers who buy quite a bit of those,” he said. They also have a patented Do Not Stack Wedge, a corrugated cone that protects products from top-loading skids. All In The Family Working alongside Mondelli is his son, Jacob Mondelli, who is a designer and sales rep. Two nephews are also sales reps, Joseph Mondelli and Matt Williams, along with Jaime Jones, an unrelated but valued member of the team. “I just turned 63. I’m talking to my son and my two neph- ews about taking over in the next couple of years. They want to take care of it, and I am okay with that,” he said. In total, there are 39 employees that make up, as Mon- delli describes, his small, little family-owned business. Though he runs the ship, there is still a ‘boss’ that he an- swers to. “My boss is my customers,” he said. The roll edge protector is manufactured in-house to protect irregular-shaped items and prevent damage during shipping.
Material Handling Solutions • Robotic load formers • Prefeeders • Stackers • And more!
alliancellc.com
CONTINUED ON PAGE 30
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It’s time to revolutionize The new CorruCUT rotary die-cutter pushes what is possible
The CorruCUT is designed for high-performance rotary production of die-cut corrugated products with ultimate flexo post-printing quality. You will achieve paramount performance from the latest embedded technology with a brand new operating concept. It is available with the industry's shortest lead time from our factory to your floor. The CorruCUT has a maximum production output of 12,000 boards per hour, including setup while running, integrated remote maintenance for the ultimate uptime, and the easiest machine to operate – the CorruCUT will increase your profitability. Call us to set up a custom demonstration. Koenig & Bauer (+1) 502 310-1368 tom.fitzgerald@koenig-bauer.com koenig-bauer.com
Packaging Fulfillment (CONT’D FROM PAGE 28)
Board Converting NEWS INTERNET DIRECTORY
The People Many of Mondelli’s production employees have been in the corrugated industry for 30 or 40 years. “My production manager is probably 30 years in the in- dustry and his assistant is at least 30 years in the industry and another one of his assistants is probably 35 years in the industry,” said.
ADVANTZWARE www.advantzware.com
Advantzware provides a flexible and comprehensive system to address the business management needs of the independent box business, as well as the ERP re- quirements of full scale packaging plants and integrat- ed companies. With modules for estimating, scheduling, production, inventory and accounting, this scalable sys- tem supports packaging plants that produce corrugat- ed boxes, folding cartons, point of purchase displays, assembled partitions, paperboard products, foam fab- rication, as well as distribution of packaging supplies. AIR CONVEYING CORPORATION www.accfilter.com Air Conveying Corporation is a recognized leader in the in- dustry 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 coun- try and the world. Let us build you the best Trim Removal System you ever had. Contact us today. Amtech offers the industry’s most innovative and compre- hensive corrugated and packaging ERP, integrated sched- uling software, and engineered automation technology. For over 30 years, Amtech has remained at the backbone of successful businesses from the independent box makers to the largest integrateds. We keep our customers competitive in an ever-changing economy with options such as custom- er digital storefronts and workflows, business intelligence, automated scheduling for corrugators, converting and shipping, proactive roll stock and inventory management. APEX INTERNATIONAL www.apexinternational.com AMTECH SOFTWARE www.amtechsoftware.com World’s largest Anilox and Glue & Metering roll manufac- turer, providing the widest selection of corrugated engrav- ings and complementary services. Anilox engraving options available from our North American manufacturing facility include elongated 75°, 60°, 45°, plus Apex’s patented GTT technology. Glue rolls are produced with Hardened Stain- less Steel and a max TIR of 10 µ for Single, Double Facers.
Not all his workers are as seasoned. Some are in their twenties and didn’t go to college but working at Packaging Fulfillment gives them the opportunity to launch a career in manufacturing as a machine operator. “I said, ‘I don’t care what you do, if you ever leave me, but I taught you a trade,’” Mondelli said. “'You are a machine operator, and you can go to work for my competitor or someone else down the road and tell them that you ran a flexo folder gluer or you ran a rotary The backbone of the Packaging Fulfillment operation gathered at the LaVergne, Tennessee headquarters.
die cutter and that’s going to put you in a better position to get hired on if you ever leave because you’ve learned a trade with me.’” Some of his best workers come by word of mouth and reputation. They know someone who works at Packaging Packaging Fulfillment's team includes, from left, Jose Gar- cia, Shipping Manager; Joseph Mondelli, Sales; Jaime Jones, Sales; Mark Mondelli, owner; Katie Emery, Office Manager; Jerry Green, Production Manager; Jacob Mondelli, Design and Sales; and Matt Williams, Sales.
ALBANY INTERNATIONAL www.albint.com
Albany International has a corrugator belt for every appli- cation. Our reputation for durable performance is the trade- mark of the most dependable belts in service today.
CONTINUED ON PAGE 32
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