BoardConverting Serving the North American Corrugated and Folding Carton Industries for 39 years February 6, 2023 VOL. 39, NO. 6
The Critical Steps Needed For A Successful Machine Installation BY RICHARD H. ETRA Over the course of my long career, I have seen excellent machines fail to live up to expectations because of missteps in their installation and startup. A good layout, experienced and motivated personnel, and a generous budget may be insufficient to prevent costly downtime, inef- ficient operation, and production errors. Here are some do’s and don’ts to help make your project run smoothly, efficiently, and successfully.
WHAT’S INSIDE 8 Cascades Launches Packaging For Fresh Fruits, Vegetables 10 Ergonomic Hazard Reviews Are Essential For Box Plant Safety 14 BHS Corrugated NA Announces Appointments, Retirements 24 Supplier Reports: Part 1 Today’s buyers define sustainability in a new way. Packaging manufacturers need to speak their language to be able to make a sale. Xperience presenters will explain the new expectations and how to communicate those solutions to customers and potential customers. Packaging Xperience will also help attendees understand what end users are looking for in retail and e-commerce so they can best help their customers. AICC Packaging Experience Slated For May In Chicago AICC, The Independent Packaging Associa- tion has announced that the AICC Packaging Xperience will take place May 22-24 in Chi- cago. Building on the success of last year’s event, this year’s presenters will answer some of the most challenging questions packaging manufacturers have about their customers. During a series of general sessions, the conference will take attendees into the minds of their customers when it comes to service, design, sustainability, and how to reach them in new ways, like through the right social me- dia channels. Registration will open soon. Direct ques- tions to Taryn Pyle, Director of Education & Leadership Development, tpyle@aiccbox.org or (703) 836-2422.
Planning for a successful machine startup begins with the purchase contract. Insist that machine specifications and capabilities such as reg- istration tolerances and speed curves have been clearly defined in the contract. Then identify representative items that will demonstrate that the machine is capable of operating within these specifications over a range of product sizes and configurations. It is important to include challenging products such as those with unusual flutes, grades, etc. specific to your operation. Define an acceptance trial in the purchase contract, specifying dimensional tolerances, run speeds, etc. for these items. Also, include a schedule for delivery, installation, and startup, and negotiate a penalty for late startup. As with any project, schedule the tasks based on a realistic time- line, paying particular attention to the task sequence and critical path. Solicit input from all vendors and contractors and get their buy-in for this schedule. Be sure to review it frequently and adjust as necessary, keeping all players aware of revisions to ensure that material and per- CONTINUED ON PAGE 18
2 February 6, 2023
BCN Again Adjusts Prices On Kraft Liner After Input From Converters After receiving multiple reports from North American con- verters, Board Converting News is readjusting the price of 42# Kraft Liner to reflect a $50/ton increase from its pre- vious published pricing. The updated chart, left, reflects the average amount PAID by North American converters in specific regions of the U.S. and Canada. Converters who wish to report their PRICES PAID can contact Len Prazych at lprazych@nvpublications.com or (518) 366-9017. AF&PA Supports Federal Legislation To Strengthen U.S. Transportation AF&PA President and CEO Heidi Brock issued the follow- ing statement in response to The Safer Highways and In- creased Performance for Interstate Trucking (SHIP IT) Act recently introduced: “This legislation will provide more flexibility and reliability to the forest products industry for receiving products integral to the papermaking process. Reliable transportation helps deliver our essential prod- ucts to their final destination faster and more efficiently. We look forward to working with our partners in the Ship- pers Coalition and on Capitol Hill to move the SHIP IT Act forward in the 118th U.S. Congress.” Visit afandpa.org .
AVERAGE CONTAINERBOARD PRICES The average prices reported are tabulated from prices PAID by various sources throughout the United States the week previous to issue. Prices in some areas of the country may be higher or lower than the tabulated average. The prices tabulated here are intended only for purposes of reference. They do not connote any commitment to sell any material at the indicated average. Transactions may be completed at any time at a price agreed upon by seller and purchaser.
REGION E. Coast Midwest Southeast Southwest
42# Kraft liner $ 9 55.00-960.00 $ 9 70.00-980.00 $ 9 70.00-980.00 $ 970.00-980.00 $ 1000.00-1 010.00 $ 9 73.00-983.00
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.
42# Kraft Liner 26#
Semi-Chem Medium
East West
$9 2 0.00 $ 96 5.00
$9 1 0.00 $9 4 5.00
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GBP Third Dimension Invests In New Kolbus Hycorr Rotary Die Cutter Green Bay Packaging’s Third Dimension division, a leading provider of corrugated converting solutions, has invested in a three-color Kolbus Hycorr 135-inch rotary die cutter. This reliable and reputable machine will significantly in- crease the company’s production capabilities and improve overall efficiency in the manufacturing process of corru- gated board converting. The Kolbus Hycorr 135 is specially designed to handle high-volume, high-speed production with precise printing and die cutting capabilities, and it can handle a wide range of corrugated board and thicknesses.
The new machine will also enhance the company’s abil- ity to offer a wide range of custom packaging solutions, as well as provide cost-effective and high-quality packaging solutions to its customers. The new machine was installed in November of 2022 and is up and running at the Green Bay Packaging’s Third Dimension plant in Geneva, Ohio. “We are very excited to add the Kolbus Hycorr 135 ro- tary die cutter to our arsenal of cutting-edge equipment,” said a spokesperson at Green Bay Packaging Third Di- mension. “This machine will enable us to increase our pro- duction capabilities and improve our efficiency, allowing us to better serve our customers and continue to provide them with the highest-quality packaging solutions.” “The Hycorr 135 is perfect for the high-volume produc- tion at Third Dimension,” said Art Crawley, Sales Manager, Kolbus America. “We are thrilled to see Green Bay Packag- ing Third Dimension investing in Kolbus Hycorr and know it will greatly benefit their business.” Established in 1933, Green Bay Packaging Inc. is a family-owned, vertically integrated manufacturing com- pany consisting of corrugated container plants, a folding carton facility, recycled and virgin linerboard mills, pres- sure-sensitive label roll stock plants, specialty converting operations, timberlands, and a sawmill facility. Green Bay Packaging is dedicated to the development of its products with a focus on safety, sustainability, quality, and continu- ous improvement throughout all 38 facilities in 16 states.
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AF&PA Releases Containerboard, Boxboard Quarterly Reports AF&PA has released its Q4 2022 Containerboard and Boxboard quarterly reports. According to the report, total containerboard production decreased five percent when compared to the full year of 2021. Most containerboard grades experienced double-digit percentage declines in Q4. Drops in both domestic and export production contrib- uted to operating rates in the 80s and in some cases the high 70s, bringing the 2022 operating rate five points be- low that of 2021. Recycled Medium was the only subgrade that had a single-digit percentage drop (-9 percent) and an increase in export production for the quarter, though ex- ports represent a very small portion of its total production. Total Boxboard production in Q4 decreased three percent compared to Q4 2021, but 2022 production was up one percent when compared to the same 12 months of 2021. The boxboard operating rate was 87.8 percent, down when compared to Q4 2021 and for the year-to-date. When comparing 2022 to 2021, production of Sol- id Bleached Boxboard and Unbleached Kraft & Gypsum were both essentially flat while Recycled Boxboard pro- duction was up two percent. To purchase he complete report with detailed historical data, contact Kory Bockman by calling (202) 463-4716 or by emailing Statistics_Publications@afandpa.org.
Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month December 2022
Year
Actual
Percent Change Avg Week Percent Change
2022 2021
30.124 34.180
-11.9
7.927 8.545
-7.2
Industry Total
Year-to Date
December 2022
Year
Actual
Percent Change Avg Week Percent Change
2022 2021
400.520 416.189
-3.8
7.979 8.291
-3.8
Industry Total
Containerboard Consumption (Thousands of Tons)
Year
Month
Percent Change Year-to-Date Percent Change
2022 2021
2.4260 2.7360
-11.3
32.5461 33.8321
-3.8
Container Board Inventory - Corrugator Plants (Thousands of Tons)
Corrugator Plants Only
Date
Percent Change Weeks of Supply
Percent Change
Dec. Nov.
2.2603 2.2586
0.1
3.5 3.6
-2.8
Shipping Days
Year
Month
Year-to-Date
2022 2021
19 20
251 251
SOURCE: Fibre Box Association
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Cascades Launches Eco-Friendly Packaging For Fruits, Vegetables Kingsey Falls, Quebec, Canada based Cascades an- nounced the launch of a new closed basket made of recy- cled and recyclable corrugated cardboard for the produce sector. An alternative to food packaging that is difficult to recycle, this new product is the latest addition to Cas- cades’ line of eco-friendly packaging. Designed using recognized eco-design principles, Cas- cades said the product is in keeping with a circular econ- omy approach. By using recycled corrugated cardboard in its design, the product is designed to support its cus- tomers efforts to reduce their environmental impact while meeting consumer demand for increasingly eco–friendly packaging. The result of the work of a multidisciplinary team, the new design allows for flat shipping, thereby reducing trans- portation costs and the need for storage space. A mount- ing jig, designed specifically for both basket formats, also helps speed up and simplify operations for producers. The product has multiple customization options to help produce brands stand out on the shelf with flexographic, lithographic and digital printing options. “This new corrugated basket for fresh fruits and vege- tables reiterates our commitment to offer innovative prod- ucts that meet the highest standards of environmental re-
sponsibility. This launch is also in line with the commitment we made in our Sustainability Action Plan to ensure that 100 percent of our packaging is recyclable, compostable or reusable by 2030,” said Mario Plourde, President and Chief Executive Officer of Cascades.
The closed corrugated basket for fresh fruits and veg- etables recently pre-qualified for the How2Recycle pro- gram, to help producers obtain certification. The basket was also a finalist in the Sustainable Design category for the 2023 PAC Global Awards, the Prix Innovation en alimentation 2022, which is awarded by the Conseil de la transformation alimentaire du Québec, as well as the Grands Prix DUX 2023, eco-packaging initiatives.
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Ergonomic Hazard Reviews Are Essential For Box Plant Safety BY CHASE KAMMERER Amazon was recently cited by the Occupational Safety and Health Administration (OSHA) for ergonomic hazards and other safety risks.
wait for an OSHA visit to take another look at your safety policies to address Musculoskele- tal Disorder (MSD) injury risks to team members. Ergonomic interven- tions have proven ef- fective, including mod-
Federal safety inspectors con- cluded that the twisting, bending, and long reaches that Amazon warehouse workers perform as much as nine times per minute put them at high risk for lower back in- juries and other musculoskeletal disorders.
ifying existing equipment, modifying work practices, and offering new tools or devices to assist with production. These changes can reduce physical demands, elimi- nate unnecessary movements, lower injury rates, and as- sociated workers’ compensation costs, and reduce team member turnover rates. So, what types of ergonomic prob- lems are typical in manufacturing jobs, and what can em- ployers do to help prevent injury and stay on top of worker safety?
Chase Kammerer
While unfortunate, this news is an excellent reminder to review ergonomics, safety, and health at your plant. Don’t
Some of the ergonomic problems that are typical in manufacturing jobs include strained postures, overexertion, repetitive actions, fixed postures, and vibrations. Some simple solutions for box plants include using devices to avoid lifting and carrying when possible, using material han- dling carts to reduce the injury risk factors of carrying items by hand, using pneumatic roll pushers to minimize efforts and strains, and promoting good body mechanics. Changing the movement behavior of workers can be made more enticing through safety wearables, small devices worn or placed on the body to collect real-time data. The sensors on safety wearables provide real-time audible and vibration feedback to problematic movements and cumulative risks. Read more about the benefits in a re- cent article from ehstoday.com . You can find a more comprehensive list of wearable safety tech companies at tracxn.com . And calculate the ROI vs. lost time and medically consulted injury costs to see how viable they might be. It is also worth checking out case stud- ies on the Soteranalytics website or other technology-based safety companies like Kinetic. This technology not only tells you where ergonomic issues may exist but also shares information with the team member about their habits and provides ergonomic tutorials on performing repetitive tasks. Be aware the federal government seems to be getting tougher on ergonomics is- sues. Start evaluating solutions today. Chase Kammerer is the Technical Ser- vices Manager at FBA. Reach him at ckam- merer@fibrebox.org.
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Superior boxes require precise printing and cutting.
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ARC Int’l Appoints Josh Kiser To Regional Technical Services Team Charlotte, North Carolina based ARC International an- nounced that Josh Kiser will join the Regional Technical Services team to provide customers with print support. Kiser’s 20 years in manufacturing and printing includes ex-
The Perfect Combo Get Peak Performance From Your Equipment with Matched Component Sets
pertise with industry leaders world- wide. He looks forward to provid- ing technical expertise in printing applications, anilox rolls, chemicals, and color matching equipment. He graduated from Western Carolina University with a Bachelor of Sci- ence in Business Administration Management. He holds certifi-
Josh Kiser
cations as a Flexographic Technical Association Level III Implementation Specialist, Industrial Time Study Methods and Procedures, Six Sigma, and Kaizen Project Manage- ment. Reach Kiser at JKiser@ARCInternational.com. TAPPI 2023-24 Academic Scholarship Deadline Set For February 15 Each year, TAPPI offers multiple scholarship opportunities to graduate and undergraduate students in corrugated and packaging related programs. There are several Technical Division scholarships totaling nearly $60,000 available for 2023-2024. Applications are due February 15, 2023. This is a great time to encourage interns and co-op stu- dents to apply for the TAPPI Corrugated Packaging Divi- sion scholarships, including: • $10,000 from the Terry S. Paulson Memorial Fund will provide two $5,000 scholarships for students pursuing careers in maintenance or engineering for the corru- gated industry. • $5,000 from the Joe Dieffenbacher Memorial Fund will grant one $5,000 scholarship to a student pursuing a career in engineering for the corrugated industry. Additional $1,000 scholarships will also be presented and are sponsored by the Bobst Group, Mitsubishi Heavy Industries, and WestRock. TAPPI also offers the William L. Cullison Memorial Schol- arship, in amounts of up to $4,000, for undergraduate stu- dents majoring in pulp and paper science. There’s also a new $1,000 TAPPI Diversity, Equity, and Inclusion Scholar- ship that was established in support of underrepresented populations which include, but are not limited to African American, Native American, Hispanic, Latinx, Asian Pacific Islander, LGBTQ+, and People with Disabilities. There are three $1,000 scholarships available this year. TAPPI encourages students to apply for all of the schol- arships for which they may qualify. To access scholarship applications and guidelines, visit tappi.org/scholarships or contact the Awards Department at awards@tappi.org.
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
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ARC.5pBCN_AnlxChmbr.indd 1
3/31/21 6:09 PM
BHS Corrugated NA Sales Department Announces Organizational Changes
Greg Grdinich, Vice President of Sales at BHS North America, has an- nounced organizational changes that have taken place within BHS’s North American Sales Team over the past year. Chris Weaver has been promoted to National Sales Manager. Chris pre- viously served as the Northeast Regional Sales Manager. He will now be responsible for the day-to-day sales activities within the USA and Cana- da. In addition to Sales activities, Chris will continue to oversee the North America Project Engineering Team.
Packaging ERP Algorithmic Scheduling Web-Based Access Online Customer Portals Paperless Workflows Mobile Sales Systems Digital Signage Production Monitoring Mobile Logistics Analytics & Reporting Cloud Hosting IT Management Services Cyber Security Management
Chris Weaver
Scott Kimlinger
Tony Leckie
Gregg Bryan
Rich Pyott Sr.
Ken Normann
Brad Johnson Pat Ciambruschini
Scott Kimlinger recently joined BHS Corrugated as the Southeast Re- gional Sales Manager. Scott comes to BHS with many years of industry experience. He previously worked for Avista, Qualitek, and most recently, Amtech. Scott will be responsible for managing accounts in the Southeast area as well as selected national key accounts. Tony Leckie joined BHS as West Regional Sales Manager. He comes to BHS with a wealth of corrugated industry experience. Tony is responsible for managing accounts in the Western Region and is the source for infor- mation on all products offered by BHS Equipment, Corrugating Rolls and Life Cycle products. Gregg Bryan joined BHS as Technical Sales – Upgrades. Gregg comes to BHS with a significant amount of experience in the corrugated industry. Gregg was previously with Southern Container, CorrChoice, KapStone, and most recently, WestRock. In addition to the recent promotions and new hires, we would also like to recognize those employees who recently retired after long, successful careers with BHS Corrugated: Rich Pyott Sr. retired from BHS as of the end of 2021. Rich’s career in the corrugated industry started with Southern Container. Rich worked for many years as a Senior Service Technician/Installation Supervisor for The Langston Corporation. He came to BHS Corrugated in 1997 and initially served as a Senior Service Technician and then later as an Installation Supervisor. Rich’s last role with BHS was as Senior Technical Sales – Up- grades. BHS would like to thank Rich for all his dedicated years of service and wish him well in a much-deserved retirement. Ken Normann effectively retired at the beginning of 2022. Ken enjoyed a long and successful career in our industry. He started his career with The Langston Corporation and spent time with Bobst and EMBA prior to joining CONTINUED ON PAGE 16
600 + Plants 60,000 Users North America Latin America
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BHS Corrugated (CONT’D FROM PAGE 14)
BHS Corrugated. We thank Ken for his years of service and wish him well. Brad Johnson recently retired from BHS the end of Oc- tober 2022. He enjoyed a long and successful career at BHS and within the corrugated industry. Brad started his career with The Langston Corporation and came to BHS Corrugated in 2000. Brad was the sales professional re- spected by colleagues and customers alike. We wish Brad well in his retirement. Pat Ciambruschini retired from BHS at the end of 2022 after 26 years of service. Pat joined BHS Corrugated in early 1997 after working several years with The Langston Corporation and prior to that, Koppers. He was first em- ployed as Sales Manager and in 2002 assumed the role of V.P. Sales & Marketing for BHS North America. Pat was a key part of the transformation of BHS from the original office on Lord Baltimore Drive to our first expansion to our previous location on Yellow Brick Road. He witnessed BHS Corrugated North America grow from eight people to the thriving organization it is today. We are sad to know that Pat will not be working with us on a daily basis, but we are excited for him and his wife Kathy as they embark on the next chapter of their lives. “I want to thank our retirees for their years of loyal ser- vice to the company and look forward to working with our new sales leaders for many years to come,” said Grdinich.
Brand Owners, Converters & Decision-makers Read BCN
Share the story of your company’s success with an ARTICLE in Board Converting News. The corrugated and folding carton industries are waiting!
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Machine Installation (CONT’D FROM PAGE 1)
Additionally, your sales force, customer service, and suppliers must be educated as to tooling requirements. If you have been using 0.250-inch plates and are switch- ing to thin plates used by most state of the art equipment, or have been using Matthews mounting strips and your new machine uses proprietary strips, be sure everyone is aware of these facts, and that existing plates may be un- suitable for your new equipment. Are your existing cutting dies compatible with the quick mounting system on your machine? Do you have nomi- nally 37-inch and 50-inch machines and wish to be able to use the 37-inch plates on the larger machine? If so, be sure that the mounting station on the large machine is positioned correctly, and that everyone understands how to order plates to ensure interchangeability. For example, don’t mount jobs that are suitable for your 37-inch ma- chine on 50-inch backing, as that will preclude your run-
sonnel arrive when needed during the installation and startup phases. Next on the list is to review ink, adhesive, and tooling specifications with your suppliers well in advance of the installation. Purchase tooling from vendors who have ex- perience with your type of machine and whose tooling has a proven track record of performance. Once you have experience with your machine, you can experiment with lower-cost vendors, but don’t complicate your startup with problems resulting from your tooling manufacturer’s inex- perience or quality. Be sure sheet suppliers – either your corrugator or sheet feeder – understand your requirements concerning bottom and tie sheets, bale heights, and other consider- ations that can affect prefeeder performance and waste.
ning them on the smaller machine and limit flexibility in scheduling, and restricting them to a slower machine. I have found it is very important to train your sales force and customer service about machine capabilities, how they differ from those of previous equipment, and how to assign jobs to the appropriate machines based their sweet spots. Remember to design jobs to machine capabilities and scrutinize existing jobs that run frequently and in large volume for potential efficiencies created by your new machine’s features. Within reason, don’t re- strict the machine (e.g. number out, config- uration, trim, and flute direction) based on existing tooling and perceptions, and con- sider replacing tooling to take advantage of these machine capabilities. Revisit and optimize specs that can affect productivity such as number in bundle, bale height, and stacking pattern. What not to do is as important as what should be done! Don’t plan on using exist- ing tooling unless caliper, mounting, etc. are compatible with your new machine, and they are in excellent condition, as this is false economy. Similarly, replace tooling if changing the number out, layout, and con- figuration will allow you to produce more efficiently. Although reconditioning of tool- ing by its manufacturer may be an option in some cases, this should be done judiciously to ensure that this is money well spent. Lim- it the quantity of new tooling until you have enough experience to be comfortable with specifications and performance. In advance of startup, contact your ma- chinery vendor and other industry contacts
CONTINUED ON PAGE 20
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Machine Installation (CONT’D FROM PAGE 18)
Be sure that vendors have been given secure remote ac- cess to their equipment for troubleshooting, downloading software, and monitoring. Some vendors do not preload their equipment with essential operating programs and must download them when the machine is in place. When you are ready to start up your new machine, be sure to have trainers for the machine and its peripherals (e.g. prefeeder and stacker), the actual crews assigned to it, and a sufficient number of disparate jobs, complete with board and tooling, to keep the machine running through- out the training period and for your acceptance trial. Use new tooling and fresh ink for your training and trial and be sure your board quality is good and delivered in a man- ner suitable for your equipment. Schedule technical rep- resentatives from tooling and ink suppliers to be on hand at startup to make any necessary adjustments. The objec- tive is to start up your machine with a minimum of disrup- tion, and keep it operating continuously; interruptions and downtime due to supplies are unwelcome distractions. Starting up a new machine requires planning, coor- dination, and – last, but not least – patience. Once it is installed and powered up, management often pushes for production to ramp up immediately. Understandably, this may be motivated by a desire for the machine to begin earning a return on investment, or by the need to get the backlog under control after the disruption caused by the installation. Whatever the motivation, resist the temptation
to learn about best performing machines and request actu- al production statistics. Establish set-up and run standards based on best industry performance. Arrange visits to one or more of these locations and bring operating personnel to observe the operation; not only will this familiarize them with the machine, but it will demonstrate that the proposed standards are achievable. If feasible, arrange for your crew to train at another facility while awaiting your machine’s installation. Develop best practices for set-up; delivery of board, tooling, and supplies; and layout of tools and sup- plies at the machine center for maximum efficiency. Selecting the right crew can make all the difference. Just because someone has been operating a flexo for twenty years is no indication that that person has the tech- nical proficiency and hustle to run current machinery at design speeds. If a crew underperforms, replace them promptly before their performance becomes the de facto standard. Similarly, don’t hesitate to change procedures, and tooling and ink suppliers that are inhibiting perfor- mance. Once undesirable procedures and performance have been established, it is very hard to unlearn them. Prefeeders, stackers, conveyors, bundlers, and unitiz- ers should all be functional when the machine is started up as failure to have them operational will prevent the crew from learning proper procedures. All plant utilities includ- ing scrap system, IT, and networking must also be in place.
CONTINUED ON PAGE 22
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Machine Installation (CONT’D FROM PAGE 20)
learn will be the basis for optimizing how to design and run jobs in the future. If you don’t experiment now when train- ers are available, you may not get the opportunity again once full production starts. For example, a new die cutter may be capable of pro- ducing no trim six-out 16” pizza boxes in a 2 x 3 cross-cor- rugation configuration rather than in a conventional 1 x 6 pizza configuration, resulting in a significant speed advan- tage as well as reduced trim. If plant procedures and IT capabilities restrict your ability to be innovative, such as producing two different items on a cutting die, develop solutions or workarounds. No matter how well a project is planned and executed, something unforeseen is sure to occur. Being able to work around obstacles and keep your project on track is argu- ably more important than your planning. Finally, despite having successfully begun production, continue trying new things and optimizing your installation. Don’t dismiss a concept if it’s not successful immediately, as it may require problem solving and several iterations to get it right. Sometimes new ideas don’t work at all; that’s ok. As Einstein said, “Anyone who has never made a mis- take has never tried anything new.” Richard Etra is a 47-year veteran of the corrugated indus- try with extensive experience in all aspects of box plant operations. He can be reached at richard_etra@etracor- rugatedsolutions.com.
to shortchange time allocated for training and familiariza- tion as it is invaluable and an opportunity that will likely never present itself again. It is important to allocate suffi- cient time for training and experimentation, as well as re- sources of crew and machine time, board, and tooling at startup even though that may delay saleable production. Try running jobs in several ways until you have determined the best way to produce them even though you may end up discarding some product and tooling. Consider this to be an investment that will pay dividends for the life of the machine when done intelligently. Don’t skimp on crew and outside training time as it is essential that crews learn how to optimize their machine’s performance in a safe and sustainable manner, and cer- tainly don’t shortchange maintenance training. Inevitably, crews will have questions once trainers have departed and they are left on their own, so schedule follow-up oper- ator and maintenance training to reinforce what they have been taught and to address questions that have arisen. Conduct your acceptance trial. Be sure to document all machine issues, and make sure the manufacturer corrects them promptly, before releasing a final payment. One of the best investments you can make is to allo- cate sufficient time during startup to push its limits. Exper- iment with new ideas such as no trim die cuts, horizontal corrugation, and number out in each direction. What you
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SUPPLIER REPORTS 2023 (PART 1) BHS CORRUGATED Knoxville, Tennessee: Greg Grdinich reports, “First and foremost, we would like to wish everyone a healthy and
“During 2022, we expanded our install base of iMotion products in North America as well as Europe with the start- up of additional systems. You can learn more about BHS Intralogistics and the family of BHS iMotion product offer- ings at www.bhs-world.com . Following the blueprint for Box Plant 2025, the BHS digital printer RSR® (Roll to print- ed Sheet in Real time) continues its path forward. “The BHS digital printer RSR® is installed and running in a box plant, running roll-to-roll as well as directly to the corrugator, keeping with its RSR® name and truly running rolls to printed sheets in real time. Additional installations are planned, so keep your eye open for announcements throughout 2023. It will be an exciting year as we bring this technology to more in our industry. “Box Plant 2025 – Think Beyond” as we say the “Time To Start Is Now.” To learn more about BHS iCorr®, iMotion, RSR® and how Box Plant 2025 can transform your busi- ness, contact your local sales representative. “In 2022 we continued with multiple corrugator installa- tions, which included the full range of corrugator products offered by BHS: 110-inch 1500 FPM Corrugators, 132-inch Corrugators, Dry Ends, Wet Ends, etc. In addition, we in- stalled a number of EF-P single facers. The EF-P is perfect- CONTINUED ON PAGE 26
happy new year as we enter 2023. We enter this year with a very posi- tive outlook for BHS Corrugated. “As we witnessed throughout the last 2+ years, our businesses had to make some quick shifts to adapt to an everchanging world. As men- tioned in previous years, BHS Digital
Greg Grdinich
and Logistics was prepared for the changing dynamics of the world and our industry. Our iCorr® products continue to be rolled out to our customers and our employees at a rapid pace to support their global operations. “The use of iCorr® and iCorr® Assist Glasses allows BHS to bring the technical expertise to site remotely, cov- ering all areas from a service visit to a corrugator start-up. The iCorr® product line with on-line monitoring, data col- lection, remote diagnostics and troubleshooting brings an unprecedented level of technology and support to the box plant at your finger tips 24/7. The iCorr platform and its line of support products are a key contributor to the BHS vision of Box Plant 2025.
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Supplier Reports, Part 1 (CONT’D FROM PAGE 24)
AIR CONVEYING CORPORATION is a recognized leader in the industry of Pneumatic Conveying Systems and has been in business since 1968. As an equipment manufacturer rather than simply a sales organization, we have complete control over the quality of material and products which make up your proposed system. Our equipment is found in Printing, Folding Carton and Corrugated plants throughout the country and the world.
ly suited for a wide range of production solutions and fits well in the portfolio of the existing family which includes the QF-P, AF-P and the MF-A. We have the solution to best fit your needs today and into the future. “Keep an eye out for new corrugator developments to be announced in 2023. It will be an exciting year. With the growth the corrugated industry has seen in recent times, we are fortunate to enter the year with a significant back- log not only for 2023 but also the years following. The in- stallations in 2023 will once again span the entire portfolio of products. “BHS Robotics offering upgrade solutions for non-BHS corrugators as well as robotic solutions in the box plant and beyond is prepared for the future. Installations of the new BHS Robotics Profeeder took place in 2022 and more are planned in 2023. The Profeeder is high speed six-axis robot with a feed rate of 400 BPM. This is just one example of robotic products developed for the corrugated market. For more information, contact BHS Robotics at (630) 784- 0800 or visit www.bhs-robotocs.com . “The development of our “Life Cycle” philosophy and product offerings continues into 2023. We are poised for growth in all “Life Cycle” areas. From full maintenance programs (M2P) to flexible programs (M2P Flex) to audit based programs (TCI), we have the right solution to fit your requirements. As with our machinery growth, so has the M2P product grown. We also have expanded our offerings in Service (ESA) and Parts (Parts+ and Pick and Pay) to bet- ter serve our customer’s needs. Contact your local repre- sentative to find out what products are best for you. “BHS Corrugating Rolls continues to set the industry standard. From consistent quality to industry leading pro- file designs, BHS Corrugating Rolls is positioned to help you in every capacity. BHS continues to be the leader in corrugating rolls in North America and worldwide by pro- ducing the most corrugating rolls with shortest lead times and most importantly, at the highest quality. “The BHS product offerings NICE Rolls® (Not Including Capital Expenditure) and C.A.R.E (Corrugating Roll Cart Ex- change) continue to lead the way by providing a cost-ef- fective solution to corrugating roll management. Not only do these programs alleviate the need for upfront capital investment, but they also take away the burden of corru- gating roll planning and execution. Allow us to review your corrugating rolls and together develop a solution allowing you to optimize production while BHS cares for your cor- rugating roll needs. From full-line corrugators and corrugating rolls along with retrofits and upgrades of existing BHS machinery, we have the solution to fit your production needs now and well into the future. “Time to Start is Now: “Box Plant 2025 – Think Be- yond.” Contact us to learn more. Call (410) 574-1550, visit www.bhs-world.com . E-mail ggridinich@bhs-world.com.
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CONTINUED ON PAGE 28
26 February 6, 2023
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Supplier Reports, Part 1 (CONT’D FROM PAGE 26)
can run all corrugated substrates, it is designed to spe- cialize in micro-flute and high graphics up to 1000 FPM. The “Thermal Dynamic Process” provides a competitive advantage over conventional technology when running these special products. “Fosber America also installed our first Smart SF5 Belt SingleFacer with a quick flute change cassette system in the USA. The Smart SF5 Belt SingleFacer is available up to 1500 fpm and in 98-inches and 110-inches. The SF5 uti- lizes a Teflon-coated non-metallic belt. The design offers precise belt pressure control, reliable tracking and easy accessibility for fast belt replacement. In addition, there is an option to add Water Decks to both the medium and liner side, creating a balanced sheet, void of any warp characteristics. This machine can be seen in production by contacting Fosber and taking a trip to the Midwest. “Tiruna America, Inc. continues to be an industry lead- er in new and refurbished corrugating rolls, pressure rolls,
FOSBER/TIRUNA Green Bay, Wisconsin: Joe Slattery reports, “Fosber Amer- ica would like to thank all our customers for helping us
achieve another record year. Our Green Bay-based Production, In- stallation, Service and Parts Depart- ments, were able to handle all our customers’ needs despite the supply chain and other issues our industry faced. As we enter a new year, we are fortunate to have a healthy back-
Joe Slattery
log to carry us through 2023 and beyond. “In 2022, we installed multiple 1500 fpm full-line cor- rugators featuring enhanced Syncro Control, full ProCare System and full Sound Enclo-sures. We also installed our very first Quantum Corrugator line. While the Quantum line
cartridge rebuilds, parts and service. Tiruna has technicians trained to assist in the in- stallation of corrugating rolls in any make single facer. Also, Tiruna has expanded their cartridge rebuilds, parts (stocking all necessary parts) and service for most types of single facers. Tiruna made some sub- stantial capital investments in 2022, includ- ing a new state-of-the-art grinder to add to our quality and capacity. “Fosber and Tiruna thank you, our ex- tended family of customers, for your contin- ued support. We are proud of our accom- plishments, excited about our future and grateful to work in this exciting industry. Contact Fosber at (920) 339-6100 or www. fosber.com and Tiruna America at (920) 338-6650 or www.tirunaamerica.com . HAIRE GROUP Merrillville, Indiana: Keith Umlauf reports, “The year 2022 was another great one for
Haire Group, thanks to our amazing em- ployees and custom- ers. Haire Group con- tinued to grow and expand. “In addition to our Apstar line of flexo
folder gluers and rotary die cutters and the Encore set-up-while-run line of flexo fold- er gluers and rotary die cutters, we began selling the Engico Jumbo flexo folder gluer. With our expansive line of machinery, we are able to pair clients with the best machin- ery solutions for the best value to meet their specific needs. CONTINUED ON PAGE 30 Keith Umlauf
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