BoardConverting Serving the North American Corrugated and Folding Carton Industries for 36 years April 6, 2020 VOL. 36, NO. 14
Founding Principles Guide General Converting, Inc. BY JACKIE SCHULTZ
FBA: The Industry Must Continue To Function
The Fibre Box Association (FBA) has issued a statement addressing the need for the corru- gated industry to keep functioning during the coronavirus pandemic. “Manufacturers of corrugated cardboard boxes are working to keep transport packag- ing flowing to makers of essential products, including packaging for food and other con- sumer products, medical and pharmaceutical products, tissue and hygiene products and more amid the COVID-19 pandemic,” said Dennis Colley, FBA’s President and CEO. “Corrugated and cardboard packaging is the backbone of the American supply chain. As COVID-19 changes our daily lives, we want to assure consumers that the box industry is continuing to operate and to deliver needed packaging to our customers who supply gro- cery stores, pharmacies, doctor’s offices and hospitals with food and medical supplies to keep us all healthy and safe.” The association says it has joined with the Washington, DC, based American Forest & Paper Association (AF&PA) in encouraging federal, state and local governments to rec- ognize the corrugated packaging industry as
General Converting Inc. (GCI) adheres to a business philosophy that has fostered nearly four decades of steady growth. Located in the Chi- cago suburb of Bolingbrook, Illinois, the independent folding carton manufacturer specializes in the candy and confections market, serving many recognizable household names. It also serves the food, electron- ics, cosmetics, automotive and pharmaceutical industries. Customers are located throughout the U.S.
When Robert and Shirley Ruebenson founded GCI in 1982 they es- tablished core values that continue to this day. The business model ad- vocates a culture of people first. No one has an official title, at least not on their business cards, and a real live person answers the telephone. Employees have a voice and their viewpoints matter, especially when it comes to producing a quality product. “We empower people to make decisions and we make it so that people look forward to coming to work,” Bob Ruebenson, President, says. “If someone has a good idea we implement it.” “It’s a different business model,” adds John Barry, General Manager. “Everyone is treated with a tremendous amount of respect, autonomy and authority. That’s the atmosphere that’s fostered here. Bob always makes sure the environment is positive.” Bob Ruebenson is the second generation owner. He joined GCI From left, GCI President Bob Ruebenson, Karina Fernandez, Braulio Her- rera, Dave Mickiewicz and John Barry in front of the new Bobst Mastercut.
CONTINUED ON PAGE 4
WHAT’S INSIDE 8 ISM: Manufacturing Shrinks, Economy Expands in March 10 AICC Continues Weekly COVID-19 Teleconferences 12 Coronavirus Unlikely To Spread Via Corrugated Packaging 14 Impact Alliance, Carton Craft Win ICG Supplier Award
CONTINUED ON PAGE 24
Thacker Industrial Service Company (T.I.S.CO.) is a machinery and equipment manufacturer that has been providing quality parts and support services to the domestic and global corrugated industry for more than 30 years .
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24/7/365: Error-free, on time and on budget, T.I.S.CO. delivers “turn-key installation of equipment and machinery anywhere in the world.
T.I.S.CO.’s. in-house electrical programmers and technicians can design and install complete electrical control systems for all your corrugated plant equipment. We can also custom design and build specialty equipment to solve your specific production needs. We also manufacture and provide parts and service for the Harper line of products, including wiper blades, print and die-cut sections and digital registers. Reliable. Professional. Dedicated.
FBA: The Industry Must (CONT’D FROM PAGE 1 )
‘essential’ when drafting ‘shelter in place’ orders. “We ask for clear exclusion of our manufacturing operations to limit disruptions to the supply chain,” says AF&PA. “Disruption in the availability of these goods would cause significant hardships to consumers across the country who depend on steady and stable supplies.” The Brussels based International Confederation of Paper and Board Converters (CITPA) in Europe says cross-border restrictions should be avoided in the case of paper and board packaging and the raw materials used to produce them. The organization says its paper and board converter members call on the European Commission and member states’ governments to ensure continued cross-border and intercountry transport of raw materials, goods and packaging.” “The industry urges governments to keep the borders open and to allow continued transport of raw materials and packaging which are vital for the medical and food sectors,” says CITPA Secretary General Angelika Christ, who noted that member states are starting to develop lists of key or critical sectors, and CITPA is calling on them and the European Commission to ensure that paper and board packaging manufacturing and related value chain activities are recognized as such. “It is a critical sector and should be included in the ‘green corridors’ for the free-flowing transport of raw materials and goods,” says Christ.
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Robyn Smith at 910-553-4055 /firstname.lastname@example.org Len Prazych at 518-366-9017 / email@example.com
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AVERAGE CONTAINERBOARD PRICES The average prices reported are tabulated from prices PAID by various sources throughout the United States the week previous to issue. Prices in some areas of the country may be higher or lower than the tabulated average. The prices tabulated here are intended only for purposes of reference. They do not connote any commitment to sell any material at the indi- cated 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 $885.00-890.00 $900.00-910.00 $900.00-910.00 $900.00-910.00 $930.00-940.00 $903.00-912.00
26# Semi-Chem. Medium
Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del. Short Ton Del.
$820.00-850.00 $835.00-855.00 $835.00-855.00 $835.00-855.00 $865.00-875.00 $838.00-858.00
West Coast U.S. Average
SHEET PRICES BY REGION (AVERAGE) Per 1MSF, local delivery included, 50MSF single item order, truckload delivery. Sheets
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OYSTER UP-CHARGE 8.34
275# DBL-WALL 350# DBL-WALL
116.54 137.25 117.82 145.56
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#
AVERAGE CONTAINERBOARD PRICES.indd 1
3/7/19 2:04 PM
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CARES Act To Expand Relief To Individuals, Businesses
The Coronavirus Aid, Relief, and Economic Security Act (“CARES Act”) was signed into law on March 27, 2020. The law is an attempt to address issues at the federal level through economic support to the business sector, employ- ees, individuals and families, and specific industries that have been impacted by the global pandemic, including air transportation, health care, and education. Highlights of the act include immediate tax rebates of up to $1,200 per taxpayer; forgivable, subsidized loansto small businesses; direct loans to the hardest hit industries; the relaxation of income tax rules and deadlines; ongoing financial aid to students, schools, and colleges; and direct stabilization of money market mutual funds. In order to assist small businesses that have seen their operations halted or cut back by the disease itself, public health measures, or loss of business due to the reaction to COVID-19, the CARES Act extends the qualifications for borrowers and the size of loans that are available through the U.S. Small Business Administration. These loans will also help businesses pay for the increased medical, family, and sick leave they will be required to offer employees un- der the recently enacted Emergency Family and Medical Leave Expansion Act and Emergency Paid Sick Leave Act. Visit www.sbc.senate.gov for more information.
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ProDrive eliminates obsolete DC motors with an AC vector upgrade and improves reliability of your equipment. DeviceLogix™ – Controls outputs and manages status information locally within the drive, allowing you to operate the drive independently or complementary to supervisory control. Configure for Your Application – Each drive has a slot-based hardware architecture that educes unnec ssary add-ons and gives you the flexibility to select option cards to suit your application and expand your drive for future needs. Supported hardware control options are common for the series to help reduce your inventory and spare parts requirements. Predictive Diagnostics – Prevent unplanned downtime with predictive diagnostics and built-in protection features to help guard your investment. These settings allow the PowerFlex 750-Series to keep track of information that affects the life of the drive components. PowerFlex 755 drives 250 kW/350 Hp and larger have additional diagnostic features including built-in protection devices. The PowerFlex 753 and 755 AC drives offer more selection for control, communications, safety and supporting hardware options than any other drives in their class.
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ISM: Manufacturing Shrinks, Economy Expands In March
Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month February 2020
Economic activity in the manufacturing sector contracted in March, and the overall economy grew for the 131st con- secutive month, say the nation’s supply executives in the latest Manufacturing ISM Report On Business. The report was issued last week by Timothy R. Fiore, CPSM, C.P.M., Chair of the Institute for Supply Management (ISM) Manufacturing Business Survey Committee: “The March PMI registered 49.1 percent, down one percentage point from the February reading of 50.1 percent. The New Orders Index registered 42.2 percent, a decrease of 7.6 percentage points from the February reading of 49.8 per- cent. The Production Index registered 47.7 percent, down 2.6 percentage points compared to the February reading of 50.3 percent. The Backlog of Orders Index registered 45.9 percent, a decrease of 4.4 percentage points com- pared to the February reading of 50.3 percent. The Em- ployment Index registered 43.8 percent, a decrease of 3.1 percentage points from the February reading of 46.9 percent. “The Supplier Deliveries Index registered 65 percent, up 7.7 percentage points from the February reading of 57.3 percent, and limited the decrease in the composite PMI. The Supplier Deliveries Index is one of five equally weight- CONTINUED ON PAGE 36
Percent Change Avg Week Percent Change
Percent Change Avg Week Percent Change
Containerboard Consumption (Thousands of Tons)
Percent Change Year-to-Date Percent Change
Container Board Inventory - Corrugator Plants (Thousands of Tons)
Corrugator Plants Only
Percent Change Weeks of Supply
SOURCE: Fibre Box Association
April 6 , 2020
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AICC Continues Weekly COVID-19 Teleconferences
AICC, The Independent Packaging Association, after re- ceiving several inquiries from members around the U.S. in response to the most recent developments in the coro- navirus/COVID-19 pandemic, hosted its first weekly video- conference on Friday, March 20. Nearly 400 companies participated. Several members shared the measures they are taking to keep their employees safe, their customers informed, and their operations continuing. Most of the hour-long forum was filled with peer to peer questions and answers. A recording of the videoconference and a copy of the typed “chat” that accompanied it are available at www. AICCbox.org/COVID . AICC held national audio and video conference calls on two subsequent Friday afternoons. The series is scheduled to end with the call on Friday, April 10, at 2:00 p.m. EST. During the calls, AICC presents the latest updates, pres- ents a forum sharing other box makers’ and suppliers’ ef- forts to mitigate the risks in their own companies, provides news on what may be happening in various jurisdictions around the country, and provides training opportunities for those who are not able to travel due to restrictions. Questions about the calls and free online education can be directed to Taryn Pyle at email@example.com.
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Coronavirus Unlikely To Spread Via Corrugated Packaging
A new study from the National Institutes of Health found that the coronavirus could last up to three days on plastic and steel, and 24 hours on cardboard. A March 1 study in the Journal of Hospital Infection found that the coronavirus could last up to four days on wood and glass and up to five days on metal, plastic, and ceramic at 68 degrees Fahrenheit. These periods could be affected by temperature and humidity and the porous nature of surfaces like cardboard, paper money, hair, and fabric. Additionally, shipping condi- tions make it more difficult for the coronavirus to survive. “We know that viruses are likely to only live a few hours to a few days under the sort of conditions we expose packages to, including shifts in temperature and humidity,” McGraw said. According to the CDC website, “There is likely very low risk of spread from products or packaging that are shipped over a period of days or weeks at ambient temperatures.” If you want to be extra cautious, clean packages with an alcohol solution before bringing them into your home. An alcohol-based solution can help you disinfect packages if that will help ease any anxiety you have about the virus. The authors of the Journal of Hospital Infection study suggested using a solution to between 62-71 percent eth- anol alcohol. Solutions with 0.5 percent hydrogen perox- ide or 0.1 percent sodium hypochlorite are also effective, according to the researchers. Spray the solutions on the package, wait five or six minutes, and then wipe it off.
People who are staying home to limit the spread of the novel coronavirus are ordering food, clothes, toiletries, and more to their house instead of going to stores. But some are increasingly worried the corrugated boxes their items are delivered in could be contaminated. Health experts say its unlikely that anyone could con- tract the novel coronavirus from a corrugated box because the virus itself can’t live for an extended period of time on hard surfaces. The coronavirus is spread mainly when an infected person coughs or sneezes and spreads virus-con- taining droplets to another person, so there is very little risk associated with a package dropped off at your home. “If we had transmission via packages we would have seen immediate global spread out of China early in the outbreak,” said Elizabeth McGraw, Director of the Center for Infectious Disease Dynamics at Pennsylvania State Uni- versity. “We did not see that and therefore I think the risk is incredibly low.” “If you want to be extra cautious, you can clean your packages,” said Rachel Graham, an epidemiologist at the University of North Carolina. “There’s evidence the corona- virus can live on certain surfaces for days, but that doesn’t mean you’ll get COVID-19. The amount of the virus that could survive also depends on the material of the surface.”
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Impact Alliance, Carton Craft Supply Win ICG Supplier Of The Year Award
The Independent Carton Group (ICG) presented its Supplier of the Year Award to Impact Alliance LLC and Carton Craft Supply. The award was presented at the ICG’s spring meeting held in Park City, Utah, on March 11 and 12, 2020.
The ICG and its members rate over 30 suppliers on a biannual basis on a series of criteria, including timeliness of delivery, contractual com- pliance, administration/invoicing accuracy, quality of materials, quality of service, expertise of staff, compliance with shipping instructions, and reporting & payments. Rick Myers, Managing Partner of Impact Alliance, receives the ICG Supplier of the Year Award from ICG Executive Director Jay Willie.
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Through the evaluation process ICG leadership works with national account managers from their suppliers to improve the quality of ser- vice each one brings to ICG members. “The bottom line is to get best- in-class suppliers serving our members” says Jay Willie, ICG Executive Director. “That’s what this program is helping assure our members of.” CONTINUED ON PAGE 16 Rick Ruckh, Equipment Sales at Carton Craft, receives the ICG Supplier of the Year Award from ICG Executive Director Jay Willie.
www.boardconvertingnews.com Copyright © 2019 Amtech Software. All rights reserved.
April 6, 2020
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Impact Alliance (CONT’D FROM PAGE 14)
“We are honored to be given this distinction again by such a distinguished group of companies as are in the ICG. Outstanding products and a team of individuals with decades of technical experience is part of the value proposition we bring to ICG members,” says Mark Doxta- der, President and Owner of Carton Craft. The Independent Carton Group (ICG) is a growing association of 20 independently owned and operated folding carton companies from 15 states and Canada. It works to ensure its members have access to competitive pricing on raw materials, equipment and consumables, as well as offering learning and networking opportunities that help them to be successful. For more information on the ICG or to inquire about membership contact the ICG at (203) 270-7578 or e-mail firstname.lastname@example.org. Graphic Packaging Completes Acquisition Of Greif CPG Atlanta, Georgia based Graphic Packaging Holding Com- pany, one of the nation’s leading providers of packaging solutions to food, beverage, foodservice, and other con- sumer products companies, through its primary U.S. oper- ating company, Graphic Packaging International, LLC, an- nounced last week the close of its previously announced acquisition of the Consumer Packaging Group Business from Greif, Inc.
Impact Alliance LLC ( www.impact-alliance.com ) has been a trusted supplier to the ICG since 2011 and is very proud to receive the Supplier of the Year award for 2019. The company provides quality cutting dies and tooling to ICG members and was one of four companies in North America to be chosen by Bobst to be a Bobst Certified Die Maker in North America. The company provides a wide variety of premium steel rule dies, inline embossing dies, counter plates and stripping and blanking tools. Founder and Managing Director of the company Rick Myers sees one of the biggest strengths of his company being his people. “We have some of the brightest and best people in the business who all strive to deliver the highest quality product with the best customer service in the industry,” he says. Carton Craft Supply Inc. ( cartoncraftsupply.com ) was awarded the Supplier of the Year for 2018 and is extremely proud to earn it again in 2019. The company supplies consumable items used to build folding carton and corrugated tooling for flat and rotary die cutters as well as equipment such as Serviform steel rule bending equipment, Boxplan QuickLock upgrades and Boxplan Hybrid-Setter automatic pin and claw setting equipment for dynamic stripping tools. Ninety five percent of the company’s products are imported from Europe from the top manufactures in their respective product categories.
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FFCRA In Effect April 1; CDC Issues Manufacturing Facility Protocols The Families First Coronavirus Response Act (FFCRA) went into effect April 1 and companies with less than 500 employees are all subject to the provisions of this law un- less granted an exception, which is only available to com- panies with less than 50 employees. Vist the Department of Labor website at www.dol.gov to see a list of FAQs and additional resources to ensure compliance with the FF- CRA. In addition, the Centers for Disease Control (CDC) has issued protocols for manufacturing facilities, including cor- rugated and folding carton plants, in the form of a Q&A: 1. If an employee in the manufacturing environment has a confirmed case of COVID-19, what are the proper pro- tocols to prevent community spread? A: For confirmed OR suspected cases of COVID-19, sick employees should follow CDC-recommended steps, which include: • Stay home except to get medical care • Separate yourself from other people in your home – this is known as home isolation. Use a separate bed- room and bathroom, if possible. • Call ahead before visiting your doctor • Wear a facemask if you are sick and one is available • Cover your coughs and sneezes with your elbow or use a tissue • Clean your hands often by washing them with soap and water or using an alcohol-based hand sanitizer with at least 60 percent alcohol. • Avoid sharing personal household items • Clean and disinfect all high touch surfaces daily in your isolation area with an EPA-registered disinfectant. Let a caregiver take care of cleaning and disinfecting high touch surfaces in common areas. • Monitor your symptoms and consult your healthcare provider if symptoms worsen. Be sure to get care if you have trouble breathing, or have any other emergency warning signs, or if you think it is an emergency. Employees should not return to work until the criteria to end home isolation are met, in consultation with health- care providers and state and local health departments. Em- ployees who develop symptoms including fever, cough, or shortness of breath should notify their supervisor and stay home. Employees who appear to have symptoms upon arrival to work or become sick during the day should be immediately separated from other employees, customers, and visitors and sent home. If possible, provide sick em- ployees with a mask while they are waiting to leave and have them wear it in transit until they get home in order to limit spread of contamination. Follow the CDC cleaning and disinfection recommen- dations, including closing off the areas used by the em-
ployee (e.g. their office or work station) as long as prac- tical, and up to 24 hours if possible. Then focusing on cleaning and disinfecting the high-touch, hard/non-porous surfaces: • Dirty surfaces should be cleaned with soap and water prior to disinfection. • To disinfect, use products that meet EPA’s criteria for use against SARS-Cov-2, the cause of COVID-19, and are appropriate for the surface. If an employee is confirmed to have COVID-19 infec- tion, employers should inform fellow employees of their possible exposure to COVID-19 in the workplace but main- tain confidentiality as required by the Americans with Dis- abilities Act (ADA). Employees should then self-monitor for symptoms (i.e., fever, cough, or shortness of breath). If other employees develop symptoms they should follow the guidance above. 2. If a manufacturing employee in a non-production set- ting has a confirmed case of COVID-19, what are the proper protocols to prevent community spread? A: The steps are the same for employees in non-produc- tion settings as in the manufacturing environment. 3. Should a plant shut down as result of a COVID-19 case or outbreak? If a plant shutdown occurs, what is the rec- ommended time offline to disinfect, and what is the ap- propriate timeframe to resume operations? A: The areas used by the sick person should be closed off. It is not necessary to shut down the entire facility. • Wait as long as practical before cleaning and disinfect- ing the affected area to minimize potential for exposure to respiratory droplets. • Open outside doors and windows to increase air circu- lation in the area. If possible, wait up to 24 hours before beginning cleaning and disinfection. • Cleaning staff should clean and disinfect all areas (e.g., offices, bathrooms, and common areas) used by the ill persons, focusing on frequently touched surfaces. • Dirty surfaces should be cleaned with soap and water prior to disinfection. • To disinfect, use products that meet EPA’s criteria for use against SARS-Cov-2, (called the EPA List N) or di- luted bleach solutions or alcohol solutions with at least 70 percent alcohol. • Cleaning staff should wear disposable gloves and gowns, coveralls, or other personal protective equip- ment (PPE) suitable for the disinfectant being used. • Be sure to remove and dispose of/launder PPE, as ap- propriate, and clean hands after. There is no additional PPE required specific to COVID-19. • Operations can resume as soon as the cleaning and disinfection are completed. 4. If an infected employee physically contacted manu- facturing equipment, inputs and/or outputs, what steps CONTINUED ON PAGE 20
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CDC Protocols (CONT’D FROM PAGE 18)
6. If an employee is diagnosed with COVID-19, should the impacted facility expect a CDC investigation? If so, what should the facility expect in order to be prepared, and what type of interruption should be anticipated? A: While CDC may deploy staff to investigate clusters of confirmed COVID-19, it does not routinely investigate ev- ery impacted workplace. Employers should cooperate with state and local health officials. 7. Is the CDC developing a nationwide rapid home test for COVID-19 that could be deployed in the workplace? A: CDC’s focus has been on increasing state and local laboratory capacity. As of March 18, 91 public health lab- oratories are now running the CDC assay, including 50 states, plus District of Columbia, Guam, and Puerto Rico. As of March 18, the CDC has tested over 4,754 samples that equate to more than 1,610 patients. Public health labs have tested more than 40,360 samples. If you are a close contact of someone with COVID-19, or you are a resident in a community where there is on- going spread of COVID-19 and you develop symptoms of COVID-19, call your healthcare provider and tell them about your symptoms and your exposure. They will decide whether you need to be tested, but keep in mind that there is no treatment for COVID-19 and people who are mildly ill may be able to isolate and care for themselves at home. For answers to additional questions for manufacturing facilities, visit the CDC website at cdc.gov .
are needed to disinfect the equipment, the raw materi- als and potentially the finished products? A: If the objects in question are not accessible to employ- ees, they may have little potential for contamination and may not present an exposure hazard of concern. If equip- ment, inputs and outputs are thought to be contaminat- ed and can be cleaned and disinfected (or laundered, for porous materials), follow the CDC cleaning and disinfec- tion recommendations, which indicate that dirty surfaces should be cleaned with soap and water prior to disinfec- tion. 5. What are the recommended strategies and practices for a workplace quarantine if employees are becoming ill? A: Employees who have symptoms including fever, cough, or shortness of breath should notify their supervisor and stay home. Employees who appear to have symptoms in- cluding fever, cough, or shortness of breath upon arrival to work or become sick during the day should be imme- diately separated from other employees, customers, and visitors, given a face mask if possible, and sent home. Sick employees should follow CDC-recommended steps. Em- ployees should not return to work until the criteria to end home isolation are met, in consultation with healthcare providers and state and local health departments.
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April 6 , 2020
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Advantzware Vows Uninterrupted Service, Fixed Exchange Rates Jacksonville Beach, Florida based Advantzware Inc., a software provider in the corrugated, folding carton and distribution industries, is committed to providing its val- ued customers with uninterrupted service and other mea- sures to assist in these challenging times. The company is setting a maximum exchange rate for all its Mexican (20/1) and Canadian (1.30/1) customers through the end of the year for any customer under maintenance including all license and support fees to support its customers. “We want to provide our customers who are both our neighbors and customers some relief due to the rapid rise in US dollar exchange rates and provide a level of con- sistency for their business,” said Advantzware CEO Jay Farr. “We have moved all operations to be home-based effective immediately and asked our employees to stay in place until it is safe for people to return to the office. Our internal investments in technology, remote access tools, home office allowance and enhanced communica- tions with cloud-based solutions allow for us to deliver the highest quality service for an extended period of time to assure uninterrupted service while continuing to sup- port our customers in any way to sustain their business operations.” Visit www.Advantzware.com or call (215) 369-7800.
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Producing Quality Board Converting News is read by more end users — your potential customers — than ever before. Tell them you’re a QUALITY PRODUCER.
Robyn Smith at 910-553-4055 / email@example.com Len Prazych at 518-366-9017 / firstname.lastname@example.org
April 6 , 2020
General Converting (CONT’D FROM PAGE 1 )
nine months after his parents started the business and purchased the company in 2000. He insists that he plays a minimal part in the company’s success and more often credits the employees. “I am not the most important per- son at this company,” he says.
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The Bobst Masterfold was installed last year.
If growth is any indication of success, GCI is thriving. When Ruebenson’s parents started the company, there were three employees producing cartons on a two-color press, a small diecutter and a gluer. Today, 70 employees work in a state-of-the-art 122,000-square-foot climate con- trolled facility producing 762 million cartons annually. For comparison, 15 years ago annual carton production was 200 million with almost the same number of people. “One of the main reasons we’ve grown over the years customer wise is because of our quality, service and quick turn time,” says Dave Mickiewicz who has been with GCI for 20 years and heads up sales. “This is an easy company to sell for from the standpoint that we have great support and we don’t have to go through levels of management to get something done.” The productivity underscores all of the aforementioned attributes as well as its cutting edge technology and au- tomation. “There are so many variables in this business,” Ruebenson says. “We have to give employees the tools to succeed and I feel we’ve done that.” Printing Efficiency In the last six years GCI has invested in three new fold- er-gluers, two printing presses, one diecutter and some ancillary equipment. Most of the equipment is from two suppliers — Bobst and Heidelberg. “My philosophy is you buy the best you can, whether it’s equipment or substrates or ink, anything. We build the quality into the product be- cause once it’s printed you can’t go back and erase it,” Ruebenson says. The changeover in new equipment began in 2014 and 2015 with the installation of two 41-inch Heidelberg Speed- master offset presses that print eight-color plus aqueous and seven-color plus inline UV. The machines print 18,000 sph and include the full complement of image control color management systems and load handling. They replaced three older Heidelbergs.
Board Converting News is read by more independent and integrated decision-makers in the corrugated and folding carton industries
than any other weekly publication. LEVERAGE YOUR REACH.
Robyn Smith at 910-553-4055 / email@example.com Len Prazych at 518-366-9017 / firstname.lastname@example.org
CONTINUED ON PAGE 26
April 6 , 2020
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General Converting (CONT’D FROM PAGE 24)
Board Converting NEWS INTERNET DIRECTORY
“In printing we gained efficiencies in both productivity and speed as well as changeover time,” Barry says. Pri- or to their installation, Heidelberg told GCI it could expect changeover times of 45 minutes on average. “With the older equipment we were at a two-hour changeover time so we estimated it would be about an hour with the new equipment,” he says. “After about four months we had our changeover time down to 36 minutes on average, and 95 percent of our jobs run at the max speed of the press.” The average press run is 25,000 sheets per order. Pressroom Manager Mike Harper has been with GCI for 10 years and has worked in the carton industry for almost 40 years. His office sits between the two Heidelbergs at eye level with the press operators. He says GCI’s ap- proach to business and equipment investments is inspir- ing. “I’ve been in printing a long time and this is a different level, with the automation on the equipment. How do you compete against this? Eighteen thousand sheets per hour — that’s five sheets a second — all day long.”
Advantzware provides a flexible and comprehensive sys- tem to address the business management needs of the in- dependent box business, as well as the ERP requirements of full scale packaging plants and integrated companies. With modules for estimating, scheduling, production, inven- tory and accounting, this scalable system supports packag- ing plants that produce corrugated boxes, folding cartons, point of purchase displays, assembled partitions, paper- board products, foam fabrication, as well as distribution of packaging supplies. Advantzware has been in operation for over 25 years and continually enhances our system to ad- dress the needs of the industry. AIR CONVEYING CORPORATION www.accfi lter.com Air Conveying Corporation has been designing, manufac- turing, and installing state of the art trim removal systems for the Corrugated, Folding Carton and Printing industries for more than 49 years. Contact us today.
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.
AMERICAN CORRUGATED MACHINE www.acm-corp.com
For a wide variety of new and used equipment on today’s market, visit our website. You can e-mail us directly from the site for all your corrugated needs.
He points out the full logistics load handling on the press, which makes the press operators’ jobs easier. “They’re not material handlers. We want pressmen who look at and inspect the sheet and use all the tools that are available to them instead of worrying about making a load change,” he says. Quality First With the increased printing volume combined with sig- nificant annual sales growth — 20 percent in 2018 and then another 8.5 percent in 2019 — the need for more ca- pacity in diecutting and gluing became apparent. Last year GCI installed a Bobst Mastercut 106 PER diecutter and a Bobst Masterfold 110 A3 folder-gluer. The Mastercut is Bobst’s top of the range machine, de- livering high productivity, exceptionally short setup times, and high quality finished product. The Matic systems allow the operator to save 25 to 30 percent in makeready times. When a repeat job is recalled, the machine sets itself au- tomatically. The Power Register system virtually eliminates CONTINUED ON PAGE 28 Pressroom Manager Mike Harper, center, with press operators Bob Singraber, left, and Felipe Jamaica in front of the 8-color Heidelberg press.
AMTECH SOFTWARE www.amtechsoftware.com
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 ship- ping, proactive roll stock and inventory management, and so much more in an integrated, single vendor environment. APEX INTERNATIONAL www.apex-groupofcompanies.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.
April 6 , 2020
SEE WHAT CUTTING CORNERS LEAVES YOU WITH?
We want you to get the most out of your rolls and machine. That’s why our new Knoxville facility was built with a dedicated cart/cassette rebuilding area. Trust our experts to safely and efficiently restore your cart back to OEM condition. You’ll end up saving time and money when you do.
Visit www.bhs-world.com/knoxville to learn more about BHS’ cart-refurbishing capabilities.
General Converting (CONT’D FROM PAGE 26)
Board Converting NEWS INTERNET DIRECTORY
feeder stops because of registration errors, ensuring max- imum running speeds of 11,000 sph. The Mastercut joins three Bobst CER 102s. With Quick- lock cutting chases on all four machines, the cutting dies are interchangeable.
ARC INTERNATIONAL www.ARCInternational .com
ARC International is a world leader in the manufacturing of roller products for flexography. The latest nano-technology laser engraving in our Charlotte and Las Vegas manufac- turing facilities ensures superior quality and consistency in anilox rollers.
BAUMER HHS CORPORATION www.baumerhhs.com
hhs is a global leader in advanced gluing, camera verifica- tion and quality assurance systems for the packaging indus- try. Zero-defect quality and elevated production speeds are key parameters in the manufacturing of corrugated boxes; hhs systems ensure efficiency and precision across the board. With hhs Xcam Box Monitoring and non-contact flap gluing of corrugated board, hhs offers every option for au- tomated quality assurance in the production of corrugated boxes with flexo folder gluers. BLOWER APPLICATION COMPANY (BLOAPCO) www.BloApCo.com BloApCo has served the corrugated industry since 1933 with a variety of scrap handling solutions, including Hori- zontal Floor Shredders, Trim Cutters, and Material Handling Fans and Conveying Systems. BloApCo Shredders allow for continuous shredding and pneumatic removal of sheet waste stacks of all sizes, roll slab, cores, carton scrap and much more.
The Masterfold produces straight-line, auto-bottom and 4-corner boxes at high speeds, enabling a large increase in GCI’s output. The machine includes Speedwave 3 to run crash-lock boxes and reduce the setup times on auto-bot- toms. The line includes Easyfeeder 4 and the Cartonpack 4 automated packer. Cartonpack 4 reduces an operator’s repeat setup by half by physically moving elements of the machine into place. There are a total of four gluing lines — three Bobst and one Vega. The Bobst gluers have automatic case packag- ing and labeling, and all four gluers have glue detection and bar code scanning, ensuring quality. The Bobst gluers have automatic case packaging and labeling.
CIMEX CORP. www.cimexcorp.com
Cimex writes affordable yet powerful CAD/CAM software for the packaging and diemaking industries. We also offer numerous samplemakers, etc., to fit all needs and budgets.
CORRUGATED MACHINERY SPECIALISTS www.cmsretrofits.com
Leading manufacturer and installer of quality retrofits, up- grades and replacement parts for S&S and Prime Flexo Folder Gluers. Specialists in reconditioning of S&S Flexo Folder Gluers, including ink, air and electrical systems.
CORRUGATED REPLACEMENTS, INC. www.corrugatedparts.com
Producing a superior quality product is paramount to success and is part of the corporate culture that the Ruebensons established from the very beginning. “One unique quality instilled by Bob’s father is anybody in the entire facility can stop any piece of equipment with a po- tential question if something doesn’t look right,” Harper says. “They empowered the employees. I find that unique.” CONTINUED ON PAGE 30 General Converting has a total of four gluing lines — three Bobst and one Vega.
Corrugated Replacements, Inc. is a production powerhouse that manufactures high quality machine parts and replace- ment parts for the corrugated and paperboard converting industries. CRI can redesign, engineer, and manufacture any part while providing a rapid turn-around rate, keeping machines running at their peak performance and limiting down time.
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