Board Converting News, August 9, 2021

BoardConverting Serving the North American Corrugated and Folding Carton Industries for 37 years August 9, 2021 VOL. 37, NO. 30

PCG Continues Booming Growth With New Machinery Investment BY LEN PRAZYCH “It’s a great time to be in the box making business!” For the last year, this has been the refrain of virtually everyone in the North American (and global) corrugated and folding carton industries, which continues to enjoy unprecedented growth and ongoing backlogs. A sheet plants’ output appears to be limited only by the amount of board it can acquire and larger independents with corrugators by the amount of paper they

Pratt Industries To Build New $400M Recycled Mill In KY Conyers, Georgia based Pratt Industries has confirmed it will invest $400 million in a new recycled paper mill in Henderson, Kentucky. This represents the largest single investment by the company in its history and will create more than 320 full time jobs plus an additional 700 in the construction phase. It is speculat- ed that the mill will have a capacity of around 500,000 tons per year. “It will be the world’s most advanced, en- vironmentally-friendly 100 percent recycled paper mill,” said Anthony Pratt. “And it means Pratt Industries will have built six of the last eight paper mills in the United States.” Construction on the 450,000-square-foot mill will begin next March with a startup date scheduled for Fall 2023. In a separate project, the company also confirmed it would build a 700,000-square-foot corrugated box plant

CONTINUED ON PAGE 5

WHAT’S INSIDE 10 Manufacturing, Economy Grow Again In July 16 Packaging-Atlanta To Invest In Second Baysek Die Cutter 26 Pamarco Showcases New Facility In Batavia, IL 42 Greif Invests $10M In NC Expansion 62 Today’s Hiring Realities: What You Need To Know 66 SCE 2021 Exhibitor Listings 82 How To Maximize ROI At SuperCorrExpo And Beyond

can procure. The fact that our industry was deemed “essential” contrib- uted to the current state of affairs, but independents and integrateds alike are now facing delays in getting product to their customers be- cause of “supply chain disruptions,” specifically, finding enough people to drive the trucks to transport the finished goods to market. Smaller independents are growing bigger, if not in physical size, then in capacity, customer orders and revenue; larger independents are growing even larger. For example, Middletown, New York based President Container Group (PCG), owned by Larry and Richard Gross- bard, who already lay claim to a 500,000-square-foot “super plant,” one of the largest in the Northeast, announced earlier this year that they are building a 100,000-square-foot addition in which they will in- vest in a second Fosber corrugator, a second Mitsubishi EVOL, a Goep- fert, and approximately six miles of conveyor. PCG broke ground in the PCG employees (in red shirts) and engineers from Engico (in black sweat- ers), from left Mike Degroat; Richard Goldberg, PCG’s VP of Operations; Keith Umlauf, VP of Sales at Haire Group; Stefano Falvo; Wedner Hyppolite; Lizandro Martinez; and Luca Borellini.

spring and construction is ongoing.

CONTINUED ON PAGE 30

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August 9, 2021

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August 9, 2021

Pratt Industries (CONT’D FROM PAGE 1 )

AVERAGE CONTAINERBOARD PRICES The average prices reported are tabulated from prices PAID by various sources throughout the United States the week previous to issue. Prices in some areas of the country may be higher or lower than the tabulated average. The prices tabulated here are intended only for purposes of reference. They do not connote any commitment to sell any material at the indicated average. Transactions may be completed at any time at a price agreed upon by seller and purchaser.

adjacent to the mill. Construction on that phase is expect- ed to begin no later than 18 months after the mill is com- pleted and become operational in 2026. “Our focus is all about the rebirth of the great American manufacturing capability, especially in regional America,” said Pratt. “This investment represents another example of our commitment to building America’s green infrastruc- ture, including clean energy. This creates high-paying, highly-skilled green-collar jobs in communities like Hen- derson and Hebron where we already employ almost 200 Kentuckians at our corrugated display factory. We see fur- ther investment potential in this dynamic state and Gov- ernor Beshear’s leadership has made Kentucky a great place to invest. “This is a significant investment in Kentucky and one that will make Pratt a major employer here for years to come,” said Gov. Beshear. “Pratt is a company with a vision for the future, and I am proud that future will include Ken- tucky. We’re not just rebuilding our economy, but surging ahead to levels we have not seen before. This is happen- ing because great strong leaders like Anthony Pratt can see where Kentucky is headed and know our skilled work- force is the partner they need to succeed.” This latest initiative brings the company’s total cumula- tive investment value in the U.S. to around $10 billion since Pratt founded it 30 years ago.

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

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

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

$970.00

$960.00 $995.00

$1,015.00

air shark

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August 9, 2021

T H A C K E R I N D U S T R I A L S E R V I C E C O M P A N Y

O P E R A T O R T R A I N I N G T A I L O R E D T O Y O U R G O A L S Before any training star ts, we need to know your goals. We’ l l help you identi f y them, customize them, measure them and help achieve the expectations set by your team. Our intensive training wi l l encompass two ful l days at your faci l ity for al l par ticipants, during the week or on a weekend. Al l you need is a room for training your group and the machine you want to train on.

O U R T E A M

Our Training team consists of three corrugated industry exper ts with nearly 100 years of combined experience. Their backgrounds are in both integrated and independent companies with roles ranging from Machine Operator to Director of Operations. Making them more than qual i f ied to tackle any machine and training issue. Cal l today to learn how your team can benef it from the industry ’s premier training program.

www. thacker i ndus t r i a l . com (682) 552 5852 For more Information:

C u r r e n t O p e r a t o r E x p e r i e n c e

S T E P 1

M a c h i n e t y p e G o a l s / E x p e c t a t i o n s

I s s u e s

Q U E S T I O N N A I R E

P l a n 2 d a y s w i t h i n y o u r s c h e d u l e

S T E P 2

1 d a y c l a s s r o o m a n d 1 d a y a t m a c h i n e

S C H E D U L E

1 - B o x S e t u p C a l i b r a t i o n T o o l i n g

S T E P 3

T R A I N I N G

T r o u b l e s h o o t i n g

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August 9, 2021

Calling Profero Systems just another equipment supplier is like calling the Tour just a bike ride. Profero Systems

Proven unsurpassed customer service over the long run, commitment to our customers is second to none!

Add value to your Corrugating Process, be the go-to Company for your customers.

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August 9, 2021

JB Machinery To Introduce AutoWash Plate Cleaning System At SCE 2021 Weston, Connecticut based JB Machinery will formally in- troduce the AutoWash automatic plate washing system. “Our focus is on helping converters maximize the produc- tivity, quality and efficiency of their converting processes,” said Warren Bird, President of JB Machinery. “Manually washing printing plates can take on average five to 10 minutes. Whether you’re doing it on the machine – after makeready or at the end of an order – or offline, you’re consuming 20 plus minutes of the crew’s time to wash plates on a four-color job. AutoWash allows us to auto- mate this process and wash all plates simultaneously in less than four minutes. So, regardless of how many col- ors you’re running, all plates can be washed and ready for storage, or to run the order, in less time than it would take to wash a single plate.” Plate washing, before, during and after a production run is necessary to eliminate print defects and maintain print quality when direct printing on corrugated board. This results in significant downtime as production is inter- rupted, or unnecessary manpower is used to clean and dry plates for storage. AutoWash automatic plate washing significantly reduc- es downtime and optimizes labor usage by eliminating the need to manually wash printing plates. The easy-to-use system is automatically configured to the production or- der and requires no further set-up. The system features an “in production” print defect removal cycle that removes hickies and impurities from printing plates in 1.5 seconds, without interrupting the production process. Once initiated it’s a fully automatic, hands-free process. Active plate cylinders come off impression. A water-based cleaning solution is applied as the brush engages the plate. The dual action deep cleaning cycle consisting of rotation and pulsation quickly and gently renders the plates clean and free of ink, dust and debris. “We are very happy with the success and converter in- terest in AutoWash,” says Bird. “We have our first ‘repeat’ AutoWash customer who, after experiencing great suc- cess with their initial installation, has decided to add multi- ple units to their operation. When plants realize how much crew-time can be saved on each order, and how they can allot that time to more value-added tasks, then justification is simple.” JB Machinery’s AutoWash Automatic Plate Washing System

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August 9, 2021

Manufacturing, Economy Grow Again In July: ISM

Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month June 2021

Economic activity in the manufacturing sector grew in July, with the overall economy notching a 14th consecutive month of growth, 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 Manage- ment (ISM) Manufacturing Business Survey Committee. “The July Manufacturing PMI® registered 59.5 percent, a decrease of 1.1 percentage points from the June read- ing of 60.6 percent. This figure indicates expansion in the overall economy for the 14th month in a row after contrac- tion in April 2020. The New Orders Index registered 64.9 percent, decreasing 1.1 percentage points from the June reading of 66 percent. The Production Index registered 58.4 percent, a de- crease of 2.4 percentage points compared to the June reading of 60.8 percent. The Prices Index registered 85.7 percent, down 6.4 percentage points compared to the June figure of 92.1 percent, which was the index’s high- est reading since July 1979 (93.1 percent). The Backlog of Orders Index registered 65 percent, 0.5 percentage point higher than the June reading of 64.5 percent. The Employ- ment Index registered 52.9 percent, 3 percentage points CONTINUED ON PAGE 94

Year

Actual

Percent Change Avg Week Percent Change

2021 2020

35.963 34.395

4.6

8.173 7.817

4.6

Industry Total

Year-to Date

June 2021

Year

Actual

Percent Change Avg Week Percent Change

2021 2020

208.632 196.828

6.0

8.279 7.749

6.8

Industry Total

Containerboard Consumption (Thousands of Tons)

Year

Month

Percent Change Year-to-Date Percent Change

2021 2020

2.9450 2.8182

4.5

14.1095 13.3029

6.1

Container Board Inventory - Corrugator Plants (Thousands of Tons)

Corrugator Plants Only

Date

Percent Change Weeks of Supply

Percent Change

Jun. May

2.1046 1.9962

5.4

3.1 2.9

6.9

Shipping Days

Year

Month

Year-to-Date

2021 2020

22 22

126 127

SOURCE: Fibre Box Association

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August 9, 2021

40 ft of paper travel from preheater to hot plates 3 seconds of heat, glue and bonding 1 chance to get it right! the ZONE

Design & Production

Chicago Electric offers 10 technology solutions to control ‘the Zone’ CORRUGATOR Sectoral preheating plate

Our sectoral preheating plates provide direct heat by means of a double steam circuit, allowing for efficient heating in hard-to-access locations, as well as to act as a steam shower to open the paper’s fibre, making it receptive to absorbing the heat and the glue.

This translates into increased speed and improved quality of the cardboard sheet finish.

The system’s main advantages are as follows:

• The plate may only be used to heat, only to humidify, or both options at the same time. • The plate is sectored, which allows for applying humidity to the sections. • It provides temperature in previously inaccessible locations and near the location needed. • It compensates the loss of temperature dissipated due to distance, speed or limitations of the exiting preheaters. • Quick transferring of heat to the paper. • The combination of the hot plate and steam shower allows for providing heat even to the hardest papers to heat. • Does not dry out the paper. • Possibility of operating as a humidifier and pre-conditioner. • Maintains and improves the fibre’s elasticity. • Acts according to the operator’s needs. • Facilitates the paper’s hygroscopy to absorb the glue and improve rubberising.

CONTROLLABILITY

1. Wrap Arm - Position & Temperature 2. Preheater Direct Drive

DOUBLEBACKER IMPROVEMENT

3. Steam Plate 4. Contact Roll 5. Glue Machine Direct Drive Touch Productivity Issue—Glue Unit Many glue units run with a rider roll or a guiding bar system. The rider roll with paper gap allows a precise glue application, but requires frequent Contact Roll

PRODUCTIVITY

C/ Orfeó Català 13-15 · 08440 Cardedeu (Barcelona) telf: +34 93 846 01 06 · comercial@al-gar.com WWW.AL-GAR.COM

DOUBLEBACKER IMPROVEMENT

calibrations and settings. Bar systems avoid this, but compensate this with the risk of exces- sive glue application. The system contains many wearing parts. Solution The contact roll combines the ad antage of both systems and ensures minimum contact between board and applicator roll. The system uses small pneumatic cylinders in order to achieve a “soft touch.”

6. Gap Control 7. Curved Plate 8. Roller Shoe Press When it comes to a short-term increas of web tension, spring loaded systems with shoes or airpressure activated system have problems in compensating these. The system is lifted for a short time. This may result in de-lamination and in the ‘double kiss’ effect. Solution For a defined and exact bonding point of the web fiv weight rollers will be installed usually over the first flat hotplate of the heating section. The rolls are mounted into a frame, which is actuated by means of two pneumatic cylinders. P oductivity Issu —Double Kiss Bonding

PRODUCTIVITY

DOUBLEBACKER IMPROVEMENT

Roller Shoe

DOUBLEBACKER IMPROVEMENT

9. Thin Wall Hot Plates 10. Pressure System Benefits —Exact glue application due to defined contact of applicator roll to web. Web is in contact to less flute tips compared to bar systems. • High precision glue application • Less moisture applied to web —No wear of shoes and springs —No adjustment of shoes or paper gap —Uniform glue application over entire w orking width for all flutes by use of pneumatic cylinders instead of springs — Less contamination by paper dust and glue remains —No jam of board because of web breaks caused by splice joints going through 630-784-0800 Benefits —Rollers secure exact defined first point of contact of liner and single-faced board - No double kiss —Frame design avoids unintended lifting of roller shoe (compared to spring or air loaded systems) - No double kiss —Pressure can be increased or released for special grades or products 490 Tower Blvd., Carol Stream, IL Contact Chicago Electric to GET IT RIGHT 630-784-0800 info@chicagoelectric.com chicagoelectric.com Solution The ProPress system ensures an optimum heat transfer to the board. It offers a wide range of set- tings. The loadi g pressure can be varied, the number of shoes can be lifted in accordance t the line speed. The outer shoes can be lifted in accordance to the paper width. The shoe bars will be delivered pre-assembled for a short installation time. —Liftable for easy paper infeed and for cleaning of the machine —Position adjustable in paper direction to avoid grooves in hotplate Press Productivity Issue—Poor Heat Transfer Rollers are usually limiting the heat transfer, since they often have contact mainly on the edges of the plates due to wear or bent plates. They also cause often loss of caliper and bearing need to be replaced frequently. Airpressure actuated systems can only supply a limited pressure and have com- pared to shoe systems a closed surface. Pressure Shoe

Plate vity Issue—Poor Heat Control l hotplates are slow to react to pressure due to high steam volume and massive y also have high heat radiation and heat profile. Worn plates can damage crease edge crush.

Thin-Wall Hot Plates

t by peripheral drilled hot plates. anufactured out of special wear and nt steel, through which a continuous is drilled, with one inlet and one outlet. ecured by a massive steel frame.

CORR24usa.com

ance from steam to paper surface results in fast heat flow

Above And Below: Suppliers Critical To Production Success At PCG In NY Middletown, New York based President Container Group’s investent in its 100,000-square-foot expansion mentioned in the this week’s feature story required that critical work was expertly delivered by industry suppliers both above and below the production floor.

ThePerfectCombo Get PeakPerformance FromYour Equipment withMatched Component Sets

Nothing’s more rewarding than a couple made for each other. That’s why the engineers at ARC

International have focused their skills and talents on crafting perfect matches between the components that must work in tandem on your exo folder gluers and die-cutters: • Anilox Rollers and Ink Chambers

The refurbishing of flooring and concrete work for the foundation for PCG’s conveyor upgrade and transport cars was performed by Anderson, South Carolina based Zefco, Industrial Contractors at Booth #1641 at SuperCorrExpo.

• Anilox andWiper Rollers • Feed and Pull Rollers • Glue andMeter Rollers You can achieve the press speeds and print quality you need to ll your most demanding orders by pairing your team with The ARChitects of Flexo. Contact ARC today to learn how these engineered matches of exo folder gluer and die-cutter components (new or reconditioned) can help you achieve a more perfect union of production and prots. Meet us at

Booth #2123

Grandview, Missouri based Paper and Dust Pros in- stalled PCG’s separator, filter, air system and baler. The company’s technicians will reconfigure and complete the project when the building expansion is finished. Visit them at Booth #3001 at SuperCorrExpo..

The ARChitects of exo

ARCInternational.com 800-526-4569

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August 9, 2021

ARC.5pAnlxChmb1BCN.SCE.indd 1

7/2/21 2:27 PM

RELIABLE PERFORMANCE TO PROTECT YOUR ENTIRE SYSTEM

DEAERATORS MANUFACTURED TO SURPASS ASME STANDARDS COMPLETE SYSTEMS OR CUSTOM TAILORED TRIM PACKAGES LOWERS OXYGEN LEVELS TO .05 CCLITER OR BELOW VARIABLE CONTROL PACKAGES DURABLE COMPONENTS AND PROFESSIONAL FABRICATION

Whether you need to design and build a new corrugator steam system or a perfectly matched retrofit, turn to Boiler & Steam Performance for the most efficient process and reliable solution. We also offer specialized expertise to solve complex challenges and practical support to help you maintain peak performance. BACKED BY A 30 YEAR HERITAGE OF QUALITY AND PERFORMANCE.

706.453.2050 | www.BSPsteam.com/vessels

BHS Corrugated Awards 2021-2022 Scholarships

needed to be the child or grandchild of either a BHS em- ployee, Chicago Electric employee, or the employee of one of our customers. While all of our recipients for this year are students at- tending 4-year institutions or beyond, technical and trade schools also qualify. The application process requires the

Baltimore, Maryland based BHS Corrugated North Ameri- ca, Inc. has announced that it has awarded its third annual scholarships for the 2021/2022 school year. BHS awarded

four $5,000 scholarships and one $10,000 scholarship in June of 2021. To be eligible for a scholarship, the student Left, Emma Wigley is the daughter of Kevin Wigley, Process Trainer at BHS; Dylan Holmes, above right, is the son of Don Holmes of WestRock in Twin Falls, Idaho.

student to tell us about their previous academic achieve- ments, volunteer and work activities and their future edu- cational plans. In addition, each applicant has to write an essay related to the corrugated industry. If you are inter- ested in information for next year, please send an e-mail to csr@bhs-world.com to receive eligibility requirements and an application form. Marissa Finger, right, is the daughter of Jackie Finger, Custom- er Care Representative at BHS.

Above, holding dog, Sonya Verke is the daughter of Melanie Krum, Mechanical Field Service Tech at BHS. Above right, Rhealyn Adkins is the daughter of Joe Adkins of PCA.

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August 9, 2021

Packaging-Atlanta To Invest In Second Baysek Die Cutter

Packaging-Atlanta Corp., based in Metro Atlanta, reported that it is in- vesting in its second Baysek Machines C-170 Die Cutter, which will be installed after the 2021 SuperCorrExpo show in Orlando, Florida.

Cosmo DeNicola Chairman, Amtech Software

Packaging ERP Algorithmic Scheduling Web-Based Access Online Customer Portals

A second-generation, family-owned independent, Packaging-Atlanta has three segments of operation: corrugated packaging for the industri- al sector on a regional level, pizza boxes and other food service pack- aging on a broader regional level, and bakery products and distribution services on a national/international level. The company uses its Baysek predominantly to run cake circles and interior diecut items. Packag- ing-Atlanta holds a FSSC22000 food safety certification. “We support a fair amount of niche type business and the Baysek Die Cutter has been ideal for this type of work,” said Pat Haddon, who along with his wife Martha, founded Packaging-Atlanta Corp. in 1983. “Throughout and post-COVID, we have experienced extended lead times with increased customer base and volume. The additional C-170 will serve to support new anticipated growth as well as assist in getting lead times back to pre- COVID expectations. “We’ve been in our From left, Nick Hourigan, Logistics Manager; Chase Haddon, Design/Sales; Pat Haddon, President; Peter Haddon, Food Safety/Sales; and Neil Crunkle- ton, Production Manager.

Paperless Workflows Mobile Sales Systems Digital Signage Production Monitoring Mobile Logistics Management Analytics & Reporting Cloud Hosting IT Management Services Cyber Security Management

600 + Plants 60,000 Users North America Latin America

existing building for the past 20 years and are looking to expand anoth- er 40,000-square feet in the near future.” Install- ing machinery that allows us to service our current customers and build new business simultaneously is extremely important to Packaging-Atlanta. The

new C-170 die cutter will run a variety of products related to Packag- ing-Atlanta’s PET/laminate business as well as corrugated packaging. The unique Baysek die cutting method conquers simple to complex food CONTINUED ON PAGE 18

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August 9, 2021

STOP GUESSING.

WE KNOW THE ANSWERS TO THESE QUESTIONS...

WHAT IF?

Get Answers-Be Proactive. • There’s a board increase or decrease? • My volume goes up or down? • I lost my largest customer? • My MIX changed ? • I bought a new machine? • I sold more sheets? • My labor costs go up 5%? • I added OT or another shift?

With Amtech’s NEW AUTOMATED PERFORMANCE COSTING To Learn More or Schedule a Demo Darren Artillio: dartillio@amtechsoftware.com 215.639.9540 www.amtechsoftware.com/accurate-costing

Baysek Enjoys Continued Growth As The Next Generation Steps In With each passing year, Baysek Machines Inc. achieves a new milestone. In 2020, the Nelsonville, Wisconsin, com- pany celebrated its 25th anniversary, marking significant growth and the transition to the next generation.

Packaging-Atlanta (CONT’D FROM PAGE 16)

grade quality jobs with one operator via an easy-to-oper- ate control screen. The innovative Baysek technique sig- nificantly reduces operational costs while increasing qual- ity of finished product yielded.” “Packaging-Atlanta has been a great customer for Bay- sek Machines for many years,” said Tim Engle, Baysek’s

North American Sales Manager. “They have truly utilized their existing Baysek C-170 and have significantly grown that part of their business. We at Baysek are looking for- ward to further partnering with Pat Haddon and his team on their second C-170 Die Cutter, which we will be install- ing right after SuperCorrExpo. Peter Haddon, left, and his brother Chase Haddon, sons of Pat and Martha Haddon, represent the second generation.

Inherent in the culture is a rich heritage that dates to Baysek’s founding in 1995 by David Helbach. He attri- butes the success to the many dedicated employees that CONTINUED ON PAGE 20 Then and now: Baysek’s first office in Amherst, WI, in 1995 (in- set) and the company’s newly expanded facility in Nelsonville, Wisconsin, today.

SOLD to Acme Corrugated Box Hatboro, PA.

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Visit Harmax at SuperCorr Booth # 1301

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August 9, 2021

Baysek Enjoys (CONT’D FROM PAGE 18)

Mark Helbach spent 25 years in the truck equipment industry in various sales and management positions. “I al- ways stayed in touch with my father about Baysek, and I took vacation time from work to join and assist him at trade shows in his early years,” he says. “I was very fortunate to have joined when I did. There was a great base of people in place, and the most difficult developmental work was complete.” Vern Engle is stepping back as his son, Tim, who joined the company last year, takes over the same position that his father has held since the company’s inception in 1995. “It has been an honor to work with Dave Helbach,” Engle says. “I learned a lot from him, had a lot of fun and man- aged to sell a few machines in the process.” Tim Engle has been in the corrugated industry for more than 20 years, owing his involvement and success to his father and Dave Helbach, who is his uncle. “I remember growing up and always wondering what Uncle Dave did,” he says. “I knew it had something to do with cardboard boxes but how many people really need a box?” Previously, Tim Engle was with A.G. Stacker and Haire Group. “I always knew that I wanted to work with family at Baysek, the timing just needed to be right for everyone,” he says. “With my father retiring last March, the timing was a natural change for me. I am excited to be here and be part of the Baysek team, and in the corrugated industry in general.

embraced his original philosophy of customer care and vendor respect. One key Baysek representative was Vern Engle, former North American Sales Agent. “I admired Baysek because customer care was always more import- ant than the next machine sale,” Engle says. “The custom- er never had to worry.”

Baysek’s legacy is strong, with several family members involved. Helbach, who was President, retired in 2017, turn- ing over the reins to his son, Mark, who joined the compa- ny in 2015. His son-in-law, David Waldoch is Vice President and has been employed since 2000, and his daughter, Heidi Pronschinske, is Marketing Manager since 2010. Baysek founder David Helbach with his son Mark, left, daugh- ter Heidi Pronschinske and son-in-law David Waldoch.

CONTINUED ON PAGE 22

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August 9, 2021

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Baysek Enjoys (CONT’D FROM PAGE 20)

Booth # 2011

“Since the pandemic started, the buying habits of the American people have changed and they are now doing more, if not all, of their shopping on-line,” he adds. “This has increased the demand for boxes and this demand will

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only grow as more people will continue to shop on-line, and even buy groceries on-line. The next few years are going to be challenging and exciting.” Steady Growth Baysek’s steady growth has prompted the addition of new employees, as well as a facility expansion. Total sales have tripled in the last 10 years, and the number of employees has doubled since 2015. The headquarters in Nelsonville was expanded by 70 percent to accommodate additional manufacturing, warehousing and office space. Growth has also extended beyond the U.S. The com- pany has had an international presence for over 15 years, establishing Baysek Machines & Engineering – UK, which was primarily an after sales, service and parts hub for the EU. Long-time affiliate dating back prior to 1995 Director Andrew Keighley and his wife, Mel, were the only full-time employees until 2019. Since then, Robert Jess for sales and Steve Sharp for technical service were hired. Baysek has several agents covering the international market. This includes Alexander Kraft of Design & Technik for Germany and central Europe. In Turkey, Nihat Kiray of Kiray Emballage, Kolbus-France for France, Belgium and Luxembourg, and Goettsch International for Latin America and Southern Africa. Product Portfolio The C-170 diecutter is Baysek’s flagship product, rep- resenting the bulk of sales and growth. New technology continues to support ongoing enhancements. The flat die, rotary anvil diecutter runs simple to complex, nick-free, ful- ly automatically stripped jobs that are difficult or impossi- ble to efficiently run on traditional rotary and platen diecut- ters. “Less than 30 years ago this diecutting system didn’t exist,” Helbach says. “I owe a special thank you to those early customers, who recognized the potential and value The next generation: Tim Engle, left, with his father Vern and Mark Helbach (right) with his father Dave.

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August 9, 2021

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Baysek Enjoys (CONT’D FROM PAGE 22)

One of the newest products is a digital post printer, the Baysek GalXE, which was developed in collaboration with DPI (Digital Print Inc.). Offering one color, two color spot and four-color process printing, ideal applications include industrial and pizza boxes, part identification numbers, bar codes and QR codes, to name a few. The printers are cur- rently only available in North America. Looking back over the years, Dave Helbach expresses deep gratitude and is thankful to Vern Engle, who was with him from the start, Rolf Erisman of RJE Machinery, Inc., and Ryan Hetzel, Technical Service Manager, who preserved the original philosophy of customer care and vendor re- spect. “And I have to recognize my dedicated wife of 63 years who allowed me to pursue my various ventures and continues to support me,” he says. Helbach is deeply dedicated to his family and the com- pany, Pronschinske remembers. “He was always the dad that came rushing to my high school sporting events on time, most often still in suit and tie from a business trip or meeting. I never fully understood his passion for the cor- rugated industry until I started working in it alongside him many years later. Seeing the impact his innovations have had on many corrugated converting plants around the globe over his 60 years in the industry is impressive and gratifying. Dad was always about the customer first and we continue to operate under his cornerstone philosophy at Baysek today.” Visit www.baysek.com for more information.

of the process for their confidence and trust, beginning with Arrow Carton Company in Richfield, Wisconsin,” Adds David Waldoch, “When I joined my father-in-law at Baysek in 2000, we serviced 20+ machines. Today, Baysek ser- vices approximately 200 machines worldwide.” A key feature of the diecutter includes significantly less manpower than other methods. Clean and orderly finished units exit the machine ready for shipping preparation at the control of one operator. “Box plants are facing a lot of challenges with the la- bor shortage as one of the biggest,” Tim Engle says. “The Baysek C-170 only needing one operator is a perfect fit for those plants. It is easy to operate, simple to maintain, and offers pallet ready multiple out diecuts, with no nick- ing and no angel hair. I have heard this from more than one existing customer, ‘Every box plant in the US should have at least one Baysek.’” The newer EL-150 diecutter was built for short to me- dium runs, as well as large format diecutting. Available in 2019, the machine has gained in popularity with several deliveries scheduled for 2021. The I-6072 and IR-6072 load turners were first demon- strated at SuperCorrExpo 2012 in Atlanta. They were built at the request of a customer for his C-170 diecutter. Now it is common for customers to order a Baysek load turner with a new C-170 or retrofit one into an existing installation.

www.boardconvertingnews.com

August 9, 2021

Pamarco Showcases New Facility In Batavia, IL BY GREG KISHBAUGH

printing better together

Obsolescence comes quickly to companies that do not in- novate and grow. So, as it celebrates its 75th anniversary this year, anilox roll supplier Pamarco continues to intro- duce new technology, refine its processes, and find solu- tions to streamline the ways in which it operates. The company recently opened a new anilox manufac- turing facility in Batavia, Illinois, and, despite working on the new facility during the chaotic backdrop of the Covid-19 pandemic, managed to do so on time and under budget. The 36,000-square-foot greenfield facility was opened in June of last year. Pamarco has operated in Batavia for 61 years. The orig- inal location, opened in 1960, stands about two-and-a-half miles from the new location. In the original location, Pamar- co produced laser engraved and mechanically engraved anilox rolls. The mechanical roll production was moved to its Roselle, New Jersey, location, allowing the new facility to exclusively produce laser engraved ceramic anilox.

Anilox Rolls RESURFACING & ENGRAVING Our laser and mechanically engraved anilox rolls are dependable, high quality, and customized to your exact specications. Ink Proong IRIS & HANDPROOFERS With Iris, you can consistently create accurate, repeatable ink proofs on a complete spectrum of substrates. Have exacting proofs to meet LAB and Delta E targets at press side. Anilox Care CLEANING Pamarco has a full range of cleaning chemicals for water-based, solvent, and UV inking systems. Cleaning chemicals and products designed to maintain consistent volume of your anilox roll, improve print quality and boost productivity. Anilox Audits PROACTIVE CARE Roll audits offer long term tracking solutions and great value by allowing you the ability to budget, prioritize for planned maintenance and minimize production downtime.

Pamarco is the single source destination for all your exography printing needs, offering a myriad of products and services to help you get the job done right and on time, every time. Coupling this with our experienced and knowledgeable team, Pamarco can assist you with enhancing your quality while improving efciencies and productivity. We are your go-to printing solution provider! Contact Pamarco today to see what we can do for you!

“The old building presented too many organizational problems to overcome, we simply could not continue to grow efficiently in the old location,” said John Burgess, President, Flexo Division for Pamarco. “We wanted to cre- Pamarco’s old facility is about two-and-a-half miles from its new one in Batavia. The company could not continue to grow efficiently there as it presented organizational problems.

ate a new workspace that would benefit our employees, provide the capacity for continued growth and provide a venue to showcase our technology and edu- cate our customers. This new facility and the capital invested is designed to meet the ever-increasing demands from

Join us at SuperCorr Expo! Booth 2349

John Burgess

the market on precision, accuracy and response time.” The new building was designed with a bridge crane system, which allows materials to travel from workstation to workstation without the need for employees to move them manually. CONTINUED ON PAGE 28

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April 26, 2021

Machinery and Handling for the Corrugated Board Industry

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August 9, 2021 Machinery and Handling for the Corrugated Board Industry

Pamarco Showcases (CONT’D FROM PAGE 26)

Finally, a final inspection is performed and a cellbase certification is issued using ultra-precision white light in- terferometry measuring not only the depth of the cell but the shape and final cell volume of the anilox. Certifying that the roll or sleeve has been produced to the highest standard and to the customers specification.

Every roll at the facility begins its journey with an in- spection to identify the work needed to return the roll or sleeve to OEM specification. After initial inspection, anilox rolls move to the prep department, where the old ceram- ic is stripped, and repairs are made to prepare them for coating and then the laser engraving processes. These

Pamarco operates four laser engraving facilities, La Pal- ma, California; Atlanta, Georgia; Warrington, UK; and the new Batavia facility, each utilizing state-of-the-art technol- ogy. Consistency and repeatability remain the cornerstone of flexo printing and Pamarco’s ERP system ties its facilities and specifically its lasers together for perfect matching/ repeatability of an engraving. This allows its laser opera- A new ALE laser was installed in Batavia earlier this year.

BCN(US)202107(o)(出血5mm).pdf 1 2021/7/8 上午 10:45:15 At the beginning of this year, a new 3.5M ALE laser was installed in Batavia, the third fiber optic solid state laser at the facility. The laser is fully equipped to produce rolls and sleeves in all screen count and volume ranges. critical processes are controlled to the highest standards, and independent laboratory testing is regularly performed to certify process control.

CONTINUED ON PAGE 30

CMY

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August 9, 2021

Kolbus Hycorr understands that quality is a reflection of the great care that takes place throughout the entire manufacturing process. From the time we pour the first casting until the equipment is prepared for shipment, our manufacturing team owns every step to maintain strict quality control. Our customers can rest easy knowing that their equipment has been built with great attention to detail. FOCUS ON QUALITY

KOLBUS America Inc. 216-931-5100 sales@kolbus.com

Pamarco Showcases (CONT’D FROM PAGE 28)

PCG will also continue its impressive streak of acquir- ing at least one new major piece of machinery every year for the past 11 years, according to Richard Goldberg, the company’s Vice President of Operations, who manages and monitors the super plant’s constant growth and con- tinuous improvement initiatives. Last year’s “investment” was that of an incredibly engineered Jumbo Flexo Folder Gluer by Engico, a small Italian manufacturer of converting machinery still relatively new to this continent. The story of how an Engico Jumbo came to be the latest piece of equipment now humming away on PCG’s production floor is almost as intriguing as the machine’s engineering itself. The story began during a late-night fishing expedition at AICC’s Northeast Region Meeting in Atlantic City, New Jersey, in August 2019. Goldberg started chatting with Keith Umlauf, Executive VP of Sales at Haire Group, which had recently begun representing Engico in North America. The conversation somehow got around to machinery – surprise! – when Goldberg mentioned that PCG was going to be replacing its flexo and jumbo. Umlauf told him about Engico’s machine and its too-good-to-be-true efficiencies. Goldberg was intrigued. He arranged a meeting with Um- lauf and Engico’s founder and engineer, Rinaldo Benzoni, and PCG’s owner, Larry Grossbard, who was impressed by what he heard. CONTINUED ON PAGE 32 PCG Continues (CONT’D FROM PAGE 1 )

tors in any location to match engravings produced in other locations, a great benefit as converters standardize pro- duction jobs in multiple locations.

Pamarco’s new facility in Batavia, Illinois.

At this moment in time, perhaps nothing is as important to customers — and consumers — as the protection of the environment, and sustainability. Pamarco has made cer- tain that those criteria have all been met at the new facility. “In addition to focusing on precision and quality we also focused on the en- vironment, this is a completely green facility,” said David Drozd, VP Man- ufacturing, Flexo Division. “We don’t produce hazardous waste, all biproducts of the manufac- turing process are recyclable.” David Drozd

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August 9, 2021

PCG Continues (CONT’D FROM PAGE 30)

The machine in question was a dual-size manufacturing marvel with 66-inch/99-inch cutting dies and print heads. It was essentially two machines in one. “The ability to cut and print from 66-inches to 99-inches, basically from the smallest box to the biggest, is huge,” says Goldberg. “The integrated stitch heads can stitch jumbo boxes on the fly at normal speed, skip feed and double skip feed. You can even run end slots and trays and tubes.” (PCG ultimate- ly purchased a customized model with three print heads; two are 66-inches and the third is 99-inches). “Engico has been around for decades. In the 90s and into the early 2000s they built a slotting section that is unique and retrofittable in other OEM machines. It’s no se- cret the key to a square box is directly linked to the slot- ting section. Engico’s is unlike anything you’ve seen on any other machine,” adds Haire’s Umlauf. “The integration of quick set up capability on the print units slotting section and die cut section, launched Engico into a league of their own. They’re doing with a jumbo machine what others are doing on a mini, including having the ability to set up while running.” Miracle Machine So where has Engico’s “miracle machine” been all our lives? The technology had its roots in the early 1990s, which was the advent of Just In Time (JIT) delivery. “We wanted to improve the flexibility and speed for converters running boxes on large machines,” said Engico’s Benzoni.

Goldberg performed his requisite “due diligence,” which he does before making any PCG machinery pur- chase. He did research, he asked questions and for “intel” on the Engico he “poked around” Italy, where his industry connections run long and deep. “Everyone I spoke to in Italy had rave reviews not only about Engico as a compa-

ny and the way it did business, but they couldn’t speak more highly of Rinaldo Benzoni, the company’s founder and mastermind behind the technology,” says Goldberg. “That made our decision to purchase the new machine an easy one.” The Engico dual-sized 66/99-inch Jumbo Flexo Folder Gluer

CONTINUED ON PAGE 34

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August 9, 2021

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