Board Converting News, September 21, 2020

BoardConverting Serving the North American Corrugated and Folding Carton Industries for 36 years September 21, 2020 VOL. 36, NO. 38

Getting The Job Done With New Technology BY JACKIE SCHULTZ

FBA: Shipments Slip In August

Industry shipments of corrugated products decreased 0.6 percent, from 33.495 bsf in Au- gust of 2019 to 34.285 bsf in August of 2020, the Fibre Box Association (FBA) reported. The decrease is partially due to the fact there was one less shipping day in August of 2020. Av- erage week shipments, however, increased 4.1 percent, from 7.840 bsf in 2019 to 8.163 bsf in 2020. Shipments of corrugated products are up 0.7 percent year-to-date. Containerboard consumption decreased 1.3 percent, from 2.8427 million tons in Au- gust of 2019, to 2.8061 million tons in August of 2020. Consumption is up 0.8 percent year- to-date over 2019, from 21.5716 million tons to 21.7415 million tons. Containerboard inventory at corrugator plants decreased 5.2 percent, from 2.0214 million tons in July to 1.9155 million tons in Au- gust 2020. Weeks of supply shrunk from 3.2 in July to 2.9 in August, or 9.4 percent. The American Forest & Paper Associa- tion (AF&PA) reported that operating rates increased from 89.4 percent in July to 92.1 percent in August. Kraft linerboard mills ran at 93.0 percent and the corrugating medium rate was 92.1 percent.

The Shelby Company has been manufacturing folding cartons for the Northeast Ohio market for almost a century. Founded in 1923 in Shelby, Ohio, it relocated in the 1930s to Cleveland. In 1968 it built and moved into its current 35,000-square-foot facility in the Cleveland suburb of

Westlake. Over the years folding cartons have remained the principal product, primarily for the food, pharmaceutical, and automotive indus- tries. The company also offers sleeves, blister cards, posters, counter displays and various other types of specialized packaging. During a recent Zoom video conference, President and owner Rich- ard J. Rapacz talked about the company’s successful long existence, attributing it to the core values of providing customers with “top notch service” and creative solutions. Rapacz, who purchased The Shelby Company in 1993, says the key is hiring people who have the qualities that align with those value propositions. “Empathy, a caring attitude, selflessness, those are important qualities. We want people in the com- pany to be responsive to co-workers and customers. We try to manage our company to a high degree of the Golden Rule – do unto others. Our current team all have that attitude.” Rapacz sets a good example, sending hand written letters to every prospect. He is gradually transitioning the leadership of the company to a new team of managers, some of whom have spent most of their careers in the folding carton industry and others who are new to the industry. Mat- At The Shelby Company, folding cartons are produced on five main machine lines, all of which can be monitored remotely.

WHAT’S INSIDE 8 Weyerhaeuser To Support Wildlife Relief In Northwest 10 Chicago Electric Establishes New Management Team 14 DS Smith Announces New Appointments Across U.S 38 Getting The Facts Straight On Ontario’s Blue Box



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.


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.

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September 21, 2020

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


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


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

AF&PA Releases August Packaging Papers, Containerboard Reports The American Forest & Paper Association (AF&PA) has released its August 2020 Packaging Papers and Con- tainerboard Monthly reports. Total packaging papers and specialty packaging shipments in August increased one percent compared to August 2019. • The operating rate was 85.2 percent, down 2.7 points from August 2019 and down 1.0 points year-to-date. • Mill inventories at the end of August increased 4,000 short tons from the previous month and were up 12,000 short tons compared to August 2019. Total containerboard production in August remained essentially flat (+0.4 percent) compared to August 2019. It was up four percent when compared to the same eight months of 2019. • August 2020 production of containerboard for export decreased nine percent compared to the same month last year; it was up 23 percent year-to-date. • The containerboard operating rate was 92.1 percent, essentially flat (-0.4 pts.) from August 2019 and up 2.7 points year-to-date. • Mill inventories of containerboard at the end of August increased 35,000 short tons from the previous month and were up 68,000 short tons compared to August 2019.

The Price is Right More readers rely on Board Converting News’ containerboard pricing to negotiate their contracts. SUBSCRIBE TODAY.

Robyn Smith at 910-553-4055 / Len Prazych at 518-366-9017 /

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September 21, 2020

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

E. Coast Midwest South-SW S. CA N.CA/WA-OR US Aver.

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200# 275#



$62.69 $82.80

$85.35 119.54

$73.13 101.29












107.46 118.45

114.69 129.32

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#

Semi-Chem Medium

East West

$920.00 $965.00

$910.00 $945.00


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September 21, 2020

AICC Webinar To Focus On Hazmat Regulations For Box Fabricators AICC, The Independent Packaging Association, is offering Executive Strategies: Incorporation of Hazmat Regulations for Box Fabricators, a new webinar, Thursday, October 1, at 2:00 pm EST. This webinar outlines the structure of the HMR with re- spect to management responsibility in the evaluation and control of regulatory and other risks in the context of cap- turing revenue associated with performing work on behalf of Hazmat customers. Registration for Executive Strategies: Incorporation of Hazmat Regulations for Box Fabricators is $250 for mem- bers. This webinar is part of the All Access Pass. Pass hold- ers can use their promo code to register at no cost. AICC members lower training costs and streamline payments with the All Access Pass. For one payment of $1,695, participating companies are given a code that all employees can use to register for every webinar through August 2021. With more than 50 webinars scheduled, the All Access Pass represents a value of $12,500. Learn more at . Register for Executive Strategies: Incorporation of Hazmat Regulations for Box Fabricators at www.AICCbox. org/Calendar . Direct questions to Taryn Pyle at tpyle@aic-, or (703) 836-2422.

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September 21, 2020

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.


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


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


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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




Roller Shoe


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 working 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 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.

ance from steam to paper surface results in fast heat flow

Weyerhaeuser To Support Wildlife Relief In Pacific Northwest Seattle, Washington based Weyerhaeuser Company an- nounced it is making an immediate $150,000 donation to the Red Cross to support emergency response efforts in communities affected by wildfires in the Pacific North- west and particularly in Oregon. With multiple fires still burning across that state, tens of thousands of residents have been displaced, and countless homes and structures destroyed. The full scope of impacts is not yet clear, and Weyerhaeuser is committed to supporting affected people and communities as they begin recovery. “These fires have brought devastation and trauma to many communities where our employees live and work,” said Devin W. Stockfish, President and CEO. “This dona- tion is just a first step in helping these communities re- cover and heal. Our company has been operating in the Pacific Northwest since 1900, and we’re going to continue to stay engaged and make sure all these areas are able to recover and thrive again.” Weyerhaeuser manages approximately 1.6 million acres of forests in Oregon and 1.3 million acres of forests in Washington. The company operates three mills in Ore- gon and two mills in Washington, one building materials distribution center in each state, and several nurseries, or- chards and offices across both states.

Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month August 2020



Percent Change Avg Week Percent Change

2020 2019

34.285 34.495


8.163 7.840


Industry Total

Year-to Date

August 2020



Percent Change Avg Week Percent Change

2020 2019

265.688 262.164


7.814 7.756


Industry Total

Containerboard Consumption (Thousands of Tons)



Percent Change Year-to-Date Percent Change

2020 2019

2.8061 2.8427


21.7415 21.5716


Container Board Inventory - Corrugator Plants (Thousands of Tons)

Corrugator Plants Only


Percent Change Weeks of Supply

Percent Change


1.9155 2.0214


2.9 3.2



Shipping Days




2020 2019

21 22

170 169

SOURCE: Fibre Box Association


September 21, 2020



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Chicago Electric Establishes New Management Team

cently with Wes-Tech Automation, after serving over 20 years as General Manager of Reis/Kuka Robotics in Chica- go. “I am humbled and honored to lead Chicago Electric and this incredibly talented team into the next phase of our company’s history,” said Clark. McIlroy has over 30 years in the automation industry, most recently as General Manager for JR Automation. “It’s such an honor to be part of the next chapter in Chi-

Carol Stream, Illinois based Chicago Electric Sales, Inc. has announced the establishment of a new Management team. The addition of Christopher Clark as President and Christopher McIlroy as VP of Operations has positioned

cago Electric’s 110-year history, as well as the opportunity to work alongside such a great c u s t ome r - f o - cused team,” McIlroy added, “The addi- tion of Chris and Chris starts a new era for Chi- cago Electric as

From left, Robert Kaska, VP of Sales & Marketing; Chris Clark, President; and Chris McIlroy, VP of Operations.

Chicago Electric for significant growth. Robert Kaska, the former President with 40 years at the company his grand- father started in 1910, continues in a new role as VP of Sales & Marketing. The new leadership team brings over 50 years of com- bined experience to Chicago Electric. Clark was most re-

we celebrate our next century in business,” said Kaska. “With the support of our parent company, BHS, we are po- sitioned for rapid growth in Robotics and Logistics, Cor- rugated Upgrades, and Automation Systems Integration.” For more information, contact Kaska at kaska@chica- or (630) 784-0800.

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Baler Service Company, Paper And Dust Pros Adds Messerly To Team Grandview, Missouri based Baler Service Company and Paper and Dust Pros reported that Robyn Messerly has

Baler Service Company and Paper and Dust Pros pro- vide air system design and installation and also sell new, used and refurbished equipment. It can also refurbish equipment on site or at its locations. Contact Messerly at (816) 966.8916 ext. 409 or parts@ Gable Named Managing Partner Of BW Forsyth Partners St. Louis, Missouri based BW Forsyth Partners, Barry-Weh- miller’s hybrid equity firm, has promoted Ryan Gable to Managing Partner. He steps into the role after co-leading the organization with Kyle Chapman, who was recent- ly promoted to Barry-Wehmiller President. Chapman will continue to provide strategic oversight and guidance for BW Forsyth Partners.

joined the team as Service Coor- dinator and Parts Manager. She will assume responsibility for all parts-related activity, technician service and maintenance sched- uling. With more than 10 years’ ex- perience, Messerly has devel- oped and maintained strong

customer and vendor relationships and will continue to provide the excellent service that customers have come to expect from both companies. Robyn Messerly

After working at Bank of America, Gable cofounded BW Forsyth Partners in 2009, alongside Chapman and Barry-Wehmill- er board member Chet Walker. Since that

time, the organi- zation has grown to a thriving $600 million-plus firm. Comprised of 29 acquisitions, BW Forsyth Part- ners’ four plat- forms serve var-

Ryan Gable

ious markets, including medical device automation and testing equipment, infra- structure equipment and services, printing process automation, and insurance and risk management services. “We want to prove that you can invest in businesses utilizing a more human ap- proach, and still drive superior gains for all stakeholders,” said Chapman. “Ryan fully embraces this approach, and has the high- est level of integrity, an intense work ethic, and a wealth of experience. He is the kind of leader who is willing to roll up his sleeves and lean in with our leadership teams to ex- ecute the organization’s unique investment strategy to buy, build and hold.” “Our hybrid equity model has been suc- cessful because of our long-term approach and the resources we provide,” said Gable. “The majority of our acquisitions have been of family-owned businesses with owners who truly care about the long-term implica- tions of selling their companies. The leader- ship teams within our platforms have never been stronger and we are very confident in our ability to continue to grow.”

John Kelley President at Dusobox

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September 21, 2020

DS Smith Announces New Hires, Appointments Across The U.S.

Atlanta, Georgia based DS Smith announced the appointment of five key leaders within the North America division to compliment an expand- ing U.S. footprint. These strategic hires will be involved in some of DS Smith’s key initiatives for the Paper and Packaging divisions, following

Packaging ERP Algorithmic Scheduling Web-Based Access Online Customer Portals

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

on DS Smith’s expansion to the U.S. and opening of its Atlanta head- quarters, the launch of its 550,000-square-foot packaging facility in Lebanon, Indiana, and the opening of its first U.S. recycling facility in Reading, Pennsylvania. The new hires are: • Ryan Roberts will serve as the sheeter business unit general manag- er. Roberts’ background includes senior leadership roles in contract packaging, manufacturing engineering, sales, marketing and com- mercial operations in the U.S. and Singapore for Unilever and Sealed Air. Roberts is based out of DS Smith’s headquarters in Atlanta. • Troy Hagenbuch joins DS Smith’s Columbia, SC, Greencoat facility as the Specialty Business Unit General Manager. Hagenbuch brings leadership experience from IP, FiberMark and Cenveo Corp. and is an electrical engineer graduate from Penn State University. • Melanie Galloway, Vice President of Sales, Marketing and Innovation for Packaging, will bring her experience from FMC Corp., Kemin In- dustries, JM Huber and MacDermid Graphic Solutions to the role. A chemical engineer, pulp and paper technology graduate from North Carolina State Galloway is based out of headquarters in Atlanta. • Steven Pittler, Sales Director for DS Smith’s Lebanon, Indiana, pack- aging facility. Previously, Pittler was midwest regional manager at Atlantic Tape and Packaging. Pittler brings extensive knowledge in operations, as well as commercial experience across multiple sites. • Adam Olson, Sales Director for Greencoat, brings extensive food in- dustry experience with companies such as Sysco, where he imple- mented strategies to drive top line growth while building relation- ships with key customers. Olson is based in Baltimore, Maryland. “As we expand our sustainable packaging, paper and recycling op- erations in North America, these new hires will help us continue to inno- vate and strengthen the vision and leadership in North America that DS Smith customers across the globe expect, and carry out our company purpose of ‘Redefining packaging for a changing world,’” said Mark Ush- pol, Managing Director of Packaging at DS Smith. DS Smith’s 550,000-square-foot packaging facility in Lebanon, Indiana.

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AICC Webinar To Offer Tips On What Plates Work Best


AICC, The Independent Packaging Association, with the support of AICC Education Investor Printron, is offering Anatomy Complete: Tips on What Plates Work Best, a new webinar, Wednesday, October 7, at 2:00 pm EST. This webinar will allow attendees to review the flexo process, with Printron providing information on how all parts need to work together for ultimate success. Plates are the “brains” of the process, and the webinar will discuss which plate and mounting systems work best for different applications. Digital workflow is here and this webinar will show attendees how it can benefit their companies. Registration for Anatomy Complete: Tips on What Plates Work Best is $100 for members. This webinar is part of the All Access Pass. Pass holders can use their promo code to register at no additional cost. AICC members lower training costs and streamline payments with the All Access Pass. For one payment of $1,695, participating companies are given a code that all employees can use to register for every webinar through August 2021. With more than 50 webinars scheduled, the All Access Pass represents a value of $12,500. Learn more at . Register for Anatomy Complete: Tips on What Plates Work Best at .

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Robyn Smith at 910-553-4055 / Len Prazych at 518-366-9017 /


September 21, 2020

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Registration Opens For Web-Based PACK EXPO Connects 2020 Attendee registration is now open for one of the indus- try’s most engaging and innovative web-based events, PACK EXPO Connects 2020, taking place November 9-13, 2020. PACK EXPO Connects will use the power of technology to connect the packaging and processing industry during these challenging times. In creating this unique experi- ence, PMMI Media Group combined its digital marketing expertise and extensive industry knowledge into one intu- itive interactive platform, making live engagement with ex- hibitors easy. With over 600 solutions-providers featuring state-of-the-art virtual showrooms, attendees can spend less time and effort searching for the latest innovations and more time fostering connections via live chats, live product demos and interactive educational opportunities. At the heart of PACK EXPO Connects is what attend- ees have asked for and what they value most: technology in action. With more than 2,600 live product demos over five days, attendees will be able to watch demonstrations of machinery and products in 15-minute increments. At- tendees can schedule one-on-one live chats with prod- uct and technical experts to find targeted solutions and expeditiously search for specific products among 12 tar- geted categories.

We recognize how busy today’s packaging profes- sional is and made it our goal for PACK EXPO Connects 2020 to maximize attendees’ time, making it easy to con- nect with the right suppliers remotely,” says Joe Angel, President, PMMI Media Group. In addition to exhibitor interaction, PACK EXPO Con- nects offers world-class virtual educational opportuni- ties covering the most pertinent industry trends. These include the daily Jumpstart to kick-off each day of the event, complete with a special Packaging and Process- ing Women’s Leadership Network session on Tuesday, November 10, featuring Jan Tharp, President and CEO at Bumble Bee Foods. Innovation Stages, Trend Chats and The Solution Room will feature expert-led interactive educational sessions, and the Showcase of Packaging Innovations will feature a web portal full of the latest in award-winning packaging from PACK EXPO Connects partners. Daily Download sessions with PMMI Media Group editors will discuss each day’s PACK EXPO Con- nects highlights. The MyConnects Planner will serve as the first stop for every attendee after registration, assisting in advance planning for the most efficient PACK EXPO Connects ex- perience. An Outlook calendar integration is available for attendees to add events to their Outlook calendars for ease of reference, ensuring the most efficient use of time during event days. Visit for more.



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FTA Announces Details For Fall Virtual Conference Sessions

• Moving Through Reality with Virtual Help: Shining a spotlight on people and companies who are success- fully conducting business despite the obstacles pre- sented by COVID-19 • File Preparation for Successful Print Production: Pre- press techniques to match flexography and digital, and an examination of print samples made with both technologies • Color Management: The Methods & the Madness: Dissecting color experts’ recommendations on how to meet brand owner color expectations and evaluating tools used in today’s color managed workflow • Print Quality Scoring: Friend or Foe?: An inside look at print quality scoring from a brand that requires it, agencies who monitor it, and printers who control it • Promoting Success at the Intersection of Technology & Emotion: How Haney bridges the gap between the aesthetic and technical components of package de- velopment, and how sustainability adds an emotional element with invisible benefits • Delivered through FTA’s Virtual Conference Center, presentations are interactive: Attendees can partici- pate in live polls, ask questions for Q&As, and interact with speakers before and after the event Virtual Fall Conference 2020 registration includes ac- cess to all six session, plus a 10-day Virtual Exhibit Visit . Register by September 28 to receive print samples, a loupe and other resources.

The Flexographic Technical Association (FTA) has an- nounced the session details for Virtual Fall Conference 2020, its fully online, three-day technical conference themed “Collaboration Achieves Perfect Vision.” Through six sessions and more than 20 technical pre- sentations, speakers will explore how design, prepress best practices, color management, plates and pressroom technologies come together to deliver the perfect pack- age. Sessions are scheduled for October 5-7. “Package printing is an essential business. Now, more than ever, brands are relying on their print partners to meet a surging demand for products that are indispens- able to everyday life. And printers are turning to the members of their supply chain for assistance, guidance and support,” said Conference Chair Paul Lancelle of Miraclon Corp. “Virtual Fall Conference 2020’s techni- cal content will focus on collaboration between every- one involved—brands, printers and suppliers—to deliver high-quality print, meet extreme demand and prepare for the future.” The sessions and their descriptions are: • Evaluation, Optimization, Control: The Complete Plate Making Package: Building an approach to adopt ev- er-changing plating technologies when transitioning legacy files, while maintaining process control


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September 21, 2020

Turn Trim Waste into Revenue

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Getting The Job Done (CONT’D FROM PAGE 1 )

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thew Tousley, who has 35 years of industry experience, was recently appointed Executive VP. He joined Shelby 14 years ago as a package engineer and then moved to sales. Previously he was with CardPak Inc., another Cleve- land-based folding carton manufacturer. Jeff Pascarella joined Shelby about a year and a half ago as General Man- ager. He has 23 years of industry experience, primarily at Graphic Packaging’s Cleveland location. The two newest members of the management team are Martina Cook, who heads up business development and marketing, and Don- yah Perine, who is the controller. “We’re celebrating our 97th year in business and we’re extremely proud of our history, however, we realize that markets and business is changing and the company has to constantly revitalize itself. The addition of Jeff, Martina and Donyah and the promotion of Matt to a leadership position provides this revitalization,” Rapacz says. “We have to be thinking about where we are today, where do we want to go, and how do we get there. And the key element for any company is its management and personnel. It’s a major re- sponsibility for a current owner to make sure this company survives and does well. We have a staff on board right now that can carry the company into the future.” Rapacz has allowed the new leadership team a great deal of freedom to implement their ideas for future growth.

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September 21, 2020

Getting The Job Done (CONT’D FROM PAGE 22)

The results have been impressive. Last year the company had double digit growth and is on track this year for similar results. The team has admirable goals. “Dick and I have a synergy especially in our thought process and our love and desire for this company,” Tousley says. “We should be the only supplier in our region for folding cartons. That’s what we want to become.” Technology has provided the cornerstone for growth, facilitating Shelby’s ability to communicate with customers and meet their needs, especially with the recent challeng- es created by COVID-19. Software management systems, video conferencing and even the telephone have been essential tools. “The lack of a physical visit can be filled with a telephone conversation, continuing to know what they need, what they’re doing,” he says. “Right now we’re

trying to make plans to start seeing our customers again. That is part of our philosophy. We have to get in front of the customers and see what they’re packaging, how they’re packaging it and what tools or resources they’re using so we can offer them the most common sense solution.” For now the message to customers is, “We’re here, we’re open. Within the first day of the Governor ordering all businesses closed, Jeff, Donyah and I, contacted all of our customers and all of our suppliers. It was a full court press,” he says. “We made sure that we’re going to sustain our business with the thought that we have to keep our customers in business.” Continuous Improvement To drive growth and continuous improvement The Shelby Company is leveraging other aspects of technol- ogy, such as implementing IIOT with the assistance of The Shelby Company is using software technology to drive continuous improvements in all departments.



September 21, 2020

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Getting The Job Done (CONT’D FROM PAGE 24)

CartonERP is Workpack Solutions’ custom-designed system for the operational and administrative processes of folding carton plants. Tousley says it is a valuable data tracking tool. “We were very poor at data collection as far

MAGNET (Manufacturing Advocacy and Growth Network), a government organization that supports small to mid-size

For this article, Jackie Schultz, bottom row, second from right, interviewed The Shelby Company management team via Zoom.

manufacturers, and using new ERP software from Work- pack Solutions, a business software company in Michigan.

as manufacturing and finding out our true costs and per- CONTINUED ON PAGE 28

We’ve got our customers covered… …with our fiberglass backed, boltless, full double-wide blankets and an extensive inventory of corrugated parts needed by virtually every box plant in the country. The innovator of the original fiberglass-backed knuckle locking anvil cover, Stafford is the industry’s go-to source for everything corrugated. 800-282-5787 IS THE MANUFACTURER OF STAFFORD ANVIL COVERS


September 21, 2020


New solutions for increased productivity

Getting The Job Done (CONT’D FROM PAGE 26)

Employees have computer terminals that they use to access the production schedule. Previously, they typed entries into the computer. “We not only streamlined that but we also started to get more accurate data. We are close to collecting almost everything that we need. It al- lowed us to see where we’re at, how we’re doing and how do we continuously improve.

formances. We’re about 90 percent there which is incred- ible considering the short amount of time that we’ve been doing it. We still have a ways to go on the interpretation of that data and what we do with it. Jeff and Donyah and I meet weekly and that’s probably most of what we talk about, using the software for bettering our management styles and our communication. We work our sales team through it. It’s trying to find better ways of efficiency for our employees through the CartonERP system and we spend a lot of time working with Workpack. Donyah is a perfec- tionist so she is always questioning everything.” Kristie Vos, co-founder of Workpack Solutions, says Perine is always looking for more ways to use the soft- ware. “She is asking really good questions as well as look- ing at costing and how profitable the jobs are and how she can use the shop floor data to analyze the efficiencies in the work force.” Shelby has five main machine lines, including a sev- en-color Heidelberg press, two Bobst diecutters, and Bobst and Post folder-gluers. The company also has a sheeter and full pre-press capabilities. When Pascarella began using CartonERP for production tasks, he says he was impressed. “We recognized that there was a lot more that the system could do for us. It started with data collec- tion and removing the paperwork from production report- ing which used to be hand-typed into the system,” he says.

“Year to date our printing department has a nine per- cent run time efficiency increase year over year and our cutting department gained 150 hours year over year in makereadies,” he says. CartonERP’s data collection also has been expanded to other departments, such as shipping and sales. “It helped CONTINUED ON PAGE 30 With the onset of COVID-19, technology is keeping employees and customers connected.

Do you need printed sheets? We have your answer.. Introducing Heartland’s ColorCorr. This is “flexo-printing in the round”. On our corrugator we can print up to 109” wide. The advantage is that we can print the equivalent of ½ roll at a time and not be required to keep several rolls of very expensive preprinted paper on the floor. Much less waste and risk. In continual print mode, we use either laser-engraved rubber rolls or solid rubber rolls to print a “flood coat” or a repeating pattern. If we are printing a repeating pattern, we can run a two-color design on the paper. Customers have found that running sheets we print can allow them to run a lighter-grade due to reduced caliper loss, and in some cases eliminate one or more machine passes.

For more information contact: Charlie Freeman | 816-500-8889 | Tim Kramer | 816-841-8317 |


September 21, 2020

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