BoardConverting Serving the North American Corrugated and Folding Carton Industries for 37 years August 23, 2021 VOL. 37, NO. 34
Complete Design & Packaging Enjoys Digital Printing Growth BY JACKIE SCHULTZ For corrugated manufacturers interested in how the addition of a pro- duction digital printer impacts a plant’s product mix and work flow, look no further than Complete Design & Packaging (CDP). It has been three years since the mid-sized independent in Concord, North Carolina, installed an EFI Nozomi singlepass corrugated printer, the first in the U.S. Since then, many changes were implemented and new equipment added as digital printing became a larger share of the product mix.
SupplyOne, Inc. Acquires Wilheit Packaging, LLC Newtown Square, Pennsylvania, based Sup- plyOne, Inc., one of the largest independent suppliers of corrugated and other value-add- ed packaging products and services in the U.S., announced last week it acquired Wilheit Packaging, LLC., a privately-held distributor of shipping, packaging and maintenance prod- ucts headquartered in Gainesville, Georgia. Founded in 1953, by Tom Wilheit, Wilheit Packaging got its start supplying packaging for the poultry and textile industries in Geor- gia. Under the leadership of Philip Wilheit, Sr., the company has become a leading supplier to the Georgia, Alabama and Carolina market- place, and a strong presence in corrugated, poly films and end-of-line packaging. Today the company serves food processors and in- dustrial manufacturers alike in more than 15 states from their facilities in Gainesville and Atlanta, Georgia; Wilmington and Warsaw, North Carolina; and Arab, Alabama. As the company has grown, Wilheit Pack- aging has maintained a reputation for its for- ward-thinking, customer-focused approach to its customers’ packaging challenges. As an early leader in sustainability, the company
Prior to installing the Nozomi, CDP did minimal digital printing, pri- marily for short runs and prototypes. Today, digitally printed packaging and displays account for about 50 percent of the entire portfolio. The remainder is industrial packaging, which includes flexo up to four-color, litho top sheets, and partitions, dividers, shrouds and caps. The com- pany also has an EFI VUTEk® h5 multi-pass digital printer for running short run business, anywhere from 50 to 500 pieces. Most of the litho and all of the six-color flexo jobs have been con- verted to digital, says President Howard Bertram. “But that’s not why we got the Nozomi. We got it to grow our model and add new busi- ness.” And grow it has. Compared to three years ago, the company is 40 percent larger from a sales and personnel standpoint. Fifty-six people were hired just within the last year and there are now seven employees in pre-press versus only one a few years ago. In addition, a second shift was recently added and major facility renovations were CONTINUED ON PAGE 24 Howard Bertram with his daughter, Sarah Mozingo, and son, Ross, who both work at the company.
CONTINUED ON PAGE 5
WHAT’S INSIDE 8 Haire Group’s Muller Inducted Into AICC/RISI Hall Of Fame 10 Sonoco’s Project Horizon To Be Completed In 2022 14 Vanguard Co. Wins Gold, Silver At Box Manufacturing Olympics 36 Esko Makes Education Donation To Support Future Generations
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.
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2 August 23, 2021
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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4 August 23, 2021
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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 indicated average. Transactions may be completed at any time at a price agreed upon by seller and purchaser.
REGION E. Coast Midwest Southeast Southwest
42# Kraft liner
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
8.34
8.34
8.34
8.34
275# DBL-WALL 350# DBL-WALL
107.46 118.45
114.69 129.32
116.54 137.25 117.82 145.56
141.08 148.46
122.76 131.80
CANADIAN SHEET PRICES (AVERAGE) In Canadian Dollars, per 1MSF, local delivery included, under 50MSF single item order, truckload delivery. 200# 275# Oyster UC 275#DW 350#DW $78.56 $99.18 $9.00 $96.32 $105.83 CANADIAN LINERBOARD & MEDIUM The average prices reported are tabulated from prices PAID by various sources throughout Canada. Prices may be higher or lower in various areas of the country. The prices tabulated here are intended only for purposes of reference. They do not connote any commitment to sell any material at the indicated average. Transactions may be completed at any time at a price agreed upon by seller and purchaser. Prices are Canadian $ and per metric ton.
42# Kraft Liner 26#
Semi-Chem Medium
East West
$970.00
$960.00 $995.00
$1,015.00
SupplyOne Acquires (CONT’D FROM PAGE 1 )
distinguished itself through logistics and waste diversion solutions in partnership with several waste and recycling centers. “Our expanded capabilities mean new growth opportu- nities for our employees and new efficiencies and savings for our customers,” said Philip Wilheit, CEO of Wilheit Pack- aging. “As a SupplyOne company, we will deliver even more benefits to our customers through access to corru- gated converting capabilities, packaging automation, and for our food processing customers, the broadest range of primary packaging solutions available.” The acquisition of Wilheit Packaging is SupplyOne’s third this year. The addition further expands SupplyOne’s footprint in the region and enhances the value created for customers by offering manufacturers and processors the benefits of custom manufacturing, packaging products, packaging equipment, services, and programs from a sin- gle point of contact. “Wilheit Packaging’s focus on helping their customers be more profitable mirrors our own. The synergies that re- sult from combining SupplyOne’s manufacturing expertise, services, and programs with Wilheit’s impressive distribu- tion capabilities position the company well for continued growth,” said William Leith, CEO and President of Supply- One. “We are delighted to welcome their exceptional em- ployees into the SupplyOne family.”
5
www.boardconvertingnews.com
August 23, 2021
Fastmarkets: OCC Prices Hit Four-Year High
Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month June 2021
For the third consecutive month, US recovered paper pric- ing has increased in every domestic region for all grades, according to industry pricing analysts at Fastmarkets. High demand and low supply shot up old corrugated container (OCC) pricing by $40 per ton at the FOB seller’s dock in the South. The August rise is the 10th month in a row for US OCC pricing hikes in North America. OCC’s national average, at $159 per ton at the FOB seller’s dock in August, is at its highest pricing point in four years. This month marks the seventh month in four years that OCC’s US average has surpassed $100 per ton, and the third month in a row since July’s $129 per ton and June’s $109 per ton. Average pricing for OCC in August has increased $30 per ton compared with July’s $129 per ton. It is up 174 per- cent compared to August 2020. While all U.S. mills contin- ue to have demand for bulk grades. According to Fastmar- kets sources, one of the largest consumers of recovered fiber sought tons off both US coasts for its mills in the US interior. This action competes with the export market to keep tons domestic. In addition to major U.S. mills seeking OCC tons, sourc- es said mills in Mexico were pulling tons from the US Mid- west via truck and paying premiums, up to $40 per ton.
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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6
August 23, 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
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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.
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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
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Roller Shoe
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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.
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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.
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ance from steam to paper surface results in fast heat flow
Haire Group’s Muller Inducted Into AICC/RISI Fastmarkets Hall Of Fame Douglas J. Muller of Merrillville, Indiana based Haire Group was inducted into the AICC/RISI Fastmarkets Hall of Fame during the third general session of SuperCorrExpo 2021 on Wednesday, August 11, in Orlando, Florida.
friends were peppered with anecdotes that portrayed him as the lovable, loyal and caring professional he is. Muller’s first job out of college was with Tom Haire, who’d just started his own company in Indiana. Muller joined the fledging Haire Group as its first salesman and its second employee. As the company grew, Muller took on more responsibilities, eventually becoming General Manager in 1981. In 1986, Haire expanded into its offices and manufacturing space in Merrillville, Indiana. Tom Haire retired and Muller took over what was then a 10-person company, which continued to grow. Under Muller’s lead- ership, Haire Group formed a partnership with Dong Fang in 2005 and as the company’s sole North American repre- sentative, Haire Group put more than 100 Apstar die cut- ters and flexo folder gluers into service. “There are so many people I want to thank for their friendship, their guidance and their support throughout my career,” said Muller in his acceptance speech. “I certainly want to thank Tom Haire, who took a chance on a young man right out of college, newly married and who needed a job. I must also thank the most important person in my life – I hit the jackpot 47 years ago when I married Linda – and she deserves this award as much as I do. I’m a very blessed individual. I’m also the guy who feels he never deserves the recognition, but I’ll take it.” Haire Group held a celebration dinner in Muller’s hon- or at the Capital Grille in Orlando, where over 90 people celebrated one of the corrugated industry’s true leaders.
Muller was introduced by way of 10-minute video that documented his more than 45 years in the industry. Ac- colades from Muller’s employees, industry colleagues and AICC Chairman Gene Marino, right, presents Doug Muller of Haire Group with a plaque honoring him as the newest induct- ee into the AICC/RISI Fastmarkets Hall of Fame.
8 August 23, 2021
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Oregon’s Governor Signs EPR Bill Into Law
Sonoco’s Project Horizon To Be Completed In 2022
Oregon SB 582, the extended producer responsibility (EPR) for paper and packaging bill, was signed into law by Governor Kate Brown on August 6, 2021. The bill will require that packaging and printing & writing papers be re- cycled through one or more producer responsibility orga- nizations (PROs). AF&PA will work with its Oregon contract lobbyist to develop a strategy for engaging the Depart- ment of Environmental Quality in the regulatory process. On July 9th, AF&PA submitted a letter to the Governor raising our concerns with the bill and requesting that the paper industry be engaged in the regulatory process and have representation on the newly established Oregon Re- cycling System Advisory Council. Contact erin_hall@afandpa.org with questions.
Project Horizon, Sonoco’s $115 million investment to transform its corrugated medium machine in Hartsville, South Carolina, to a state-of-the-art uncoated recycled paperboard operation with annual production capacity of 180,000 tons, is expected to be completed by the end of the second quarter of 2022, the company reported. A key element is construction of a new stock prep sys- tem to provide approximately 650 tons per day of recycled fiber to the rebuilt #10 machine and other Hartsville cyl- inder machines. The new system will allow for increased consumption of lower-cost mixed paper, along with OCC and should be operational in October 2021. To reduce paper finishing and warehouse complexity and cost, Sonoco is also building a new offline winding
operation and 102,000-square-foot finished goods warehouse in the Hartsville complex. Sonoco will be exiting the corrugated medium market by early 2022 and expects URB capacity through its U.S. and Cana- da mill network to remain neutral at ap- proximately 1.2 million tons. Based on the progress of Project Horizon, the company now expects to permanently shut down its Hartsville #1 and #9 URB cylinder machines which will reduce annual capacity by ap- proximately 70,000 tons. The exact timing of the closures will depend on market con- ditions as well as the start-up of the convert- ed Hartsville #10 machine. In 2020, Sonoco permanently shut down a 30,000 tons/year machine in Hartsville and its 95,000 tons/ year Trent Valley, Ontario, Canada mill. The new Hartsville machine is being de- signed with the goal of being the lowest cost URB machine in the world, with the capabil- ity of producing a wide range of high-value paper grades to service Sonoco’s industrial and consumer converted products busi- nesses and external trade customers. Proj- ect Horizon is projected to drive $30 million in annual cost savings by 2023, ensure the long-term viability of the Hartsville mill com- plex and place its U.S. and Canada URB mill system into the top quartile of performance. Sonoco is one of the world’s leading pro- ducers of URB with the capability of produc- ing approximately two million tons annually. The company is also one of the largest URB producers in the U.S. and Canada operating 11 mills and 18 machines in South Carolina, Tennessee, Virginia, Massachusetts, Kan- sas, Wisconsin, California, Washington and Ontario, Canada.
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10 August 23, 2021
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AF&PA Applauds Senate For Passing Bipartisan Infrastructure Package The American Forest & Paper Association (AF&PA) Presi- dent and CEO Heidi Brock issued the following statement in response to the Senate passage of the bipartisan infra- structure package:“The paper and wood products industry values bipartisan leadership and we commend this agree- ment. The bipartisan infrastructure package seeks to build a more sustainable future by modernizing our nation’s in- frastructure and investing in U.S. manufacturing jobs. “Sustainable practices are the foundation of our indus- try. AF&PA members and their employees—the approxi- mately 950,000 individuals who make up the forest prod- ucts industry—create innovative and essential products made from renewable and recyclable resources. “Senate passage of this landmark agreement is an im- portant step for our industry and our nation. But there is still work to do. House leaders must move the bipartisan infrastructure package over the finish line, and quickly. We need this legislation passed, to strengthen American jobs and manufacturing, supply chains, as well as the broader circular economy.” “We applaud the legislation which addresses a number of key infrastructure priorities for AF&PA including Trans- portation, Energy Infrastructure, and Waste Management/ Recycling Infrastructure.”
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Vanguard Companies Win Gold, Silver In Box Manufacturing Olympics At SCE
Kansas City, Missouri based Vanguard Companies won two gold awards and one silver award in the first-ever 2021 Box Manufacturing Olympics. TAPPI’s CorrPak Competition and AICC’s Package Design Competition joined forces to create the new competition. The competition was open to all TAPPI and AICC members from around the globe who produce corrugated, rigid box, and folding car- tons, as well as their suppliers. Entries were evaluated on a number of levels, including design, quality, graphic excellence, technical difficulty and innovative application. “Creating award winning packaging and displays require great cus- tomer collaboration, innovation and teamwork. Congratulations to our valued customers and the entire team at Vanguard Companies for mak- ing awesome happen,” said Chris Stoler, Vanguard Companies CEO. “This was truly a team effort—from the collaboration of our sales team with their clients, through the design phase, planning and manufactur- ing. Vanguard Companies delivers award winning results for our cus- tomers.” Vanguard and Remington, from Spectrum Brands, won a Gold Award in the Innovative Structural Design Consumer Focus category and a Gold Award in the Best Application of Spot or Full Label category for their Remington iLight IPL3500VDN for Costco Canada. Costco requested the Remington iLight product come in a large package for their stores. Due to the small size of the product and it hav- secondary package design had an integrated insert to hold the product package in place and allow for the Med- ical Certification Serial Num- ber to be seen through a cutout on the bottom of the package. The design also allowed for easy setup and assembly along with easy locking of the product pack- age inside. The reduced fill- ers and inserts also made it quick and easy for the customer to access and remove the product. Vanguard and Manna Pro Products won a Silver Award in the Digi- tal Printing—Containers and Displays - Ink Jet/Digital category for their Manna Pro Flock Party TSC End Cap. Manna Pro, creator of Flock Party, had a vision to design an eye catching semi-permanent end cap that would build brand awareness, support new product launches, and drive consumers in-line to explore every-day products. Manna Pro’s overall goal was to grow annual sales through incremental shelf placement at Tractor Supply. The objective ing a Medical Certification with a specific serial num- ber, it was cost effective to place original product pack- age into a larger secondary package. The unique All-in-One
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CONTINUED ON PAGE 16
14
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August 23, 2021
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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
Vanguard Companies Win (CONT’D FROM PAGE 14)
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was to design a free-standing end cap that was able to withstand 10-12 months on the floor and 5 rotations of dif- ferentiated product assortments. The program is currently still set-in stores and Manna Pro has achieved 150 percent of expected forecast for the first 17 weeks.
“Vanguard Companies’ superior and innovative in- house design team is ready to make your vision reality,” continued Stoler. “These displays demonstrate our atten- tion to insights, creativity, quality, durability, and revenue generation. The Vanguard Companies team is the right partner to help our customers improve display effective- ness, drive brand awareness and sell more product.”
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TAPPI Presents Gunnar Nicholson Gold Medal Award To Benjamin Frank SuperCorrExpo (SCE) 2021 hosted thousands of exciting, intriguing and impressive members of the corrugated in- dustry for the first time in well over a year-and-a-half. This year’s conference saw a wide variety of exhibitors and suppliers on the Expo Floor, presented phenomenal key-
University. Following post-doctoral research at Stanford and IBM, he started his career in the forest products in- dustry at International Paper and joined PCA in 2001 as the Manager of the Packaging and Materials Testing Labs. In his role at PCA, he leads a team involved in research, technical support, and product development. Their research efforts focus on better understanding our materials and improving existing test methods in both accuracy and precision. Through these efforts, they’ve been able to advance modeling and prediction of com- pressive strength for containerboard, corrugated board and corrugated packaging, as well as assessments of overall package performance in the supply chain. Dr. Frank has also run a co-op program while with PCA, training and mentoring over 60 students. The students become integral parts of the group and go on to contrib- ute significantly in their careers after graduation. This out- reach effort has also provided Dr. Frank the opportunity to guest lecture, teach and guide undergraduate and gradu- ate students at many of the top packaging schools across the country. Over the years, Frank’s involvement in TAPPI and the industry has grown. With TAPPI, he has held leadership roles in Fiscotec, the Corrugated Awards Committee and the Quality & Standards Management Committee (Q&SMC) and has been active in Corbotech and ISO TC6. His in- volvement with the standards process includes authoring and revising for both TAPPI and ISO.
note speakers and displayed some of the most innovative designs and concepts through the first-ever Box Manufacturing Olympics. In addition, SCE acknowledged some of the most extraordinary leaders by presenting numerous awards, including the Gunnar Nich-
Benjamin Frank
olson Gold Medal Award. Established in 1928, the Gunnar Nicholson Gold Medal Award is granted to those “who have made preeminent scientific and engineering achieve- ments of proven applied benefit to the world’s pulp, paper, board, and forest product industries. This is the highest honor TAPPI can bestow upon an individual. This prestigious award was presented to Benjamin Frank, Director-Materials Research and Innovation at Packaging Corporation of America (PCA). Frank received a Ph.D. in physics and M.S in Colloids, Polymers and Surfac- es (Chemical Engineering) in 1995 from Carnegie Mellon
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Case Paper Completes Large Solar Installation At Chicago Facility Harrison, New York based Case Paper has announced that it has completed a large solar panel installation on the roof of its Chicago facility. The solar panels cover over 60,000 square feet and will provide 90 percent of the en- ergy needed to run Case’s Chicago plant. This project is
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one of many initiatives the company is working on as they continue to maximize their commitment to sustainability. “We have awesome employees that continue to bring us opportunities to get involved in activities that help to create a better world for today and for generations to come,” said Case’s President Simon Schaffer-Goldman.
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ICG Awards Supplier Of The Year To W.H. Leary Company, Inc. The Independent Carton Group (ICG) has announced that it has presented its 2020 Supplier of the Year Award to W. H. Leary Co., Inc. The presentation was made during ICG’s quarterly meeting held on August 5th. The ICG and its members rate over 30 suppliers on a biannual basis on a series of criteria including: Timeliness of delivery, quality of materials, quality of service, exper- tise of staff, contractual compliance, administration/invoic- ing accuracy, compliance with shipping instructions, and reporting & payments. Through the evaluation process, ICG leadership works with national account managers from all their suppliers to improve the quality of service each supplier brings to ICG members. “The bottom line is to get Best-in-Class sup- pliers serving our members and that is what this awards program is helping to assure our members of,” said Jay Willie, ICG Executive Director. “Especially in 2020 with all the COVID restrictions and supply chain challenges all our suppliers came through for our members but Leary really excelled.”
In receiving the award during the virtual meeting, Kevin Leary, President and CEO of W. H. Leary, said, “We are in- credibly humbled in receiving this award, the Independent Carton Group means a lot to us. We all were incredibly challenged in 2020 but we all move forward together. We are grateful to receive this prestigious award and I hope that Leary continues to help ICG members to reach their goals and objectives while earning their respect.” W. H. Leary Co., Inc. is dedicated to being a leader in manufacturing in-process controlling, monitoring, extru- sion and data acquisition systems for the packaging in- dustry. As an engineering company, they are continually developing new solutions which exceed their customers’ expectations and improve plant performance. Located in Chicago, Illinois, Leary solutions are dis- tributed and supported worldwide. In 2014 they formed a partnership with Robatech Group, a leading worldwide manufacturer of Hot Melt and PUR Glue Application Solu- tions, which expanded their reach and product offering even further into the paper converting market.
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CDP Enjoys Growth (CONT’D FROM PAGE 1 )
entrance in the sales and marketing room, which was re- cently renovated and expanded with cubicles and a large display of digital, flexo and litho printed samples. In addition to the facility renovations, the growth in dig- ital printing prompted major changes on the production floor with several machines being replaced. There are now fewer machines producing more throughput.
completed, including relocating the fulfillment staging area to a separate building a few blocks away. Founded in 2002, CDP specializes in high-end graph- ic packaging and POP displays, a niche for which digital printing is well suited. The quick turnaround of litho quality printed sheets is helping the company to expand into new markets, such as e-commerce, and is widening the geo- graphic reach. “We were already in the print market, but it opened up a new customer base and new opportunity,” Bertram says. “Now we sell coast to coast. Before, if we couldn’t drive to a customer, someone in the next town five hours away would and should be running the job.” Facility Upgrades The Nozomi is an imposing machine, measuring 120- feet long — about one-third the length of a football field. CDP’s printer is installed in the main production area, just around the corner from the analog equipment, on the op- posite side of the 120,000-square-foot building. A sepa- rate outside entrance with an attractive lobby and large conference area was built for customers and visitors inter- ested in learning more about digital printing. The VUTEk is also located on the production floor in a temperature controlled room, just steps away from the Kongsberg C44 and C64 cutting tables. A third Kongsberg C44 will be in- stalled later this year. A second conference area is located closer to the main
Bertram admits to a certain fascination with new tech- nology and recognizes the value in upgrading and switch- ing out equipment regularly. Within the last two to three years CDP removed a label laminator, a flatbed diecutter Mike Mason, who has become an expert in digital printing, op- erates the EFI VUTEk for short run business.
CONTINUED ON PAGE 26
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CDP Enjoys Growth (CONT’D FROM PAGE 24)
downstackers from A.G. Stacker. Having identical Apstars with interchangeable anilox rolls helps from a setup and maintenance standpoint. CDP adheres to a strict preventive maintenance schedule. “We’re down every single week on every single machine a minimum of four hours for preventative maintenance,” Bertram says. “Since these are the same machines they are easier to maintain and repair.” Keith Furr, Plant Manag- er, adds, “It’s very rare for a machine to go down and it be a surprise. We plan when they’re down.” The second Apstar and the Young Shin diecutter were installed in the last 12 months along with a Felix XY glue plotter from Poland. The Zenith diecutter offers large for- mat capability of 82.5- x 59.05-inch, rapid makeready and can run up to 5000 sheets per hour. It was purchased to diecut the output from the Nozomi and VUTEk. The Felix gluer replaced a hand gluer and is used pri- marily to glue displays. It uses both hot and cold glue. “We can use it on jobs that would previously take three min- utes to hand glue. This machine can do it in under one minute,” Bertram says. “The beauty of it is dispensing the same amount of glue and the same exact position every single time.” For high-speed specialty gluing the company has a Magnus 230 specialty gluer from Duran Machinery of Tur- key with an EAM Mosca bundler with SONIXS strapping technology. CDP also has a Langston flexo folder-gluer.
and two rotary diecutters, replacing them with a Young Shin high-speed flatbed Zenith 210 Plus diecutter and a second Apstar HG 1628 rotary diecutter from Haire Group. Two print stations from the existing six-color Apstar were moved to the new Apstar so the company now has a four-color and a two-color rotary diecutter. “Why did we
do that? Because the six-color was collecting dust,” Ber- tram says. “Since we added digital, we haven’t purchased a print plate set that’s more than three colors.” Both Apstars have KleenPlate printing defect and plate wash eliminators and IR dryers from JB Machinery and A second Apstar rotary diecutter was installed last year.
CONTINUED ON PAGE 28
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CDP Enjoys Growth (CONT’D FROM PAGE 26)
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Production Efficiency Above every machine center are large monitors that provide operators with real-time data and averages for up- time, speed and setups. They are part of Amtech’s Score- Keeper production monitoring system and are integrated with order entry, inventory control, shipping, receiving and invoicing. Jesse Yates, an operator on the four-color Ap-
says,
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star, says the monitors help the crews be more efficient. “What I like about it is it helps you keep track of time, how long you’ve been on one job and your setups.” A red screen signals potential delays or bottlenecks. The goal is a green screen. “Once an order turns red on the screen we know something is late and then we can immediately react and use another machine or do whatev- er is necessary,” says Nathan Christy, Production Manag- Above every machine center are large monitors that provide operators with real-time data and averages for uptime, speed and setups.
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er. “Now the operators can see live what works and what doesn’t,” adds Furr. “When you know what doesn’t work you can adjust to what did work. You don’t have to speed up just to change what you’re doing.” Bertram says the system facilitates teamwork and friendly competition between the crews, motivating them From left, Nathan Christy, Production Manager; Keith Furr, Plant Manager; and Bryan Allman, Operations Manager.
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CONTINUED ON PAGE 30
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CDP Enjoys Growth (CONT’D FROM PAGE 28)
To shift from that to digital and have everyone on board, it was tough. We all were on board but the learning curve was hard. We’ve come a long way.” Indeed, the company is now a go-to source for many still learning about digital printing. It is not unusual for fel- low board converters to reach out to Bertram to get more information. “People who visit the plant often say, ‘You’ve
to put up better numbers than previous shifts. It also cre- ates a less harried work environment. Yates agrees. “It’s all about finding a rhythm, especially with your operators and setup guys.” Bryan Allman, Operations Manager, encourages the operators to approach setups like a NASCAR pit crew, a fitting analogy since the Charlotte Motor Speedway is just eight miles away. “Just get in and get out,” he says. “That’s another thing with ScoreKeeper, when it starts the run time they know if they have time or have to make time up.” Family Culture The level of investment and commitment to produc- ing a quality product translates to high morale and pride among the employees, which is clearly evident to anyone who visits. “We are all family. I don’t own this company, but I’m going to treat it like I do,” says Christy. Furr agrees. “We all take care of each other.” When Bertram talks about CDP’s success he is often overwhelmed with emotion. He is humbled and exceed- ingly proud of the culture and the way employees have embraced the new technology. However, he does not sugar coat the challenges faced in 2018 and 2019. “When we installed the Nozomi we only had one Gerber sample table and it was in the room we’re sitting in (the sales and marketing room). We also had a six-color Apstar and we installed the new Duran Magnus specialty gluer in 2017.
got this figured out.’ A lot of it is our maintenance. Those printers don’t last forever. You have to take care of them,” he says. “You need to clean print heads. They don’t clean themselves. These machines don’t fix themselves.” Next year CDP will commemorate its 20th anniversary. There is a lot to celebrate and be thankful for, first and foremost the employees. Bertram emphasizes that the company’s growth and achievements are the result of a winning team effort. There is a strong core group of veter- an employees as well as many rising stars. “We’re in good hands,” he says.
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