BoardConverting Serving the North American Corrugated and Folding Carton Industries for 38 years September 19, 2022 VOL. 35, NO. 38
The Widera Entrepreneurs Put WTC On The Map In El Paso, TX BY LEN PRAZYCH In the corrugated box business in Southern California, the last name “Widera” brings with it a certain cachet, especially among container- board industry illuminati. While not quite the red carpet in Hollywood, the concrete production floor of any Widera family facility in the Cal Box Group (CB Group) is the ideal place to learn the entrepreneurial side of box making business from true masters of the So Cal trade.
Corrugated Week 2022 Kicks Off In San Antonio
Coming to you live and face-to-face from the heart of historic downtown San Antonio, Tex- as, is the highly awaited Corrugated Week 2022 on September 19-21. It’s showtime! This is the big event held every two years when the Technical Association of the Pulp & Paper Industry (TAPPI) and The Independent Packaging Association (AICC) team up to cor- ral the nation’s corrugated box makers and suppliers to network and discuss the latest products and services for three event-filled days. Independent and integrated box manufac- turers will be sending a contingency of their buyers and influencers to the event, which has 14 built-in networking opportunities including the Texas Rodeo and the annual Corrugated Classic Golf Tournament where connections are made and deals are closed.
CONTINUED ON PAGE 46
WHAT’S INSIDE 5 Containerboard Normalizes: More Supply, Lower Demand 12 TAPPI’s Kristi Ledbetter Retires, Rushin Named Division Manager 14 Richard Flaherty Leaves ICPF With A Legacy Of Success 44 Domtar Pledges $50K To AICC’s Packaging Education Foundation 62 EAM-Mosca Celebrates Its First 40 Years Of Innovation 78 Scheduling Projects Efficiently 86 Conscious Curiosity: The Skill That Enhances Great Recruiting
CB Group is one of the highest quality producing and successful independents in Southern California. The “group” is comprised of Cal Box I (CBI, Los Angeles) in Santa Fe Springs, CA; Cal Box II (CBII) in Rancho Cucamonga, CA; Tucson Container Corp. (TCC) in Tucson, AZ; Arizona Corrugated Container (ACC) in Mesa, AZ; and West Texas Con- tainer (WTC) in El Paso, TX, located a half-mile from U.S.-Mexico border. “I grew up telling people that my uncle owned a box company and remember them asking me what that meant,” says Nick Widera, Gener- al Manager of CBI and WTC, of his introduction to the wonderful world of corrugated and the education learned at the knee of his uncle, John Widera, the venerable owner, author, and chairman of CB Group. John’s son, Chris Widera, is President of CB Group and oversees all operations at the five plants. Along with John and other managers, The entreprenuers of CB Group, from left Chris Widera, President; John Wid- era, owner and Chairman; Nick Widera, General Manager of CalBox I and WTC; and Joe Yocam, Sales Manager and John Widera’s son-in-law.
CONTINUED ON PAGE 32
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Containerboard Normalizes: More Supply, Lower Demand Ahead BY PHIL PERRY After two years of frenetic activity fueled by a bustling econ- omy, the containerboard industry is poised for a breather.
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
“We see the global market as being increasingly well supplied,” said George Staphos, Senior Research Analyst covering paper, forest and packaging for Bank of Amer- ica. “Because capacity has grown while consumption has slowed, we believe containerboard pricing will remain flat through 2024.”
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
The new environment represents a profound shift from the heady days when COVID-19 forced homebound shop- pers to binge on the Internet. “During the pandemic there was a historic boom in U.S. box demand because of un- precedented government stimulus and a massive spend- ing shift from services to goods,” said Adam Josephson, Managing Director, Equity Research, KeyBanc Capital Markets Inc. “Because of those factors, box demand has jumped by six percent over the past two years. To put that in perspective, over the past decade demand had grown at a compound rate of only about one percent per year.” George Staphos CONTINUED ON PAGE 7
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
Celebrating 20 YEARS! We thank our loyal customers and manufacturing partners for contributing to our growth and success. We look forward to the next 20 years, serving the corrugated industry with innovation and technology, while showing what’s possible for plant production and employee safety.
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Containerboard (CONT’D FROM PAGE 5)
to convert a machine that had formerly made printing pa- per. Powers said the result will be an additional 600,000 tons of annual containerboard entering a 45-million-ton North American market. “Other companies are making similar changes into the containerboard space because it’s growing, and the products that they’re currently mak- ing are not.” These companies apparently see substantial potential in the containerboard market, given the significant time and money required for the conversion process. “You don’t just flip a switch and add containerboard capacity,” said Josephson. “A company needs to either build a new mill or convert an existing paper machine, and that pro- cess typically takes a couple of years.” Given that a lot can happen with the economy in the two years between conversion idea and execution, sup- ply and demand mismatches are certainly possible. The current state of affairs offers a case in point. “The addi- tional capacity the market will be receiving is the result of projects announced years ago when demand was far stronger,” said Josephson. “Containerboard inventories at the end of the second quarter of this year were about 20 percent above historical averages, and inventories in June were the highest in any June since 2000.” Other nations are seeing the same increase in capacity as more paper and packaging companies enter the con- tainerboard space. “The problem is that supply tends to in-
A hike in production is a key force expected to exert downward pressure on containerboard prices. “Roughly 2.7 million tons of addi- tional North American container- board capacity will hit the market over the next year and a half,” said Josephson. “That equates to about seven percent of last year’s US production—a substantial increase at a time when supply is already abundant—even excessive.” Greater Supply Where’s all that new capacity coming from? It’s not just a case of new companies looking to climb aboard the box bandwagon. Veteran players are also upping their game. Adam Josephson
“There are a number of conver- sions underway from paper ma- chines that had been making other grades with significant demand de- clines over the last 15 years,” said Tedd Powers, director of strategy, consulting, and analytics at Fisher International, a pulp and paper in- dustry research firm. He cites the
Tedd Powers
example of Domtar Mill in Kingsport, Tennessee. The com- pany has decided to invest a significant amount of money
CONTINUED ON PAGE 100
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NEWW Invests In New Kolbus RD115S 5-Color Flexo RDC
Gardner, Massachusetts based New England Wooden Ware Packaging and Display (NEWW) reported that it is celebrating its 185th year of business with an investment in a new 66-inch by 115-inch Kolbus RD115S 5-color flexo rotary diecutter. NEWW is an independent, family-owned business, which began as a manufacturer of wooden products and containers in New England, later transitioning to corrugat- ed packaging in the early 1940s. Today, the company is a leading supplier of premier packaging and retail displays for customers throughout the Northeast. The company is the first on the East coast with this Kol- bus die cutter, offering customers unmatched, exception- al print quality with efficient, dependable production. The German built, fully servo-driven Kolbus RD115S replaced a 2008 115-inch 6-color Hycorr Hygraphics. “After looking into several machines, we are pleased with our purchase of the Kolbus RD 115S,” said Steve Mac- Donald, Production Manager, NEWW. “We felt that Kolbus was the best option, not only for our current customer base, but for our future growth as a company. The RD 115S allows us to offer a higher level of print quality and im- prove our capabilities.
“We have been thoroughly impressed with the machine quality. Simply put – the machine is an engineering marvel. From the 4-inch thick cast iron side frames, print quality, on-time installation with exceptional training, and after-in- stallation support, we couldn’t be more pleased with our investment in the Kolbus RD115S. It’s allowed us to print jobs immediately, that took us years to perfect.” Along with offering their customers impeccable print quality, NEWW has benefitted from partnering with Kolbus in other ways. “Not only was our delivery and installation completed on time, their service team has responded quickly to address our questions and concerns with prompt support for this machine installation,” said MacDonald. “Our growth as a company can be attributed to the CONTINUED ON PAGE 10
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NEWW Invests (CONT’D FROM PAGE 9)
Box Shipments ( U.S. Corrugated Product Shipments) Industry Shipments In Billions of Square Feet Month June 2022
talented people and capable machines that we have at NEWW,” says Ben Urquhart, Sales Manager, NEWW. “Our original Hycorr RDC enabled us to become one of the premier flexographic corrugated printers in the region, but the new Kolbus is an improvement in almost every re- spect. The performance of the machine has already deliv- ered significant benefits to our operation. Print jobs that were once painfully challenging due to print registration, sheet size, ink coverage or other issues are now running smoothly at good speed. “This impressive rotary die cutter was delivered and installed in a time frame that was simply unthinkable for some machine vendors suffering under the significant and real supply chain challenges of the pandemic. Kolbus has delivered an impressive machine at an opportune time. Our ability to accept and deliver on new business opportu- nities has increased significantly. I am extremely excited to present our new capabilities and capacity to customers.” “New England Wooden Ware has proven to be the per- fect partner for Kolbus with the introduction of the Ger- man engineered and manufactured RD115S, into the North American market,” said Jeff Dietz, President, Kolbus Amer- ica. “The trust they have placed in our organization to de- liver and support such a sophisticated piece of machinery, and their advanced understanding of flexo printing has been a great benefit.
Year
Actual
Percent Change Avg Week Percent Change
2022 2021
34.771 35.948
-3.3
7.903 8.170
-3.3
Industry Total
Year-to Date
June 2022
Year
Actual
Percent Change Avg Week Percent Change
2022 2021
205.855 208.569
-1.3
8.019 8.170
-2.1
Industry Total
Containerboard Consumption (Thousands of Tons)
Year
Month
Percent Change Year-to-Date Percent Change
2022 2021
2.8451 2.9436
-3.0
16.8851 17.0466
-0.9
Container Board Inventory - Corrugator Plants (Thousands of Tons)
Corrugator Plants Only
Date
Percent Change Weeks of Supply
Percent Change
Jun. May
2.4415 2.3469
4.0
3.8 3.6
5.6
Shipping Days
Year
Month
Year-to-Date
2022 2021
22 22
127 126
SOURCE: Fibre Box Association
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TAPPI’s Kristi Ledbetter Retires, Rushin Named Division Manager TAPPI President and CEO Larry N. Montague has officially announced that longtime employee and Corrugated Divi- sion Manager Kristi Ledbetter has retired. Ledbetter will receive the Division’s Leadership and Service Award at TAPPI/AICC’s Corrugated Week in San Antonio, TX, Sep- tember 18-21, 2022. “Kristi has been a fixture, and a trusted leader, with- in the TAPPI family for more than 26 years,” noted Mon-
TAPPI Local Section. She took over as facilitator of the Cor- rugated Packaging Council (CPC) in 2006. The CPC is an advisory board made up of box makers and suppliers who work with TAPPI to ensure that the needs of the industry are met from a technical and educational perspective. Ad- ditionally, Ledbetter also served as Division Manager for TAPPI’s International Flexible Packaging and Extrusion Di- vision (IFPED) and served on TAPPI’s Senior Strategy Team (SST) since 2016. Ledbetter attended Auburn University, where she ma- jored in Fashion Merchandising prior to coming to TAPPI. She also held a position as Accounts Payable Manager for Showcase Photographics. Her plans for retirement include relocation to Appleton, WI, to be near family. In reflecting on her long career, she observed, “I continue to be amazed at the dedication of the people who work in the industry, and have learned so much from them. It truly has been the most rewarding career I could have ever imagined, and I will never forget everyone I met and the lifelong friends I have made. I’ll never look at a box the same way again!” Montague also announced that another longtime TAP- PI employee, Lisa (Stephens) Rushin, would replace Led- better as Corrugated Division Manager. Rushin has been with TAPPI for 32 years and has worked in every depart- ment, from Membership to Press/Publications and Mar- keting. Most recently, she served as Division Manager for the Pulping, Engineering and Nanotechnology Divisions
tague. “Twenty years ago she took on TAPPI’s Corrugated Division responsibilities as the Technical Program Manager and then moved into the Division Manager role in 2004 where she helped lead joint efforts with AICC on our inaugural SuperCorrExpo, and in 2014 played an integral part in creating the first
Kristi Ledbetter
Corrugated Week. She has also helped manage seven CorrExpo conferences. Her efforts on behalf of this group, and her many years of service to TAPPI and the industries we serve, provide an outstanding example for all to follow. We wish her well, and thank her for her dedicated service.” In addition to the Corrugated Division, Ledbetter also managed TAPPI’s Corrugated Committees and Chicago
CONTINUED ON PAGE 14
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Flaherty Leaves ICPF With Legacy of Success
TAPPI’s Ledbetter (CONT’D FROM PAGE 12)
where she oversaw all Committee operations, as well as the annual Pulping, Engineering, Environmental, Recycling and Sustainability (PEERS) Conference, the International
As announced earlier this year by the International Corru- gated Packaging Foundation (ICPF), its President, Richard Flaherty, will be leaving the foundation in October for an- other opportunity. “I am excited about this new challenge and the foundation’s partners can be proud of the growth and impact of the initiatives during the 16 years I worked with them in serving at the helm,” said Flaherty. Some highlights of the accomplishments during this past decade include: • Provided millions in funding assistance, corrugated packaging equipment and software at colleges and universities in the U.S. to educate students in concepts and skills needed for a corrugated packaging career. • Directly enabled the annual hiring of 100-150 college
Bioenergy and Bioproducts Con- ference, (IBBC), both taking place this year October 30 – November 22, and the International Confer- ence on Nanotechnology for Re- newable Materials. “I am thrilled to take on manage- ment of an exciting Division like Corrugated,” said Rushin. “By as-
suming the many different roles I’ve had at TAPPI, my career has been diversified and rewarding. While Kristi’s shoes will be difficult ones to fill, I look forward to helping take the Corrugated Division to its next level of success.” Lisa Rushin
graduates for entry level openings and stu- dents for internships through ICPF’s annual student and university programs and online resources. • Jumpstarted, created or expanded 19 corrugated packaging programs at U.S. col- leges and universities. • Established and maintained partnerships with 26 colleges and universities annually providing industry speakers, mentors, plant tours, and other specialized assistance. • Expanded annual participation in ICPF’s annual Teleconferences on the Business of Corrugated Packaging and its Careers from 75 students who participated from four to six campuses to over 500 students from 18- 20 campuses who now participate. • Created the Careers in Corrugated Pack- aging & Displays Social Network that annu- ally has 700-1,100 students and future grad- uates who have joined to pursue student internships and careers in the corrugated packaging & displays industry. • Expanded outreach beyond packaging design and packaging students to include business, sales, graphic design, supply chain management, chemical engineering, industrial engineering, industrial design, mechanical engineering, tech and relat- ed students. These students regularly join ICPF’s career network as well as post their resumes on ICPF’s Career Portal. • Developed the regular use of ICPF’s Cor- rugated Packaging Curricula at colleges and universities around the country to support real-world corrugated packaging instruction. ICPF’s corrugated curricula is accessible from ICPF’s website.
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CONTINUED ON PAGE 98
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H&H Corrugated Boosts Profits With Baysek’s C-170 Die Cutter
The first time Jim Houk saw the Baysek C-170 die cutter in operation and saw the clean partitions it could produce – all without hand strip- ping – he was sold. Since adding the Baysek machine to the factory floor at La Vernia, Texas basedH &H Corrugated Services, Inc. it has been beneficial to the company, as well its customers. Houk, the second-generation owner of H&H, said that the Baysek
Packaging ERP Algorithmic Scheduling Web-Based Access Online Customer Portals Paperless Workflows Mobile Sales Systems Digital Signage Production Monitoring Mobile Logistics Analytics & Reporting Cloud Hosting IT Management Services Cyber Security Management
is providing faster, relaible service at an affordable cost. The company was able to decrease prices to be more competitive and increase their profit margins by implementing the single-operator machine. “The C-170 has increased production and lowered labor costs. We had large orders that were taking five days with eight people,” Houk said. “We now run this same job in two days with three people. It’s a huge savings and a faster turnaround for the customer.” It was at a trade show in Orlando, Florida, in 2016 that Houk first had contact with the Amherst, Wisconsin based Baysek Machines In- corporated. Now in regular contact with the specialty machine maker, Houk says it continues to be a pleasant experience with top-notch customer service. “From start to finish the process has been professional and timely,” he said. “The crew at Baysek are very attentive to all our questions and concerns. Someone always answers the phone.” Tim Engle, Baysek’s North American Sales Manager, said that Houk and his team were great to work with as well. “Everyone was enthu- siastic about getting the machine in place and running. It has been a pleasure getting to know Jim and developing a lifelong friendship,” Engle said. The state-of-the art C-170 was a fitting addition to H&H, which has grown exponentially since Houk and his father, Jim Houk Sr., founded it in 2002. In the beginning, it was just a father-and-son operation in a 750-square-foot bay. One of the first pieces of equipment they bought was a flat roller bed die cutter. “Looking back, it sure looks slow next to the Baysek,” Houk said. Over the years, H&H, which specializes in corrugated partitions, pads and specialty gluing, grew out of and added more building From left, Scott Lyons, Operations Manager; Jim Houk Jr, second-genera- tion owner; and Roman Houk, Design Manager, with samples of the many products H&H Corrugated manufactures with its Baysek C-170 Die Cutter.
600 + Plants 60,000 Users North America Latin America
CONTINUED ON PAGE 18
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H&H Corrugated (CONT’D FROM PAGE 16)
The Perfect Combo Get Peak Performance From Your Equipment with Matched Component Sets
space. They invested in more equipment and added more employees, including a third generation Houk in the fold, Roman Houk. Currently, H&H Corrugated operates in a 25,000-square- foot shop built in 2017, and even that is beginning to get crowded.
“We now employ 12 full-time employees. But we still run as a small family business,” Jim Houk said. “You’re only as good as your employees and we have the best employees and the best supporting vendor.” Before buying the Baysek, H&H converted 30-million- square-feet a year. By next year, the company is expected to double that. “As H&H continues to grow, we look forward to working closely with our corrugated partners, vendors and equip- ment specialist to move into the next generation of spe- cialty packaging,” Houk said. “It should be a fun ride.” ARC Int’l: 40+ Years On The Cutting Edge Of Laser Engraving Technology ARC International’s President, CEO and founder, Micheal Foran, is very proud of how his company has evolved since 1984 through substantial investments in new technologies to become the premier full-service supplier of rollers and technical services to the corrugated industry. ARC’s one-stop shop reputa- tion has proven to be beneficial to large integrated and versatile independent box plants. With manufacturing facilities strate- gically located in Charlotte, NC, on the east coast and Las Ve- gas, NV, near the west coast, ARC is able to provide efficient and timely service to box plants in the USA, Central Amer- ica and Canada. ARC first invested in laser engraving equipment for an- ilox rollers in 1987, mostly to supply the wide web, narrow web and preprint industries. So in the early 1990s, when corrugated box plants started demanding more laser an- Micheal Foran
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 • Anilox and Wiper Rollers • Feed and Pull Rollers • Glue and Meter 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 pro ts.
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ARCInternational.com 800-526-4569
CONTINUED ON PAGE 20
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ARC.5pAnlxChmb1BCN.CWk.indd 1
6/20/22 2:28 PM
ARC International (CONT’D FROM PAGE 18)
This led to the development of fiber optic technology and faster engraving speeds. Today, ARC utilizes Fibret- ronics™ technology to create precision hexagonal, extend- ed hexagonal, tri-helical and custom engravings. In addi- tion, ARC is the only roller supplier to offer Twin-Track™ engraving technology, offering higher volumes with flatter cell bottoms, critical in coating applications. Even on jum- bo flexo machines, higher quality graphics have become a priority. ARC has numerous machines that can handle rollers up to 250-inches inches long. In the late 1990s, due to an airport expansion in Char- lotte, NC, ARC was forced to relocate. This provided the opportunity to design and build a state-of-the art manu- facturing facility for the most efficient production of all types of rollers. This included an investment into rubber covering technology with an infra-red dry heat autoclave for manufacturing feed and wiper rollers, as well as splicer and knife rollers for the corrugator. Similar equipment was installed in the Las Vegas plant, as well. ARC has also made a substantial investment in pre- cision grinders and anilox sleeve technology, commonly used in the wide web industry due to lighter weights and the ability to change print stations to a different screen or volume in a matter of seconds. In the corrugated preprint industry, this technology is being utilized on the latest equipment (Bobst, Allstein) that employs robotic arms to mount and dismount the anilox rollers/sleeves.
ilox rollers, ARC was ready and willing to help. The major- ity of laser engravings were 45-degree diamond-shaped cells, just like the mechanical rollers that plants had used for years. However, this trend would change over time. Shortly thereafter, ARC’s west coast manufacturing fa- cility first opened in Ontario, California, in 1989 with laser engraving capability. As west coast business grew during the first five years of operation, there became a need for more production capacity and space. Thus, ARC West made the move to Las Vegas, NV, in 1994 as the state was offering substantial benefits to lure new manufacturing companies. In addition, for a number of years ARC was involved in another satellite operation first in Manchester, England,
near Foran’s birth- place, and later in The Netherlands to serve the European market. Throughout the years, ARC has always been on the cutting edge of laser engrav- ing technology. With
the help of laser specialists, they developed their own Opticell™ 60-degree hexagonal engraving process which increased efficiency significantly and minimized costs. BCN(US)202002(o)(出血5mm).pdf 1 2021/2/6 上午 09:19:31
CONTINUED ON PAGE 22
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September 19, 2022
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ARC International (CONT’D FROM PAGE 20)
to keep a press in operation for years to come, the carbon fiber units are certainly worth the investment. ARC International is truly a one-stop shop for corrugat- ed box plant requirements. During the extended pandem- ic, neither ARC manufacturing facility had to shut down. Integrated and independent box plants were able to get the rollers, products and services that they needed as the demand for corrugated packaging increased even more. ARC International has been and will be committed to serv- ing this industry for years to come. FSEA Forms Digital Embellishment Alliance The Foil & Specialty Effects Association (FSEA) has an- nounced the formation of the Digital Embellishment Alli- ance (DEA), a community developed to create educational and communication opportunities directed to the growing digital embellishment segment of the printing industry. “We are excited to welcome the Digital Embellishment Alliance as part of our mission under FSEA,” stated Jeff Peterson, FSEA Executive Director. “We believe by having a focused Advisory Committee in the area of digital embel- lishments, we can create educational programming spe- cific to this growing segment of the packaging industry as more designers, and print finishers utilize digital enhance- ment processes to add value to their print projects.”
Before any anilox rollers are used on flexo folder-gluers or flexo die-cutters, the board has to be manufactured on the corrugator. For the wet end of the corrugator, ARC provides single facer glue applicator, glue metering and splicer rollers. Applicator rollers can be engraved and chrome-plated, but most box plants choose to invest in a cladded stainless-steel surface which is guaranteed for five years against rust or delamination. Meter rollers are supplied with ceramic, tungsten carbide, stainless-steel or chrome plated surfaces. The same applies for glue and meter rollers in the double glue unit. On the dry end of the corrugator, ARC supplies pull and exit rollers in the cut- off knife. Surfaces include molybdenum, tungsten carbide and carboxylated nitrile for wear-resistance. To keep equipment performing up to par, ARC offers a complete line of cleaning products. Their anilox clean- ers can be used in conjunction with anilox cleaning plates which mount to the print cylinder just like a printing plate. For dirty or plugged glue applicator rollers, special clean- ers are also available. ARC also supplies 100 percent carbon fiber doctor blade chambers in a mono-blade version or dual-blade chamber. These are most often used to replace older, leaking and deteriorated aluminum chambers. However, they can also be supplied to replace a two-roller wiper sys- tem with an addition of a drive upgrade. If a plant intends
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. TM
www.go2stafford.com 800-282-5787 IS THE MANUFACTURER OF STAFFORD ANVIL COVERS ®
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CCM® OCT Filters Reduce Downtime, Improve Safety, Increase Production Baghouse and cartridge style filters have long been the go-to solution for removing dust from manufacturing op- erations, but there are some significant downsides to this type of dust collector. They require explosion venting, abort gates, sometimes building make-up air, additional fire protection, in addition to the long and costly down- times to maintain and unplug them. Servicing them can take an entire weekend, but many companies in the paper industry are oversold with orders. Some of them are booked well into 2024. They cannot afford to stop production for two or three days and lose hundreds of thousands of dollars while the filter is being properly maintained or unplugged. “I’ve had a lot of problems in the past where they plug up and you can’t get in to see what’s going on,” said one ERS customer. Some companies have policies that do not allow em- ployees to enter confined spaces. They must hire out- side crews when their baghouses are up for inspection or maintenance. Even when they can perform this function in-house, baghouses create liabilities that include the use of ladders and cranes. After a spot fire burned down the baghouse at the cus- tomer’s facility, the customer decided to try a different kind
of baghouse, but maintenance costs were still cost-pro- hibitive, with a new filter bags costing $25,000 a set plus another $10,000 for labor. These costs were incurred quarterly to properly maintain the unit to keep it running correctly. In search of a solution, the customer presented this problem to Engineered Recycling Systems (ERS). They
wanted something that would be easier to service, less expensive and not as dangerous. Mike Carver, a Mechan- ical Engineer by degree and Managing Partner at ERS, recommended the Continuous Cleaning Modular Filter (CCM® OCT). After seeing the drawings and proposal, the customer decided to try it out. CONTINUED ON PAGE 26
It's Time
Let's Print Our Story Garrett Jackson - Director of Creative Marketing Corrugated Supplies Company, LLC Email - Gjackson@vancraft.com
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All CCM® OCT-Filters meet NFPA, OSHA and local code requirements.
CCM ® OCT THE GAME CHANGER
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Engineered Recycling Systems takes decades of engineering experience and integration expertise to provide turnkey solutions. We design, service and install world-class recycling and dust control systems. By providing our customers with equipment and system designs that deliver unprecedented levels of quality and craftsmanship, our solutions increase efficiency and cut labor costs.
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CCM® OCT Filters (CONT’D FROM PAGE 24)
they are asking for a P.O. number,” the customer said. “If there is a problem, they want to rectify it and move for- ward. You do not have to wait weeks for somebody to come in. ERS becomes your partner.” ERS worked with a major integrated and their consult- ing firm specializing in fire protection engineering to en- sure that the filter met all OSHA and NFPA requirements
“We set it all up in a weekend and started it up on Mon- day morning,” the satisfied customer said. Safety Is Paramount ERS designed the CCM® OCT filter so that it can be kept safely indoors in a dry environment anywhere in the plant. Since it is not boxed in, the conditions for explosion are not present. Explosion vents, high-speed abort gates and expensive fire protection systems are not needed, and if the filter were to catch fire, the sprinkler system would extinguish the fire and the damage would be minimal. Be- cause of its wide-open design, the only thing that would burn is the filter media itself. The media would simply be replaced, and production would continue. The CCM® OCT filter can also be safely inspected from the ground without ladders or cranes. Unlike traditional fil- ters, you can see inside the unit and monitor it while it is running much like a see-through filter on a vacuum clean- er. “All you have to do is walk by and you can tell if it’s working,” the customer said. “If there is a problem, you can see it right away. Whereas with a baghouse you have got no idea what is going on inside of it.” Listening to customer feedback played a significant role in improvements that were made to the filter as it was being developed. “ERS will come right in and take care of it. It is not like
for non-explosives. Several standard designs resulted from this and the filter was fine-tuned to be compliant with all industry standards and local codes moving forward. ERS further refined the system so that companies can change out the filter media in-house and have it back in service within minutes resulting in minimal disruption. No
CONTINUED ON PAGE 28
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CCM® OCT Filters (CONT’D FROM PAGE 26)
the new industry standards, as ERS’ CCM® OCT filter is in a class of its own. “Our ERS system meets all codes and insurance com- panies have approved it across the board,” the custom- er said. “I will argue with any insurance company and win that argument. They cannot give us an engineering reason The cost of owning a CCM® OCT filter, is less than half the cost of owning a baghouse or cartridge style filter. Cus- tomers can save money and most importantly gain valu- able time annually on every unit. Servicing the filter is so quick and easy that downtime has been cut by 80 per- cent. Instead of having to hire an outside crew for an entire weekend, two people can perform a complete preventive maintenance and filter media change out in 2-6 hours de- pending on the size of the unit – and it is all done indoors, without the use of a ladder or special tools. why they would not insure it.” Downtime Cut By 80 Percent The best dust collector is the one you do not have to think about. With explosion hazards out of the way, simple maintenance and a window to monitor the internal opera- tion, the CCM® OCT filter is a solution that is engineered to give you peace of mind. ERS’s satisfied customer went on to install five more units across the Midwest, with a few more in the works. There are currently more than sixty-five fully operating, in- sured CCM® OCT filters in service throughout the United States, with many more on order.
special tools are required, and employees do not have to go outside and fight the elements. “We don’t have to pay to bring somebody else in any- more,” the customer said. Once sales for the CCM® OCT filter took off, there were no problems getting them insured. Insurance companies came to the facilities to inspect them and approved and insured them every time. Though, in the beginning some
insurance companies were not willing to pre-approve the filters prior to installation, it was found that they were bas- ing that on pre-approval requirements that were written for filters with older technologies that are not applicable to CCM®’s new type of construction and operation. Users are now urging insurers to update their policies to fairly reflect
See us at Corrugated Week, Booth 424. Sept. 18-22, 2022
All CCM® OCT-Filters meet NFPA, OSHA and local code requirements.
No dry chemical fire protection required No explosion vents required
No high speed abort gate CCM® OCT Filters = SAFE to operate and maintain No need for compressed air
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Apex International Breaks Ground On New PA Manufacturing Facility Donora, Pennsylvania based Apex International, a glob- al leader of anilox rolls, sleeves, glue sets, and metering solutions, held a celebratory groundbreaking to mark the commencement of construction on their new Pennsylva- nia manufacturing facility. The new facility, located in the Alta Vista Business Park in Fallowfield Township, Pennsylvania, will replace the existing location in Donora, Guardian Construction Man- agement Services, an established southeast construction management partner, is the selected contractor for the building initiative. Leadership teams from Apex Interna- tional and Guardian Construction were onsite to conduct the groundbreaking in mid-August.
From left, Richard King, Superintendent, Guardian; Kevin Dew- ar, Project Manager, Apex; Dean Clark, Director of Business Development, Guardian; Dennis O’Hara, President, Guardian; and Ruud van Cuijk, Managing Director, Apex North America at the groundbreaking of the new Apex manufacturing facility.
The new property will sit on more than 12 acres of land and occupy over 58,500 square feet, more than twice the size of the Donora manufacturing site. The facility’s primary purpose is to expand and elevate the manufacturing and warehousing ca- pabilities of Apex International’s anilox roll and sleeve, glue set, metering roll and print maintenance products. Construction on the property began August 22, 2022, with an expected occupancy date in 2024. The Fallowfield facility is part of Apex’s “Vision: 2020s” plan, a multi-phase growth strategy, announced in Spring 2021. Vision: 2020s entails investments in new buildings, new production equipment, and new per- sonnel, in order to scale up production ca- pacity and elevate product quality. “Apex International planned major in- vestments into global facilities and capital equipment to address anticipated industry growth,” states Ruud van Cuijk, Managing Director of Apex North America. “It is excit- ing to witness the initiative come to fruition - this long-awaited expansion will give our customers much quicker order turnaround and much more.” Apex International’s Vision: 2020s plan includes significant expansion in each of its five global manufacturing facilities. As part of it’s phased growth strategy, new build- ings, new production equipment, and new personnel will enable Apex to scale up pro- duction capacity while elevating industry benchmarks for quality. Apex will be better positioned to meet increased demand from its flexo, label, and corrugated customer base for reliable, predictable, and durable metering products.
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