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BoardConverting Serving the North American Corrugated and Folding Carton Industries for 36 years August 24, 2020 VOL. 36, NO. 34

Custom Packaging’s Digital Journey Leads To G7 Standard BY JACKIE SCHULTZ The year 2018 was a banner year for Lebanon, Tennessee based Cus- tom Packaging. The sheet plant celebrated its 50th anniversary and the installation of two major machine lines – a 1636 Bobst two-color large format flexo folder-gluer and a Barberán Jetmaster 1680 digital printer.

U.S. Display Group Acquires GCC In CA

Tullahoma, Tennessee based, U.S. Display Group has announced its expansion to the West Coast with the acquisition of General Container Corporation (GCC) of Buena Park, California. The company has acquired all GCC assets and the local facilities will continue to operate and service their customers as they currently do. “U.S. Display Group’s acquisition of GCC provides a major growth opportunity for both businesses through an expanded geograph- ic footprint that will help us better serve our clients,” said Greg Moore, President of U.S. Display Group. “We are excited to bring high- speed, single-pass digital printing, among other technologies, to GCC customers.” “General Container Corporation is pleased to join in a transaction that positions our busi- ness for modernization and future growth,” said Tim Black, GCC CEO and Principal Share- holder. “We believe the GCC team and its cus- tomers will benefit from the merger into U.S. Display Group. My family and I have benefited greatly over the years from the hard work of our employees and the loyalty of our custom- ers. We were determined to find the right fu-

Custom Packaging was the fifth U.S. installation of a Barberán print- er, which is intriguing because high-speed digital printing was not something that initially was on the company’s radar. The original plan was to find a replacement for its Gerber flatbed printer, which was used for prototypes and samples. While researching options, Stephanie Shelton, Digital Operations & Graphics/Prepress Manager and G7 Ex- pert, became convinced that single pass digital printing on corrugated offered significant benefits, especially for customers. After visiting U.S. plants that had machine installations and sending corrugated sheets to the various manufacturers, including Barberán in Barcelona, to evaluate print quality, the decision was made to purchase the Jetmaster. Relentless Pursuit Before the machine was installed, Shelton began exploring ways to leverage the technology to take advantage of the litho-like print quality. The Barberán team, from left, Jesse Thatcher, Javin Stone, Richard ‘Bubba’ Jennings, Danielle Cane, Stephanie Shelton, Justin Morales, Tony Parkerson and Evan Bracken.

CONTINUED ON PAGE 4

WHAT’S INSIDE

6 GBP To Build New ‘Super Plant’ In OK 8 FBA: Shipments Up Again In July 14 DS Smith Introduces

‘Circular Design’ Principles 20 AICC To Offer Its First Hybrid Event: The Leadership Mirror

CONTINUED ON PAGE 24

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

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

O U R T E A M

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

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

2

August 24, 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

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

U.S. Display Acquires (CONT’D FROM PAGE 1 )

ture for all stakeholders in our business, and we are con- vinced joining with U.S. Display Group is the proper path to achieve that goal,” he added. The expanded business will be one of the first corru- gated display manufacturers to have high-speed, digital printing in two U.S. locations, efficiently serving markets throughout the country. In addition to digital printing, U.S. Display Group will offer similar manufacturing and fulfill- ment capabilities from both facilities.

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

AICC To Offer Webinar To Discuss Tax Breaks

AICC will be offering a free webinar to discuss tax breaks for its members on September 11 at 2:00 p.m. EST. It’s the ideal time to learn about a key tool for economic revival: The Research and Development (R&D) Tax Credit. While many packagers are currently taking advantage of this powerful incentive, others aren’t aware it’s available. Tyler Noesser, alliantgroup’s Technical Director, will share the differences between the credit and other re- lief incentives. He will also review the latest changes to the credit that will impact AICC members, as well as how members can use this incentive to help their business ac- cess critical capital. Visit aiccbox.org to register.

Robyn Smith at 910-553-4055 /[email protected] Len Prazych at 518-366-9017 / [email protected]

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August 24, 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.

200# 275#

$62.26

$72.05

$62.69 $82.80

$85.35 119.54

$73.13 101.29

TRUST THE INDUSTRY LEADER

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

122.76

148.46

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.

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42# Kraft Liner 26#

Semi-Chem Medium

East West

$920.00 $965.00

$910.00 $945.00

AVERAGE CONTAINERBOARD PRICES.indd 1

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August 24, 2020

GBP To Build New ‘Super Plant’ In OK

Green Bay, Wisconsin based Green Bay Packaging Inc. (GBP) announced it will begin construction of a new 550,000-square-foot corrugator plant in Tulsa, Oklaho- ma. Construction is set to begin on September 1, 2020, with operational start up scheduled for October 2021. The new “super plant” will be replacing GBP’s current 180,000-square-foot corrugator plant in Tulsa, where GBP has operated a plant for more than 50 years. The new plant will be equipped with a new 110-inch Fosber corru- gator and all new flexo folder gluers and rotary die cutters. The Tulsa announcement is another step in the con- tinued growth and expansion of GBP. Over the last 24 months, GBP completed substantial expansions of their Green Bay Shipping Container and Minneapolis Shipping Container plants. They have installed a new 110-inch BHS corrugator in Green Bay and installed new high speed and high graphic lines in plants across the country. “We believe in this industry and our employees and customers”, said Bryan Hollenbach, Executive Vice Presi- dent of GBP. “Our new paper mill is tracking right on time with a projected startup in the first quarter of 2021. The new Tulsa operation is a significant investment in our per- sonnel and the future of this business. It’s a fun time to be working for Green Bay Packaging.”

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August 24, 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.

CONTROLLABILITY

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

DOUBLEBACKER IMPROVEMENT

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

PRODUCTIVITY

C/ Orfeó Català 13-15 · 08440 Cardedeu (Barcelona) telf: +34 93 846 01 06 · [email protected] WWW.AL-GAR.COM

DOUBLEBACKER IMPROVEMENT

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

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

PRODUCTIVITY

PRODUCTIVITY

DOUBLEBACKER IMPROVEMENT

Roller Shoe

DOUBLEBACKER IMPROVEMENT

9. Thin Wall Hot Plates 10. Pressure System Benefits —Exact glue application due to defined contact of applicator roll to web. Web is in contact to less flute tips compared to bar systems. • High precision glue application • Less moisture applied to web —No wear of shoes and springs —No adjustment of shoes or paper gap —Uniform glue application over entire 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 [email protected] chicagoelectric.com Solution The ProPress system ensures an optimum heat transfer to the board. It offers a wide range of set- tings. The loadi g pressure can be varied, the number of shoes can be lifted in accordance t the line speed. The outer shoes can be lifted in accordance to the paper width. The shoe bars will be delivered pre-assembled for a short installation time. —Liftable for easy paper infeed and for cleaning of the machine —Position adjustable in paper direction to avoid grooves in hotplate Press Productivity Issue—Poor Heat Transfer Rollers are usually limiting the heat transfer, since they often have contact mainly on the edges of the plates due to wear or bent plates. They also cause often loss of caliper and bearing need to be replaced frequently. Airpressure actuated systems can only supply a limited pressure and have com- pared to shoe systems a closed surface. Pressure Shoe

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

Thin-Wall Hot Plates

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

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ance from steam to paper surface results in fast heat flow

FBA: Shipments Up Again In July

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

Industry shipments of corrugated products increased 3.1 percent, from 33.734 bsf in July of of 2019 to 34.784 bsf in June of 2020, the Fibre Box Association (FBA) report- ed. The increase is partially due to the fact there was one more shipping day in July of 2020. Average week ship- ments, however, decreased 1.6 percent, from 8.032 bsf in 2019 to 7.905 bsf in 2020. Shipments of corrugated prod- ucts are up 0.3 percent year-to-date. Containerboard consumption increased 1.7 percent, from 2.7517 million tons in July of 2019, to 2.7993 million tons in July of 2020. Consumption is up 1.1 percent year- to-date over 2019, from 18.7289 million tons to 18.9354 million tons. Containerboard inventory at corrugator plants de- creased 3.1 percent, from 2.0865 million tons in June to 2.0214 million tons in July 2020. Weeks of supply shrunk from 3.3 in June to 3.2 in July, or 3.0 percent. “Containerboard inventories at mills and box plants dropped by 72,000 tons in July, the first monthly July de- cline in 17 years,” noted Dick Storat in his Scoring Boxes newsletter. “This continued last month’s record inventory decline. Containerboard inventories last declined in July in 2003, then by less than 3,000 tons. CONTINUED ON PAGE 38

Year

Actual

Percent Change Avg Week Percent Change

2020 2019

34.784 33.734

3.1

7.905 8.032

-1.6

Industry Total

Year-to Date

July 2020

Year

Actual

Percent Change Avg Week Percent Change

2020 2019

231.403 227.669

1.6

7.765 7.744

0.3

Industry Total

Containerboard Consumption (Thousands of Tons)

Year

Month

Percent Change Year-to-Date Percent Change

2020 2019

2.7993 2.7517

1.7

18.9354 18.7289

1.1

Container Board Inventory - Corrugator Plants (Thousands of Tons)

Corrugator Plants Only

Date

Percent Change Weeks of Supply

Percent Change

Jul. Jun.

2.0214 2.0865

-3.1

3.2 3.3

-3.0

Shipping Days

Year

Month

Year-to-Date

2020 2019

22 21

149 147

SOURCE: Fibre Box Association

8

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August 24, 2020

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Domino Digital Printing Adds Kent As Senior Sales Manager, Corrugated Gurnee, Illinois based Domino Digital Printing announced that it has added Lloyd Kent as Senior Sales Manager for Corrugated, Digital Printing North America. Kent brings to

the labels sector, entered corrugated in June 2020 with the introduction of the X630i digital aqueous inkjet cor- rugated press. Immediately, Kent wanted to be part of the company. “I am excited to join Domino with the respon- sibility of debuting a new digital single-pass printer, the X630i, to an industry I have been involved with for over 20 years,” he said. “Domino is a remarkable global orga- nization, but it truly feels and acts like a smaller company, being able to pivot and react quickly.” The X630i is a new machine, and the technology is proven with many installations in the label industry. Dom- ino places great emphasis on listening to its customers and this shows with offerings like its In-House Leasing pro- gram, trade-in/trade-up capabilities, water-based AQ95 inks, and local service teams throughout North America. “Most companies looking into digital print have been craving most, if not all, of these offerings over the past sev- eral years,” said Kent. “I believe a strong company behind the equipment you install is most critical, and my job is to facilitate the interactions ensuring a positive and success- ful relationship.” Bill Myers, Marketing Manager at Domino Digital Print- ing North America adds, “I worked with Lloyd over 20 years ago. He is a consummate professional, excellent with customers, a solution provider, highly dependable, very considerate, and someone you want on your team.” Kent can be reached at [email protected] or (281) 702-4656.

Domino over 30 years of expe- rience. His career includes roles as sales development manager, national & regional sales manag- er, and regional market director. Companies fortunate to have had Kent on their team over the past 20+ years include EFI, HP, and Bobst, where he was respon-

Lloyd Kent

sible for sales of digital and traditional corrugated printing machinery. Prior to that, he spent 12 years at Diagraph, providing coding, marking & labeling solutions to brand owners for their products and packaging. Kent is involved with AICC, where he serves as an Am- bassador by introducing new members to existing mem- bers and helping them get acclimated and feel welcomed within the association. His LinkedIn profile sums up his business focus: “I help corrugated and packaging compa- nies with their transition from traditional flexo printing and litho-lam technologies into single-pass digital printing.” Domino, a major player in digital inkjet printing within

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August 24, 2020

Money making machine

Domino X630i digital aqueous inkjet corrugated press

…MORE PROFIT per job. …MORE CAPACITY in a given day. …MORE CORRUGATED out the door faster. …MORE MONEY in your pocket sooner.

Why DOMINO? • 40+ years of inkjet technology experience • Financially strong and stable • Heavily invested in digital technology • 1,000 industrial inkjet installations • Service & Support,Trusted Business Partner • Small footprint (10’H x 38’W x 21’D) • Change SKUs & print jobs on the fly • NO PLATES to make, mount, or inventory • Less downtime, MORE UPTIME • Print SPEED up to 246 fpm • AQ95 aqueous ink, POLYMER-based • Prints on COATED & UNCOATED stocks • Swiss Ordinance & Nestle COMPLIANT • Environmentally FRIENDLY • LOWER Total Cost of Ownership Why X630i?

Contact us today for X630i print samples, product brochure, and more information on the press engineered and built to transform your business. Digital Printing for everyday corrugated box production that MAXIMIZES productivity & efficiency, while MINIMIZING cost & consumption. Experience the DOMINO dierence

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AICC’s All Access Pass Lowers Training Costs

Delivering ultra-high performance S-Board ™ liner and medium grades and world-class technical service. Bonus: those boxes make really awesome places to play

AICC, The Independent Packaging Association, is offering more than 50 webinars for one price with its All Access Pass. It provides the best way to meet a company’s profes- sional development needs. AICC members will 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 sched- uled from September 2020 to August 2021. When a company invests in professional development, they equip their team with shared knowledge that helps them perform at a high level, and improve the compa- ny’s bottom line. The All Access Pass gives participating companies flexibility in choosing education offerings and which team members take them, simplicity and accuracy in budgeting for professional development, and the best available price for AICC webinars. All employees can use the pass to register for webinars important to their devel- opment without delay or additional payments. The average registration for a webinar is $250. With more than 50 webinars scheduled, the All Access Pass represents a savings of more than $10,000. The pass can pay for itself after only seven webinars. Visit www.AICCbox.org/Pass to purchase the pass.

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DS Smith Introduces ‘Circular Design’ Principles To Eliminate Waste

As pandemic-induced online shopping has boosted demand for boxes, Atlanta, Georgia based DS Smith launched its Circular Design Principles, citing company research that shows better packaging design could save the industry $46 billion a year in logistics costs globally. New research reveals that consumers are carefully considering com-

Packaging ERP Algorithmic Scheduling Web-Based Access Online Customer Portals

pany sustainability practices before purchasing, especial- ly when it comes to wasted space. Nearly all consumers (93 percent) reported they have received packages with wasted space, and nearly three-fourths (73 percent) have received packages that were twice the size or more needed. All this wasted space has left a “bad taste” in consumer’s minds and wal- lets, as 54 percent reported they would think twice before ordering again from a compa- ny that had excessive space in their packaging. DS Smith developed the design principles in collab- oration with the non-profit

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Ellen MacArthur Foundation, a global organization that promotes a cir- cular economy to reduce consumption, waste and pollution by keeping products in use. The new program helps guide companies in designing reuse and recyclability into packaging. DS Smith recently marked its first successful year of collaboration with the Foundation, and in its second year will be working on a series of activities to further its circular econ- omy agenda including innovation and circular design projects, training and development of its teams and engagement in its communities. According to a survey of executives by Forbes Insights and DS Smith, eliminating empty space in packaging can produce big benefits for busi- nesses that ship goods, from scoring big savings to gaining an advan- tage over its competition – while reducing its environmental impact. About 60 percent of those surveyed estimate more than a quarter of their e-commerce packaging is empty space, from misshaped delivery boxes to partially filled international shipping containers. DS Smith said that based on its proprietary research, cutting those unnecessary logis- tics costs would result in $46 billion a year in potential savings for the industry worldwide. “Sustainability is at the core of every business decision we make, and the issue of wasted space has been a pain point for many years and a key reason we developed our Circular Design Principles,” said Mark Ushpol, Managing Director of Packaging at DS Smith. “We see design as one of the essential elements of the circular economy and look at pack- aging through the lens of imagining not only the impact of design on the end user, but also the impact that design has across all stakeholders, from creation of the product to its final destination.”

  

CONTINUED ON PAGE 16

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August 24, 2020

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IMMEDIATE SOLUTIONS

Customer Service Disruptions Remote Workforce Platform

Online Customer Ordering Portals

Paper-BasedWorkflows

Paperless, Electronic Document Management

Out-of-Date Pricing

Automated, Real-Time Costing Update

Viruses

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