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The Final De Pere Walk

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We will be doing the FINAL walk in De Pere. We recognize that De Pere has a number of other companies in the 5P Industries! We will be covering other cities in the upcoming issues in the GBIG NEWS to show the strength of our 5P, Converting and Supporting Manufacturing Base providing services to the Paper Industry in Wisconsin. Unfortunately, the Paper Industry in Wisconsin has been declining and we as a business community need to address it. The Green Bay Innovation Group will be putting together a group of individual and companies to focus on RE- BUILDING the paper industry. We are in process of putting together an overview of the industry and the strengths of Wisconsin to support re-investing in paper. We will be putting out information in the upcoming issues. If you are interested in joining our group, please contact me at: 608-698-3333 or email at martinpochs@gmail.com Remember, the Paper Industry built Wisconsin!

Be the Leader you would like to have

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I recently spoke at a conference on Leadership. A portion of the presentation was centered on some simple concepts to prompt attendees to reflect upon their personal approach to leading. This was one of the “aha’s” I shared. “Be the leader you would like to have”. It sounds rudimentary, but it resonated with many and lead to several subsequent conversations.

Brian Van de Water presenting at a leadership conference

When I think back over my career and time spent with clients, I was able to work with both good leaders and some that I would categorize as “not so good”. I worked with a client that was one of the best technical experts in their field and were known and respected for their technical expertise. This leader’s approach proved to be ineffective, and their company struggled to survive. Their default style was one of judgment, volatility and explosive anger resulting in a culture that was reactive at best. No matter how much they yelled, screamed, and fired people performance did not improve. Turnover at this company was extremely high and team members lived in fear of who was the next person to feel the boss’s wrath.

Another leader I worked with was very nice and seemed open to conversation when someone sought them out. They also softly avoided conflict at all costs. Team members loved the owner but remained frustrated and feeling that issues they brought forward would not be acted upon. They also observed team members who were destructive to the company and culture be disrespectful and at times knowingly produce bad product with no repercussions. It also created a very divided leadership team.

SPL Consulting, LLC logo

In assessing the effectiveness of their leadership styles, we uncovered similar outcomes perception of ineffective leadership with the company struggling to remain profitable. Other typical symptoms range from team members giving up, poor quality and unpredictable processes. People are looking to their leader to provide vision and set the tone for culture.

When I lead teams through a Strategic Planning or Leadership Development process, I often ask the participants to take a few minutes and summarize traits or characteristics of a great leader. Traits like these often are brought forward:

  • Visionary
  • Good listening skills
  • Produces results
  • Empathy
  • Tough but fair
  • Consistent
  • Team focused

I challenge each of you to think about the kind of leader you are and if you are the leader you would like to have.  Seek input from your team on their perception of your leadership style.  It could be the first step in becoming a stronger leader and the becoming the leader your team is looking for.

Brian Van de Water
CEO
SPL Consulting, LLC.
vandewaterb@outlook.com

Printing is Alive and Strong!

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Marty Ochs

The Green Bay Innovation Group announced an event:  The Printing Showcase on September 27, 2022. 

The exhibit starts at 10:00 am to 4:00 pm followed by networking to 5:00 pm.  The event will focus on the printing industry.  It will be at the Stadium View Bar and Conference Center.

Wisconsin has a large concentration of offset, flexographic, gravure, screen, digital and ink jet imaging second to none.  We have an outstanding group of exhibitors from ALL sectors of the printing industry. To register and exhibit, go to:  www.greenbayinnovationgroup.com EVENTS – Printing Showcase 5P Expo.

Printing is Alive and Strong!  If you go to any store or order online, you will see row’s and row’s of printed cartons, labels, overwraps, displays, information sheets and many other printed products.

The Essential Types of Printing for Paper, Paper Board, Corrugated, Labels and Other Substrates:

Gravure printing is a direct printing process using an etched cylinder printed directly to the printing medium with superior reproduction.  Gravure is used in packaging and publication printing for high-volume printing requirements.

Flexography is a process which utilizes a flexible relief plate utilized in label, flexible packaging and the corrugated printing industries.  

Offset printing is a very common used process with a plate transfer to the image onto a blanket cylinder, then onto the substrate. Offset can produce a vast range of products with sheets and roll applications with a lot of flexibility with excellent reproduction.  

Screen printing is not as widely used as the other printing processes.  It is perfect for non-traditional substrates like fabric, stickers, signs vinyl, posters, point of purchase, etc.  With the screen process, you can produce just any quantities with any material.

Wide Format uses large inkjet devices to print graphics onto large sheets or rolls of substrates including paper, vinyl, point of purchase, floor graphics, apparel, fabric, etc.  This relatively new technology incorporates advanced software, design, cloud computing offering endless versatility and cost-effective for short and medium printing runs.  The inks are printed through inkjet printing heads and then cured by oxidation, heat or UW.   

Digital Printing is the process of printing digital-based images directly onto a variety of media substrates. There is no need for printing plates with direct transfer of the image. Digital Printing is the fastest growing area of printing due the ease of set up and flexibility.  Digital is evolving with improved print quality for high-quality images and variable data requirements.

A Perfect 10 At Legacy Flexo

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This article is one of our features on printing leading up to the event, PRINTING SHOWCASE, September 27 in Green Bay at the Stadium View Bar & Conference venue (just a couple blocks east of Lambeau Stadium.) Legacy Flexo will be on hand as an exhibitor. Contact us for details or sign up today online at www.GreenBayInnovationGroup.com and register at the Event tab.

Legacy Flexo Laura Comexi close up

Use of 10-color flexographic technology has taken companies making that investment into far more than 10-deck printing. Still this question often opens a discussion: “What kinds of jobs require you to run that many colors?” It’s a question that managers hear all the time. “I’m constantly asked why 10 decks are needed,” says Dan Aberly, at Legacy Flexo, Green Bay, WI. The answer to that question and another,”Why invest in this type of press?” are keys to a wide-ranging summary of advancements in flexo printing. This overview explains some of the basic reasoning as well as the increasingly sophisticated jobs being printed.

The capability of a 2021 COMEXI F2 MP10 installation of a 10-color, gearless press sports cutting-edge features like second pass in-register printing, automatic impression setting, automatic viscosity control and the ability to track performance 24/7 worldwide. The press is a symbol of continued, steady growth and a commitment to providing customers with high-quality, cost-effective products.

Worry-free installation was closely related to the quality of pre-planning, specifications and communication with the press design-build provider. Some of the elements on the rundown of considerations for major installations like this, include the long list of capabilities as well as safety, environmental, plates and sleeves, workflow, storage, quality assurance, waste handling, recycling, and more.

Support items such as material handling, trim removal, roll delivery to the press, nearby fixtures, racks and other surrounding systems are all part of a complete installation process. “Everything from washer stations to storage were planned as part of the project,” says Aberly. “We learned a lot from earlier installations and startups.” Operation of eight-color flexo presses has steadily moved Legacy into better press sleeve turnaround and nearby storage; as well as total quality, touch-screen paperless press-side systems.

No-Surprise Installation

During the installation timeframe, a good working relationship between the press provider and printer are especially crucial in terms of:

  • On-time installation and trouble-free startup
  • Flexibility in the build and installation or add-ons
  • Determination of what and where “shakedown trials” will occur
  • Accuracy of dates for start-up and commercial production
  • Definition of turnkey delivery & results
  • Problem solving process when problems occur

Working a good plan and having a committed, flexible team allowed Legacy to bring in this installation on time. “We drove a lot of this because our customers for the press grew their business fast,” said Aberly. “We had customer service incentives to expedite the assembly and installation since our other presses were rapidly becoming sold out.” Helping to determine needs and meet the timeline was a project with key customers. Together we worked on developing new products, plus running print trials. A new product launch and resulting high growth are compelling motivators when an investment is pending.

10 Decks and More

How are the 10 decks used? The need for six stations is easy to understand with jobs that require four colors, plus a metallic and a protective overprint. Beyond that, Aberly says Legacy does much of these on various jobs:

  • Break some colors onto two decks. For example, some heavy coverage colors can be printed with better results using higher volume anilox rollers. Or break out a color using a deck with a screen for delicate shading and another one with line color.
  • Use of colors beyond CMYK for spot color or enhancement of specialty colors.
  • Addition of fluorescent, metallic or precise ink matched colors.
  • Logo or customer-requested special color add-ons.

Examples of particular print jobs rounds out the picture of capabilities. One job category consists of a primary product and line extensions using five-to-nine colors. “Even though this family of printed products does not usually require all 10 decks, the sophistication of the technology provides better results than other presses,” notes Aberly. “In addition, these latest presses allow us to handle a range of film substrates.” 

Special inks are part of the picture where the printed area may be subjected to high heat and require good water and rub resistance. Print developments led Legacy to meet market demand by brand leaders.

When all decks are not being used on a current job, there is also the ability to begin to set up the next job on unused decks.

Runnability Advancements

Web handling advancements, automatic registration, superior drying systems, fast changeovers and great defect detection—are all factors that contribute to the ability to run complex jobs. Other examples of print jobs made possible by this latest flexo technology include:

  • Running substrates such as films that have challenging properties like high-stretch or new synthetic content.
  • Handling shrink film that many 6-color presses don’t process well.
  • Other specialty film substrates such as those used to connect and pick up a 36-pack of water bottles.

Efficiencies Pay Off

Investors in 10-color flexo continue to sing its praises in terms of quality and output. From setup to line speeds, changeover and washup, precision automation has allowed printers to process high volumes.

Even training time on start-up and for new press operators occurs in a short timeframe, at modest cost. This is largely due to automation systems that reduce the need for operators to make adjustments.

Flexibility for printers to assist in the design of the press to meet their market requirements allows them to assure results. For printers pushing the edge on complex jobs, or just pushing the multi-color envelope, the latest 10-color flexo presses cannot be overlooked. And at Legacy Flexo, a full lineup of 10 presses rounds out capabilities. See LegacyFlexo.com.  

– By Susan Stansbury

Become More Innovative & Competitive with 3D Printing

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Join GBIG for a free webinar with experts from Advanced Tek and Stratatsys 3D Printing

10-11 a.m. Thursday, Aug. 25 | Webinar Hosted by Packerland Websites

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July 20th, 2022 Newsletter

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Read the July 20th, 2022 Green Bay Innovation Group Newsletter here.

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GBIG NEWS | 58 Stories and Links on the Internet 7/20/2022

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GBIG News

Get links to the latest news, events, stories, and interviews from our 5P news members. Our goal is to remind the decision makers in Wisconsin of the importance of our industry both historically, and more importantly, into the future.

Read the latest 58 Stories and Links on the Internet below.

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DePere Tour

Here are some of the Latest Paper and Printing Industry Updates | July 20th, 2022

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Marty Ochs

Demand is exceeding the supply of Paper Products especially in the fine printing and label paper market.  We are now seeing some catch up along with strict allocations and long lead times.  Planning and Paying All of your BILLS is the key to success! The Paper Mills are not able to keep up with demand in the uncoated and coated free sheet market.  We are seeing companies like ND Paper get out of the lightweight coated groundwood paper for publications and catalogs which will drive customers to digital media and hurt the large printing companies like Quad Graphics in Wisconsin! We will see a minus 5 – 6% CAGR over the next 5 years in publication printing and catalogs will recover at 2.5% CAGR. However, we will see a very good growth in digital publications expected at 10% CAGR.

We have seen major price increases from 30 to 70% in some cases in the printing paper markets. We will also see modest price increases in the paperboard and corrugated markets.   However, the pulp prices continue to increase which is a BIG part of the paper costs.  Harwood pulp prices in China are up 40%.  Europe is in the same position and the Urkraine conflict will continue to put pressure on the European suppliers of paper products.  We will see limited supply exported to the USA.

We have witnessed rising inflation due to fuel increases, logistics and employee compensation.  We expect it to flatten and possibly see a decline in fuel prices in the USA.  Europe will continue to see fuel and shortages of fuel due to their dependence on Russia.

Strategic partnerships between Paper Companies and Paper Merchants are invaluable and critical for one to survive.  We are witnessing the Printing Companies that were buying seconds or price sensitive have NO ALLOTMENTS available to them.  The Paper Merchants and Paper Mills are in control and we see this continuing through December 2023.

We are seeing FOB Dock from a number of Paper Manufacturers and the printers will be picking up the costs.  We expect the Paper Mills focus to deliver close to home.  We expect that the East and West Coast will be forced to purchase paper overseas due to limited supply of paper from domestic suppliers.

Lead Times:  Look ahead 90 days forecast for what you are going to need.  It is recommend too get standard sizes and basis weights.  Special Orders and Special Papers are a thing of the past! In addition, move to a HOUSE STANDARD SHEET arrangement.

All Printing Companies are facing series issues finding employees and prepare for the challenge.  In many cases, the Printing Industry is upgrading equipment for automation at all levels.

Supply Chain issues:  Keep close track of inventory, track cancelled or rescheduled orders.

We recognize the importance of cash flow management due to larger inventory.  We suggest that you pick up a SECOND BANK or increase your line of credit.   Your Bank relationship is critical to survival.

We recognize that the market for printing paper has changed.  However, the commercial printing market has rebounded to pre-covid levels with the expected growth of 2.2 to 3.0 CAGR for the balance of 2022.  In the first quarter of 2022, the growth was unexpected for the paper companies producing the needed paper product and they anticipated a decline in the demand.  The label market for C1S and pressure sensitive papers is strong with a CAGR of 3.3 to 5% growth rate.  Interesting the label market has had increases for the past 29 years. The Direct Mail Printing companies have seen continued growth especially with the integration of variable data and personalized direct mail.  We anticipate a 2-3.2 CAGR through 2025.  

Domestic Fuel Costs:  We anticipate seeing a pullback on the cost of fuel due to the increase in supplies and the worry of a recession.  However, the consumer still is willing to pay the high fuel costs regarding of the price so businesses are passing on the costs even if their costs are reduced!    

The Mid-Term Elections:  We will see a historic RECORD amount being spent on the ELECTIONS which will put a BIG DEMAND on the Printing Industry.

Overseas Paper Supply will very slowly come back and Europe will take care of their customers.  China is still recovering from their lockdown and will serve their local market first.  We have seen containers go from $2,500 to $25,000.  We anticipate that the prices will end up around $6,000 with long lead times for product.

The War in Ukraine will continue to have a major impact on Europe and the USA.  China will continue to support Russia buying cheap oil and forest products.  The TIME IS RIGHT to re-invest in the Paper Industry!

TRENDS AND FACTS IN THE COMMERICAL PRINTING INDUSTRY

We have over 25,000 US companies specialize in commercial printing.  The Great Lakes States produce over 42% of printing products in the USA.

Commercial Printing generates nearly $900 billion in annual revenue!

Digital printing is growing at an average of 10%.  We see major companies like Hewlett Packard continue to invest in the printing industry!

72% of corporations utilize direct mail campaigns supporting digital media.  Direct mail open rate is 10 times e-mail, linkedin, etc. and has proven very effect due to new technologies with variable data.

The latest report (See the Industry Report in GBIG NEWS) is the return of profitability of the commercial printing market and we are starting to reinvestment in new automated equipment.

Quad Plus | Industrial Circuit Breakers: Preventing Costly Downtime

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Quad Plus

A number of electrical problems can create hazardous conditions for your crew and machinery, including  short circuits, overloaded circuits, and more. Circuit breakers are the primary method of protecting people  and equipment from these dangers. As in all aspects of workplace safety, regular maintenance systems and  preventive maintenance will help keep workers safe while avoiding expensive breakdowns and costly  repairs. 

The Cost of Avoiding Maintenance 

One leading factor of industrial circuit breaker deterioration is the fact that they are rarely in operation and  spend most of their time idle. While most machinery makes it obvious when a breakdown occurs, you may  be unaware of a problem until a breaker fails and brings your production to a halt. 

Dirty circuit breakers can also fail to operate correctly; grime and debris must be prevented from  accumulating in the breakers. Over time, the lubrication used in circuit breakers can also break down and prevent the components from operating correctly and safely.

Common Routine Tests 

man looking in front of a monitor

The easiest way to ensure that industrial circuit breakers are functioning correctly is through routine testing.  This can usually be completed without stopping production lines. To ensure a thorough test for your  breakers, NETA specifications should be used to ensure that the devices adhere to NETA-certified  acceptance standards.  

While the exact testing protocols will vary depending on your specific operations, there are standard  procedures that are likely to be performed to assess industrial circuit breakers. For example, all key  components such as contacts, connections, and arc chutes, should be examined. Low-voltage breakers  should undergo primary and secondary injection testing to ensure fault trip and overload protection. 

A circuit breaker analyzer is a device used to test the timing of the open and close functions of a circuit  breaker and ensure the synchronism of the poles in different operations. A micro-ohmmeter is used to  perform resistance testing to prevent hot spots in the breaker and look for potential problems. Lastly, an  infrared inspection may be done to search for hot spots resulting from defective components or connections  that lead to component failure.

Routine Breaker Maintenance 

Some types of industrial circuit breakers will require more maintenance than others. For example, a molded  case breaker needs very little attention, while others should be included in a periodic maintenance program. 

Two employees fixing machine

The frequency of routine maintenance should be determined based on the environment of your operations  and your specific equipment.  

One crucial routine task is to clean the breakers. The accumulation of debris in a breaker can prevent the  breaker from tripping, cause deviations in the power supply, and more. Cleaning a breaker can be  completed by taking off the cover and removing any buildup using vacuum tools, lint-free swabs, and  isopropyl alcohol. 

Industrial circuit breakers also require lubrication to function properly. A number of items should be  inspected for adequate lubrication, including operating mechanisms, pivot points, the main contacts, and  primary and auxiliary connections. 

Lastly, many types of industrial circuit breakers require regular tightening and retorquing. The breaker’s  manufacturer will list the recommended values for specific breakers, and these figures should be confirmed  on a regular basis.

Schedules to Avoid Downtime 

Rather than an unexpected shutdown, planned interruption to production schedules will always be better for  virtually all industrial situations. Regular maintenance and testing according to a set schedule are critical  factors in ensuring that maintenance is completed when it is convenient for your operation. 

What this routine looks like will depend on the type of breaker as well as the environment in which machines  are running. A relatively clean environment, such as those found in the manufacturing of electronics, will  likely require less maintenance than one with a great deal of dirt or debris.  

A testing schedule should also be created to ensure that all circuit breakers are in working order. This  schedule will also be determined by the type of breakers being used. For example, high-voltage breakers  should be tested every six months, at minimum, whereas low-voltage breakers can go a maximum of three  years between tests. Molded-case breakers need very little maintenance at all.  The most critical factors for routine maintenance and testing for industrial circuit breakers are not only  creating a schedule that is appropriate for the environment and the equipment, but also ensuring adherence  to this schedule. If you’re not sure how frequently to test and inspect your electrical equipment or what type  of routine maintenance is necessary, Quad Plus can help. Please contact Jim Woulf at (920) 515-4155 or  via email at jwoulf@quadplus.com. Routine maintenance and testing are far easier to work into your  production schedule than unexpected downtime.

The DePere Walk

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Innovative Companies

Green Bay Packaging signage wide shot

I recommend that you exit Scheuring Road in De Pere and go east to American Boulvard just past RR Donnelley and go south.  You will see a MEGA Industrial Park  with companies focused on the 5P, Converting and Manufacturing Industries.  Currently, Georgia Pacific is building a 1.1 million square foot distribution center.  In addition, the park has a number of large national companies along with some very innovative smaller companies doing business worldwide.   

Green Bay Innovation Group

Bringing Green Bay Companies Together. Green Bay Innovation Group is committed to building an authentic networking experience where innovation can thrive.

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Phone: 608-698-3333 
martinpochs@gmail.com
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