With the right tools in place, warehouses can operate with optimal productivity and efficiency while ensuring the safety of employees. By utilizing Precision Airconvey technology, warehouses can streamline the process of removing production waste from the press and conveying it to the compactor. Not only does this make the workplace safer, but it also increases productivity exponentially.
These engineered pneumatic systems are suitable for a range of industries, including converting, paper, print, label, and battery production, where waste removal is a critical part of the production process. Unlike manual methods, PAC’s hands-free, continuously running systems incorporate advanced technology to whisk away trim, matrix, and other types of production waste. And because the production presses/machinery can continue to run during the waste removal process, production output is significantly improved.
Implementing a PAC system in your facility can yield significant benefits such as a reduction in manual operations, decreased operational costs, optimization of the flow of goods, and other benefits such as:
A safer workplace environment, potentially saving your staff from injuries and you from costly litigation. A recent survey identified overexertion as the most disabling workplace accident in the United States in 2021, followed by falls and being struck by objects. With a PAC system, employees can avoid having to lift and move heavy items, thus reducing the risk of injury.
Boosted employee satisfaction. Labor-intensive and repetitive tasks, such as lifting heavy items, can cause frustration, low morale, and a loss of motivation among employees. By automating such tasks, employees can focus on more meaningful work, which can help reduce their stress levels and improve overall job satisfaction.
Increased productivity and efficiency in your facility. With the freedom afforded by a PAC system, employees can work more efficiently and effectively, freeing up time for other tasks.
Financial savings. PAC guarantees a 12-month return on investment for its engineered systems, but many clients realize returns much sooner. Our ROIs are measured in months, not years, ensuring that you see significant financial benefits from your investment in a PAC system.
At PAC, we take pneumatic conveying systems to the next level using industry expertise and precise engineering. Our solutions boost accuracy and productivity, improve employee safety and reduce space requirements.
Learn more at: www.PrecisionAirConvey.com For additional information, contact Eric Keebler at EKeebler@AirConvey.com or 314-226-8298
The Children’s Museum of Green Bay, is looking for corporate sponsorships in their expansion of their exhibits. The new proposed exhibit would feature Green Bay’s thriving industrial sector, the pulp, paper, packaging, print, & plastic industries; the pillars of our community.
It’s crucial that we educate the youngest members of our community, in a fun and interactive way, about the significant role these industries play in shaping our lives.
Women in the 5P and Green Bay Innovation Group will host a kick-off event, “A Night at the Museum: The Future of Manufacturing,” at the Children’s Museum, 1230 Bay Beach Road, at 5:00 pm Thursday, Sept. 21. Refreshments and hors d’oeuvres will be served. Registration is on the GBIG event page or follow the link below. A Night At the Museum : The Future of: Thu, Sep 21, 2023 (eventgroove.com)
Please contact Heather Heil for more information regarding this sponsorship opportunity. hheil@gbchildrensmuseum.org | (920) 432-4397
Grab a friend and join us at our inaugural Tossing for Inclusion bag toss fundraising event on August 17 at GameDay Sports Bar in Appleton.
This inclusive bag toss tournament fundraiser is designed to raise money to support our community programs, but more importantly, will offer teams of all skills and abilities the opportunity to compete against one another, as peers, in support of the cause.
Team registrations are $100/team and include lunch, drink tickets, and an event shirt for each player. Tournament is double elimination – two games are guaranteed.
REGISTRATION INFORMATION:
Please register your team by July 30. You can register online through Eventbrite by clicking the button below or by filling out our team registration form and mailing it in or dropping it off at VPI, Inc. 2730 N Roemer Rd. Appleton, WI 54911 with your team entry fee.
Individuals of all ages, skills, and abilities are encouraged to participate!
By simply registering a team to compete, you are making a difference in your community.
Precision AirConvey, a leading provider of innovative trim and matrix conveying solutions, is excited to announce its participation in the September 26th Printing~Packing~Converting Showcase in Green Bay. As part of the event, Precision AirConvey invites attendees to visit their booth for a chance to win a state-of-the-art 50″ Smart TV.
Product Description: This cutting-edge Smart TV promises an immersive and unparalleled viewing experience and is equipped with 4K Ultra HD and High Dynamic Range, delivering stunning results that enhance your favorite TV shows, movies, sports and more. Dolby Vision boosts your viewing experience by delivering improved picture quality with detailed images. An LED backlit LCD screen surpasses your expectations for an enjoyable movie night. Made for the ultimate entertainment experience, versatile connection options give you the ability to upgrade your home theater to the best of its potential.
To participate for a chance to win this incredible 50″ Smart TV, be sure to visit the Precision AirConvey booth at the Printing~Packing~Converting Showcase. Our knowledgeable team will be available to showcase our latest trim and matrix conveying solutions and discuss how they can benefit your business operations.
“We are thrilled to offer attendees the opportunity to win a 50″ TV at our booth,” said Eric Keebler, Regional Manager at Precision AirConvey, “It’s our way of expressing gratitude to our valued customers and the industry for their continued support. We look forward to welcoming everyone to our booth and showcasing our innovative products.”
Join Precision AirConvey at the Printing~Packing~Converting Showcase on September 26 at the Radisson Conference Center in Green Bay. Visit the Precision AirConvey booth for your opportunity to experience the latest in trim and waste conveying solutions and enter the giveaway.
About Precision AirConvey: Precision AirConvey is a leading provider of innovative trim and matrix conveying solutions designed to streamline material handling processes and improve operational efficiency. With over 50 years of industry expertise, Precision AirConvey serves a wide range of sectors, including label and narrow web, converting and wide web, film and sheet, mail insertion, printing, paper and paperboard and non-woven. Our cutting-edge solutions are engineered to optimize performance, reduce downtime, and enhance overall productivity.
News Release: August 2023 Update on our Guest Speaker and a Panel of 3 Speakers on Innovation.
Sam Schlaich Council of Government Affairs at the Flexible Packaging Association.
Rodney Pennings Sales Director Paper Converting Machine Corporation.
Dr. Rebecca Mick, Amcor Innostream Program Manager
Dean F. Benjamin Director of Product Development Pixelle Specialty Solutions
On September 26, learn about the businesses that set the region apart for its manufacturing strengths. From printers to paper, plastics, and roll goods converters, this Showcase event expands in its second year. Hosted by Green Bay Innovation Group (GBIG), the full day takes place at Green Bay’s Radisson Hotel & Conference Center.
Rodney Pennings
Rodney Pennings is the sales director for the printing, coating, and laminating division of Paper Converting Machine Company. He has a Master’s of Science degree in engineering and more than 27 years of industry experience. Rodney has held roles at PCMC in engineering, operations leadership, and commercial leadership, all primarily focused on the printing industry. In his current role, Rodney is responsible for global sales of printing presses (central impression and inline), digital printing solutions, and laser anilox roll cleaners.
Sam Schlaich
Sam Schlaich is a government affairs professional with over 10 years of experience in both the private and governmental sectors. He is currently Counsel, Government Affiars at the Flexible Packaging Association (FPA), the association representing U.S. converters of film, foil, paper, and other materials into packages for food, medical device, and industrial products. Prior to joining the FPA in 2021, he served as an analyst in the Office of Governor Larry Hogan.
Other employment experience includes the Maryland Chamber of Commerce, the Maryland General Assembly, and multiple political campaigns. Sam has his BA in Political Science from Salisbury University and his JD from the University of Baltimore School of Law.
Dr. Rebecca Mick
Dr. Rebecca Mick, Amcor Innostream Program Manager will represent Amcor on our Panel Discussion on Innovation at the 5P Showcase on September 26, 2023, starting at 1:30 p.m.
Rebecca Mick, PhD combines her passion for polymers and the environment as the Technical Sustainability Lead in the global Core R&D group at Amcor. She applies her technical expertise to the entire sustainable package lifecycle: from pellet to package. Rebecca is currently leading Amcor’s flexible R&D sustainability program, helping to leverage Amcor’s sustainability developments around the world. She looks forward to educating customers about these efforts and the ever changing recycling landscape. Rebecca has a PhD Chemical Engineering specializing in polymer rheology from the Illinois Institute of Technology.
Dean Benjamin
Dean Benjamin received a B.S. degree in Paper Science and Engineering from the University of Wisconsin – Stevens Point and then went on to earn a Ph.D. in Chemical Engineering from the University of Minnesota. While at Minnesota, he studied computational and experimental fluid mechanics of the roll coating process under Professor L.E. Scriven.
Upon graduation, Dean joined Avery Dennison as a Research Engineer at the Avery Research Center in Pasadena, CA where he led projects to develop coating processes for the production of pressure sensitive labels and tapes.
Dean then joined Consolidated Papers, Inc. as a Senior Research Engineer at their R&D facility in Wisconsin Rapids, WI. His research focused on developing new coating and finishing equipment and he eventually became the manager of the Coater Research & Engineering Department. He also worked in the areas of coating color preparation, paper finishing technology, high-speed coaters, fountain applications, corrosion engineering, kraft chemical recovery systems and product development. Dean then became the manager of the Product Development – Publication Papers where he worked on a variety of product developments including high bulk paper, alternative finish paper and high brightness, carbonate based paper coatings, and later was appointed as Director of Research for NewPage. Dean then served as the Director of Product Development for Verso Corporation and is now the Director of Product Development for Pixelle Specialty Solutions.
“This expo features companies with industry updates in several categories and provides outstanding networking opportunities,” says Marty Ochs of GBIG. “We live at the center of innovation, technology, and production capabilities. We have planned for a larger expo and visitor attendance this year.” Aspects include:
Paper, pulp, and related producers where Wisconsin still dominates.
Packaging and printing on substrates including paper, film, and nonwovens materials.
Providers of analytic data services and equipment where growth continues.
Technologies to increase volumes on production lines in converting and packaging.
Suppliers who assist with branding strategies, marketing, and promotions.
Testing companies who assist in meeting quality and processing specifications.
Breakthroughs in digital, 3D Printing, and flexographic printing for packaging.
Innovation in the nonwovens industry with fabrics that wipe and filter viruses/Covid.
“We plan to spotlight exceptional exhibitors as they come back this September, and we’re offering a forum for new companies coming on board,” says Susan Stansbury co-host. “You can find these companies at national shows, but they appreciate showing off their wares in their home territory. This area is ‘the converting corridor.’”
Notes Marty Ochs, “Over the next couple of months, we will be reporting on a cross-section of exhibitors and plans, including a keynote speaker from the Flexible Packaging Association. In addition, a panel of other speakers on innovation is on board.”
The location at the Radisson Hotel and Conference Center represents an expanded space for exhibitors. The cost to attend for the day is $50.00 including lunch and refreshments. The Expo Hall will be open from 9:00 a.m. to 4:00 p.m. followed by networking until 6:00 p.m.
To exhibit, call or email: Marty Ochs, GBIG, 608.698.3333 martinpochs@gmail.com Susan Stansbury, Industry Consultant, 920.265.6407 SusanRStansbury@gmail.com
This event is hosted by Green Bay Innovation Group, providing news and platforms for paper, packaging, printing, plastics and converting industries.
Pioneer Metal Finishing needed to replace its existing, non-functional temperature control system. They also wanted to add a visualization of the measured value, hi/low-temperature alarms, and a 24-hour trend chart. They wanted a web publishing tool for visualization from a PC or cellphone over the plant network.
Ben and Amy Bertram recently acquired Performance Insulation of Wisconsin, LLC. Ben and Amy are also Owners of Fiberglass Solutions LLC located at 995 Waube Lane, Green Bay, Wisconsin. The deal was finalized in early January of 2023, and the Bertram’s are in the process of transitioning Performance into their existing facility in Ashwaubenon. The business will allow the Bertram’s to provide additional services to their existing client base, while focusing on growth within the Upper Midwest with existing clients.
Performance Insulation of Wisconsin LLC has been a leader in the commercial mechanical and plumbing insulation market since its beginning in 2000. Performance Insulation specializes in pipe, duct and tank insulation services that provide its customers with energy savings, temperature retention, process control, condensation control, noise reduction and protection of personnel. Performance Insulation is located in Green Bay, Wisconsin, and services the entire State of Wisconsin and into the Upper Peninsula of Michigan.
The Village of Wrightstown is a growing and prosperous community with a population of 3,308 located between Green Bay and Appleton on the Fox River. As you enter the city, you witness tremendous growth with new housing and industrial buildings! Wrightstown has a major presence in the 5P and Converting Industries with companies like Retroflex, Inc., Print Pro, Inc. and ProAmpac involved in the printing industries focused on flexible packaging. The companies are leaders in the industry servicing customers nationwide.
Governor Tony Evers along with the Wisconsin DOT announced grants in the Village of Wrightstown to allow rail spurs to be built at Alliance Plastic, Inc. and Drexel Building Supply, LLC and will add more than 120 manufacturing jobs. New rail spurs will facility economic development and provide important connections to markets across the nation as well as Canada. In addition, Wrightstown is adding a new massive new industrial building to support its growth in manufacturing.
When people think about paper production in Wisconsin, they normally think about one of our large pulp and paper mills. Pulp and paper mills use vast quantities of pulpwood from Wisconsin’s forests to produce a variety of bulk paper products. Without a doubt, these mills play a crucial role in managing our forests by providing markets for pulpwood from our forests and chip residues from Wisconsin sawmills. There are a large number of paper converters in Wisconsin that often go overlooked. Paper converters use the bulk paper products produced at primary pulp and paper mills and add value to those products. For this reason, we call them secondary producers. Primary producers, like pulp mills, get their raw materials from the forest. Secondary producers, like paper converters, get their raw materials from the primary paper producers.
In 2022, there were more than 145 paper converters operating in Wisconsin. Paper converters play an important role in Wisconsin’s larger paper industry by adding value to the primary products produced at our paper mills. Simply put, a paper converter takes a base paper and manufactures it into a value-added paper product. For example, a large roll of kraft paper could be printed, coated, and sheeted into sandwich wrappers for a specific client. Classes of paper converters operating in Wisconsin include corrugated and solid fiber box manufacturing, folding paperboard box manufacturing, other paperboard container manufacturing, paper bag and coated and treated paper manufacturing, stationery product manufacturing, and sanitary paper product manufacturing to name a few.
Wisconsin’s pulp and paper and paper converting industries have a large impact on our economy. Overall, the forest industry generates $23.4 billion in output annually and employs more than 50,000 people. This includes forestry, logging, solid wood, and paper. Paper makes up roughly 75% of this impact. Our primary paper producers generate $6.5 billion in output annually and employs 8,459 people. Our secondary paper converters generate $10.9 billion in output annually and employs 19,265 people. The secondary paper converting industry has seen a 16% growth since 2018.
In the fall of 2022, the Wisconsin Paper Council in conjunction with the University of Wisconsin conducted a survey of Wisconsin’s paper converting industry. The survey reached 142 companies with 48 responding for a 33% response rate. This article reports the findings of this study.
Paper Stock Origin
We asked the responding companies to indicate what type of paper stock they purchased for conversion. Table 1 shows the responses with cartonboard, containerboard, and specialty grades with the highest responses. Several respondents reported contract/toll conversion, so they do not take ownership of the paper stock.
Table 1: Raw Material Paper Stock Categories Purchased
Raw Material Paper Stock
Respondent Percentage
cartonboard
57.1%
containerboard
54.8%
newsprint
7.5%
non-papers
27.5%
packaging papers
22.5%
printing or writing grades
39.5%
specialty grades
47.7%
tissue or towel grades
17.5%
Do Wisconsin’s paper converters use paper manufactured by Wisconsin’s paper mills? Respondents were asked if their paper stock was manufactured in Wisconsin, Minnesota, Michigan, other state, or other country. This question is more complicated than it appears on its surface. About 19% of the study respondents buy 100% of their paper stock from Wisconsin paper mills. In contrast, only 2% of the respondents buy 100% of their paper stock from another state and none of the respondents buy 100% of their paper stock from another country. Figure 1 shows the manufacturing origin of paper stock used by Wisconsin’s paper converters based on the total volume respondents reported using. Wisconsin paper mills represent the bulk of the paper stock raw material with immediate neighboring states and Canada representing very little volume. Other states providing significant volume include Georgia, Indiana, Maine, and Ohio.
Figure 1: Manufacturing Origin of Paper Stock used by Wisconsin’s Paper Converters (percentages do not total to 100% due to rounding error)
Virgin vs. Recycled Fiber
The total volume of paper stock purchased by the respondents totaled 8,035,676 tons in 2021. Of this total, 12.5% of respondents stated their facility only used 100% virgin fiber in 2021. These companies were primarily box manufacturers. For those respondents that reported volumes of paper stock converted, virgin fiber constituted 38% of the total volume reported with pre- and post-consumer recycled fiber totaling 62% of fiber used (Figure 2).
Figure 2: Virgin vs. Recycled Paper Stock.
Certification
Certification systems have played a role in the forest products industry for several decades. These include forestland certification, chain of custody certifications, and more. Forty percent of respondents stated their facility was chain of custody certified. Table 2 shows which certification systems were employed by the respondents with the Forest Stewardship Council and the Sustainable Forestry Initiative representing the bulk of the responses.
Table 2: Certification Participation.
Certification System
% Participation
American Tree Farm System or ATFS
0%
Forest Stewardship Council or FSC
74%
Sustainable Forestry Initiative or SFI
68%
Canadian Standards Assoc. Sustainable Forest Mgmt. System or CSA-SFM
0%
Programme for the Endorsement of Forest Certification or PEFC
11%
other certification
0%
The state of Wisconsin offers a group forestland certification in the Sustainable Forestry Initiative, American Tree Farm, and Forest Stewardship Council systems for forestland owners.
When asked if a similar group certification for paper converters would benefit their facility, 38% replied that it would be a benefit.
Labor
Finding labor (skilled or unskilled) has plagued all industries since the pandemic. Table 3 details employment numbers as well as open positions for responding companies. The data shows that participating companies were well represented across all employment size categories. Smaller companies tended to have more part-time employees. Only 16% of companies reported no open positions. Nearly 75% of responding companies reported between 1 and 19 open positions with 9% reporting more than 20 open positions.
Table 3: Employment Numbers and Open Positions.
Employment Category
None
1 to 4
5 to 19
20 to 99
100 or more
Full-time employees
0%
10.4%
8.3%
50.0%
31.3%
Part-time employees
32.6%
39.5%
23.3%
4.7%
0%
Open positions
16.3%
51.2%
23.3%
9.3%
0%
Business Climate
Many of the responding companies have operated in the paper industry for decades. The average company age of operations was 42 years with some operating for only 5 years and one respondent having been in operation for 130 years. Just over half of the respondents, 52%, said they plan to grow or expand their facility in the next five years with 81% planning on investing in new converting equipment. Investments range from hundreds of thousands to hundreds of millions of dollars as shown in Figure 3. The annual capital expenditures for paper converters in Wisconsin has averaged $400 million over the past 5 years.
Figure 3: Investment Amount on Converting Equipment in the Next 5 Year.
Figure 4: Certification & Labeling Regulatory, Logistics, Production, and Workforce Challenges within the Converting Industry.
We asked a series of questions about the challenges within the converting industry. The major topics included certification and labeling, regulatory, logistics, production, and workforce challenges (Figure 4).
Certification & Labeling and Regulatory were two of the least challenging categories (Figure 4). The large dark blue bars shown in Figure 4 align with not at all challenging on our study scale. That does not mean there are no challenges in those categories as shown by the grey, yellow, and light blue bars. Given the diversity of companies within the paper converting industry, there is also a diversity of challenges depending upon what market segment each company operates within.
The Logistics category proved significantly more challenging for the respondents. Access to trucking, trucking or shipping costs, and reliable freight were challenges for most respondents (Figure 4).
The Production category showed significant variability across respondents (Figure 4). Finding paper stock has been problematic in recent months. One company stated, “We need paper. Our industry is $18 billion and growing and we do not have enough domestic supply of paper face or liner. Please help.”
Finally, the Workforce category showed challenges across all respondents. Hiring a quality workforce, retaining a quality workforce, and matching workforce hourly wage in competing industries were all problems (Figure 4). One company stated that finding employees was extremely difficult. Whatever profits they made go back to shipping and employees because of inflation.
Training
There are numerous opportunities for training within Wisconsin’s paper converting industry. All topics shown in Figure 5 show training needs by certain respondents. Topics such as advances in paper-based packaging and functional coatings and additives show significant interest by respondents. Diversity across the industry plays a role in training since not all companies have the same specialties.
Figure 5: Interest in Attending Training Paper Conversion Workshops by Topic.
Concluding Remarks
Paper converters are essential for sustainable forest management and the smooth functioning of wood and fiber markets that account for a sizable portion of Wisconsin’s economy. Keeping these businesses healthy will be important for the wood supply chain and the many rural economies it helps support.
The authors would like to thank the Wisconsin SFI Implementation Committee grant program for funding this project. We would also like to thank Wisconsin’s paper converters for responding to this study – Your time and efforts are appreciated!
Authors: Scott Bowe, University of Wisconsin-Madison; Paul Fowler, University of Wisconsin-Stevens Point; Julie Ballweg, USDA Forest Products Laboratory, and Stacey Johnson, Wisconsin Paper Council.
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