Category: General

By Susan Stansbury, Industry Consultant

This is Part Four of our series: Rust to Tech. This edition is another indication that converting and associated industries have made a leap from the old rust belt days into a world of technology and advancement.

Here I cite instances of converting markets with related manufacturing technologies. One example of how to begin the overview is to look at one company supplying numerous markets and using tech developments to serve customers using a nucleus of strengths.

A Rebel Converter

Labeling and product identification in packaging are essential to consumer interest and recognition. In the canister wipes segment, Rebel Converting’s X-Treme canisters feature digital high-resolution printing which allows print of any design or graphic. Labels can be sequentially numbered, have different sets of numbers on them, or include unique images. The labels are in-molded — melted into the canister for durability.

With the approach taken by Rebel Converting to do digital printing, prototyping becomes easier. Artwork changes are quick with short lead times. Full digital technology allows Rebel to provide customers with sample canisters identical to those from a final production run. Canisters are prototyped for customers to test market new products, brands, and designs.

Sustainability & Environment

• Some say plastics will never be biodegradable. Responding to market interest, Suominen, a U.S. and European supplier, has introduced a nonwoven substrate, Hydraspun Circula, which is bio-degradable, plastic-free and can be used in multiple applications.

• STEM is a new line of bug killer sprays and mosquito repellents that is powered by botanical extracts formulated in combinations to optimize effectiveness. The entomologist-tested and scientifically engineered one-stop pest control shop is designed to be effective in killing or repelling bugs, but safe to use around humans and pets. The plant-derived active ingredients like lemongrass, mint and rosemary oils help fight nature with nature. STEM insecticides and repellents have no added dye, fragrance or harsh chemical odor.

• Producers are addressing traditional blister packs with paper, film, plastics and foils used to protect medical and specialty contents. For example, Keystone’s Ecoslide-RX compliance package includes updated re-closable safety features. The award-winning Ecoslide-RX is made from 100 percent recyclable paperboard and is easily separated from its internal blister for recycling. The blister is disposed of but contains only a fraction of disposable plastic when compared to bottles.

According to Converting Quarterly which features web processing and finishing technologies, there are three “top trends:”

1. Flexible structures, including flex packs, emphasizing medical devices and pharmaceuticals;
2. Sustainability with newer recyclable polymers as an alternative to biodegradables; and
3. Printed electronics specifically with growth in the healthcare industry.

Digital Manufacturing

Procter & Gamble and Microsoft Corp. have announced a new collaboration to leverage the Microsoft Cloud impacting the future of digital manufacturing at P&G. The two companies will co-innovate to accelerate and expand P&G’s digital manufacturing platform and leverage the Industrial Internet to bring products to consumers faster and improve productivity to reduce costs.

“Together with Microsoft, P&G intends to make manufacturing smarter by enabling scalable predictive quality, predictive maintenance, controlled release, touchless operations and manufacturing sustainability optimization — which has not been done at this scale in the manufacturing space to date,” according to P&G.

Further on the equipment side, current production lines increasingly include automation with complete system integration to ensure that synchronized conveyors, modules, and robots work perfectly with up-stream and downstream equipment.

Following the pandemic, with supply chain materials and logistics issues, U.S. manufacturers are moving to make more parts and substrates domestically. In addition, according to Deloitte, “The manufacturing industry is building back fast, undeterred by significant labor and supply chain challenges.”

The stress on disposables retailers from wipes to masks and tissue products has led to manufacturers making a wider array of items in-house. Why order from afar when, “We can expand our capabilities and make it right here.” Enabling that determination is continued sales growth. Protective inventory build-up also is far removed from the just-in-time era.

Many of these examples are leading indicators of the next generation of technologies that will be “disruptive.” This will change the converting world for manufacturers. Coming up is the last chapter in this series focusing on disruptive technologies.

This article is reprinted with permission of PFFC-Online.com with some updates.

LITTLE CHUTE – ATCAM LLC will prepare for their next 30 years in business by expanding with
additional large diameter turn tables as well as incorporating robotic cells to provide efficient
uniform thermal sprayed coatings; along with a new logo.
The first-generation family business began in Little Chute in 1993 and has continued to operate
under the same management. ATCAM, a thermal spray and custom/CNC machine shop found
success and growth by offering customers cost effective solutions and industry leading
turnaround times with most jobs completed in under two weeks. The company’s growth can be
attributed to quality service, dedicated long term employees and embracing automation and
robotics.
Founder Peter Andres built the business from a small shop of less than 5,000 sqft and 2
employees into a business with over 35,000 sqft and 20 employees. Expanding into custom CNC
machining has allowed the company to machine and thermal spray under one roof. During that
time there has been incredible innovation with thermal coating allowing ATCAM to formulate
custom coatings specific to their customers desired application. The company utilizes twin wire
arc spraying and combustion flame technologies, along with powder/liquid top coatings for
various release or traction applications.
Since their founding, ATCAM has continued to invest in technology and grow the company
while maintaining incredible customer service. Company president Peter Andres has insisted
that healthy employees are the key to the company’s success and consistent customer service.
To ensure his vision of healthy employees, ATCAM is one of only a few companies to provide
100% medical coverage to employees and their families. According to Peter, “Fully paid medical
is just a small token of appreciation to our dedicated employees.”
Even with the robotics and dedicated employees, the company is still looking to fill several roles
as loyal customers continue to increase orders. The company is hoping to hire additional
employees in coating services as well as a CNC VTL machinist; however coating positions and
applications are available with little to no experience necessary. According to Peter “Training
employees on the job has always been a core strength of ours.”
Contact ATCAM at (920) 766-7880 or email atcam@atcam.org

The Wisconsin 5P, Converting and Supporting Industries will be PAYING A BIG PRICE for neglecting our
Paper Industry!

• Northeastern Technical Council has shut down their flexographic printing center! Wisconsin is home to the largest concentration of narrow web printing companies in the United States!
• Printing Industries of Wisconsin was the premier printing organization in the United States. Today, it has been replaced by the Great Lakes Graphics Association.
• The Paper Discovery Center is a museum and is replaced by The Atlas Discovery Center refocusing their efforts on STEM.
• Verso shuts down Wisconsin Rapids, Clearwater closes, Neenah Filtration cuts back, Sonoco in Wisconsin Rapids shuts down their core plant, GP close Day Street and GP closes their Oshkosh Corrugated plant!
• With ALL the shutdowns of the paper and pulp mills, it has had a BIG impact on the Membership Organizations across Wisconsin providing the education that is needed for employers!
• UW Stout cuts back on their Graphic Arts Educational Program for the packaging industry!

We want to thank Paper Converting Machine Company for building their NEW state-of-the art Packaging
Innovation Center. It will be the hub for the latest flexographic print and package converting
technologies. Amcor Innovation Center in Neenah is developing new materials and products! The Great
Lakes Graphics Association based out of Wisconsin has expanded to represent the Great Lakes Region
Printing Companies representing the largest areas for printing in the United States. Billerud has
announced a $1 Billion Dollar plus Investment in their Escanaba plant offering opportunities for
Wisconsin Manufacturers. St. Paper based in Oconto Falls has finished installing a new tissue paper
machine in Duluth, MN. BPM, Inc. is making upgrades in water recovery and equipment. Green Bay
Packaging $500 + million investment in their Green Bay plant and the Georgia Pacific investments in
their Broadway plant and their distribution center has a major impact on the Wisconsin economy.

The Wisconsin Paper Council has been successful in building a non-partisan legislative group to support
the Paper Industry in Wisconsin. In addition, WPC is working on Financial Grants that support our
forestry and paper industry. The WPC and UW Oshkosh have put together a very good report on the
Paper and Pulp industries with recommendation on what the industry has to do! UW Stevens Point has
over 100 students in their Paper programs with 100% job placement plus adding Chemical Engineering
to their program. UW Green Bay has added Engineering Programs. The University of Wisconsin under
the leadership of George Huber is making huge progress in plastic recycling industries with the
development of new technologies and products! We are hearing Universities in Wisconsin looking into
developing and building packaging programs to support the 5P and Converting Industries. Currently, we
have outstanding programs at UW Madison, UW Platteville, UW Stevens Point, UW Green Bay, UW
Oshkosh and UW Stout. We ALL need to support all of our universities to build back the Wisconsin Paper
Industry! GBIG will be providing student scholarships for the 5P Industries!