Packaging Powered Through Information

The famous quote "Knowledge is Power," commonly attributed to Sir Francis Bacon, can be tied to a transformation that has taken place at Yuba City, Calif.-based Deluxe Packages. Just a few years ago, employees at the company struggled when it came to securing accurate information about production, quality, and customer service.

The problem was, they were lacking a way to obtain reliable information throughout the production process. Something needed to change going forward in order for the company to remain competitive and successful.

Info transformation

Deluxe Packages, a subsidiary of privately held Paperboard Packaging Corp. (PPC), has a history dating back to 1969 when it was founded by Jack Williams in South Gate, Calif. With a steady stream of expansion, both organically and via acquisitions, the company settled into consolidated operations in Yuba City under the leadership of Jack Williams' son Mark, who took over as president and CEO in 1999.

Through this time, Deluxe Packages was using a home-grown information management system, patching together different modules from various manufacturers. Not surprisingly, nothing interacted.

"The amount of information we had with our [prior] system wasn't providing the level of information needed to grow our business," recalls IT Manager Lisa Cunningham. "The need for accurate and timely information across all functional areas drove our decision to upgrade."

So in June 2009, the company went live with the EFI Radius ERP/MIS solution. It now had the knowledge and information needed to thrive and grow in the package-printing industry. There was no looking back after the company leveraged the information and capabilities provided by its new system.

Deluxe Packages uses EFI Radius software with the Shop Floor component and dedicated data control units. The Pecas Scheduling Assistant and PSA Connect integrate all the modules together, Cunningham notes. For accounting, the company uses EFI Open Account software, which again is fully integrated with the EFI Radius software.

"We looked at many systems and some of the factors [we looked for] were ease of use, timing of implementation, an out-of-the-box product that would fit our needs, and acceptance and use within our industry," Cunningham points out.

The benefits of the EFI Radius ERP/MIS solution were noticed immediately. Deluxe Packages personnel were able to see what was happening on the production floor in real time. They could then immediately make shifts in the jobs they were producing and make the operation more productive and profitable, without affecting the quality of the product. This was a game changer.

"We have been able to streamline products and do more with less," Cunningham says. "The higher level of information has allowed us to provide improved levels of service and quality to our customers."

Customer focus

Deluxe Packages prides itself of producing high-quality, competitively priced flexible packaging products to major food, pharmaceutical, and industrial companies from around the world. Its customers include names like Fresh Express, Ruiz Foods, American Licorice, and Sun Maid. It is these valued customers that helped make the decision to upgrade the information system an easy one.

"In January 2010 we added the EFI Radius Business Intelligence product that took us even to a higher level of understanding of what was happening daily, weekly, and quarterly in our business," Cunningham maintains. "It displays the information in a graphical, easy-to-access view."

2010 was a big year overall for Deluxe Packages, as it consolidated its 79 employees and multiple plant operations under one roof at the 100,000-square-foot Yuba City facility. This project was part of the company's three-year plan to maximize its customer service, quality, and cost efficiency within the competitive flexible packaging marketplace.

The addition of two new Fischer & Krecke wide-web presses, a 65˝ laminator, and new perforating and scoring equipment were also part of this project.

With all of these changes, it helped to have an IT manager who understood the intricacies of the package-printing industry. Cunningham, who started as the company's customer service/graphics manager and then continued on to study information systems, has been involved in the printing industry since 1995. She had the firsthand experience with the procedures of the printing process, and was able to apply that knowledge to help develop the best workflow and reporting processes for the company.

Cunningham contends that the EFI Radius ERP/MIS solution is most valuable because it is completely integrated. Information is immediately accessible throughout the entire company. "Customer service personnel can now answer questions from customers while they have them on the phone," she says. "This gives the customer the best possible service and saves us time, too. Deluxe Packages is also always looking at new technologies that can help improve our productivity, quality, and service."

As a commitment to its continued customer service focus, Deluxe Packages is looking at the addition of a Customer Portal, Cunningham says. This would allow the company's customers to access information regarding their accounts at their own convenience. "Another technology that we are considering is a document management system," she adds.

The company's concentration on outstanding customer service has not gone unnoticed. Deluxe Packages was recently given an Outstanding Vendor for 2011 award by Ruiz Foods. This award was given to Deluxe Packages for providing quick turnarounds, expediting new item orders, and handling quick changes to current items. The honor is only given to four of Ruiz Foods' numerous vendors each year.

Some other accomplishments for Deluxe Packages include scoring a 'Superior' rating while participating in an American Institute of Baking audit. In addition, the company considers itself to be a leader in process printing using water-based inks with 175 to 200 line screen capabilities.

Most of the markets served by Deluxe Packages are food-related. The growth in these markets continues at a steady pace, and as customers continue to use packaging as an advertising resource, the demand for high-quality printing is becoming even more important, company execs contend. The company provides a wide variety of packaging options for items such as fresh-cut produce, frozen food, nut and dried fruit, bakery, candy, coffee, condiments, confectionery, dried grains, industrial, and pharmaceutical.

"As a manufacturer we continue to believe that quality and service remain the two attributes customers demand," says Tom Brehm, vice president and general manager. "Our decisions, capital expansion, hiring philosophy, and commitment to growth all incorporate this belief."

To satisfy the growing printing needs of customers, Deluxe Packages relies on a 10-color, 65˝ Fischer & Krecke gearless press and an 8-color, 58˝ Fischer & Krecke gearless press. The company also boasts 6-color expanded-gamut printing and 175 and 200 line screen process capabilities.

"Deluxe Packages has made significant capital expenditures in equipment to support the need for improved graphics," adds Tim Burri, vice president of finance.

The company is home to a fully-equipped quality control and R&D lab with the ability to do ASTM and fitness-for-use testing. It also employs Lean Manufacturing techniques. Technical support is offered at customer facilities, and vendor-managed inventory support is also available. Other company offerings include on-site graphics support and state-of-the-art color management and web inspection systems.

With its enhanced information management system, extensive equipment list, experienced staff, and forward-thinking attitude, Deluxe Packages now has the information, knowledge, and power to excel for its customers. pP