Top Flexible Packaging Converters
One flexible package printer looked across the Atlantic to save its shop.
ALMOST TWO YEARS ago, Lawson Mardon USA Inc., an Alcan Packaging Company in Bellwood, Ill. realized it was at a competitive disadvantage. Other companies in the flexible food packaging industry were beginning to deliver flatter, clearer products. Suddenly, some of Alcan's most important customers began scaling back their orders. To make matters worse, Alcan needed to increase capacity, but because of its location in a residential area, there was no room for expansion.
Alcan's management team contemplated integrating, for the first time in the history of the site, solventless, off-line lamination technology. This would require not just new technology in the plant, but creating a whole new culture. They hit the trade show circuit with their dual-tiered problem and a host of other specifications that would need to be met to solve this unique challenge.
Searching for the Innovative Solution
Alcan Packaging saw about six presentations from various machine manufacturers, before one company, Nordmeccanica, stood out. After inquiring about the manufacturer's reputation among adhesive suppliers, a trip to Italy was in order to see a Nordmeccanica solventless lamination machine in action.
Alcan Packaging purchased Nordmeccanica's Duplex Compact SL off-line solventless laminating machine. While the new equipment would more than double their in-line speed from 500-800 feet per minute to a top speed of 1,600 feet per minute, it was just one of the benefits Alcan hoped to gain. Other benefits included less time and waste per job, and reduced energy costs
This would translate into an ability to deliver a flatter, clearer sheet to customers, while increasing the bottom line as more product could now travel out the door.
Solventless lamination has been the standard in Europe for years, but the technology has yet to take hold in the United States and was new to Alcan. Making the transition would be a big challenge on two fronts: the physical installation of the machine and helping employees adapt to a new way of thinking and working.
Nordmeccanica had a plan to assist Alcan with the major technology change, beginning with the installation of the machine, which would have to be done without increasing the square footage of the plant. Many installations of this kind are done by drilling a hole in the floor, and then leveling the installed machine. Nordmeccanica, however, streamlined the installation by digging through the floor, then bringing in a pre-assembled frame upon which to install the machine.
"I was impressed with the ingenuity and efficiency of their installation process," said John Uniejewski, operations manager at Alcan. "It was amazing how everything just fit together."
With the decision finalized, Alcan made a commitment to giving its employees the necessary tools to make the switch. Nordmeccanica developed a week-long training curriculum for the half-dozen Alcan employees charged with running the machine. The program included both classroom instruction and hands-on training in the plant.
According to Uniejewski, the training efforts worked, as many of the "growing pains" associated with new machine installations were minimized, and the plant was up and running sooner then expected.
"Product quality has dramatically increased and customer satisfaction with the improved product characteristics has been extremely positive," says Douglas Becker, quality assurance manager at Alcan. "Nordmeccanica was instrumental in helping Alcan Packaging exceed the expectation of its customers because they exceeded our expectations."
Here are PDF files of the 2003 Top Flexible Packaging Converters (requires Adobe Acrobat Reader):
- People:
- Nordmeccanica
