Lean, Clean & Ready for Scrap — PAX Corrugated

Contributions by:
Stan Bernard, president and co-owner of PAX Corrugated Products, Inc.
Norb Wolke, vice president of Cegco Enterprises, Inc.

There is no such thing as an ordinary box. That's the key philosophy driving PAX Corrugated Products, a custom box company offering a broad range of top quality corrugated containers, designed for protecting, shipping, storing and displaying products.

There is no such thing as an ordinary box. That's the key philosophy driving PAX Corrugated Products, a custom box company offering a broad range of top quality corrugated containers, designed for protecting, shipping, storing and displaying products.

Since start up in 1991, PAX has seen a growing trend among customers to use boxes more and more to advertise and sell. The company responded with innovative packaging solutions and high-quality graphics. In addition, a complete line of retail-ready, point-of-purchase (POP) displays became a market niche and growth segment of the firm.

The increased production of these unique boxes required more die cutting - and with it, improved scrap handling methods. According to co-founders Stan Bernard and Jim Cory, the focus was on improving productivity without increasing labor.

The opportunity to move toward automated solutions came in 1995 when PAX made the commitment to build a new 65,000 sq ft sheet plant in Lebanon, Ohio. The old 40,000 sq ft facility has served its purpose during the early years of operation, but lacked the needed trucking docks and storage space for finished product. They enlisted the help of Cegco (pronounced seg' ko) Enterprises, Inc., a Cincinnati-based firm specializing in recycling and waste handling systems.

Both firms had previously worked together on scrap handling solutions including baler specification and installation. Now, however, the goal was to combine automated scrap conveyance with automated baler operation. In addition, the scrap recovery cyclone needed to be kept inside the new plant, under the roof and away from the outdoor elements.

The next production line would have a new rotary die cutter with 2/color printing capability and a Flexo folder-gluer with an inline die cutting section. The additional equipment increased production capacity significantly. It also required the containment of concentrated scrap. While PAX made plans for the purchase of the new production equipment, Cegco was busy engineering the scrap conveyance and cyclone recovery system.

The scrap collection and recovery solution in operation today is a totally automated system. From start to finish, there is little or no labor required outside of routine maintenance.

On the production machinery, die-cut scrap drops directly through the machines onto conveyor belts that feed awaiting air conveyance tubes stationed along side. Larger scrap is kept to a limited size through the proper configuration of the cutting die. A BloApco blower/fan creates the air pull through the conveyance tubes. Scrap pieces pass through fans on the way to the cyclone and baler.

One of Cegco's unique contributions to the project was the cyclone scrap collector and the dust collection system. To keep the entire system under the roof, the cyclone was essentially designed to lie on its side directly over the baler. Immediately inside the cyclone, air pressure is released allowing scrap pieces to free fall down a discharge chute to the baler. Stan Bernard described the effect saying, "It simply snows scrap right into the baler."

Air from the cyclone is exhausted to the filter housing. Filter banks collect suspended dust while air jets automatically blow the filters clean. Dust falls into 55-gallon drums that are sent to the landfill when full. All duct work for the scrap recovery system, including the dust removal housing, was designed, fabricated and installed by Tennessee-based Mid South Conveying.

A misting system, installed in the chute coming down from the cyclone to the baler, not only controls paper dust, but aids in uniform compaction of bales. Controlling dust within the new facility was a key objective for PAX when specifying the new system. This goal also had to be met by the new baler.

The new baler, manufactured by American Baler Company, was recommended for this installation by Cegco because of its unique dust control seals as well as advanced automated operating features.

The American Baler PAC Series baler is one of many models offered by this 66-year old baler manufacturer located in Bellevue, Ohio. The PAC baler is a fast and powerful model designed specifically for the demands of a continuous baling operation. Its automated features also made an immediate reduction to PAX's labor needs.

The previous scrap system required the attention of a full-time person, Jim Cory explained. "An operator loaded scrap by hand and then activated the horizontal baler. An alarm would sound when the bale was compacted. The bale wires had to be tied by hand, and then the bale manually ejected by hand. A forklift was needed to pull the bale out of the baler before it could be hauled away to temporary storage." According to Cory, the baler operation is now totally automatic.

This particular PAC baler model has a 29" x 30" feed opening and a 26.8 cu ft charge box, plenty big to accept the volume and size of "snowing" scrap. A sensor in the baler hopper now detects when the charge box is full. The baler then activates automatically.

The new baler for PAX was specified with a 30 hp motor and a 7" cylinder to create 115,000 lbs of force and 109 PSI of compacting pressure on each charge of scrap.

According to Stan Bernard, "The fully automated bale tying system was something that fully addressed our needs. It was easy to set up, easy to maintain, and was engineered to save significantly on wire consumption."

The automatic wire tier is designed as a swing-away assembly that allows for easy access during routine maintenance or wire loading. The tier achieves optimum wire tension through its unique through-the bale wire pulling process. Large, steel inserter needles push through to hook and pull wires through the platen for final tying. The positioning, twisting and cutting of the wire is all done on one side. The entire assemble, containing both inserters and twister mechanisms, can be positioned on either side of the baler.

When the wires are tied, the bale is automatically ejected from the baler. A forklift operator simply swings by to remove bales as they accumulate.

While bale length is adjustable on the PAC Series baler, PAX produces a finished bale 30" W x 43"H x 65"L. Each bales weighs 1100 lbs. In the economics of handling and shipping recycled material, these high-density bales created another significant cost savings for PAX.

"In the past, 40 to 42 bales were required to maximize a trailer limit of 40,000 pounds," states Bernard. "Before we didn't have consistent bale weight, and sometimes the bales were breaking open during transit. Now we optimize every shipment with 38 bales. Because our bales are now a better quality - consistent size, consistent high-density and weight, easier to handle and not broken - we get top dollar from our recycling broker."

According to Bernard, the same quality issues benefit PAX when handling bales, too. Forklift operators now handle fewer bales per ton of scrap. And more scrap tonnage is stored in less space prior to shipping to the broker.

In addition to these new operating efficiencies from the baler, the dust recovery system also provided two more welcomed benefits. Once filtered, the air was returned back into the plant instead of exhausted to the outside. This eliminated the loss of heated air, an important consideration given the cool climate of Ohio.

The filtering system also provided a much cleaner work atmosphere. "This helped us in maintaining the controlled environment that some of our customers - especially those with food products - wanted." Bernard adds, "In fact, very soon, we are hoping to secure FDA certification needed for food-handling packaging plants."

Even after increasing plant size over fifty percent, PAX still inventories very little raw material. Product coming in goes right into production. The expanded space, however, allows PAX to warehouse stock and finished product inventory. With this capacity, PAX can provide customers with fulfillment services, storing and shipping their corrugated display with product packages as needed.

With the plant close to main transportation routes, PAX ships routinely throughout Ohio, Kentucky, Indiana, Pennsylvania, Tennessee and Iowa. The company has also established contracts with other corrugated manufacturers in different regions of the country to serve as part of an integrated supply group.

In less than four years since initiating the plant expansion with automated scrap recovery, PAX Corrugated has doubled production with marginal increase in labor. Bernard clarifies the company focus by stating, "Our goal is to become the preferred supplier. Our diverse equipment configuration has allowed PAX to deliver on the service we promise. And we're always looking for ways to improve." Since start up in 1991, PAX has seen a growing trend among customers to use boxes more and more to advertise and sell. The company responded with innovative packaging solutions and high-quality graphics. In addition, a complete line of retail-ready, point-of-purchase (POP) displays became a market niche and growth segment of the firm.

The increased production of these unique boxes required more die cutting - and with it, improved scrap handling methods. According to co-founders Stan Bernard and Jim Cory, the focus was on improving productivity without increasing labor.

The opportunity to move toward automated solutions came in 1995 when PAX made the commitment to build a new 65,000 sq ft sheet plant in Lebanon, Ohio. The old 40,000 sq ft facility has served its purpose during the early years of operation, but lacked the needed trucking docks and storage space for finished product. They enlisted the help of Cegco (pronounced seg' ko) Enterprises, Inc., a Cincinnati-based firm specializing in recycling and waste handling systems.

Both firms had previously worked together on scrap handling solutions including baler specification and installation. Now, however, the goal was to combine automated scrap conveyance with automated baler operation. In addition, the scrap recovery cyclone needed to be kept inside the new plant, under the roof and away from the outdoor elements.

The next production line would have a new rotary die cutter with 2/color printing capability and a Flexo folder-gluer with an inline die cutting section. The additional equipment increased production capacity significantly. It also required the containment of concentrated scrap. While PAX made plans for the purchase of the new production equipment, Cegco was busy engineering the scrap conveyance and cyclone recovery system.

The scrap collection and recovery solution in operation today is a totally automated system. From start to finish, there is little or no labor required outside of routine maintenance.

On the production machinery, die-cut scrap drops directly through the machines onto conveyor belts that feed awaiting air conveyance tubes stationed along side. Larger scrap is kept to a limited size through the proper configuration of the cutting die. A BloApco blower/fan creates the air pull through the conveyance tubes. Scrap pieces pass through fans on the way to the cyclone and baler.

One of Cegco's unique contributions to the project was the cyclone scrap collector and the dust collection system. To keep the entire system under the roof, the cyclone was essentially designed to lie on its side directly over the baler. Immediately inside the cyclone, air pressure is released allowing scrap pieces to free fall down a discharge chute to the baler. Stan Bernard described the effect saying, "It simply snows scrap right into the baler."

Air from the cyclone is exhausted to the filter housing. Filter banks collect suspended dust while air jets automatically blow the filters clean. Dust falls into 55-gallon drums that are sent to the landfill when full. All duct work for the scrap recovery system, including the dust removal housing, was designed, fabricated and installed by Tennessee-based Mid South Conveying.

A misting system, installed in the chute coming down from the cyclone to the baler, not only controls paper dust, but aids in uniform compaction of bales. Controlling dust within the new facility was a key objective for PAX when specifying the new system. This goal also had to be met by the new baler.

The new baler, manufactured by American Baler Company, was recommended for this installation by Cegco because of its unique dust control seals as well as advanced automated operating features.

The American Baler PAC Series baler is one of many models offered by this 66-year old baler manufacturer located in Bellevue, Ohio. The PAC baler is a fast and powerful model designed specifically for the demands of a continuous baling operation. Its automated features also made an immediate reduction to PAX's labor needs.

The previous scrap system required the attention of a full-time person, Jim Cory explained. "An operator loaded scrap by hand and then activated the horizontal baler. An alarm would sound when the bale was compacted. The bale wires had to be tied by hand, and then the bale manually ejected by hand. A forklift was needed to pull the bale out of the baler before it could be hauled away to temporary storage." According to Cory, the baler operation is now totally automatic.

This particular PAC baler model has a 29" x 30" feed opening and a 26.8 cu ft charge box, plenty big to accept the volume and size of "snowing" scrap. A sensor in the baler hopper now detects when the charge box is full. The baler then activates automatically.

The new baler for PAX was specified with a 30 hp motor and a 7" cylinder to create 115,000 lbs of force and 109 PSI of compacting pressure on each charge of scrap.

According to Stan Bernard, "The fully automated bale tying system was something that fully addressed our needs. It was easy to set up, easy to maintain, and was engineered to save significantly on wire consumption."

The automatic wire tier is designed as a swing-away assembly that allows for easy access during routine maintenance or wire loading. The tier achieves optimum wire tension through its unique through-the bale wire pulling process. Large, steel inserter needles push through to hook and pull wires through the platen for final tying. The positioning, twisting and cutting of the wire is all done on one side. The entire assemble, containing both inserters and twister mechanisms, can be positioned on either side of the baler.

When the wires are tied, the bale is automatically ejected from the baler. A forklift operator simply swings by to remove bales as they accumulate.

While bale length is adjustable on the PAC Series baler, PAX produces a finished bale 30" W x 43"H x 65"L. Each bales weighs 1100 lbs. In the economics of handling and shipping recycled material, these high-density bales created another significant cost savings for PAX.

"In the past, 40 to 42 bales were required to maximize a trailer limit of 40,000 pounds," states Bernard. "Before we didn't have consistent bale weight, and sometimes the bales were breaking open during transit. Now we optimize every shipment with 38 bales. Because our bales are now a better quality - consistent size, consistent high-density and weight, easier to handle and not broken - we get top dollar from our recycling broker."

According to Bernard, the same quality issues benefit PAX when handling bales, too. Forklift operators now handle fewer bales per ton of scrap. And more scrap tonnage is stored in less space prior to shipping to the broker.

In addition to these new operating efficiencies from the baler, the dust recovery system also provided two more welcomed benefits. Once filtered, the air was returned back into the plant instead of exhausted to the outside. This eliminated the loss of heated air, an important consideration given the cool climate of Ohio.

The filtering system also provided a much cleaner work atmosphere. "This helped us in maintaining the controlled environment that some of our customers - especially those with food products - wanted." Bernard adds, "In fact, very soon, we are hoping to secure FDA certification needed for food-handling packaging plants."

Even after increasing plant size over fifty percent, PAX still inventories very little raw material. Product coming in goes right into production. The expanded space, however, allows PAX to warehouse stock and finished product inventory. With this capacity, PAX can provide customers with fulfillment services, storing and shipping their corrugated display with product packages as needed.

With the plant close to main transportation routes, PAX ships routinely throughout Ohio, Kentucky, Indiana, Pennsylvania, Tennessee and Iowa. The company has also established contracts with other corrugated manufacturers in different regions of the country to serve as part of an integrated supply group.

In less than four years since initiating the plant expansion with automated scrap recovery, PAX Corrugated has doubled production with marginal increase in labor. Bernard clarifies the company focus by stating, "Our goal is to become the preferred supplier. Our diverse equipment configuration has allowed PAX to deliver on the service we promise. And we're always looking for ways to improve."