Top Ten USA Folding Carton Manufacturer, Caraustar, Invests in VSOP

Many varied experiences in both the recycled mill and folding carton divisions give him a broad perspective where the packaging market is heading.

27/10/06 Caraustar, a recycled paperboard and packaging company, is one of the world's largest integrated manufacturers of converted recycled paperboard. Caraustar has developed its leadership position in the industry through diversification and integration from raw materials to finished products.

Paul Curtis, Caraustar’s Vice President Manufacturing – Folding Carton, is experienced in the folding industry. With a degree in engineering he has spent 23 years in the paperboard/folding carton industry. Many varied experiences in both the recycled mill and folding carton divisions give him a broad perspective where the packaging market is heading.

Compete in tough arkets

Curtis is responsible for capital spending and manufacturing improvement processes. Not only manufacturing improvements, but also on purchasing projects or projects to lower printing costs.
 
“We have to compete in a tough market place. Therefore Caraustar made the strategic decision to be in the top segment of the market. This means we operate in challenging markets like the dry and frozen food packaging industry.”

To cope with these demanding markets the Caraustar team decided to invest in a seven tower VSOP from press builder Drent Goebel, with one flexo unit and EB-curing. The innovative web offset press, designed and manufactured by Drent Goebel in Europe, has a width of 33.5 inches or 850 mm. The Electron Beam Curing is important because this drying technique produces extremely high gloss and yet is widely accepted by food producers/packagers.

Future proof

“We came in contact with Drent Goebel through one of our executives. We spent much time with Drent Goebel representatives from Germany and The Netherlands along with their US representatives, PacSys. We also visited Drent in Germany and were impressed by the European engineering capabilities. In the long run we decided on offset, because our clients are demanding very high quality graphics. While Flexo continues to improve, offset printing sets the standards. Also the making of offset plates is inexpensive compared to Flexo.”

“Furthermore we see a decline in the number of packages that are printed in one run. The speed to market is also becoming shorter every day. We increasingly see smaller jobs and therefore need a flexible printing press with short make-ready times. The concept of variable repeat web offset is perfect for the markets we are in and wish to pursue. We consider it to be future proof.”

Snap shot Caraustar

Caraustar is spread out all over the United States. The total employment of Caraustar is over 4.500 people. The Folding Carton Group, who bought the VSOP, is situated in at the company’s headquarters in Austell, Georgia. This Group counts a workforce of 1.300 people.

Caraustar serves the four principal recycled boxboard product end-use markets: tubes, cores and composite cans; folding cartons; gypsum facing paper and specialty paperboard products.

With significant growth, Caraustar will have 2006 revenue of almost a billion dollars. The company is comprised of four business groups. The Mill Group manufactures 100 percent recycled paperboard and specialty converted products and represents one of the largest recyclers of recovered fiber in the United States.
 
The Drent Goebel VSOP is expected to be delivered in May 2007.