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Warehouse Manager Lauro Moreno Comments on New WMS System

We’ve been making a lot of changes here at our industrial packaging company in the last 12 months. We went full force last January implementing a new ERP system which set us up for a warehouse management system (WMS). In October we launched our first ever WMS system while simultaneously welcoming some new team members to our warehouse and transitioning roles of existing members. We sat down with Lauro Moreno, our Warehouse Manager, to talk about some of those changes.

Lauro came to us in 2019 after fellow co-worker Randy mentioned it to a mutual friend. Lauro started out picking and pulling orders and working in receiving. In October he was promoted to Warehouse Manager after showing strong initiative, leadership, and enthusiasm for great new ideas. The following is a quick Q&A with Lauro regarding the WMS transition, how it has improved Colony’s industrial packaging services to our customers, and his role at Colony.

What has changed in operations since taking over as Warehouse Manager?

Since starting 3 years ago we had a lot more paper and now we are becoming more paperless in our warehouse. Before becoming Manager we weren’t even doing WMS yet. We went forward my first week with launching WMS. I had a choice but I thought sink or swim and we did it. Things have changed for the better like receiving and locating products. There is more efficient picking of the industrial packaging equipment. I think we know more ahead of time for deliveries so planning loads ahead of time is easier too and alerting customers to changes is easier. WMS has made things a lot simpler and faster.

How has the warehouse team and operations changed since you started?

We used to have single roles before I took over, but now I am working on cross-training everyone so no one is stuck in a particular role. Everyone is learning everything to create more of a team environment. It is helping everyone become more educated with the system, and allows everyone to help the team out in a greater way.  It has also helped with communication and finding answers to problems faster. I also shifted my day to stay into the evening versus leaving earlier so we have been better able to refine our checking process to help decrease mistakes. We also changed the staging areas to not cross material going in and going out. Our labeling process has also changed which has been better for customer deliveries.

What goals have you set for yourself and the operations in the warehouse?

I’d like to continue cross training so everyone can slide into roles, but also I want to help the company grow. I want to be the one here when we need to punch more holes in the wall for receiving doors and add warehouse space. I know we do that by making sure we are sending out the right product and being available to meet our customers’ needs.

What do you like about working at Colony?

What I like about working here is it is a family-owned business. But, not that it is just family-owned but it is family-oriented so it seems like everyone here is like one big family. Everyone is willing to help each other out. When we switched to the new WMS system it was a lot to handle, and no one cared about their title, they just stepped up to get the job done to move forward. It was really helpful and felt like no one was too big for any given job. Colony is also a trustworthy company. It there are problems they are going to fix it and they value their customers and their employees. The little turnover speaks for itself and the longevity of employees is really good. You don’t see that much, and they keep in touch with retirees which shows me management really does care about their employees. That’s why I like working here.

Lauro resides in Dallastown with his wife, three children, their Shih-Tzu Biggles, and new puppy Coco– a mini Australian Shepard. Lauro is an avid gamer and enjoys working in his vegetable garden.

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When the Olympics Give the World a Lesson on Corrugated

This weekend marks the start of the Olympics and like most things these last couple years the Olympic Village, or more specifically, the beds the athletes will be sleeping in look completely different than past games. If you haven’t heard throughout the media the athletes were supplied with corrugated bed frames in Tokyo’s mission to make these games the most eco-friendly yet. It’s no surprise athletes like volleyballer Kelsey Robinson have been putting those beds to the test in durability by jumping and body slamming themselves into the frames to really test the claims.

https://www.tiktok.com/@kelseymarierobinson/video/6986977403016973574?sender_device=pc&sender_web_id=6987454114985428485&is_from_webapp=v1&is_copy_url=0
https://www.tiktok.com/@thelibero/video/6986784711423053062?sender_device=pc&sender_web_id=6987454114985428485&is_from_webapp=v1&is_copy_url=0

It instantly made us think about our Ecorrcrates® offerings because of its durable, eco-friendly, and cost-effectiveness compared to regular wood crating. Ecorrcrates® take a patented approach to crating materials by layering corrugated into custom configurations to meet the durability need of the product. Our current customers using this product have found success in customizing the sizes to meet their production needs.

The following are highlights from a case study done by the manufacturer which outlines the true benefits of switching to Ecorrcrates®.

Background:

In Wichita Kansas, a leading company fabricates high cost, sensitive parts and assemblies for shipment to First Tier Aerostructures Manufacturers domestically and internationally.

Previous Method:

Shipping protocols in aerospace often require use of a crate. For many years, the only cost
effective option was to use a traditional wood crate. The shipping manager of this large
machine shop set out to find a better option because wood crates were an expensive hassle.

The company’s leading challenges concerning wood crates:

  • Wood crates are bulky and take up too much
    room.
  • They are heavy and difficult to move.
  • Constantly concerned about safety and the
    potential injuries associated with the handling
    and use of wood crates.
  • Parts damaged if they make contact with
    the wood, so a lot of extra
    packing materials used.
  • If there is any issue with the wood in Export, it
    can delay the shipment anywhere from a week to
    10 days, and no one can afford that.

New Method:

After a successful initial test, the customer began ordering the Ecorrcrates® in “knock down” form to store easily before use. This also allowed production to load the product first and build the crate around the product, or load the product into the crate depending on the application. The company saved more than $100,000 per year and now has a safe, durable and easy way to get high value products to customers.

Straight from the Customer:

“Now that we have made the switch to Ecorrcrates®, I can’t see us ever going back to using wood crates”. Not only was there a cost savings in the crate cost, the Ecorrcrate® cost is not volatile like wood crate pricing. We were constantly having to choose between paying more or going with a lower grade wood crate to control costs. With Ecorrcrate® we receive a consistent, high quality product and are better able to plan our budgets with stable pricing.

Floor space in Aerospace manufacturing is scarce. Ecorrcrates® storage density is 2 or 3 to 1 as compared to premade wood crates, saving on the floor space needed for storage. This was a big cost savings and stress reliever for us!

The parts we ship are relatively light weight. The wood crate alone weighs 2-3x our product weight. Because the Ecorrcrate® weight is around ½ the weight of a wood crate, we were able to trim an average of $100 per shipment from our shipping costs. That is HUGE savings! The Ecorrcrate® is easier and safer in handling, so our shipping department can pack in a fraction of the time it took to pack in the wood crates. Being a busy shop, this adds up to a lot of labor savings very quickly!

Ecorrcrates® are more durable for re-use. We were only getting 5-6 turns out of our wood crates but now we have Ecorrcrates® that have been in use for more than a year and we are able to continue to re-use them. Ecorrcrates® really resist damage including careless forklift drivers. Also, we believe that freight carriers are more careful with items that appear to be packaged in boxes. Little do they know, that although Ecorrcrates® are constructed from the same base material as boxes, they are NOT boxes. They are robust, shipping containers constructed from a bidirectional, crossed-strength corrugate building material. And, if a part of the Ecorrcrate is damaged beyond use, we are able to purchase the replacement component only, rather than replace the entire crate.

In addition to being 100% recyclable, all of the materials used in Ecorrcrates® are earth friendly and made from renewable Resources. We are better able to meet our sustainability initiatives. This has the added benefit of being a great shipper for Export. Other than the wood pallet, the Ecorrcrate® is made from all corrugate material. This is a significant benefit to our Export customers and partners as we receive more and more push back on the use of all-wood crates. In many countries, including all of Europe, it is difficult and costly to dispose of wood crates. But, it is easy to dispose of and recycle corrugated boxes without added cost.”

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Blown vs Cast Stretch Film

Stretch film comes in varying gauges, lengths, chemical make-ups, colors and can be used in numerous applications. Not all stretch film works on all loads and for all applications. One interesting variable and starting point for stretch films is deciding between blown or cast manufacturing processes. But first, if you are unsure of the differences between shrink and stretch start with this blog post.

Blown stretch film is created by blowing heated resin out vertically into a bubble. The bubble is then transformed into rolls while it is cooled by the surrounding air. This simple animation shows the basics of the process. Alternatively, another way stretch film is manufactured is by feeding a sheet of heated resin along a rolling path with chilled rollers while the cooling solidifies the film.  This process produces cast stretch film and like blown film is then turned into large master rolls. Check out this video showing the process.

Blown film is tougher and has less of a chance to puncture than cast. This occurs due to the slower cooling process, which allows the molecules in blown film to spread out as opposed to aligning in long lines like in cast. Blown film also has a higher level of cling (think Reynolds Wrap) than cast, making it stick to itself easier.

So, why would anyone use cast film? Cast stretch wrap has a clear, glossy finish allowing greater success with RFID and other scanning technology while blown film can be hazy and dull. Cast stretch film unwinds much quieter than blown. It is also easier to stretch and control the gauge with cast film.

Both films have great benefits for different applications.

Multiple variables can determine what film to use including the ones we talked about in this past blog post, but here are a few others when determining blown vs cast film:

  1. What type of machine is being used, if not applied by hand?
  2. What kind of load is being wrapped?
  3. Where does your skid go after leaving your dock? Is it temperature controlled?
  4. How is this skid transported and stored?
  5. How many variants of loads does your facility wrap?
  6. Do you use labels/barcodes under the film that need to be scanned?

Does your distributor ask you these types of questions and provide solutions based off of your answers?

If you are purchasing films based on the one with the cheapest price per roll, you may be surprised what kind of information and insight can be gained and the real savings you are missing out on. Our industrial packaging company represents several leaders in the market including Berry Plastics, Paragon Films, StretchTape, and Alliance Plastics with stock ranging from blown and cast hand and machine films, pre-stretch films, vented films, UVI, and specialty color films.

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Equipment Highlight: Orion Sentry LP Stretch Wrapper

Orion Packaging has a deep line of stretch wrappers. With the (still pending) 2020 PackExpo in Chicago coming up quickly it had us thinking about some of our finds and top packaging suppliers in 2018. Orion debuted their newest Sentry iteration during the expo and it remains one of the best entry-level wrappers on the market for its low price, reliability, and onboard pre-stretch capabilities.

Check out some of the key features for the LP and HP versions:

  • 200% powered prestretch film carriage: Helps you save on film costs and give you a superior holding force compared to hand wrapping or mechanical tension wrappers.
  • IntelleVue HMI: Full color,high resolution 7” touchscreen display with powerful microprocessor to stores recipes, user-manual and more!
  • 3 Year warranty: Backs time tested designs and built to give you year after year of dependable, trouble-free operation with steel construction, heavy-duty components and reliable electronics.
  • 4,000 pound weight capacity: On maintenance-free turntable with 52” x 52” x 80” load capacity.
  • 12 Revolutions per minute: Delivers steady wrapping performance.
  • RevoLogic technology: Precisely applies the correct number of top and bottom wraps compared to competitive models.

Check out other top products like the cold seal packaging machine.

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Ranpak Introduces New FillPak Trident Void Fill Packaging System

It has been awhile since we saw an upgrade to Ranpak’s void fill and cushioning automation lines of equipment and for good reason. But, Ranpak recently saw a gap in its offerings and announced the new FillPak Trident void fill packaging system.

From Ranpak’s website:

Trident is a 100% paper-based protective packaging solution that potentially delivers a 15% or more reduction in paper usage compared to other paper-based machines and can eliminate the use of non-sustainable plastic based package fill products like air cushions. The in-line machine features a patented triangular paper shape and can serve the dual purpose of void fill and blocking & bracing for safe product delivery in shipping. All key benefits to high volume shippers.

Paper Options:

45# Brown Kraft: 1200′ x 15″, 22lbs/bundle

55# Brown Kraft: 1000′ x 15″, 24lbs/bundle

The FillPak Trident is fast! So fast in fact it spits out the patented triangular cushioning pads up to 96″ per second. The quickness and easy re-load makes the Trident a perfect option for 3PL, fulfillment, and distribution centers. Additionally, with a HMI touchscreen and five operation modes, like EDS, batch, and recipe, users can quickly navigate and utilize custom packaging solutions and pre-set modes.

Our industrial packaging supplies company is currently hosting a unit on the floor for demonstrations – contact us today!

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Understanding Packaging Boxes and Corrugated Cartons

Understanding cartons can make or break your product – literally – by the time it gets to your customer’s door.  For instance, recycled corrugate is not created equally, and there are several ways to determine what kind of box you need besides the actual carton type.  Depending on the application companies can save money when it comes to changing the way their box is configured or even manufactured (for custom cartons).  Check out Colony Packaging & Machine’s top 4 points when looking into corrugated boxes.

Strength

The strength of a corrugated box starts with its material. A corrugated sheet consists of two major components – linerboard and medium. Linerboard is the flat paper that covers both sides of the sheet and the medium is the “fluted” or arched paper found between both liners. The flute, when anchored to the linerboards with a starched based adhesive, resists bending and pressure from all directions. When placed vertically on its ends, the flutes form vertical columns, capable of supporting considerable amounts of weight.

SingleWallCorrugated2
Single Wall Corrugated

DoubleWallCorrugated2
Double Wall Corrugated

TripleWallCorrugated
Triple Wall Corrugated

Material

The amount of virgin pulp fibers and the length of those fibers in a corrugated sheet substantially contribute to box strength. For example, the difference between a 200# test box and a 275# test box is that the latter has more pulp fibers in its corrugated linerboard. The 200# test box is rated to hold up to 65 lbs. of  contents while the 275# box can hold up to 95 lbs. A 350# test box is rated to hold up to 120 lbs. of contents.

Flute

Flutes come in five basic heights and shapes – the most common are “B-Flute”(used for die-cut boxes) and “C-Flute” (used for RSCs – regular slotted cartons and the most common of carton types). B-flute is compressed and appears thinner, but don’t be fooled. It is made with more paper to provide stronger side wall protection from blows and punctures during shipping.

C-flute is taller, with more air space, but offers enhanced stacking strength. For excellent graphic reproduction, consider E-flute because of its smooth surface and ability to hold up well during printing.

Flute Comparison

Measurements

Measure a box using the inner dimensions of an assembled box – Length (L) x Width (W) x Depth (D). Looking at an assembled box, the longer of the two sides is considered the length, the shorter of the two sides is the width, and the side perpendicular to the length and width is the depth of the box.

How to measure a box

The “Manufacturer’s Joint” is where the two ends of the side panels meet to form the box. At that point, the panels are fastened together with tape, staples (double or triple wall) or glue (single wall). This description applies to regular slotted shipping cartons (RSCs). The side panel thickness and content weight determine the type of seal used for the manufacturer’s joint.

Right-sizing your package is even easier nowadays with multiple, competitive options for custom and stock sized boxes.  We offer thousands of stock sizes and have relationships with several custom corrugated boxes manufacturers, which can decrease the amount of cartons you need to order – usually minimums start at 15 – 25 per size.  Browse cartons now!

Looking to take your cartons to the next level? Consider custom printing or custom printed tape to give your brand that wow factor when it hits doorsteps. Printing plates and die-cut charges don’t have to break the bank for mid-size and up companies. Not sure if your box usage would meet the minimum? Contact Colony Packaging and ask us. Quotes are free!

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New Partnership: LEIBINGER Continuous Inkjet Systems

We are excited to announce our new partnership with LEIBINGER Coding and Marking Systems. LEIBINGER helps fill the gap in our marking and coding equipment with their state of the art CIJ printer and printhead. If you know anything about CIJ you may have rolled your eyes at the “state-of-the-art” bit in that last sentence. But, we’ve got to tell you, they are seriously changing the game when it comes to their patented printhead.

LEIBINGER is within its third generation of family management and manufacturers all of its equipment from their headquarters in Germany. They are a ISO 9000 : 2015 certified company.

LEIBINGER caught our Service Manager’s eye a few years ago at the PackExpo in Chicago specifically for the maintenance dream their system offers. If you aren’t your company’s maintenance manager grab them now to read about some of these features that are changing the industry standard when it comes to CIJ printing, maintenance, and uptime.

  • “Sealtronic“, the automated nozzle seal in all LEIBINGER industrial inkjet printers, closes the nozzle and gutter airtight. This keeps the ink in the print head from drying out – the industrial inkjet printer is always ready to use. No time-consuming cleaning is required, even after long downtimes. During breaks in production, the gutter and the nozzle form an airtight circuit: No ink can leak out of the circuit and no air can get in. This keeps the ink fluid at all times – just like a sealed paint can – and the industrial inkjet printer is always ready to go.
  • Auto-Cycling – One of the worst parts about printing systems is always the headache dried ink causes in the lines. LEIBINGER’S CIJ has an automatic cycle feature which keeps the ink cycling through the lines once every 24 hours when not in use.
  • The large variety of interfaces allows you to integrate their units at any desired integration level – from simple data connection to complete full integration. And the compact print head with stainless steel housing also adapts seamlessly to your system – in any installation position, even for overhead applications.

We also have an entry-level unit on our floor ready for demo. We are factory-trained and ready to show off LEIBINGER’S full potential within your building.

LEIBINGER rounds out our full marking and coding options. We continue to work with Digital Design for TIJ (thermal inkjet), Matthews Marking and Loveshaw for DOD (drop on demand) and hi res. We also offer integration services through a third party for database-driven set-ups.

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5 Things to Consider When Buying Stretch Film

Understanding the difference between stretch film and shrink film is just the beginning to understanding stretch film’s capabilities in your production line.  Here are some points to discuss with your sales representative when determining the best film for your budget and application.

1. Determine the Load Size

Type A Loads: Uniform in shape. The load size closely matches the pallet size. These are obviously the easiest loads to wrap. Few film puncture points exist. This type of load is often seen at manufacturing locations where the same product is prepared for shipment load-after-load.

Type B Loads: Less uniform than type “A” loads. The stacking pattern may be irregular and /or the load size may not match the pallet size. Several film puncture points exist. More film selection judgement is required, especially at high levels of film stretch and /or high film application tension. Type “B” loads appear at smaller manufacturing locations and distribution warehouse locations. Each pallet contains two or three products palletized for a single destination.

Type C Loads: The worst of all to stretch wrap. No two loads are the same. Their size and shape range are all over the place. Sharp points seem to be everywhere and /or there is a major difference between the load and the pallet size. Film selection is critical. Type “C” loads are assembled at the distribution centers who supply retail store locations (i.e. grocery, drug, pet supply, automotive). Each load may contain dozens of different products.

stretch-film-load-types

2. Determine the Type of Equipment

Just as is true with any industry, the stretch film industry has gone through some huge changes when it comes to innovation in film manufacturing.  Because of these innovations, it is important to make sure your film matches the equipment being used to save on costs.

  • Spiral wrap film should generally be used when the loads vary in configuration.
  • Fully automatic high speed stretch wrappers equipped with pre-stretch usually require a premium grade of stretch film to make sure the equipment is being fully utilized.
  • Economy stretch films can be used for low stretch on conventional equipment.
  • A mid-range stretch film is needed for pre-stretch equipment operating at moderate levels.

For instance, if your piece of equipment can only pre-stretch your film 200% at most, you wouldn’t want to spend the extra amount on film that can stretch 400% because you aren’t benefitting from that added innovation.  Generally, the film that can stretch 400% is a premium film compared to the film that can only stretch 200% and you pay premium dollar for it.  Likewise, if your piece of equipment can pre-stretch your film up to 400% then you want a film that can meet that expectation without breaking – it will save you money per load in the long run.

3. Determine the Type of Product being Unitized

The weight of the pallet load and type of product being wrapped must be considered when selecting film type, gauge and number of wraps.  A significantly heavy pallet load will generally need a heavier gauge film than a very light pallet load.  For instance compare a pallet of cinder blocks and the impact of the weight of the load during the vibration that occurs in transit vs a pallet of pillows.  Although the loads might be the same L x W x H, different films might be necessary to secure the load efficiently at the lowest cost possible.

4. Determine Special Requirements

Some end users will have a need for a special requirement such as a one side cling, UVI or colored film. Reinforced film or vented film is also available. A one side cling is commonly used for bundling or on a pallet load that may shift in transit. Products that are stored outside for long periods of time normally require a UVI (Ultra-Violet Inhibitor) film. Heavy tinted colored films are often used to mask the product being wrapped for security reasons or for color-coding in large warehouses.

5. Determine Shipping Distance

The distance and method of shipment are important considerations. Films being transferred across the country in a flat bed truck or by rail would require a different film than a product shipped a short distance by truck or inter-plant.  Your warehouse set-up might ship both ways and could need two different films.  To help keep inventory on packaging products down it is important to discuss this when testing different films.

Contact Colony Packaging & Machine today to learn more.

 

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Bubble It!

Okay, we may not be starting the bubble wrap jacket craze (yet), but we are still crazy about bubble wrap. Bubble wrap has been getting a bad rep lately from companies talking big about environmentally-conscious packaging. But as an industrial packaging company, we are here to tell you bubble wrap is here to stay for good reason. Made-on-demand options, curbside recyclable features, historical success in packaging valuable products – air filled packaging is a tried and true method of getting your products safely to your customer the first time. Plus, it is easily reusable!

Made on Demand

Our top cushioning vendors like Sealed Air offer great bubble on-demand systems that allow companies to free up space on their floors with rolls of film in many configurations. That film takes up less trucking power also, cutting down on your company’s carbon footprint. Classic bubble wrap, pouches, tubes, pillows and more are all available for on-demand machines.

Curbside Recycling

Not all bubble wrap is recyclable, but we do offer options that are. Most lower grade bubble can be recycled with most other plastics. We offer several grades (strengths) of bubble in different bubble sizes that are curbside recyclable – ask us!

Tried and True

Did you know bubble wrap was actually invented because of a failed textured wallpaper attempt? It’s true! Many years later it is a fantastic option to get your product to your customer safely the first time which cuts down on returns and re-shipments.  Because of its lightweight and durable features it keeps the weight of your packages low while maintaining excellent cushioning.

Color Customization

We now offer custom colored bubble wrap and custom shapes through our made-on-demand options. Dog bones, hearts, stars, and more are all available to help customize your packaging for that perfect unboxing experience! We suggest adding your favorite hashtag to the inside of the box so your consumers know who to tag when they post their favorite packages!

This was just a quick run-down on the benefits of using bubble wrap. For more information on the bubble wrap options available to you contact your Sales Representative!

 

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Now Partnering with H. B. Fuller for Adhesives

We are excited to announce our new partnership with one of the top adhesives companies in the world, H.B. Fuller. We still represent other adhesive manufacturers including Gluefast, 3M, and Technical Adhesives.

Two of H.B. Fuller’s pillars of success are customer-focused innovation and collaborative problem solving. We at Colony always keep the customer as our main focus and aim to deliver solutions to problems, not just products. Because of their expertise in the adhesives market and customer-focused sensibility we are confident our partnership will add another avenue of success for our customers.

Here are just a few areas within the packaging and paper industry H.B. Fuller delivers success stories to:

  • Paper Converting
  • Panel Laminating
  • Case and Carton Sealing
  • Closing and E-Commerce
  • Container Labeling
  • Flexible Package Conversion
  • Handle Reinforcement
  • Packaging Reinforcement and Containment
  • Retail Ready and Easy Opening

From their website:

The History of H.B. Fuller

Our founder, Harvey Benjamin Fuller, had a vision more than a century ago to formulate innovative, convenient and economical adhesives. That spirit still permeates everything we do today as a global leader in adhesive technology.

It all began in 1887 when the company introduced Fuller’s Premium Liquid Fish Glue, which was known to “cement everything” from tin cans for mechanics to barrels for factories. Fueled by the success of his first adhesive, Harvey Fuller formulated more specialized adhesives, including Fuller’s Premium Wet Paste Adhesive used for gluing shoes, hanging wallpaper, mending books, attaching labels and manufacturing boxes. And, we’ve been solutions-minded since our earliest days. Harvey Fuller invented adjustable scaffolding so wet paste adhesive customers could hang wallpaper more safely. Throughout our history, H.B. Fuller has built upon our knowledge to continually innovate. From the first hot pick-up “gum” to being one of the first U.S. companies to specialize in waterproof adhesives, H.B. Fuller has paved the way for adhesives to improve products and lives across the globe. Today, our focus on innovation brings together people, products and processes that answer and solve some of the world’s biggest adhesion challenges.

We are excited to offer our customers this new avenue for competitive pricing and top adhesive products with H.B. Fuller. For more information or to set-up a meeting please give us a call or contact your Sales Representative directly.