FOR IMMEDIATE RELEASE
ARLINGTON, Vt. (July 14, 2011) – While minimizing cardboard consumption in its own packaging, Mack Molding expects to simultaneously recycle six times more corrugated during the next 12 months, from its current 45,000 lbs annually to 135 tons per year. This dramatic improvement is the result of three steps the company has recently taken to revamp its corrugated packaging operation.
First, Mack will reduce its corrugated spend and improve operational efficiency through the on-demand packaging system it just installed that produces right-sized boxes as needed for roughly 80 percent of its packaging needs. Called Packsize, the system significantly minimizes the need for generic boxes that have to be ordered, received, warehoused, and ultimately tailored to suit various product sizes. “This wasted time, space, material and resources,” says Jeff Somple, president of Mack’s Northern Operations. “With Packsize, we fully expect to reduce our overall packaging costs by 20 percent.”
Produced by Packsize International LLC, based in Salt Lake City, the system feeds an interconnected stack of cardboard into the machine. The operator punches into a key pad the desired dimensions and number of boxes required. The machine takes it from there, cutting the cardboard to size and spitting out a flattened box with score lines and a glue tab. Changeover to a different package size is as simple as re-keying in the new dimensions. Any off-fall from the system is 100 percent recycled.
While Packsize frees up space, uses less material, and streamlines Mack’s packaging operation, it also set the stage for step two – the purchase of a PTR Model 3400 60-inch downstroke baler from Recycling Equipment Corporation (Lansdale, Pa.). The super heavy-duty baler produces 60″ x 30″ x 48″ bales, weighing up to 1300 lbs each.
As a custom contract manufacturer, Mack purchases thousands of unique components from suppliers all over the world. “All incoming product brings packaging through our doors that needs to be reused or recycled,” says Marc Colety, director of procurement. “Previously, we were manually cutting down boxes, separating the prime and clean corrugated, and recycling it – an investment for the environment, but not to our bottom line.” Now all packaging material will be baled and sold, which leads to the third phase of the program.
Rand Whitney Recycling, which owns and operates three paper recovery facilities in New England, receives, sorts, and bales all grades of waste paper, including corrugated containers, newsprint, mixed-use office paper, pulp, and envelope cuttings. Starting this summer, Rand Whitney will pick up and recycle Mack’s bales of corrugated, which it estimates will total approximately 15 tons per month. “Proceeds from the corrugated will offset the cost of the baler, allowing Mack to be environmentally responsible while also remaining competitive,” adds Colety.
Beyond corrugated, Mack is looking into similar solutions for metal, plastic, paper, solvents, and every waste stream it generates, with the goal of achieving zero-landfill status.
About Mack Molding
Mack Molding, designated an Environmental Leader by the state of Vermont, is a leading custom plastics molder and supplier of contract manufacturing services. Mack specializes in plastics design, prototyping, molding, sheet metal fabrication, machining, and medical device manufacturing. Founded in 1920, Mack is a privately owned business that operates 10 facilities throughout the world. Don Kendall is president and CEO.