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FLEXO Magazine : November 2010
Plants & Processes and there, and after many years, you have a hodgepodge,” he says. Crossley adds, “When we look at our evolving customer base, the retail business is more into sustainability than our old customers, although they are coming around now too. It is far more important to the Wal-Mart’s and Costco’s of the world because they are seen as the big waste generators.” The new facility, built right down the block from the old one, is touted as being green from the ground up. While not required by the state, it hosts its own waste water treat- ment plant. “ What we put into sewers is ‘near drinking-water quality,’” says Oursler, who quickly adds, “I’m not saying I’d want to taste it, but that’s how clean it is. And what’s leftover is chemical-neutralized so that it is landfill-able.” T he new site features a slew of other innovations to help control its environ- mental footprint, including: • Heat is reclaimed from the corrugator operation and distributed throughout the area in large energy socks. • Scrap recovery system was designed so that warm, filtered air could be returned to the plant during heating season, and exhausted to the atmosphere during non- heating months. • T8 fluorescent lamps with electronic ballasts are installed in the office areas and T5 lighting exists throughout the production areas. • A conveyor system moves product from one work area to the next. It is designed so that power is provided only to sections of the conveyor that are actually moving product at the time. • 53ft. trailers replace old 45ft., 48ft. and 50ft. trailers, reduc- ing the fleet by four since more product could be hauled on fewer trailers, along with the miles driven for delivery. Advance Packaging is also a considerate neighbor. Cross- ley explains, “A drain field around our building was re-located to maintain the frog population. Otherwise it would have caused an ecological imbalance. Every year we have to count our frog population.” Looking to the Future While the brown box business that helped make Advance Packaging so successful continues to be part of its operation, that doesn’t preclude Crossley from investigating technolo- gies that he sees coming around the bend. “I’m intrigued about the low-speed digital printers,” he confesses. “ To cut plate time and costs down would be great. We worry a little because we’ve got all this money invested in flexo and I don’t want it to all go digital in the next two years. Right now it’s so slow, though; you can’t service high-volume customers. Will there be enough of a market for those printers down the road? I’m not sure, but it will likely happen in our lifetime.” n advance Packaging’s 110in. , seven-color Gopfert evolution rotary die-cutter. stacks of corrugated on advance Packaging’s automated material handling conveyer system. the façade of the eco-friendly headquarters of advance Packaging, Grand rapids, MI. 66 FLEXO noveMber 2010 www.flexography.org even two-color line work is produced with the same care and diligence as four-color process. Photo courtesy House Industries/ carlos alejandro. Excellence in Flexography Awards dEAdlinE: JAnuAry 19, 2011 Graphic design Awards dEAdlinE: JAnuAry 19, 2011 Technical innovation Award dEAdlinE: FEbruAry 2011 Environmental Excellence Awards dEAdlinE: dEcEmbEr 31, 2010 If you are interested in becoming a judge in these prestigious awards competitions, please send an email to Shelley Rubin at email@example.com Join the Ranks of the tRuly accomplished FTA’s 2011 AwArds compETiTions Excellence Awards ad2011_mech.indd 1 9/1/10 11:54 PM FLX_Nov10_mech.indd 66 11/1/10 2:26 PM
Sustainable Fall 2010