Press release submitted on behalf of Koenig & Bauer

Leading North Carolina packaging firm turns to Koenig & Bauer for a key capital investment

• The firm’s focus lies with custom-designed, high graphics point-of-purchase displays, e-commerce packaging, and the components that accompany them
• The large-format Allpro 145 57-inch folder gluer increased speed-to-market and has attained much higher efficiency
• Overall sales have increased due to the Allpro 145

When printers seek to invest in a new piece of equipment, there’s usually a specific reason why. It could be to expand their operations, enter a new market, or solve a specific challenge. At Complete Design & Packaging (CDP), a manufacturer of custom corrugated packaging and point-of-purchase displays, its newest Koenig & Bauer Allpro 145 folder gluer has achieved all three goals.

“Since operating the Allpro 145, we’ve dramatically increased our speed to market, attained much higher efficiency, eliminated bottlenecks, and allowing our sales team to add high-volume jobs,” says Keith Furr, general manager at CDP.

The new high speed Allpro 145 folder gluer began operation earlier this year at the firm’s Concord, NC 110,000 sq ft manufacturing site joining an existing Koenig & Bauer folder gluer. Having both machines operating in tandem allows CDP to provide new capacity and bring in additional new customers.

“With both folder gluers in operation, we’ve been able to shorten our lead times by running the same item on both machines, if need be,” says Bryan Allman, CDP’s plant manager. “We’ve also been able to gain much more versatility and flexibility on the most complex range of carton styles including both infold and outfold trays due to the machine’s modular design. E and B flutes are the most common substrates.”

Internally, the Allpro 145 has provided better efficiency and relieved bottlenecks and allowed for faster job turnaround times. The workload balance between the new Allpro 145 and the older Koenig & Bauer folder gluer have improved efficiencies by allowing operators to produce auto bottom jobs on one and straight line on the other, says Allman. He is also pleased to have eliminated the bottleneck in the post press department by adding more production hours with the new folder gluer and reduce the potential for overtime.

One of the new surprising capabilities that CDP achieved on the Allpro 145 is the outfold tray, a specialized component used to produce certain types of packaging, particularly multi-panel or Z-fold boxes. The specific part may be described as a backfold or folding hook assembly, which is integrated with the machine’s unique backfolding and folding sections.

Complete Design & Packaging counts itself as one of several high-profile manufacturers in this central North Carolina area. Its sprawling site includes a 110,000 sq ft manufacturing plant and new 85,000 sq ft distribution center along with a 100,000 sq ft fulfilment center, which are home to millions of dollars of technology and machinery investments, all of which significantly expands the company’s operational capacity to meet growing demand.

“Our company continues to enjoy strong growth due to our innovation and staying on the cutting edge with new equipment. The new Koenig & Bauer Allpro 145 is giving us an outstanding return on our investment based on our current needs, our customers’ needs, and future growth plans,” says Allman.