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Creative ways to cut costs are carving out new opportunities for corrugators.

Creative ways to cut costs are carving out new opportunities for corrugators.

Surviving in the uber-competitive corrugated business means sheet feeders must think out-of-the-box when it comes to reducing costs. “Pennies can make the difference between making or losing a sale — we need to explore every opportunity to reduce our operating expenditures,” says John Bolender, president, Niagara Sheets LLC. It is this increasingly competitive marketplace and the growing interest in sustainability that has encouraged Bolender to keep an open mind when it comes to new cost-cutting ideas. So when he heard about the significant savings other sheet and corrugated plants had earned with a customized energy-saving solution, he was all ears. Niagara Sheets partnered with WPS Global to implement the plan tailored specifically for the Tonawanda NY plant. Just 60 days after WPS Global installed its comprehensive energy solution, Niagara Sheets realized over $10,000 in savings. NIAGARA SHEETS’ ENERGY SAVINGS AFTER WPS GLOBAL’S INSTALLATION Month % From Average Effect on Energy Bill 1 -13.59% ($3,198.14) 2 -10.00% ($2,244.01) 3 -20.10% ($4,988.33) Avg Savings To Date -14.56% ($10,430.48) Bolender says the results to date have met his initial expectations. “The data so far already demonstrates a nearly 15 percent reduction in kilowatts consumption compared to last year.” The Guarantee makes it a Low-Risk Decision WPS Global offers a 10 percent reduction guarantee – an insurance policy for savings – with each plan. William Behrmann, president of WPS Global, describes corrugating equipment as big consumers of energy.  The reduction guarantee along with projected savings and success stories help Behrmann articulate the generous opportunity for cutting a plant’s operating costs. “For financial and sustainability reasons, decision-makers want to know if and how we...

Bad News for your Corrugated Facility

Dear Corrugated Facility Management, I have good news for you, and some bad. First, the bad news: if you don’t have a WPS Global Inc. energy reduction system running in your plant(s) right now, you’re never going to earn the significant savings that are available to you (and with zero effort or employee resources on your part). Your competitors and peers in the corrugated and sheet plant industry ARE ALREADY reaping the benefits. There are dozens of success stories. Recently PFFC featured one of those success stories. They reported: Corrugated | Converter Forecasts $1 Million Savings with Energy Reduction System You may have to read the whole story to believe it. In short, the system has been in place for two years. And, Freedom Corrugated’s WPS Global energy management system has already earned it a 15.38 percent overall reduction in kWh usage and an energy cost savings of over $177,000. The savings will continue for at least another 13 years, resulting in an anticipated savings of more than $1,300,000 over a total of 15 years. Other than cost savings, there are sustainability benefits as well. The WPS Global solution has lowered Freedom’s CO2 (carbon dioxide) emissions an average of 72.85 tons per month over 24 months. By year 15, the company expects to have cut its CO2 emissions by a total of 13,113 tons. Since the installation, Freedom Corrugated has seen savings in maintenance costs as well. Now, the good news. Your operation is a simple WPS Global audit away from reducing its energy consumption by a double digit percentage. This translates to thousands of dollars in savings each month. This is no exaggeration. Can you imagine where you could re-invest that...

What do you believe?

  This month we thought we’d step away from our typical update about the trends in energy reduction, electrical savings and environmental sustainability. Instead, your colleague, Bill Behrmann, senior systems designer at WPS Global Inc., would like to share a topic that’s a bit more personal. It’s about the concept of “belief.” [hr] I know.  Right away your mind goes to religion when you hear or read it.  But that is not the version of Belief I am talking about… Belief sparks creativity!  It also gives us a sense of empowerment.  Belief is what put us where we are today.  What is hard for most people is choosing to believe even when others insist that you are wrong.  Sometimes the evidence is overwhelmingly in your favor and sometimes it is not.  But, people hate to be embarrassed and wrong, so often – when someone says it can’t be done – most people will agree because of the fear of looking unwise. We know that being wrong isn’t shameful, and in fact, it is what teaches us and helps each of us learn how to improve.  But, for us to achieve greater goals, we have to believe.  Whether that belief is in another person, company, machinery, process, or something off the wall that “can’t be true,” belief is at the core of innovation! I see this innovation every day in my customers. It isn’t always a business’ CEO or executive leadership that are paving the way. On nearly every site visit I make, I see innovation coming from management and taking place on the plant floor. So, no matter who...

WPS Global's million-dollar savings success story makes PFFC headlines

Paper, Film & Foil Converter recently featured WPS Global Inc.’s million-dollar savings success story for Freedom Corrugated. What made the headlines? Six-digit energy cost savings in 24 months. CO2 emissions cut by thousands of tons. This WPS Global kilowatt-reducing success story covers a very relevant topic in today’s marketplace; one that will intrigue and inspire other converting industry professionals. In place for two years, Freedom Corrugated’s WPS Global energy management system has earned it a 15.38 percent overall reduction in kWh usage and an energy cost savings of over $177,000. The savings will continue for at least another 13 years, resulting in an anticipated savings of more than $1,300,000 over a total of 15 years. The system is also producing other positive results: environmental sustainability and surge protection. The WPS Global solution has lowered Freedom’s CO2 (carbon dioxide) emissions an average of 72.85 tons per month over 24 months. By year 15, the company expects to have cut its CO2 emissions by a total of 13,113 tons. Since the installation, Freedom Corrugated has seen savings in maintenance costs as well. Read the PFFC feature story to see the impressive numbers and photos of Freedom Corrugated’s...

Sustainability in the US Corrugated Industry

What strides are American corrugated industry businesses making to reduce their Carbon Footprint? While sustainability leaders such as RockTenn are experiencing some progress — it reported a 4 percent reduced energy use in 2010-11 — by implementing several changes across multiple operations, WPS Global customers are seeing better results by implementing one custom-developed solution within each plant. The WPS Global installation requires zero effort or employee resources on the customer’s part and shows positive results after just one month after installation. And, WPS Global guarantees its system will reduce the facility’s energy usage by 10 percent and produce enduring electrical savings for up to 15 years. Read on to find out how much progress the U.S. corrugated industry is making toward sustainability and what you can do to make better progress and a faster return on your investment. —————————————————————————— According to FEFCO (European Federation of Corrugated Board Manufacturers), the European corrugated sector has decreased the Carbon Footprint by 4.8 percent between 2009 and 2011. This is on top of a reduction by 11.7 percent between 2006 and 2008. The organization attributes the reduction mainly due to a considerable drop in electricity usage by kraftliner producers. Here in the United States, The Responsible Package initiative says the forest products industry has made great strides in reducing its carbon footprint. Between 2000 and 2006, the industry collectively reduced its greenhouse gas intensity by 14 percent. The Responsible Package initiative is an industry-wide effort to promote the versatile and sustainable packaging solutions provided by paper-based packaging. The group reports that in the U.S., the carbon sequestered by forests and products each year is enough to...