Indiana Carton Co Checks All the Boxes, Thrives at 85

Maintaining its independence, building momentum, evolving with the times, living up to standards, delivering high visual impact—Indiana Carton Co checks all those boxes and more.

Family owned and operated, efficiency minded, proud of its expanding green credentials, this Bremen-based business has dutifully served the folding carton world for decades and decades—nearly a century. While the tools of the trade have changed over the years, the company’s drive to anticipate and meet its customers’ needs remains its No. 1 priority.

Indiana Carton continues to forge a reputation for delivering top-echelon customer service, resulting from consistent production of high visual impact cartons that allow retailers to maximize marketing opportunities by promoting the brand, and maintaining quality “over the curb”—from shipping to in-store display.

Current President Kenneth D. Petty, who succeeded his father, David L. Petty, and grandfather, Kenneth H. Petty, is quick to credit his elders for the company’s continued success, stating: “We have more than eight decades of experience and knowledge supporting our every move, and it is all unconditional with the company’s best interest in mind.”

Under third-generation management, the numbers at Indiana Carton are impressive. A production unit of 164,000 sq. ft., plus an off-site warehouse of 20,000 sq. ft. and a team of 100 dedicated employees that is poised to exceed sales goals for 2019, with plenty of scope for growth. As a proud member of the ICG (Independent Carton Group), an informal but close-knit community of similarly sized converters, Indiana Carton enjoys the buying power and redundancy made available by the Group.

As Alicia Petty MacDonald, VP marketing and administration, commented: “Our customers know they can rely on us and depend on the consistency of our service. To meet their expectations, we continue to work hard at making it easier for them to succeed in their marketplace. So, when we approach a game-changing project, like adding flexo, we always make sure we can perform before making any promises—even if it does take more time and energy!”

Independent & Innovative

Indiana Carton, like so many of its kind, had gone through a long period of under investment during the 1980s and 1990s, and matters came to a head at the turn of the century when the family board of directors, chaired by Ken Petty (senior), had to choose between selling out to one of many offers on the table, or changing tack and bringing in new talent from a younger generation.

To his eternal credit he chose the latter, and while the intervening years were not without their challenges, the company is thriving today, thanks in no small part to a major investment program that most recently brought wide web flexo carton production to its existing sheetfed capability.

To understand the reason behind adding flexo services to an already high-performing offset shop, one needs to look at the company’s background and its business. Early days saw production of boxes mainly for permanent press shirts and pizza cartons, before that trade all went to plastic and corrugated, respectively. Today, the company’s main business is supplying high-impact boxes, 85 percent of which are windowed, to the in-store bakery, supermarket, restaurant and wholesale food manufacturing chains, where first impression is key.

All products manufactured at the Bremen plant meet the internationally recognized GFSI (Global Food Safety Initiative) standard, and the company is proud that it was one of the first carton houses in the US to be accredited and certified SQF Level 2 and SQF Quality (formerly Level 3).

With a wealth of expertise that allows it to match the packaging to the product it contains—whether it be a cookie, a cake or a doughnut—Indiana Carton deploys targeted technologies to make certain each product maintains its freshness and visibility. Given the nature of the contents, the cartons have to be resistant to all threats. These include heat, cold, moisture, handling and microbial influences.

For example, solutions for hot, cold or ambient temperatures dictate the box design and materials used, as well as the ability to stack, its anticipated shelf life and the recyclability of the board used. Products with high food oil or fat content require a barrier to prevent decomposition and cross contamination, just as the window must be able to control airflow around the product.

Tech/Turnout Match

With such specific requirements, the company has always researched technology very carefully prior to making the investment choice. This led to a Manroland 900 press being installed along with Bobst die cutters some 10 years ago.

The 6-color press, supplied by an industry workhorse 2008 GMC-1600 sheeter, is fitted with a coater and IR drying, and logistics at both feeder and delivery to allow continuous running at speeds up to 14,000 sheets per hour. In addition, the Petty family completely overhauled the diecutting department with multiple wide-format Bobst diecutting and blanking platens, all configured with automated carton handling and power register systems. These are complemented by several wide-format, purpose-built Bobst folder/gluers, customized to suit specific target markets.

Game-Changing Project

So, when the time came for additional investment, the decision to add web flexo—made after an intensive three-year research program—was a major sea-change in policy. The end result was the 2017 installation of a Heidelberg Intro 7-color line, capable of speeds surpassing typical wide-format lines, while maintaining offset quality with flexo consistency. The new press delivers the printed sheets to the diecutting department without requiring either new tooling or modifications to existing tooling.

The Intro is equipped with the latest technology and includes an inline sheeter and an automatic washing system for all print units. It is fitted with carbon fiber chambers, which offer excellent stiffness and rigidity, some 300 percent better than aluminum. With their lighter weight, they also allow quicker cleaning and maintenance, and therefore a safer working environment. Heidelberg Web Carton Converting GmbH provided training during the startup and the early production period to ensure that Indiana Carton was able to realize the press’ capability at an early stage.

“We looked at every flexo press on the market, and in the end chose to align ourselves to the Intro, given its strong pedigree, print repeatability, scalability and technical support from Heidelberg,” Ken recounts. “It had a good track record and first-rate testimonials from other users, and we liked the print quality we saw being delivered.”

To maximize on the Intro’s capability, Indiana Carton had to choose from a short list of specialist roll handling manufacturers for unwind and splicing technology, and accepted the recommendation of Heidelberg in choosing Martin Automatic. “We were keen to use tried-and-trusted technology, because learning flexo was going to be challenging enough, and we did not want to invite additional machine trials to an already sophisticated project,” he adds.

The Martin equipment chosen and installed is an MCBWW model automatic butt splicer. Matching the press speed of 1,000 fpm on web widths on the standard model up to 67-in., it has a maximum roll diameter of 72-in. and can handle weights up to 8,000-lbs. The system includes an inertia-compensated dual festoon system, a butt splice unit and two-position, side by side, inline cantilevered unwind spindles. Floor-mounted integral lift tables load new rolls onto the spindles effortlessly. The controls integrating these components are all mounted in the equipment, allowing automatic roll unwinding, splicing and tension control.

Efficient by Intent

A custom roll-handling system, designed by Material Handling Sales Associates and manufactured by Harmax, allows operators to prepare up to seven rolls safely and maintain production. The system also includes a turntable, a lifting and stripping station for unwrapping new rolls, and kickers to deliver the rolls automatically to the unwind lift tables, on signal given by the splicer.

Plant and equipment layout also enables the same track to present rolls to a separate sheeting line adjacent to the press. “The enhanced efficiency of delivering prepared rolls to the splicer allows the production department to maintain a continuous flow of material, and maximizes operator safety in roll handling,” Ken notes.

Continuing with the theme of efficiency, Indiana Carton is very proud of its green credentials. “We recycle 100 percent of our board scrap and all the water used in the printing process. We’ve fitted low-energy lighting and high-efficiency heating for minimal consumption, and all heat generated from production is re-used in the factory. Our forklift trucks even run on rechargeable batteries—so we feel our carbon footprint is as good as most, and better than many,” he explains.

The forklift trucks, fitted with iPads, facilitate tracking and delivery. Indiana Carton insists on accurate management of all work in progress.

About the Author: Nick Coombes is a 42-year veteran of the printing industry, and independent marketing adviser to a number of leading technology manufacturers. He is also an editorial consultant to a number of leading international print media owners.