On any given day, countless colourful sheets destined to become luxurious packaging are printed, coated, embossed, hot-stamped and die-cut by Curtis Packaging at its headquarters in Sandy Hook, Connecticut. They are produced for globally recognised brand retailers in the health and beauty, sport, liquor, entertainment, software and pharmaceutical markets.

To help make this happen, Curtis invested in a Rapida 106 with 15 printing and finishing units, as well as UV capabilities, in 2018. Don Droppo Jr., president and CEO of Curtis Packaging, is delighted: “This is the only press in the world in our unique configuration. We can apply up to 11 colours and multiple coatings in a single inline process. This fully customised Rapida 106 gives our company endless possibilities.” Immediately after the installation, the Rapida 106 was already meeting Curtis’ expectations with some amazing work, and contributed to reductions in internal costs from the very beginning. “Our job changeover times have improved by 65 per cent,” says Kerry C. Brown, vice president of operations. “We have been able to line up so much more work on the press as a result. The press is easily paying for itself. We have seen a 30 per cent increase in production, and that has helped us to increase our sales dramatically. We could not be more pleased.”

Sales grow by 20 per cent

As an established leader in the luxury packaging market, Curtis has recently gained at least 10 to 15 new customers. “2019 was our best year yet,” says Don Droppo. We posted strong 20 per cent sales growth, and the investment in the new press has definitely contributed to this growth. It gives us higher speeds, faster production and increased embellishments with only one pass. This new press has certainly surpassed the expectations of our business plan.” To maintain its exceptional printing promises, Curtis has invested in a whole suite of sheetfed offset presses from Koenig & Bauer. The latest Rapida 106 is a perfect complement to the existing seven- and eight-colour Rapida 130 models, and ensures that Curtis can operate competitively across the full spectrum of run lengths from as little as 500 to over five million sheets. To safeguard the efficient handling of such a variety of jobs, performance data from the Rapida 106 are acquired automatically and analysed via the LogoTronic Professional management system. Detailed reports are generated on all activities taking place on the press – right through to OEE data. It is thus possible to evaluate performance in every situation, with the result that print quality, waste reduction and increased production output become measurable indicators.

Acceptance testing in the Koenig & Bauer assembly centre (l-r): Don Droppo, president of Curtis Packaging Corporation, Chris Travis, director of technology at Koenig & Bauer (US), and Kerry C. Brown, vice president of operations

Expectations exceeded

Curtis is always glad to open its headquarters for customer visits. “We had one valued client who came to visit while we were printing their job,” says Kerry C. Brown. “Their graphic designer came along too and brought a new design which they wanted us to print. With our new Rapida with its colour control and one-pass efficiency, we were able to produce both high-end jobs in ten minutes. We knocked it out of the ball park.”

The finest printing technology over a length of more than 33 metres

Curtis Packaging produces high-quality folding cartons for discerning global brands. Its products are characterised by both outstanding beauty and enduring value. Each carton produced at the company passes through the hands of numerous experienced packaging professionals. Dedication, knowledge and tradition have been cultivated ever since Curtis was established in 1845. The company is a global leader in innovation and environmental stewardship. It can point to a rich heritage of excellence in production, not to mention an exemplary environmental record. Curtis is the first packaging company in North America to achieve 100 per cent carbon-neutral production, using 100 per cent electricity from renewable sources and with certification from both the Forest Stewardship Council (FSC) and the Sustainable Forestry Initiative (SFI). Responsible action is a core business principle.

Interesting website:

curtispackaging.com

Eric Frank

Background photo: The latest investment at Curtis Packaging: A Rapida 106 with 15 printing and finishing units