By Emily Leonczyk, Director of Operations, Paperboard Packaging Council
In the surprisingly dynamic world of packaging, the Paperboard Packaging Council (PPC) plays a pivotal role in connecting industry players, fostering innovation, and championing excellence. Recently, I had the privilege of embarking on an insightful journey to the West Coast, where I visited five distinguished PPC members at their manufacturing facilities. Each visit provided me with a unique window into the state-of-the-art practices, innovative approaches, and customer-centric philosophies that define these industry leaders. This trip was a transformative experience, giving me the opportunity to explore the operations of PPC members Royal Paper Box, Superior Lithographics, Advance Paper Box Company, Ink Systems Inc., and Preferred Printing & Packaging.
Stop 1: Royal Paper Box – Extending the Royal Treatment
My journey began with a visit to Royal Paper Box, where I was greeted by President Darryl Carlson, an industry leader who epitomizes “the royal treatment.” The encounter not only offered me an intimate perspective into the company’s ethos but also underscored the significance of meaningful customer relationships. I was deeply impressed by their focus on both their customers and team members.
Royal’s commitment to excellence, even in the face of adversity in the form of a recent tornado striking Los Angeles, left a lasting and noticeable impact on company culture and morale. Through effective crisis communication and operational resilience, Royal Paper Box demonstrated the importance of being prepared for the unexpected. Their team banded together and did not miss a beat (although maybe some sleep), and were diligently focused on serving their customers, even while operating under stress.
Darryl plans to take the stage at PPC’s upcoming Fall Meeting to share his key takeaways from the experience. While the tornado may have put their expansion plans a bit behind schedule, their team worked quickly to ensure it was just a blip on the radar (figuratively and literally). I was inspired by the chance to walk the freshly broken ground as they continue to expand their royal reach.
Stop 2: Superior Lithographics – Showcasing Lean Manufacturing Mastery
My journey continued with a stop at Superior Lithographics, where I met with President & COO Jeff Ku, an industry success story in his own right. Jeff spent over a decade working his way through the ranks, and is leading the operation today, for good reason. Ku’s noticeable background in lean manufacturing struck me, and my
visit highlighted his commitment and leadership, evidenced by the incorporation of employee suggestions on safety and operational efficiency.
The core of their vision is to be the most respected independent printer in the Western United States, and they achieve this through their innovative approach of engaging team members in the problem-solving process. I learned that Superior Lithographics had implemented over 3,000 team member suggestions since launching the program 11 years ago, a testament to their dedication to creating a fulfilling work environment. Every member of the Superior Lithographics team has an opportunity for their voice to
be heard, and this process of listening to new ideas is how we push our industry forward.
This includes engaging new talent, too. Ku shared his commitment to supporting recent graduates like those from his alma mater, Cal Poly. I was delighted to see a familiar face on my tour, a recent Student Design Challenge winner who we hosted during last year’s Fall Meeting via the Paperboard Packaging Alliance (PPA), a joint initiative of the American Forest & Paper Association and PPC. The total experience solidified how involving your workforce at every level in continuous improvement leads to elevated performance and a culture of innovation.
Stop 3: Advance Paper Box Company-Packaging Spectrum – A Century of Excellence
Celebrating a remarkable milestone of 100 years in business, Advance Paper Box Company-Packaging Spectrum opened its doors to me, with owners Nickie Silk, Evan Gardner and Vice President George Rodarte offering me a glimpse into their expansive 500,000 square-foot manufacturing and warehouse facility. My visit coincided with the anticipation of the company’s centenary celebrations, creating an atmosphere charged with history and accomplishment. It’s not every day that companies turn a hundred years old! Paperboard packaging has existed since the mid-1800s, and the fact that Advance Paper Box Company-Packaging Spectrum has been in business for over half of that time is a testament to their hard work and fortitude.
As I walked through the facility, I was immersed in the legacy and evolution of packaging over the past century. The experience underscored the enduring power of innovation and adaptability as Advance Paper Box Company-Packaging Spectrum continues to thrive in an ever-evolving industry.
Stop 4: Preferred Printing & Packaging – Forging a Path to Sustainable Growth
My next stop was at Preferred Printing & Packaging, where I engaged with Vice President Jim Frassetto, a visionary leader passionate about sustainable growth. As I
toured the plant, Jim shared his insights into the company’s success and their holistic approach to turnkey production processes. The experience illuminated the company’s dedication to staying lean and agile while achieving impressive growth.
The emphasis on a “turnkey production process” resonated with me, showcasing how a seamless approach can drive both operational efficiency and customer satisfaction. Everything in the world is getting more expensive, and unfortunately, our industry is not immune to these strains. We’re excited to see Preferred Printing & Packaging growing in spite of such challenges, and we can’t wait to hear Jim present at the PPC Fall Meeting to help others in the industry who might be struggling. The site visit painted a vivid picture of a family-owned business forging a path to a sustainable future while maintaining its commitment to personalized service.
Ink Systems Inc. – Pushing Manufacturers to Dream Big
My journey took a final colorful turn as I stepped into the world of Ink Systems Inc., led by President Carl Hirsch. A fascinating tour through the ink process revealed the intricate science and artistry behind ink manufacturing for the offset printing industry.
Ink Systems manufacturing headquarters demonstrated one of their quality assurance tests in their UV ink laboratory. They showed me how they ensure inks are dried and cured properly for cartons produced by many of our PPC members’ converting operations. Connecting my recent tours with Ink Systems’ operations provided a more complete understanding of the essential role ink application experts play in the entire packaging process. A vital part of PPC’s mission is to connect the best manufacturers with the highest quality suppliers, and Ink System’s success in our industry is a testament to that.
The Return Flight
My West Coast tour offered a wide view of the packaging industry’s innovation, resilience, and customer-centric philosophies. Each encounter with PPC members reinforced my understanding of the ideas and people that make the paperboard packaging industry so unique.
From weathering storms to embracing lean practices and celebrating heritage to pioneering precision, these organizations epitomize the Paperboard Packaging Council’s mission to foster excellence and collaboration. As I return home, I carry with me a wealth of insights that will undoubtedly shape the future of the packaging industry through PPC’s ongoing endeavors.
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The Paperboard Packaging Council has an exciting fall ahead! From October 25-27, we’ll be hosting our annual Fall Meeting in San Diego, which includes the can’t-miss Women’s Leadership Council, Carton Competition Awards, and more. If you make it to either one of these events, make sure to say hi to Emily!