New Indianapolis facility invests in a single-pass four-color bottom print plus top print station die cutter

• Serving its consumer clients with 50% gains in die cutting speeds
• Customers gain more flexibility with in-house machine and Opus promotes its green footprint
• Solid relationship with Kolbus Hycorr spurs second Hycorr machine purchase

As it continues to answer its customer’s corrugated box needs and expedite demand for orders, Opus Packaging Group, a leading corrugated packaging and supplies manufacturer, is investing in the latest automated equipment to pursue those goals. Its newest facility in Indianapolis, IN is accelerating its production with the recent installation of a Kolbus Hycorr 66 x 115 rotary die cutter, which began its current online shift in November. It features a four-color bottom print plus one-color top-print station.

“Demand for our corrugated boxes is very high, and has grown stronger during the pandemic” says Mike Seifert, director of manufacturing services. “Our customers are seeking new ways to attract more business and often it entails colorful graphics on the outside of the box and one-color messages and advertising on the inside. With the investment of the new Hycorr RDC, we can accomplish those orders efficiently and quickly all in a single pass. I expect we will quickly be operating the Hycorr RDC at a two shift level producing a wide array of products including graphic packaging, packs and kits, interior dunnage, custom partitions and packaging supplies.”

Opus began tracking requests from its retail customers for more color and more messaging applications inside the box as e-commerce took off. By providing more capabilities, Opus saw an opportunity to increase its customer base. New to its product offerings is the ability to print additional one color inside the box advertising on the Hycorr RDC.

The popular Hycorr RDC is an efficient means to printing and die cutting in one pass. It can print on both sides of the sheet, which eliminates an entire set-up, saving time and reducing waste with no additional handling. Coatings can be applied or messaging, instructions, or advertising can be printed inside the box. Users praise it for its increased flexibility and attracting new business.

Prior to the RDC arriving in Indianapolis, the firm had to transport its jobs to a sister facility for manufacturing and then back to its own facility. Now, the new Hycorr RDC, which was assembled at Hycorr’s Michigan manufacturing facility, is operating under its own roof in Indianapolis. The new investment allows the team additional flexibility to schedule jobs, more efficiency and productivity, and a green footprint with decreased trucking between plants.

Seifert reports that the Hycorr installation went very smoothly and his operators are excited to use the new machine. “The RDC is fully automatic with touch screen controls,” he says. “Our operators can perform all adjustments, such as registration and set-ups, using the HMI interface. It makes our younger generation of employees, who are computer savvy, very happy.”

The management team did look at other solutions and considered a used die cutter before signing the contract for the new Hycorr RDC. A similar Hycorr die cutter is operating very well at the New Bremen, OH facility.

“We like to partner with our manufacturing vendors and that includes Kolbus Hycorr,” says Seifert. “Their support has been excellent and we’ve been happy with their training staff. What sets them apart is having a quick and free 24/7 online support, which gives us peace of mind.”

The Indianapolis facility opened in August 2019 after Opus Packaging Group invested nearly three million to construct and equip the 170,000 sq ft manufacturing plant with 35 employees. The site was chosen as a good fit for Opus to better serve its clients and increases its production for clients in Indiana and other parts of the Midwest. Opus Packaging, which also has operations in Michigan, Ohio and Illinois, employs 375 associates nationwide. Opus Packaging Group is a family of companies dedicated to providing superior customized packaging solutions to its clients. It offers a wide array of products and services including graphic packaging, packs and kits, interior dunnage, custom partitions and packaging supplies.

Left to right: The team of Joe Wagner and Chris Michel, plant supervisors at Opus Packaging’s newest facility in Indianapolis, IN, are pleased with the operation of the recent installation of a Kolbus Hycorr 66 x 115 rotary die cutter, which began its current online shift in November. It features a four-color bottom print plus one-color top-print station.