Menasha Packaging, Neenah, Wis., says it will expand its corrugated box plant in Yukon, Pa. The company will spend $10 million in capital improvements at its 300,000-sq-ft packaging and display plant over the next 12 months. It expects the expansion to increase plant capacity by 35 percent. The Yukon packaging and display operation opened in 1980 and employs 160 people.

“The expansion will help us produce even higher quality prod- ucts at larger volumes, provide superior service to our customers, and prepare us for continued growth,” says General Manager Pete Widolff. “We are here to thrive. These investments demonstrate that we are serious about our position in this market.”

The project consists of three stages. The first phase, already underway, involves modernizing the main line conveyor and installing two new Mosca Sonix unitizers. The fully automated unitizing system will increase production efficiency and reduce maintenance costs.

The second phase, scheduled for the second quarter of 2011, includes installing a high-speed order change dry-end from Fos- ber and a new MarquipWardUnited Vanguard singlefacer to the corrugator. The equipment upgrades will give Menasha greater flexibility to make continuous order changes, increase capacity, and produce superior board quality. Improvements include less starch used in the gluing process and a reduction of board waste.

The third phase, slated for completion in early 2012, involves installation of an Isowa four-color flexo folder-gluer. The new equipment has shorter set-up times and faster run speeds, which will improve print and box quality. The flexo folder-gluer also uses less water, reduces ink waste, and supports a lean supply chain.

“The plant expansion will give us the capability to produce shorter runs, and increase our capabilities for direct print graphics, litho labels, and preprint,” says Ed Stuczynski, staff engineer at Menasha Packaging.