“confidential”malnoveoverview. malnove’s “platforms of competency” malnove is a company...
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“Confidential”
Malnove Malnove
OverviewOverview
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Malnove’s “Platforms of Competency”
Malnove is a company committed to establishing “intimate” relationships with our clients, and delivering true total packaging solutions based on our unique knowledge of the customer’s business and related brands.To support our “total packaging solution” strategy we have developed (3) “platforms of competency”.
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Malnove’s “Platforms of Competency”
Delivering innovation through “Intelligent Package Design” and manufacture based on focusing on the social, economic and environmental requirements of the customer’s packaging requirements Commitment to “Joint Process Improvement” with a focus on delivering “long-term”, compounding and measurable economic value far exceeding the cost of the package
Commitment to and investment in our operations and associates across North America. Malnove can meet your “Speed-to-Market” program timelines. A empowered team is in is in place that works “hand-in-hand” with the Customer, Customer Service, Malnove Electronic prepress, Quality Systems and Standard Operating Procedures to give you “piece of mind” during each phase of process.
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Malnove is constantly searching for new ways to deliver convenience, value and the environmental attributes in demand by today’s consumer. As an extension of the customer’s product development team, Malnove provides the experience and technology to create the industry’s most advanced paperboard packaging.
We are firmly focused on our customer’s top line (“retail velocity”), while delivering on bottom line metrics (continuous process improvement through collaborative supply relationships).
Malnove Packaging & Packaging Systems Create “Measured” Value
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Innovation Examples / Metrics:
• Optical Lens Packaging for Esilor Patented package secures & protects by “suspending the product” Significant Source / Labor reduction for Esilor
• Facial Tissue Carton Converting for P&G Insert and score window film Single pass operation-multiple functions Saved P&G $1,000,000 annually
• Stack Right™ Carton Design Used as a “Set Box” Alternative Allows .002-.004 caliper reduction Eliminates case packing cost
Saved Harry & David’s $600,000 annually
Malnove Packaging & Packaging Systems Create “Measured” Value
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Innovation Examples / Metrics:
• Pouch Packaging at CPR Goya Foods .010 reduction in paperboard caliper Source reduction and lower packaging costs
35% productivity gain for CPR Goya Foods300% increase in converting speed for Malnove during finishing59% increase in printing / die cutting productivity
• Redesigned all major carton designs and related equipment at Siemens Osram Sylvania Improved Retail “Velocity” on Par Platform Saved Sylvania $165,000 annually and increased line productivity by 16%
Designed and installed new Malnove SSG Packaging Cell on Incandescent PlatformSaved Sylvania $700,000 annually and increased line productivity by 14%;converted from .016 SBS to .016 CCNB saving an additional $300,000 annually
• New Carrier Design Revolutionized the European Beverage IndustrySignificant reduction in materials Comparable performance to “traditional” U.S. “Mill-Driven” design1,000,000,000 carriers now in use throughout the world Leveraged our Joint Venture with FCP Europa AR
Malnove Packaging & Packaging Systems Create “Measured” Value
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Products
• Folding Cartons
• Thermoformed Plastic Solutions
• Packaging System Engineering, Installation, Training
Facilities
• (4) folding carton plants in the United States
• Malnove - Jacksonville
• Malnove - Omaha
• Malnove - Salt Lake City
• Creative Malnove - Hawaii (+ thermoforming)
Annual sales and conversion
• $135,000,000 (U.S.)
• 90,000 tons of paperboard converted
• SBS 43% SUS 31% CCNB 26%
About Malnove
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Malnove Incorporated “Top 10” Customers; Markets Served; Solutions Provided
Osram Sylvania (Lighting Products; 50+ sizes; 200mm cartons; KANBAN Supply Chain Management; JPI; G8D)
Johnson and Johnson (McNeil Nutritionals; Packaging Category Manager; Full MRP Supply Chain Management; JPI)
McKee (Baked Goods; 50 SKU’s; 200mm cartons annually; JPI)
Unilever (Health and Wellness; Nutrition and RTD Products; Full MRP Supply Chain Management; JPI)
Dairy Queen International (Single Source Supplier Across 5,000 QSR’s Full MRP Supply Chain Management)
Con Agra (Prepared Foods; 500mm cartons annually; Focus on “Joint Process Improvement”)
Wal-Mart (In-Store Bakery; Distribute to 1,800 Supercenters; Full MRP Supply Chain Management; JPI)
CPR Goya (Ethnic Foods; Highest Productivity Manufacturing / Packaging Plant in North America through JPI)
Interstate Brands (Baked Goods; Full MRP for 25 Plants; 225mm cartons annually; 300 Packaging Lines Installed)
Johanna Foods (Dairy Products; 12 Packaging Lines Installed; Full MRP Supply Chain Management; JPI)
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Malnove Incorporated Folding Carton Operations
Salt Lake City, Utah
Omaha, Nebraska
Jacksonville, Florida
(9) Sheet Fed Offset Presses(2) Web Flexo Presses(1) Rotogravure Press
4 Thermoformers (Hawaii)
Honolulu, Hawaii
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Malnove Printing Equipment
Jacksonville: Litho-Sheet fed offset - 3 presses, 7 color, 50” & 7 color 55” Flexo-Web fed - 2 presses, 4 and 6 color, 45”
Omaha: Litho-Sheet fed offset - 4 presses, 2-6 and 2-7 color, all 55”
Rotogravure-Web fed - 1 press, 8 color, 44”
Utah: Litho-Sheet fed offset - 2 presses, 1-7 color 55”, 1-7 color 50”,
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Malnove…Over Fifty (50) Years Of Experience
1948 Malnove Inc founded in Omaha, Nebraska
1976 Malnove opens a new plant in Omaha
1981 Malnove purchases plant in Jacksonville, Florida
1988 Malnove purchases plant in Salt Lake City, Utah
1995 Malnove begins planning & design of new plant in Jacksonville
1998 Malnove establishes a joint venture with Europa Carton
1999 Malnove starts up new 250,000 square foot plant in Jacksonville
2005 Malnove Completes (3) Year - $35mm Capital Project
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Malnove Mission
The goal of our corporation is to consistently exceed our customer’s expectations.
Our people are our most valued asset.
Our business is built around our customer’s needs.
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Malnove Business Philosophy
Our Customers needs determine how we think about:
Our Overall Business
Plant Capabilities
Full-Service Support
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We strive to align our resources with your needs.
We demonstrate this in many ways with a comprehensive approach to packaging:
Package Design (Structural & Graphics)
Product Development; Prototyping and Testing
Packaging System Audits & Effectiveness
Packaging Equipment Engineering; Installation; Training and Documentation
Malnove Business Philosophy
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Malnove Business Strengths
National Capability
We are “Market Driven” by our Customers unique needs
We offer a comprehensive approach to packaging solutions rather that selling “what is on the shelf”
Long-term partnership agreements with board manufacturers of all substrates
Employ all major printing technologies: Offset, Rotogravure and Flexography
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Malnove Business Strengths
A Strong Entrepreneurial Spirit
Total Quality Management
Commitment to “state-of-the-art” equipment & systems
Mechanical Packaging Systems
Development of New Technology, Systems and Packaging Concepts
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Malnove Specific Evidence Of Strengths
Continuous capital investment in our folding carton operations - one of the newest plants in U.S.
Total Quality Management - Stochos quality management data base is thefoundation of our common quality system in our three plants.
Full service mechanical packaging systems-we have over 900 systems installed to-date.
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Commitment to ongoing training.
Development of innovative production processes and packaging lines.
Long term partnership agreements with board manufacturers of all substrates.
Malnove Specific Evidence of Strengths
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Utilize latest technology available in our industry.
Consistent preventive maintenance systems.
New product development / innovation - Stack Rite I and II are our latest new packaging platforms.
A focus on continuous “Joint Process Improvement”.
Malnove Specific Evidence of Strengths
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Malnove Quality Assurance
Corporate Quality Policy
* To consistently exceed our customer’s expectations.
* Our people are our most valued asset and accept this challenge daily.
* This is done by focusing on the process, not by focusing on results alone.
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Corporate Quality Manager - Reports to our Chairman
Consistent Quality Direction / Systems in all Plants
Plant Quality Team - Process Audits / Variables Control
Operating Personnel - Variables Test / Process & Product Control
Malnove Quality Assurance
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Stochos Quality Management Database
• Terminals at each process - input and monitoring.
• Hourly Operators perform checks, input data and monitor product using the system.
• Provides excellent traceability.
• Strong “Quality Action Report” (Q.A.R.) process.
• Global 8D is Deployed to Address Systemic Issues
• Control charts-real time.
Malnove Quality Assurance
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Standard Operating Procedures
• Built on ISO 9000 standards.
• Operations are controlled using SOP’s.
• SOP’s in place and kept current.
• SOP’s are at each Machine.
• Employees have SOP’s as part of job training.
• Clearfield ISO Certified in 2005
• ISO Certification Scheduled in Jacksonville in 2006
• ISO Certification Scheduled in Omaha in 2007
Malnove Quality Assurance
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Two year quality plan / schedule for continuous improvement:
• Customer Focus
• Training - continuous
• Color control & X-Rite
• SPC-Process Capability
• Quality measures / improvement
• Waste reporting and reduction
• PPM Defect Level Track and Trace
Malnove Quality Assurance
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The goal of our corporation is to consistently exceed our Customer’s expectations. To attain our goal we strive to make every Customer, Vendor and Malnove Associate a partner in our business. From receipt of raw materials and throughout each conversion process, every detail of our business is scrutinized to be continually improved in order to delight our Customers with our product. Malnove remains a quality leader through continuous improvement techniques. We strive to continually improve our quality while reducing our costs. This is done by focusing on the process, not by focusing on results alone.
Our people are Malnove Incorporated’s most valued asset and accept the challenge daily:
To consistently exceed our Customer’s expectations.
Paul Malnove, ChairmanBruce Marro, Corporate Quality Manager
Malnove Corporate Quality Policy
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• American Institute of Baking (AIB)Jacksonville Overall rating in February 2006--SUPERIOR 965 RATING
Omaha Overall rating in March 2005--SUPERIOR 905 RATINGSalt Lake City Overall rating in May 2005--SUPIRIOR 925 RATING
• Supplier to Medical Devices industry/food industryGMP / QS capable
• Customer Specific Requirements:Certificate of Analysis
FG evaluation-AQL’s, MIL-STD 105-E
• Excellent traceability and line clearance.Stochos-electronic data-maintained 7 yrs.
• Preplanning-contract review / order reviewAll pertinent disciplines involved
Malnove Quality Assurance
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Develop initial concept, modify existing structure to improve converting processeffectiveness, reengineer existing structure to improve “effect-in-use”.
State of the art CAD CAM hardware and software.
Continuous electronic process from design to production.
Produce a “Prototype” of proposed carton.
Malnove Structural Design Capabilities
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• Carton performance is, in part, determined by machinability.
• Applying knowledge of Malnove of product, carton and machine application,Malnove integrates new or existing equipment to improve productivity.
• Our associates create effective packaging solutions.
Packaging Systems Engineering Support
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• Select, customize and install new or used equipment.
• Application consulting
• Educational training
• Project Management
• On-going service support
• Emergency field service 24/7
• Carton / Machine audits
Packaging Systems Engineering Support
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• $ Savings
• Fast track product introduction
• After warranty field service
• Field technicians are recognized as best in industry
• Reduced lead time to receive machinery
• Investigate used equipment
• Reduced start-up time means faster cash flow
• Efficiency audits
Malnove Packaging Systems Offers Quantitative Benefits
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Malnove PackagePerformance Testing
Malnove’s alliance with companies such as International Paper; The Institute of Paper Science and Aspen Research Labs provides progressive research and development resources and activities. We also sponsor package development and testing through a grant process at The Packaging School at the University of Florida.
State-of-the-art analytical services help solve packaging problems, refine processes, and explore new packaging opportunities for our customers while eliminating risks.
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• Fingerprint, identify and quantify unknowns using enhanced detection capabilities.
• Provide problem-solving expertise at Malnove operations.
• Pre-manufacturing evaluation of new materials and processes.
• Evaluate, screen and benchmark ink/paperboard coating performance.
• We use test procedures such as head space analysis, for food packaging applications to detect and measure volatiles.
• Provide MVTR barrier information and simulated aging test.
Malnove Package Performance Testing
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Malnove Printing Capabilities
Printing Processes
Sheet-Fed Offset Lithography Nine( 9) presses
Web-Fed Flexography Two (2) presses
Rotogravure One (1) press
Printing Process Features
50”, 55” widthsSemi-automated make-ready capabilityPattern in-line coatingPerfectingOffset printing up to 7 colors
Environmentally friendly water-based inks and coatings (up to 6 colors)Back side grease barrier coatingsConsistent in-line cutting attributesMultiple site process capabilitiesOn-press collating
8-color capability2-color perfecting Print metallic, fluorescent, pearlescent inksGrease barrier coatingsMold resistant coatings
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Malnove Cutting Capabilities
Platen Cutting Processes / Benefits
• In-House laser die manufactureLow cost entry to marketplace is immediate, enhancing speed to market.
• Steel dies and counter platesGreater productivity, longer die life, consistent scoring attributes.
• Embossing / DebossingEnhances graphics and impact of “facing” at P.O.P.
Increase Package MVTR (i.e.; “Sift-Proof” Applications).
• Blanking capabilitiesIncreases throughput and decreases lead-time.
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Malnove Finishing Capabilities
Finishing
• Straight-Line Gluing
• Right-Angle Gluing
• Leary Glue Detection Systems; Vision Systems
• Bar Code scanning
• Auto Case Pack
• Electronic Case Scanning
• Standard Windowing
• Specialty Windowing (Single Lane; 2-Sided; Registered Printed Film)
• Collating
• Critical Attribute Certificates of Analysis
• Label/Coupon Attach
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Thank you for your fine efforts on behalf of Malnove Packaging and Packaging Solutions.
Our goal is to continually add long-term and compounding economic value to our business through our “Total Packaging Solution” business strategy.
The key competencies Malnove will deploy will be our commitment to delivering innovation through intelligent and sustainable package design and development, our focused approach to true process / product improvement and meeting our customer’s “speed-to-market” needs.