Growing Pains for a Packaging Maker


Client: A national flexographic printer and converter recognized in the industry for a $20 Million plant upgrade to top-of-the-line equipment by Heliostar, Totani, Lusch, Fuller, Triumph, and Karville.

Problem: After delivery, the equipment stood under-used for more than 6 months. The operators were all 20-year veterans, but their experience and instincts, honed on obsolete machinery, did not serve them with after the upgrade. Raw materials were wasted, gears were stripped, and one operator was injured during what should have been a routine process.

Solution: Sunnyday’s experts understood that all the problems had a root cause: The manufacturer had trained the client on maintenance as part of the installation process, but not on its operation. Sunnyday took a two-fold approach to the solution:

  • First of all, they developed a new set of standard operating procedures. Comprehensive in scope, it ensured that key components of the machinery were inspected at the beginning of each shift, and that operators new how to adjust setting “on the fly” to meet changing printing conditions. On a plant-wide scale, the new SOP ensured that regular/repeat orders had everything needed to complete the job on hand prior to starting the run, so that the most common types of production could be turned around quickly and without interruptions.
  • Secondly, they implemented a program of pre-emptive maintenance to ensure that “downtime” did not coincide with “busy season”, allowing salespeople to guarantee delivery dates with confidence.

For information about Flexible Packaging, Call Sunnyday at 204.783.0912 or Toll Free at 1.855.778.5271 or visit our “Contact Us” page.

About Sunnyday Environmental Inc.

Our company founder, FELIX PAO, has over 45 years experience in solving complex problems regarding process design, equipment design, and consulting, to make your company more efficient and profitable.

Our team includes many highly qualified and experienced personnel who have the ability to complete your project in a prompt and efficient manner.

Contact Info:

1101 Pacific Ave, Winnipeg, MB, Canada, R3E 1G7
Phone: 204-775-8571
Toll Free: 1-855-778-5271

Eastern Canada Office
8-3511 York St. Toronto, Ontario, M5J2Y2
Toll Free: 1-855-778-5271