2009 Converting Innovator: Sustainability—Next Generation Films

Wind-powered recycling, net zero-waste production, nanotechnology and a new film line every year puts the Ohio company miles ahead in packaging sustainability.

By Contributing Editor Barb Axelson -- Converting Magazine, 11/1/2009 1:00:00 AM

From concept to manufacturing to end-use to recycling, Next Generation Films of Lexington, OH, is out to change the “anti-plastics” mindset of many environmentalists. For incorporating high-tech source reduction in its packaging-film structures, maintaining a net zero-waste operation and establishing a breakthrough, wind-powered recycling center, the company takes the 2009 Innovator Award for Sustainability.

Next Generation Films management and operators

Next Generation Films operators (back row, left to right) Brian Ellis, Dave Niss and Jason Frecka are joined by (front left) president Daniel Niss and founder/CEO David Frecka (front right) at one of the company's four W&H blown-film lines.

First off, Next Generation Films clearly wants to own its niche. “We're very lean; we're good at specialization; we don't have a commodity mindset,” says David Frecka, founder and CEO of the fast-growing, independently owned company.

Currently in the third year of a three-year business plan, things are going well. Along with Next Generation president Daniel Niss, described as an “eternal optimist,” Frecka anticipates doubling the company's revenues over the next five years. That may not be so hard to do because that's exactly what has happened in the last four years.

The equipment fulcrum

When revenues increase then to around $200 million, it will be due in part to the company's reliance on world-class equipment such as its four Windmoeller & Hoelscher (www.whcorp.com) blown-film extrusion lines (a fifth W&H system is to be installed shortly). The newest 3-layer W&H VAREX® co-extrusion line features an 87-in. width and a FILMATIC® T dual-turret winder.

In all, Next Generation runs 23 blown-film lines—none more than 12 years old. In recent years, it has purchased top-quality equipment on an average of every nine months. According to Frecka, most commodity plastic-film manufacturers operate with equipment 15 or more years old, which is incapable of adapting to compete in the specialty markets that Next Generation dominates. Some of its materials' end uses: Fresh-cut produce, lamination/sealants, flash-freeze products, dry goods, overwraps, adhesive bonds, mailers, masking, protective-packaging film and barrier structures. Most products are sold domestically, although 10 percent of the company's volume goes overseas.

Less is more and more

Through its patent-pending nanotechnology, Next Generation seeks to be on the leading edge of source reduction by developing nylon-barrier alternatives. Its proprietary structures are designed to reduce the raw materials needed and enable the production of more-easily recycled, 3-layer films that are stronger than 5- and 7-layer films.

Next Generation Films' new headquarters in Lexington, OH, is a centerpiece of the company's recent $5-million building boom.

“It depends on the application for exactly what we do,” Frecka explains. “A lot of [high-barrier film] is over-engineered; a lot of blending is involved. With our nanotechnology, we don't need a nylon layer with two tie layers. We can produce the same result with only three total layers.”

The company's engineering expertise and ability to create custom formulations that make it possible to solve many existing packaging problems. All its resins are FDA-compliant for direct and indirect food contact. Along with less raw material in the first place, Next Generation's gauge-control methods permit faster line speeds, reportedly saving customers about 5 percent on every film run.

Despite the positive industry buzz over polylactic-acid films, PLA doesn't work for all applications, the way petroleum-based plastics do, Frecka says. “Source reduction is the answer.”

Blowing in the wind

Another clear example of its environmental commitment: Next Generation focuses on alternative use of production scrap, so much so that it operates as a zero net-waste (closed-loop) manufacturer. Equipment-design changes, a repelletizing program to sell scrap and a method to reuse other recycled scrap-based resin within new products unite to provide the solution. Also along the way, film scrap from job changes is sent to the company's in-house bag division where it becomes a hidden middle layer in recycled-content film.

Artist's conception of the HPM America 150-kilowatt wind turbine that will provide power to Next Generation Films' new Recycling Center.

Adding to the roughly $5-million building boom at the company, which occupies more than 350,000 sq ft (the Custom Bag Div., the Engineered Films Div., the Distribution Center) are a new company headquarters, and, next spring, the highly anticipated 100,000-sq-ft Recycling Center. That site will then house the current repelletizing line, as well as a second line, now stored in a warehouse on the premises.

In what will be the most visible sign of Next Generation's sustainability approach, a 150-kilowatt wind turbine will rise above the new Recycling Center, generating power for its operation. Supplied by HPM America LLC (www.hpmwind.com) of nearby Mt. Gilead, OH, the mammoth machine boasts 80-ft blades and is expected to adorn the landscape early next year about the same time the Recycling Center will be dedicated.

“It's a renewable-energy source to lower our carbon footprint,” Frecka says. “We want to be a leader in our industry, so we devised the wind-turbine plan.”

Recipe for success

Next Generation has been successful for a number of reasons. Niss points to several: “We have a specialized product; we do not sell a 'me-too' product. We are big in re-engineering; we also have a long-time customer base. And we're on top of the technology.”

“We bring lower cost to our customers,” adds Frecka, and Niss observes, “Growth has been controlled; we make our own decisions.”

The two are available to customers 24/7, and both agree they are backed up by 150 other great people. That includes a full-time industrial engineer, working under the concept of quality management to maintain a well-trained and educated workforce.

The traditional vendors, in Frecka's opinion, don't possess the same kind of knowledge. “We're entrepreneurial plastics guys. This is our only career; we know this business inside and out.”

MORE INFO:
CONVERTER:
NEXT GENERATION FILMS, 800/884-8150, www.nextgenfilms.com

Talkback

We would love your feedback!

» MORE

Featured Company

Kodak

Kodak has manufacturing operations in North and South America, Europe, and Asia, and Kodak products are available in virtually every country across the globe... more