Adapting to succeed

Catty Corp. transformed a used paperboard press into a foil laminator and printer. But it wasn't easy.

By Senior Editor Laura Butalla -- Converting Magazine, 6/1/2003

Catty Corporation, Huntley, IL, has met many obstacles within the past few years, but it hasn't stopped them from meeting their goals in the long run—producing a quality product. Back in 2000, this flexible-packaging manufacturer for the food, confectionery, and pharmaceutical markets was being pressured by one of its customers to purchase a newer press. Because Catty's existing presses were built in the 1950s and couldn't run 6- or 8-color jobs, they were falling behind. The lead times for purchasing a new press were far too long, so president and owner Bruce Scott went in search of a used press through a local press broker.

Within no time, the broker found a used Bobst Champlain paperboard press. However, it would need to be transformed into a foil laminating and printing press. "They probably thought we were nuts, buying a board press and using it for foil," says Scott. "We like a little extra challenge."

Scott sent out his maintenance manager, Richard Bell, and head of production, Russ Inks, to look at the press. "Richard looked at it from a mechanical standpoint and Russ looked at it from a printing standpoint," Scott says.

Good retrofit gone bad

Before the final decision to buy a newer press came about, there was the thought of where to put it. The press wouldn't fit in the 36,000-sq-ft Huntley facility, so a new location was needed. The new equipment would have to be stored until a facility became available.

The 150-ft-long used Bobst Champlain press was purchased in 2000 and stored in Chemung, IL, until it could be assembled in a new facility. The company that moved the equipment for Catty was also contracted to retrofit the press.

The place in which the Champlain press was being stored turned out to be its new home. A section of an old 120,000-sq-ft grain facility was turned into four separate 30,000-sq-ft sites for rent. Catty took over the north-end space for its second plant.

Once the Chemung plant was environmentally-controlled with an HVAC system, the retrofitting of the press could take place. That's when the project started to go wrong in a hurry. The retrofit turned out to be a disaster, says Scott. "The retrofit-company's employees were way over their heads, and they couldn't finish the job."

Ron Klint was hired in February as Catty's general manager and had to jump into the project as things were getting ugly with the retrofit contractor, Scott comments. The contractor didn't align the press properly, and it couldn't run faster than 50 fpm before the web would snap.

It wasn't long after that the contractor was pulled off the job, and Bobst was thankfully brought in. "We had several different companies that were involved in helping put the press together. I think Bobst was probably the biggest helper," states Ken Zentner, Catty Corp. facilities manager. "They were the ones that finally helped us get the press aligned so we could get a good web path through it."

When Bobst came in, they took one look at the press and realized it wasn't aligned properly. "That was one of the earlier confirmations of Kenny's and Richard's suspicions of 'this wasn't done right'," says Scott.

Custom Controls was another small company that helped make the press what it is today. Custom Controls' Dave Stuber helped in understanding the drive controls and getting the tensions correct, states Zentner.

Despite these setbacks, the press was operational by August 2001. It began running at 900 fpm that month, and continues to run at that speed today. Although it was a long struggle with the Champlain press, Scott says he thinks the press is running pretty well now.

What's on the press?

The only original part of the Champlain is the 8-oven press, states Scott. A paper unwind was added and the nip is standard.

A Fife Corp. web inspection system was added to help reduce wasted time and materials and achieve higher quality output. A MAGPOWR Digitrac2 tension controller manages web tension throughout the press.

There were two embossers added to the press. One is a used Memco embosser with new Northern Engraving rolls, and the other is a new Northern Engraving embosser with the company's rolls as well.

A custom wax coater was created for Catty and installed on the press, which gives the ability to laminate wax or water-based glues. The finished-product rewinder is a used Black Clawson unit.

Reprogrammed registration

The registration system is a Bobst 2002 used to operate and control the machine throughout the printing process. When Bobst came in to help Catty out, they also reprogrammed the registration system.

The PLC placed on the Champlain was an Allen-Bradley Slick 500. The drives found throughout the press, which range from 7½ through 30 hp, are all Indramat. "When the contractor left us high and dry, Indramat stepped in and was very, very helpful in piecing some of the puzzles together," says Scott.

A Novaflow system was installed to customize Catty's inks, which are supplied by INX International. Zentner claims INX International recommended Catty purchase the Novaflow system for consistent match quality on their inks. "They [INX International] helped with getting the Novaflow system up and running," says Zentner. "They had their specialist come out and train us."

Offline and away from the Champlain press, Catty added another Deacro Model 653D slitter that was also purchased in 2000 and sat in storage until the Chemung plant was complete. Catty had purchased the same model back in 1998, which is now running at the Huntley plant. The only difference between the two is that the newer slitter is equipped with separate rolls with quick cam locks, more even tension controls, and it's capable of handling heavier parent rolls.

Huntley, the future and more

In the Huntley plant, there are several presses originally built in the 1950s. One particular press was custom-built to run paper, foil-wax lamination jobs. It's the first press to be built with AC-vector drives from Baldor, says Scott. A Kidder flexo press is among the old presses still running as well as a Hudson-Sharp, which was one of the first presses to print on unsupported foil.

Why keep such old presses? Catty uses these presses to laminate and print foil and they've been doing it for 50 years. "They're good for one-, two- and three-color jobs," says Scott.

According to Scott, all the presses at Huntley have been retrofit at some point with new dryers, drives, control systems, motors and such, so they've worked well. "Next time it would be nice to get something more modern," states Scott.

And as for the Catty staff, who helped with the entire installation of the press, it was a major accomplishment to finally see the project come to an end. But one member of the team will not be able to see the future growth of the company. Catty Corp.'s maintenance manager, Richard Bell, was killed in a car crash several months ago while driving from one plant to the other. Scott states, "We not only lost an employee, but a good friend."

All in all, Catty Corp. has exceeded its growth in equipment, employees and sales since Bruce Scott bought the company from his father, Ray, in 1996. "Catty's goal is the customer's needs," says Scott.

The customers are always put before production. "We've built up a good reputation and good quality, which enables us to grow," he says.

More information from:

Bobst Group, Inc., 888/226-8800, fax: 973/226-8625, www.bobstgroup.com

Fife Corp., 800/639-3433, fax: 405/755-8425, www.fife.com

Magnetic Power Systems, Inc. (MAGPOWR), 800/624-7697, fax:636/326-0608, www.magpowr.com

Northern Engraving & Machine, 920/437-0848, fax: 920/437-3201, www.northernengraving.com

Black Clawson Converting Machinery Inc., 800/338-3660, fax: 315/593-0396, www.blkclawson.com

Allen-Bradley, 414/382-2000, fax: 414/382-4444, www.ab.com

Indramat Div., Mannesmann Rexroth Corp., 847/645-3600, fax: 847/645-6201, www.indramat.com

Novaflow Systems, Inc., 613/925-5926, fax: 613/925-5928, www.novaflow.com

INX International Ink Co., 877/209-4383, fax: 414/438-4390, www.inxink.com

Deacro Industries, Ltd., 905/564-6566, fax: 905/564-6533, www.deacro.com

Baldor Electric Co., 800/828-4920, fax: 479/648-5792, www.baldor.com

Hudson-Sharp Machine Co., 920/494-4571, fax: 920/496-1322, www.hudsonsharp.com

Company history leaves interesting trail

Catty Corporation was founded in 1907 by Hugh D. Catty, an Englishman, as a cellophane converter. Back in those days, cellophane was the popular upstart of the packaging industry. In the late 1920s, the company started experimenting with foil by bringing in Ted Lawther, retired vp/gm of H.D. Catty Corporation from Alcoa.

During his tenure, Ted had overseen responsibilities for what at one time were seven plants and sales offices located in the U.S. In the 1930s and 40s, the number of plants would decline to two, but its cellophane focus would now mostly be foil, the new wonder product of packaging—supported, unsupported and laminated.

In 1921, Catty opened a sales office, which sold gold leaf, cellophane and aluminum foil imported from Europe. The Huntley, IL, plant was opened in 1946 when an old creamery was purchased from Fencil Co. The original portion of the building was built in 1905 for Hezel's Milk Factory. Rumor has it that gangster Al Capone took over the factory at one time to produce his illegal alcohol. Whether the rumors are true is yet to be determined.

The Huntley plant became the Flexible Packaging Division with the capabilities to laminate, lacquer, overcoat, print, emboss, die-cut, sheet, slit, and cut sheets. The Norwalk, CT, location was the Gift Wrap Division.

After the death of Hugh D. Catty in the late 1950s, his family sold the business to Geo W. Krug & Associates in 1964, which then consolidated all Catty business into the Huntley location. Krug sold Catty in 1985 to Rostra, a holding company, which sold the Gift Wrap Division to Shamrock and the Flexible Packaging Division to Ray Scott, who made significant investments in upgrading production equipment.

In 1996, Bruce Scott purchased the business from his father and continued the upgrading of equipment, as well as adding new computer technologies, and doubling sales of the business.