Sometimes, finding the best solution requires first identifying what isn’t the solution.
That was the case at Paper Systems in Des Moines. Paper Systems manufactures liquid bulk packaging— cleverly designed bags enclosed in recyclable, disposable cardboard boxes, making the transport of nonhazardous liquids more convenient and economical.
The company aimed to streamline the box-laminating process by bringing it in house and enhancing efficiency through automation.
Paper Systems collaborated with two different companies to create two separate machines. However, the process was still less efficient than expected. Five people were required to operate the machines, and two more employees had to flip the cardboard panels between them.
To reduce labor costs, Paper Systems wanted to automate the cardboard flipping process. They worked with CIRAS to identify project objectives, technology options, and risks to pinpoint companies that could bid on the project.
“CIRAS came out, analyzed the situation, and helped us talk through our ideas and what was needed,” said Melissa Mauro, vice president of Paper Systems. “The more we discussed potential designs with them, the more we realized we had the in-house resources to design and build the solution ourselves,” Mauro said.
“They helped us affirm that our designs were the best solution with today’s available technology,” Mauro said. “Ty Hill and his team quickly understood what we needed to achieve, which made it easier for us to determine whether the proposed solutions were viable. The support we received from CIRAS reassured us that we were making the right decision to invest more in automation.”
President and owner William Chase, who has designed many of the company’s other machines, created the design for the cardboard flipper. A Paper Systems staff engineer drew up the plans, and the company’s special projects maintenance person, along with the operations manager, built the flipper in the company shop. “It was truly a team effort,” Mauro said.
“Paper Systems was initially looking for a solution from an outside source,” said Ty Hill, a CIRAS project manager. “But they discovered they actually had the internal resources to accomplish their goal. CIRAS helped them realize that.”
For more information, contact Ty Hill at tyhill@iastate.edu or 515-357-4379.