In the fast-moving environment of corrugated converting, creating a seamless interaction between various departments—from the machine floor to internal strategic hubs—is not just beneficial; it’s a necessity. The integration of digital collaboration solutions like A.G. Stacker’s GO AG™ application is revolutionizing how these interactions occur, fostering enhanced connectivity and communication that drive operational efficiency and productivity. Let’s take a look…
Breaking Down Silos with Technology
Historically, corrugated box production processes have been compartmentalized. The physical and informational disconnect between departments such as production, maintenance, accounting, shipping, and scheduling could be the source of various company inefficiencies and delays. When departments don’t have effective collaboration tools, employees can fail to empathize with the realities of their colleagues. Giving the right players visibility across company silos creates informed synergies that can lead to incredibly profitable operations.
Not only the sharing of knowledge, but the storage and retention of knowledge within your company is your data gold mine. As digital technology and manufacturing continue to collide, the quality and organization of your data will make all the difference. Add to this, the influx of top employees retiring, it’s important to capture the valuable knowledge from your veteran employees to build a solid training program for future ones.
New collaborative technologies like GO AG™ address these challenges head-on. By digitizing your communication flow and knowledge storage abilities, GO AG™ ensures that all departments can work together, where necessary to create a seamless business operation.
Enhancing Inter-Department Collaboration
The GO AG™ application facilitates collaborative communication across all departments. You can customize it for your specific processes and roles. It’s your tech – your way.
Here’s what that may look like:
First shift operators receive machine communication (KPIs, faults, etc) directly to GO AG, even if the event occurred on 2nd or 3rd shift.
Live and controlled revisions of manuals and processes to ensure operations is efficient, effective, and timely.
Project schedulers can check maintenance logs and recent machine feedback to better plan job orders and avoid down time.
With access and visibility to other departments, employees are empowered to do their jobs more efficiently and effectively. From machine availability to employee allocation, purchasing to scheduling, you can find many synergies between departments and optimize them with the GO AG Digital Collaboration Application.
Fostering Continuous Improvement
Beyond the operational benefits, the connectivity fostered by GO AG™ aids in building a culture of continuous improvement. The ability to incorporate maintenance and training processes, that include photos, videos and screenshots, can speed up machine troubleshooting and operator onboarding for maximum operational efficiency. Staff can continually focus on improving operations, adding to their knowledge base and building their team’s independence with every upload. With easier access to data, employees from other departments can also contribute to problem-solving and process optimization. This collaborative approach not only enhances employee engagement but also leads to innovations that might not emerge in a more siloed setting.
The data collected through GO AG™ also supports a deeper analysis of production trends, machine performance, and workflow efficiency. This intelligence can be leveraged to further refine processes, reduce waste, increase performance, and enhance product quality.
The GO AG™ Application That Does It All!
The A.G. Stacker’s GO AG™ application is the digital tool for corrugated converters to create a transformative impact in their processes, teamwork, and operations. By enhancing connectivity and facilitating inter-department communication and synergy, technologies like GO AG™ not only streamline production processes but also empower employees to perform at their best.
For boxmakers coordinating diverse roles, the ability to communicate effectively and share key information across departments is not merely an operational advantage; it is a strategic investment that requires technology. Discover the advantages of collaborative operations and stored tribal knowledge with GO AG™ Digital Productivity Application.
GO AG™ is designed to be customized to your unique processes, production mix and operations. With the GO AG app, boxmakers can take advantage of the following:
Customization – Create, save & upload custom information, not only for your A.G. equipment, but for all assets & departments!
Standardization – Retain, standardize and distribute key knowledge across multiple equipment lines & departments for streamlined operations.
Security – Using user permissions, Wifi IP list, data encryption and more, GO AG safeguards your data and restricts access to ensure the integrity of your most valuable files and procedures.
Digitization – Complete a full digital transformation with safe and secure access and distribution on any digitally connected device. iOS, Androis and Web enabled.
Are you ready to break down the silos and foster collaboration and innovation in your box plant? Talk to your A.G. sales representative about the GO AG Digital Application and to request a live software demonstration, visit www.agstacker.com/GO-AG.
In the fast-paced world of corrugated production, efficiency and speed are paramount for maintaining a profitable operation. To increase production, some converters have invested in a high performance rotary die cutter only to find they are still not reaching the rated speeds offered by these OEM’s. Often, the delivery end equipment simply can’t keep up with the new system or is restrictive with regards to finished product mix flexibility. Though your new RDC can run faster, it is limited by the back end and you may have to settle for reduced speeds of your star asset to ensure that finished goods make it to the end of the line and out the door with quality maintained.
A.G. is proud to manufacture cutting-edge material handling solutions designed to meet and exceed the speeds of today and in the future. Capable of running up to 13,500 kph+, our G3 RDC Stacker is equipped with multiple patented and patent pending systems designed to increase production efficiency. Optimized for stacks or bundles, in a single machine, A.G. has engineered a modular full line system, including the eBreak Bundle Breaker, eZF Load Former, Bundle Conveyor System and more – fully integrated for maximum thoughput.
In this blog, we’ll explore how you can increase rotary die cutter speeds through investments in post-RDC machinery and innovation upgrades with A.G.
High-Performance Layboy Section (HPLX): Elevating Die Cutter Speeds
The layboy is the first touchpoint with the stacker as it catches and controls the board as it comes out of the rotary die cutting nip. To reach top speeds, your layboy must quickly and precisely catch the board and remove scrap before it moves on to be stacked in full piles or bundled. Capable of running at speeds exceeding 13,500 KPH, the High-Performance Layboy Section (HPLX) is a powerhouse in die cutter speed optimization. Offering three nip points and a second air knife at the exit of the layboy, the HPLX enhances the quality of finished goods by effectively catching the board and removing scrap at top production speeds.
SRX Scrap Release Layboy: Precision Scrap Removal
To take it up a level, A.G. has engineered a patented scrap release layboy with high-velocity blowers, a new engineered air knife and variable speed control. Working in tandem with the HPLX, the SRX has a patent-pending gap built into the belt pulleys allowing scrap trapped under the belt, a relief area to fall. Assisted with a blast of air from the new air knife design, the belt pulley gaps are offset to maintain control of the sheet while allowing the most scrap to fall through.
Divert & Separate System (DSS): Streamlining Corrugated Sheet Handling
The Divert & Separate System (DSS) is a game-changer in corrugated sheet handling optimization. Positioned behind the layboy, this patented transfer deck is perfect for the plant that runs numerous jobs that are 2-4 outs with a high repeat rate. Equipped with eight arms, The DSS automatically diverts, separates, and neatly streams corrugated sheets coming off the stacker. Adjustments can be made with a simple swipe on the HMI, enabling automatic diversion and separation at full production speeds. The DSS also facilitates order recipe recall, completing the flexibility with your production process.
eTAMP™ Servo-Driven Tampers: Automation for Efficient Stacking
The perfect complement to the DSS is the auto hopper set-up offered by the AG eTAmp. The only solution for converters running multiple outs without a bundle breaker, and for handling automated set-ups when confronted with a high percentage of 2, 3, or 4-out unnicked die cut orders. The eTAMP™ Servo-Driven Tampers can automate the setup of the entire hopper section, dividers, side tampers, backstop, and rear tamping.
Dynamic Bundle Breaking Mode with no Feed Interruptions
For boxmakers running orders with nicked together sheets, the eBreak bundle breaker and HSHE can quickly and easily collate and break bundles of all configurations, without any feed interruption on the RDC. Here’s how:
High Speed Hopper Ejector (HSHE): Uninterrupted Operation at High Speeds
Eliminate feed interrupts with the high speed hopper ejector (HSHE)upgrade on the G3 stacker. A patented system designed for speeds of up to 12,000 kph, the system utilized a backstop with a second set of “fingers” allowing the board to continue stacking while the X12™ Lift Table cycles down and back, creating room for the new bundle. The result is uninterrupted operation, contributing significantly to the overall efficiency of the production line. Paired with the bundle conveying system, it ensures the fastest cycle time during the discharge or movement of bundles.
eBreak Bundle Breaker: Dynamic Breaking in a Single Log
The eBreak™ Bundle Breaker is engineered to break bundles of various configurations and heights, quickly and easily. Using its patent-pending movable platens, the eBreak™ system allows for a fully dynamic and customizable positioning of the entry and exit platens. These components can be set up to move independent of each other or synchronized together to provide a clean break for a variety of nicked bundle configurations. Variable, straight, nested, offset configuration etc. – the eBreak can break it all in a single log.
X12 Pitless Lift Conveyor Table: Continuous Operations with Safety Benefits
The X12™ Pitless Lift Conveyor Table eliminates the need to wait for discharge and stacker reset, enabling continuous stacking and feeding operations. Beyond its operational advantages, the X12™ Lift Conveyor comes with safety and financial benefits, as it requires no pits. This proven solution streamlines the infeed and outfeed process, contributing to both efficiency and worker safety.
A Full Line of Rotary Die Cutter Productivity with A.G.
A.G. has been committed to stacker innovation since 1996. With multiple patented and patented pending systems, we understand the impact your end-of-line machinery can make on overall performance and throughput. Not only the stacker, but the remaining systems such as bundle breakers, load formers, bundle conveying systems etc. can become a chokepoint in your production. In production since 2021, A.G. has released our fully electric, fully integrated new eBreak Bundle Breaker and eZF no-pit load former to offer a full line of innovation and speed.
By investing in equipment upgrades, retrofits or a full line system designed to optimize your production mix, you can elevate the speed, quality and overall performance of your existing rotary die cutter operations. Contact the A.G. team to learn more about our innovative, modular systems, upgrades and retrofits and start reaching top speeds with your RDC workhorse in no time!
True profitability requires a streamlined approach to corrugated converting, from infeed to outfeed and every machine in between. If you’re considering a new high speed rotary die cutter or flexo folder gluer, you may want to re-evaluate the surrounding machinery, such as stackers, bundle breakers, conveyor systems, load formers etc. Or maybe you’ve already purchased a new workhorse but haven’t achieved the speeds and performance expected. It could be your infeed and outfeed machines that are impacting your new machine’s productivity. Afterall, you’re only as strong as your weakest link.
Corrugated productivity is not siloed to one machine. All your machines must be capable of achieving the same speeds, performance, and throughput as the other, to achieve maximum profitability. Even more, your production team must be equipped with the knowledge and support to keep all components running in harmony. Don’t waste the potential of your greatest assets. It’s time to reimagine what productivity in your full line can truly be, with innovative material handling systems and technology from A.G. Stacker Inc.
Reimagine Production Speed
G3 stacker main deck
What good is a rotary die cutter capable of running 12,000 sheets per hour if the stacker can only catch 9,000? Why upgrade to a high-speed bundling system if production is limited by bundle breaking? If you want true productivity in your line, you should invest in innovative equipment all the way through.
A.G. manufactures innovative outfeed solutions engineered for the speeds of today, AND is prepared for the speed demands in the future. Our outfeed lines include the G3™ Stacker, the fully electric eBREAK™ Bundle Breaker and eZF™ Load Former, as well as the patented X12™ pitless lift conveyor and bundle line conveying system. With an A.G. Stacker capable of 13,500+ kph, an automatic, servo controlled bundle breaker and a no-pit load former with fast cycle and set up times, you can reimagine productivity through your full line and take full advantage of your high speed converting equipment.
Reimagine Human & Machine Connectivity
A.G. Operator Control Station
For ultimate productivity, your machines must speak the same language. Having a fully integrated system will ensure all machines are running at the same speeds, with the same production plans, achieving the same goals. A machine that is not fully integrated is more vulnerable to jams, unplanned downtime, and operator error. All A.G. systems are fully integrated, utilizing the same, familiar user interface and simplified controls for standardization, efficiency, training, and ease of use.
In this digital age of information, accurate tribal knowledge is also a major factor in production throughput. By putting maintenance, parts, tutorials, and troubleshooting information in a digital application, your staff can quickly predict, plan, and prepare to keep unplanned downtime to a minimum. The GO AG™ digital application is the perfect solution to capture and distribute key production information to your production and maintenance staff. With GO AG™, operators and managers have access to custom and standard manuals, equipment models, training videos, troubleshooting guides, work instructions and more. Don’t let legacy knowledge retire with your employees! Knowledge is uptime and uptime is money. Utilize a customizable, digital application, like GO AG™, to capture the important information that keeps your full line running profitably.
Reimagine the Future of Corrugated
The future of corrugated printing will focus on creating lean, sustainable production. Machinery will be engineered for productivity like always, however they will achieve even greater results through more energy-efficient, eco-conscious and occasionally, patent-protected technologies. Trends dictating the future of our industry include: staffing shortages, supply chain volatility, automation, competing processes and more.
To take advantage of full line productivity, both now and in the future, you must reimagine your facility with machine assets that are incredibly fast, fully integrated, digitally enabled, and eco-conscious. A.G. Stacker is committed to innovation and manufacturing all equipment and parts in the USA. With various retrofit and modular systems, we encourage you to reimagine your full line equipment to discover the true source of what’s holding you back from ultimate productivity.
With over 25 patents and counting, A.G. has innovated a full line of solutions that increase throughput, improve quality and safety, and streamline the outfeed of RDC’s, both bundles and stacks. A.G. is more than stackers – Reimagine A.G. as your full line solutions partner for ultimate productivity and innovation. To learn about our full catalog of stackers, bundle breakers, load formers, conveyor systems and digital technology solutions, contact our team at (540) 234-6012 or schedule a consultation online at: www.agstacker.com/sales-quote.
At A.G., converters have several machinery options when it comes to material handling equipment for post-RDC finishing. From the innovative eBreak™ Bundle Breaker to the patented Divert & Separate system, A.G. offers multiple equipment solutions engineered for sheet stacking, bundle batching, bundle breaking, load forming and more. It’s important to understand which machine(s) fit your product mix to ensure that productivity is increased and the process is streamlined, all while improving quality and safety.
Is your production mix primarily single or multi-out stacks? Is it multi-out designs collated into nicked together bundles? Or both? Often, the primary finishing functions are built into the machine as a stacking or bundle-making system. Depending on if you produce more premium stacks vs large bundles will determine the best A.G. solution to achieve the requirements of these packaging markets. Choosing the right A.G. material handling machinery will not only depend on your expected job order mix, but also floor space, speed requirements and other factors we’ll discuss in this blog.
To Break or Not To Break
To break or not to break, that is the question. A.G. Stacker has innovated two system combinations to suit your preference for separating stacks or breaking bundles: the eBREAK™ Bundle Breaker and High Speed Hopper Ejector (HSHE) system combination or the Divert and Separate System (DSS) and eTamp™ Servo-Driven Tampers systems. The eBreak and HSHE are ideal for breaking nicked-together bundles, small or large, without any feed interruption on the RDC. While the DSS and eTamp are engineered for separating a stream of sheets into full stacks with auto set-up for diverting, dividing and tamping. Both systems can be combined into a single machine capable of achieving world class production with full stacks or bundles. Let’s take a closer look.
eTamp™ Servo-Driven Tampers
Divert and Separate System and eTAMP™ Servo-Driven Tampers. For converters operating predominantly in the eCommerce and premium packaging space, quality is top of mind. Boxmakers in this market are often challenged to produce nick-free boards, clean cuts and ultimate board control/scrap removal in order to achieve the quality found in this premium packaging space. The DSS and eTamp™ system combination was engineered for this specific task.
Coming off the rotary die cutter, the high performance layboy will catch the sheet and drop the scrap at record speeds. The patented DSS system then uses its 8 arms to automatically divert and separate sheets, up to 4-out, with the simple swipe of a finger on the HMI. With the sheets shingled orderly onto the main deck, the eTAMP™ automatically sets the entire hopper section, dividers, side tampers, backstop and rear tamping using fully electric, servo-driven technology. These innovative machine components carefully stack the sheets, up to 4 out, as they come off the main deck at full speed. The eTAMP™ system is capable of running up to 4 outs, without the need for a bundle breaker, and is ideal for automating set-ups with a product mix that has a high percentage of 2-, 3-, or 4-out unnicked die cut sheets, that regularly repeat.
With auto recipe recall and adjustments at full speed, these two patented technologies are engineered specifically for maximizing performance for fast set-up, high speed stacking operations.
eBreak™ Bundle Breaker
eBreak™ Bundle Breaker and High Speed Hopper Ejector. For boxmakers running orders with sheets nicked together, speed and quality are the name of the game. Often, standard RSC, HSC, and FOL box customers tend to be indifferent to whether their box has visible nick points. This allows a converter to run multiple across, utilizing agile die cut designs and variable bundle shapes, to move sheets through the machine faster, with higher throughput. As your bundle percentage gets higher, we recommend investing in the eBreak™ Bundle Breaker and High Speed Hopper Ejector combination to quickly and easily collate and break bundles of all configurations.
As the sheets are collated in the hopper, the patented high speed hopper ejector utilizes a backstop with a second set of “fingers” that catch the next bundle as the first moves down the line. With no feed interrupts at speeds of up to 14,000 sheets per hour, the HSHE can produce a new log every 8 seconds and is fully integrated with the X12™ lift table and bundle conveyor system. Next up, the eBreak™ Bundle Breaker steps in to break bundles of various configurations and heights, quickly and easily. Using its patent-pending movable platens, the eBreak™ system allows for a fully dynamic and customizable positioning of the entry and exit platens. These components can be set up to move independent of each other or synchronized together to provide a clean break for a variety of nicked bundle configurations. Variable, straight, nested, offset configuration etc. – the eBreak can break it all in a single bundle log.
With integrated safety features, order recipe recall, no feed interrupt and fast set up, these two patented and patent-pending technologies were engineered to exceed world class speeds with bundle production.
Important Considerations
At this point, you most likely have a good idea of which system would be in favor of your production mix. But will it work for your facility and processes? Here’s a few things to consider with each system.
Divert and Separate System and eTAMP™ Servo-Driven Tampers.
The DSS/eTamp™ combination requires space – not in width, but in length of your running direction. These systems will make your line longer and it’s important you consider the real estate needed for them.
Regardless of whether you’re running bundles or stacks, with the eTamp™/DSS you will need to interrupt the feed to cycle your stack through the line.
The combination of both systems is an incredibly versatile option for converters with a diversified production mix and a focus on reducing assets.
eBreak™ Bundle Breaker and High Speed Hopper Ejector.
Multi-Directional Bundle Conveying System (BCS)
The eBreak™ is extremely modular and can be installed straight with the line or veer off to the left or the right (or both if you’re running multiple bundle lines). Using the bundle conveyor system with patented ball belt technology, you can discharge your bundles in any direction.
The HSHE is engineered with two sets of “fingers” to catch nicked sheets. The HSHE combination is for bundle lines only and will not accommodate multi-out stacks or bundles.
Choosing the Right A.G. Material Handling Equipment
All systems proudly #MadeInAmerica at A.G. in Weyers Cave, VA
For over 25 years, A.G. Stacker has been a leader and innovator in custom sheet material handling equipment. Our full line of solutions include stackers, bundle breakers, load formers, conveyor systems and integrated technologies. Now that you’ve reviewed the recommended equipment systems for bundle and/or stack production, it’s important to ask yourself the following questions: Do I have more stacking or bundling jobs? Do my customers care about nick points? Do I have the space for the equipment I think is best? What gaps do I have in my current production fleet?
All corrugated production environments are different. There is no one-size-fits-all line configuration. Our knowledgeable sales and service team can help you comb through the details to decide the best material handling equipment for your production mix, facility, goals and opportunities. Speak with our team today to learn more.
Since 1996, A.G. Stacker, Inc. has been committed to innovation. As a leader in the custom manufacturing industry, we are proud to have evolved into a multi-patent holding designer of full-line solutions and custom machinery for corrugated material stacking and handling operations.
The secret to our success, and many other businesses, is to have a culture of innovation that rings throughout the company. Culture is more than just state-of-the-art machinery and digital solutions. At A.G., there are three pillars that make up the foundation of our culture: People, Processes and Technology. Here’s how we’ve maintained the core value of innovation at A.G. for over 25 years.
People are the Key to Success
A.G. production staff collaborate in a clean, bright work environment
As a family-owned business, A.G. Stacker places an emphasis on trust, respect and having a good work-life balance. We take pride in treating all employees like family, listening to their needs, and equipping them with the innovative tools for growth. We offer 100% paid health, dental, disability and life insurance, 401(k) with company match, tuition assistance, continuing education opportunities, paid holidays, and time off, and stipends for tools and much more, often at no cost to the employee. A company that looks out for its employees will reap the benefits of staff loyalty and productivity all year long.
Safety is also a key component to creating a culture focused on people. If you don’t care about their safety, do you truly care at all? We think not. At A.G., we have invested in bright, clean production spaces, extensive onsite and digital twin training for new team members, separate workspaces for electrical safety and COBOT and CNC machines. Employees at A.G. know they can learn and develop new systems and technology in a clean, safe workspace, empowering them to test the limits of what’s possible. A.G. Stacker takes pride in their staff and recognizes their contribution to an innovative work culture.
Proven Processes and Key Areas of Focus
In 2017, A.G. Stacker shifted their focus internally, to further develop an innovative culture. This ultimately led to the full digital transformation that A.G. Stacker is now known for. The processes are synthesized down to four key areas of focus, essential to the company’s success.
Key Areas of Focus
We Build to Suit
Engineers at A.G. customize designs to the needs of our customers. Remaining open to new concepts or challenges is essential. We use our innovative DUO™ Digital Twin systems to collaborate with customers and custom engineer solutions built for their exact process goals.
We Build to Last
All A.G. systems are made from 100% quality steel
A.G. Stacker systems start with raw steel and are built in-house by an experienced team of builders. We’ve developed a national vendor network that keeps raw materials coming in and innovative solutions going out. All A.G. solutions are not only built to last the long haul, but also designed with features that will meet the speeds of future corrugated technology – up to 20,000 KPH!
We Stand Behind Our Systems
A.G. aims not only to deliver a best-in-class product, but also a level of service uncommon in the corrugated industry. Using CRM systems, our team has multiple service and support processes and technologies that empower our team to assist yours. The goal is to always be a trusted manufacturing partner, long after the asset is installed.
We Always Innovate
A.G. Received the 2022 SVTC Innovation Award for its DUO Digital Twin Technology
Holding over 25 patents, A.G. Stacker is proud to be incredibly innovative in our machine and technology offerings. We’ve empowered our team with both the processes and technology to achieve, but also the freedom to fail. To create anything innovative, you must give room for failure. At A.G. we use our digital twin assets to speed up the innovation process and reduce risk in the R&D stages of machine development. Using these proven technologies, we continue to innovate new full line solutions for the future of corrugated.
These four key areas of process then connect back to the people pillar. A.G. Stacker employees develop the processes that lead to successful results, thus creating the majority of the company’s recipe for a culture of innovation.
Leading Innovation Through Technology Solutions
A.G.’s Digital Innovations Lab provides a space for learning, innovation, user feedback and machine optimization.
Since 2017, A.G. Stacker has been working toward a full digital transformation of A.G. Systems. The goal of this transformation is anywhere, anytime connectivity for operations, engineering, service, and production. We’ve created new technology solutions that not only empower our customers, but also empower our team. From the DUO™ digital twins assisting with R&D and engineering to our GO AG™ mobile application improving remote service, A.G. has developed technology solutions that create a culture of innovation.
A.G. Production Staff train with the new COBOT welding system
As stated, A.G. has also invested in multiple COBOT technologies and CNC machines that work alongside A.G. production staff to assist with safety and productivity. Using these manufacturing technologies, A.G. employees can build systems faster, safer and better.
In conclusion, we’ve discovered the recipe to creating a culture of innovation is People, Processes and Technology. When you invest in the right people, establish the best internal processes, and equip them with productive technology, the result is a company capable of achieving ultimate innovation.
“If you want to achieve 26 years of consistent growth and innovation, it’s all about investing in your people and the technology that makes their job easier,” concludes Clarence Allen, Co-Founder of A.G.
JP Morgan Global Manufacturing 2022 PMI shows lowest reading since October 2020.
Delayed orders, rush delivery rates, increased downtime and operator shortages are just some of the symptoms US boxmakers are experiencing with the global supply chain crisis in 2022. According to the recent J.P.Morgan Global Manufacturing PMI™, “Supply chain delays remained substantial in January, as average vendor lead times lengthened for the thirtieth month running.” Key findings in the report show, as of January 2022, the Manufacturing PMI is at a 15-month low – the lowest reading since October 2020.
Now with rising tensions in Russia and the China shutdown due to growing COVID-19 cases, the global supply chain has become even more concerning.
With box manufacturers struggling to get their hands on new equipment, parts, consumables, and raw materials, American OEMs are finding innovative ways to combat this global issue. At A.G. Stacker, we believe choosing the right corrugated machinery partner is key to minimizing the effects of these shortages and remaining productive and profitable during these uncertain times. In this article, we discuss three ways the right OEM can help maximize your operations amid a volatile supply chain.
Prepare With Digital Twin Technology
When crisis calls, U.S. manufacturers have always answered with technology and innovation – this global supply chain issue calls for the same. One tool that is extremely useful is digital twin technology. Digital Twins take the exact blueprint of your machine and recreate it in a digital format. The system is developed with a complete replica of the specifications, component configurations, operator interface and more, unique to each machine. This allows your team to run a multitude of simulations that can assist with:
New digital twin systems in commission for the eBREAK Bundle Breaker, eTAMP and DSS.
Operator training before equipment arrival. Boxmakers can now train operators using the digital twin software, prior to equipment installation. Though OEM lead times may remain unsteady, operators can use the month(s) between purchase and installation to train. The faster your team is up to speed on the new equipment, the faster your operations can be more productive and profitable once the machine is in commission.
Reduce waste and downtime by testing job runs through simulations. In a time of raw material shortages, no sheet can go to waste. Managers can now utilize digital twin technology to run new jobs with variable sheet sizes and shapes through the machine digitally. The simulations can help visualize areas of waste and inefficiency and inspire the most productive job configurations.
Digital solutions available to boxmakers expand far beyond digital twin technology. Mobile applications, virtual factory environments, and equipment in augmented reality are just a few new technologies manufacturers are also using to better plan and prepare for the unpredictable future ahead.
A.G. Stacker is among the first to apply and effectively utilize digital twin technology on commissioned machines in the corrugated converting market. With 3 digital twin assets and counting, A.G. is preparing the way with expanded business solutions tailored to the future of the industry. Learn about A.G.’s digital twin technology and other digital solutions, incuding the AG+ mobile app and AR/VR solutions, HERE.
Adapt With Custom Machining Equipment
Does your OEM machine, weld and fabricate all equipment in house? Or do they assemble the machine from parts and components manufactured outside of their facility? During a global supply chain predicament, equipment manufacturers capable of machining in-house have the upper hand, and so do the boxmakers that work with them.
When lead times become longer and longer, assembly-only manufacturers have few options but to wait on the parts and components they need to build the equipment, causing lead times to become excessive for their customers.
A.G. welders train on the new COBOT welder system, installed Fall 2021.
OEMs that manufacture 100% in house, like A.G. Stacker, have multiple options during material shortages and can quickly adapt to the supply chain environment. Machining OEMs can source steel, aluminum, brass and other raw materials from a variety of suppliers, rather than having a small pool of companies capable of manufacturing their exact parts. In emergencies, they can utilize readily available materials and machine them as temporary solutions until the raw materials arrive. Furthermore, with in-house engineers, OEMs can engineer retrofits and upgrades to adapt to the new global supply chain and reduce the need for unavailable materials.
When parts and components are in short supply, OEMs with custom machining equipment can innovate their customers through the logistic nightmares haunting their purchasing team.
With a large fleet of machining equipment and an army of skilled operators, assemblers and engineers, A.G. Stacker has helped converter customers navigate the unsteady global supply chain of the 2020s, successfully. A.G. also recently installed a COBOT welder and HAAS CNC system for more efficient parts manufacturing, reducing lead times for the road ahead. See how our team fabricates material handling equipment in house in this Manufacturing Marvels TV segment featuring A.G. Stacker on Fox News.
Accelerate With American-Made Equipment
As stated in the AICC 2022 Economic Report, “Supply chain constraints, raw material shortages and the spread of the omicron variant slowed activity in markets around the world.” As the COVID pandemic still looms over humanity, global sourcing has become a logistics horror.
A.G. Production Floor
Getting equipment, parts and consumables from manufacturers overseas often comes with long lead times due to the distance, trade constraints and paperwork associated with imports – and that was before the pandemic. With the added materials shortages in the global supply chain, boxmakers can easily fall behind on production goals while they are waiting, waiting and waiting for their international shipments to arrive.
Many US boxmakers are turning to quality, domestic manufacturers for solutions that ease logistic constraints and accelerate lead times. With less procedural barriers, faster shipping times and local technicians on stand-by, partnering with a local OEM could save a ship load of time and money. American corrugated OEMs also understand the unique landscape of manufacturing in the USA and are better prepared to help you navigate the road ahead.
Founded by Clarence and Helen Allen in 1996, A.G. Stacker machines and assembles all equipment and parts in our production facility in Weyers Cave, VA. Additionally, A.G. chooses American suppliers and technology vendors to partner with for quality assurance, synergy and collaborative innovation.
Prepare, Adapt and Accelerate through the Global Supply Chain Crisis with A.G. Stacker
A.G. Technicians offer remote support after the first eBREAK Bundle Breaker installation.
As box manufactures forge through uncertain supply chains, A.G. Stacker is preparing the way with technology-focused solutions. From digital twin technology to digital service, A.G. has developed digital technology solutions that keep operations moving forward. With the creation of digital twin assets for the eBREAK Bundle Breaker, eTAMP servo-driven tampers and divert & separate system, A.G. customers can take advantage of the digital twin training simulations to prepare operators before equipment arrival and plan new jobs with efficiency.
A.G. will continue investing in more digital twin assets to optimize production planning and training for converters nationwide. Additionally, A.G. now offers expanded business solutions including VR, AR and a mobile application to empower converters with visual planning, training and collaboration tools.
A.G.’s longest tenured welder wears his American flag shirt with pride while fabricating steel stacker frames.
A.G. takes great pride in being a 100% American manufacturer. All equipment, components and parts are machined, welded, and assembled in our Weyers Cave, VA facility, since inception. For 25 years we have remained committed to innovation in material handling equipment for corrugated board and have partnered with a network of American suppliers to support our production.
With advanced digital technology, in-house machining capabilities, and a domestic location, A.G Stacker is ready to help you prepare, adapt and accelerate through the global supply chain crisis of our day and beyond. Contact our team today to discuss your unique logistic challenges and production goals and we’ll collaborate with your team to innovate the best solution for your operations.
Committed to Innovation. Committed to Service. Committed to You.
n departments such as production, maintenance, accounting, shipping, and scheduling could be the source of various company inefficiencies and delays. When departments don’t have effective collaboration tools, employees can fail to empathize with the realities of their colleagues. Giving the right players visibility across company silos creates informed synergies that can lead to incredibly profitable operations.
Here’s what that may look like:
Beyond the operational benefits, the connectivity fostered by GO AG™ aids in building a culture of continuous improvement. The ability to incorporate maintenance and training processes, that include photos, videos and screenshots, can speed up machine troubleshooting and operator onboarding for maximum operational efficiency. Staff can continually focus on improving operations, adding to their knowledge base and building their team’s independence with every upload. With easier access to data, employees from other departments can also contribute to problem-solving and process optimization. This collaborative approach not only enhances employee engagement but also leads to innovations that might not emerge in a more siloed setting.
For boxmakers coordinating diverse roles, the ability to communicate effectively and share key information across departments is not merely an operational advantage; it is a strategic investment that requires technology. Discover the advantages of collaborative operations and stored tribal knowledge with GO AG™ Digital Productivity Application.
The layboy is the first touchpoint with the stacker as it catches and controls the board as it comes out of the rotary die cutting nip. To reach top speeds, your layboy must quickly and precisely catch the board and remove scrap before it moves on to be stacked in full piles or bundled. Capable of running at speeds exceeding 13,500 KPH, the 
To take it up a level, A.G. has engineered a patented scrap release layboy with high-velocity blowers, a new engineered air knife and variable speed control. Working in tandem with the HPLX, the 
The perfect complement to the DSS is the auto hopper set-up offered by the AG eTAmp. The only solution for converters running multiple outs without a bundle breaker, and for handling automated set-ups when confronted with a high percentage of 2, 3, or 4-out unnicked die cut orders. The 
Eliminate feed interrupts with the 
The 
By investing in equipment upgrades, retrofits or a full line system designed to optimize your production mix, you can elevate the speed, quality and overall performance of your existing rotary die cutter operations. 
To take advantage of full line productivity, both now and in the future, you must reimagine your facility with machine assets that are incredibly fast, fully integrated, digitally enabled, and eco-conscious. A.G. Stacker is committed to innovation and manufacturing all equipment and parts in the USA. With various retrofit and modular systems, we encourage you to reimagine your full line equipment to discover the true source of what’s holding you back from ultimate productivity.
