Weyers Cave, VA – Abbott-Action Packaging has significantly improved print quality, operational efficiency, and waste reduction following the integration of A.G. Stacker’s Sample Quality Rejection System with Valco Melton’sPrintChek technology. This cutting-edge solution has transformed quality assurance and production processes, setting a new industry standard.
Addressing Industry Challenges Before this integration, Abbott-Action’s operators manually monitored print quality, relying on spot inspections that posed risks at high production speeds. With machines running at 15,000 boxes per hour, achieving 100% defect detection and elimination without stopping production was nearly impossible. The manual process also led to customer returns, credits, and rework costs, impacting efficiency and trust. While these challenges were minor, their goal was, and has always been, zero defects.
A.G. G3™ Stacker with SQR — rejected board shown
“This new machine technology represents a major leap forward in our commitment to innovation and efficiency. By integrating cutting-edge automation and smart analytics, we’re not only improving performance and reducing downtime—we’re also setting a new standard for what our industry can achieve.” –J. Samuel Abbott, CEO, Abbott-Action Packaging
A Transformational Solution Since integrating A.G. Stacker’s Sample Quality Rejection System and Valco Melton’s PrintChek, Abbott-Action has seen a significant reduction in misprints and waste, while ensuring defective products never make it to final packaging.
Automated Quality Control: Defects are instantly detected and rejected, eliminating manual intervention.
Increased Efficiency: Operators can now focus on running machines at peak speeds rather than manually inspecting print quality.
Improved Waste Reduction: Fewer rejected products mean lower material and labor costs.
Enhanced Customer Satisfaction: The company is better positioned to deliver flawless products, strengthening client relationships.
“At Valco we embrace challenges as opportunities. We continue to thoughtfully develop our inspection systems to meet and surpass the demands of our customers. The result is a product that not only meets customer expectations but also raises the bar for excellence across the market.” –Jeff Pollack, National Sales Manager, Valco Melton
PrintChek screen displaying detected errors
PrintChek scanning bar and camera system
Competitive Advantage & Industry Leadership This integration has positioned Abbott-Action at the forefront of the corrugated packaging industry, delivering the highest print quality at high-speed production. As an early adopter of this technology, Abbott-Action is setting new benchmarks for quality assurance.
Looking Ahead While the data is still being collected, early results indicate a significant drop in quality issues and returns. Abbott-Action is confident that this technology will continue to drive efficiency, customer retention, and new business opportunities.
About A.G. Stacker Founded in 1996 and located in Weyers Cave, VA, A.G. Stacker is a leader in the design and manufacturing of custom material handling equipment for the corrugated industry. With a strong focus on innovation, automation, and customer collaboration, A.G. Stacker continues to drive the future of boxmaking with patented technologies and modular, scalable solutions. www.agstacker.com
About Valco Melton Headquartered in Cincinnati, OH, Valco Melton has been a global leader in adhesive dispensing and vision inspection systems for over 70 years. Serving corrugated manufacturers in 96+ countries, Valco Melton delivers innovative solutions like ClearVision® camera inspection, backed by world-class service and support. www.valcomelton.com
About Abbott-Action Packaging Founded in 1935 and headquartered in Attleboro, MA, Abbott-Action Packaging is a third-generation, family-owned leader in corrugated packaging and POP display solutions. Built on a legacy of innovation and strategic growth, the company continues to deliver high-quality, customized packaging that helps brands stand out in today’s competitive market. www.abbottaction.com
Weyers Cave, VA – A.G. Stacker, a leading manufacturer of innovative corrugated material handling equipment, is proud to announce the appointment of Cory Deavers to the role of Vice President, effective immediately.
Deavers has been an integral part of A.G. for nearly a decade, beginning his journey in the accounting department. Throughout his tenure, he has demonstrated exceptional leadership and a commitment to operational excellence. Under Deavers’ guidance, A.G.’s accounting and human resources departments have seen significant improvements in structure, efficiency, and interdepartmental communication.
While advancing through his roles at A.G., Deavers earned his Master of Business Administration (MBA), applying his knowledge and strategic thinking to strengthen the company’s relationships with banks, insurance providers, and key vendors. Most recently, he assumed responsibility for A.G.’s facility and manufacturing operations, where he successfully integrated these teams into broader company workflows—fostering greater transparency, collaboration, and productivity.
Please join us in congratulating Cory Deavers on this well-deserved promotion.
About A.G. Stacker Founded in 1996 and located in Weyers Cave, VA, A.G. Stacker is a leader in the design and manufacturing of custom material handling equipment for the corrugated industry. With a strong focus on innovation, automation, and customer collaboration, A.G. Stacker continues to drive the future of boxmaking with patented technologies and modular, scalable solutions.
Weyers Cave, VA – A.G. Stacker officially announces its ongoing partnership with Yaskawa Motoman in the development of their eZFa Automatic Load Former, a cutting-edge solution engineered to fully automate the unit load forming process.
eZFa in progress — full automation powered by Motoman cobots.
This partnership marks a significant milestone in A.G.’s mission to revolutionize automation in the corrugated converting industry. After several months of collaborative engineering and integration, the Motoman team has demonstrated exceptional dedication and support, ensuring the A.G. team had every resource necessary to bring this next-generation solution to life.
At the heart of the eZFa is a robust, six-axis collaborative robot specifically designed for palletizing and well-suited for heavy-duty packaging environments. This collaborative robot, or cobot, is engineered for safety and built to work directly alongside humans in a shared workspace, enabling efficient, fenceless production while keeping worker safety and operational flexibility at the forefront.
“The cobot acts as the ‘operator’ of the eZFa system, eliminating the need for manual lifting and repetitive physical tasks,” said Jerry Blosser, Electrical Design Engineer at A.G. Stacker. “Our goal was to automate the load forming process without compromising safety and did not require robot programming knowledge to operate, and Motoman delivered.”
With the Motoman cobot integrated into the new eZFa, A.G. Stacker customers can expect a fully automated, operator-free solution for unit load forming — setting a new standard for efficiency and ergonomics in the corrugated industry.
The eZFa is currently in the advanced stages of testing, with plans for commercial launch later this year.
About A.G. Stacker Founded in 1996 and located in Weyers Cave, VA, A.G. Stacker is a leader in the design and manufacturing of custom material handling equipment for the corrugated industry. With a strong focus on innovation, automation, and customer collaboration, A.G. Stacker continues to drive the future of boxmaking with patented technologies and modular, scalable solutions.
About Yaskawa Motoman Founded in 1989, the Motoman Robotics Division of Yaskawa America, Inc. is a leading robotics company in the Americas. With over 600,000 Motoman® robots installed globally, Yaskawa provides automation products and solutions for virtually every industry and robotic application; including arc welding, assembly, coating, dispensing, material handling, material cutting, material removal, packaging, palletizing, spot welding and clinical laboratory specimen processing. For more information, please visit our website at www.motoman.com
Weyers Cave, VA – A.G. Stacker Inc., manufacturer and innovator of corrugated material handling equipment and technology, will be exhibiting at CorrExpo 2025. Attendees are invited to visit Booth #407 to explore A.G.’s latest innovations in machinery, simulation software, and digital technologies.
CorrExpo is a premier trade exhibition serving the corrugated industry in North America. Hosted by TAPPI, the event will take place in Savannah, Georgia, October 20–22. A.G. is proud to support the success of the event as a Premier Bronze Sponsor, Tuesday Night Special Event Sponsor at The Grove, and Golf Beverage Cart Sponsor.
At the show, A.G. will feature its DUO™ digital twin technology, offering an interactive, HMI-driven experience for three of its patented flagship systems: the eXT™ front end system, eBREAK™ bundle breaker, and new eZFa™ automatic load former. These exact digital replicas allow attendees to operate equipment in a simulated environment, with the eXT™ system showcasing additional digital shadow capabilities—blending physical operations with real-time data tracking.
In addition to equipment twins, A.G. will highlight collaborative tools designed to enhance communication, planning, customization on the production floor, and much more! The GO AG™ digital application and SIMCORRA™ planning software will be on full display, enabling visitors to test factory layouts, run simulations, and explore data-driven platforms tailored to today’s corrugated operations.
Featured Patented Technologies:
eXT™ Front End System – Built for speeds up to 20,000 kph, this high-performance system offers exceptional scrap control, a modular design, and is part of A.G.’s all-electric eSERIES™.
eZFa™ Automatic Load Former – Powered by LayerCraft and integrated with Yaskawa Motoman cobots, this system streamlines bundle handling and connects seamlessly across the eSERIES™.
eBREAK™ Bundle Breaker – Handles variable, straight, nested, and offset breaks within a single log, boosting throughput and flexibility.
“A.G. is committed to pushing the limits of what’s possible in corrugated,” says Joe Wunder, President of A.G. Stacker. “From our DUO™ digital twin systems to planning tools like SIMCORRA™, we’re delivering not just machinery, but meaningful innovation that gives converters the power to plan, produce, and perform at the next level.”
Visitors to Booth #407 can expect DUO™ Digital Twin interactive machine stations, a digital shadow, factory simulations, and a fully open bar for converter attendees. A.G.’s sales, service, and engineering teams will be on-site to answer questions and showcase how their integrated systems support future-focused operations.
Experience hands-on innovation, immersive tech, and industry-leading service with A.G. at CorrExpo 2025—where performance meets the future. To learn more, visit www.agstacker.com/events/correxpo-2025/.
About A.G. Stacker Founded in 1996 and located in Weyers Cave, VA, A.G. Stacker is a leader in the design and manufacturing of custom material handling equipment for the corrugated industry. With a strong focus on innovation, automation, and customer collaboration, A.G. Stacker continues to drive the future of boxmaking with patented technologies and modular, scalable solutions.
Weyers Cave, VA – A.G. Stacker is expanding its operations to 100,000 square-feet with the completion of their second 25,000-square-foot facility addition in the last six months. This latest expansion will increase production capacity to meet growing market demand for A.G. Stacker products.
Installing our network infrastructure to our expanded industrial space.
The expansion will provide additional space for assembling and testing equipment, as well as upgrades to the facility’s electrical and network data infrastructure. These improvements will enable A.G. Stacker to continue meeting the rising demand for its bundle breakers, load formers, and RDC stacker equipment while maintaining its high standards of support and quality.
Once completed, this expansion will allow A.G. Stacker to manufacture RDC stackers, bundle breakers, and load formers at an increased production rate, while enhancing efficiency, safety, and cost-effectiveness for its customers.
“We are excited to continue expanding our operations to meet the growing demands of the industry. This investment in our facilities will allow us to not only increase production but also maintain the high level of quality and service our customers expect. We remain committed to driving innovation and efficiency as we grow alongside the corrugated industry.” – Joe Wunder, President, A.G. Stacker
For more information, visit www.agstacker.com or call (540) 234-6012.
About A.G. Stacker Founded in 1996 and located in Weyers Cave, VA, A.G. Stacker is a leader in the design and manufacturing of custom material handling equipment for the corrugated industry. With a strong focus on innovation, automation, and customer collaboration, A.G. Stacker continues to drive the future of boxmaking with patented technologies and modular, scalable solutions.
Joe Wunder, President of A.G. Stacker, with his Blockbuster video card and Motorola pager, reminders that technology changes rapidly, and businesses need to keep up.
Under the leadership of President Joe Wunder, A.G. Stacker is embracing Industry 5.0 by advancing its efforts in artificial intelligence, collaborative robotics (cobots), and smart machine connectivity. With a strong focus on human-machine collaboration, A.G. is working to enhance safety, efficiency, and scalability in the corrugated industry.
“Companies that fail to evolve risk becoming obsolete,” said Wunder. “At A.G. Stacker, we’re continuously innovating to ensure our customers have the most advanced, adaptable, and future-proof solutions available.”
Key Innovations & Industry Leadership
Modular & Scalable Equipment – A.G. Stacker’s eSERIES machines are designed for long-term adaptability, allowing boxmakers to integrate new technology without replacing entire systems.
Collaborative Robotics (Cobots) – Enhancing safety and efficiency by working alongside human operators.
Smart Machine Connectivity & Optimization – Moving beyond traditional remote access by enabling real-time performance adjustments and predictive analytics.
Customer-Centric Digital Tools – A.G. Stacker’s DUO Digital Twins and SIMCORRA Factory Simulationallow customers to optimize production line efficiency before making capital investments.
Customer Success: Real-World Impact
Eric Stempihar, Senior Design and Project Engineer, demonstrates A.G.’s eTAMP system.
Recent installations at Royal Containers Ltd.demonstrate the effectiveness of A.G. Stacker’s advanced technology. Customers have praised touchscreen layboy controls, laser alignment features, and Accu-Nip pressure control for improving accuracy, efficiency, and safety.
“A.G. Stacker’s innovations align with our mission of continuous improvement,” said Michel Alvarez, Plant Manager at Royal Containers. “Their technology has streamlined our operations while ensuring operator safety and product quality.”
Investing in the Future: Supply Chain Control & Manufacturing Excellence
A.G. Stacker has made significant investments in automation and advanced manufacturing, including:
Automated CNC machining & robotic welding for increased precision and reduced lead times.
Industrial 3D printing with Kevlar reinforcement to produce high-strength components faster and more cost-effectively.
Digital training & connectivity to provide customers with real-time insights and remote support.
A Trusted Partner for the Corrugated Industry
Steve Craig (left) operator of A.G.’s recent machining investment, the Trumpf TruLaser 7000 with Steve Young (right) former President of AICC.
For nearly 30 years, A.G. Stacker has been more than just an equipment manufacturer—it has been a trusted advisor to its customers, offering cutting-edge solutions and expert consultation to help them stay ahead in an evolving market.
“Our customers don’t just want machines; they want a partner that understands their challenges and helps them navigate the future,” said Wunder. “That’s exactly what we deliver.”
For more information about A.G. Stacker and our industry-leading solutions, visit www.agstacker.com or call (540) 234-6012.
About A.G. Stacker
Founded in 1996 and located in Weyers Cave, VA, A.G. Stacker is a leader in the design and manufacturing of custom material handling equipment for the corrugated industry. With a strong focus on innovation, automation, and customer collaboration, A.G. Stacker continues to drive the future of boxmaking with patented technologies and modular, scalable solutions.
