One of the largest Independent box makers in the Pacific Northwest, Commencement Bay Corrugated (CBC) delivers high-quality packaging, graphics, sheets, and high levels of service to customers throughout the northwest and North America. From the 360,000 sq ft facility in Orting, Washington, CBC produces over 1 billion sq ft of corrugated boxes and sheets per year. From their full line-up of state-of-the-art equipment and experienced staff, to supply strategy and scheduling, their philosophy is focused on supporting the core values of unsurpassed quality and customer service.
Founded in 1980 by Ferd Nist and John Kiehl, CBC’s roots in the region and in packaging go much deeper. A wholly and equally owned joint venture of Seattle Tacoma Box Co and Pacific Box Co, CBC traces its roots back through six generations of family ownership. In 1889, Jacob Nist founded what would become Seattle Tacoma Box Co and John Kiehl founded Pacific Box Co in 1971. Today, both companies, and subsequently CBC are still under the leadership of the founding families with the founders’ sons Rob Nist and Brett Kiehl serving as rotating president, while Ferd and John continue to serve on the company’s Board of Directors.
“The commitment to the business and our customers starts at the top of leadership and flows down through everyone in the organization,” says Matt Nagy, Plant Operations Manager, Commencement Bay Corrugated. “The ongoing growth and capital investment that goes into CBC reinforces the pride and dedication to our customers and everyone in our organization.
“We’re equipped to handle practically any graphic requirement a customer sends our way,” says Nagy. “And that’s not limited to end user customers. We have invested in technology and equipment that not every box maker has or has a need for on a continual basis. We’re open to partnering with others in the industry who don’t have the same graphic capabilities. For instance, certain projects may involve quantities that are too large for digital but not large enough for pre-print. We can help fill the gap. Converters may have the occasional need for UV coating. We can fill that gap too. We’re accustomed to being an outsource option, whether it’s a short term or long-term arrangement.”
Over the past nine years CBC has experienced an almost complete transformation which included a major building expansion and a new state-of-the-art Fosber 110” corrugator in 2018. “Our Fosber can run 5-7 million sq ft a day on two shifts. We offer a wide variety of flutes and board combinations,” says Nagy. “Everything from lightweight E flute to heavy doublewall combinations for produce, seafood, beverage and many other industries. For high graphic print applications, our combinations are typically E, EC, EB and even ET with a clay coat white outside liner.”
CBC’s most recent investments include three new converting lines, new BOBST 4-color 924 and 7-color 1228 flexo folder-gluers, and a 7-color Masterline DRO 1628. These machines replaced older converting lines and updated CBC’s capacity and graphic capabilities to the industry’s latest technology. “We’ve been providing customers with high-graphic flexo print for over twenty years,” says Nagy. “These new machines replaced machines of similar size and function, but they have significantly improved graphic capabilities. They take our capabilities to a whole new level. We can provide higher print resolution, enhanced consistency, more high graphic capacity.”
In total, CBC currently has eight converting lines including a wax cascader and a specialty folder-gluer.
CBC has taken advantage of the latest automation, printing, and quality control technology on the new converting lines. The 1228 and DRO are both full Bobst lines including Bobst pre-feeders and fully automatic palletizers. Each machine also includes a full complement of JB Machinery products.
All three lines (including the new Bobst 924) are equipped with JB Machinery’s ColorDry XL3000® Final Flexo IR dryers with AutoDryer Control™ (ADC). AutoDryer Control automatically controls power output to the dryers removing that responsibility from the operators resulting in at least 20% less power usage. In addition to the ColorDry systems on all downs, the 7-color Bobst 1228 and 7 color Bobst DRO 1628 also have JB’s InKomand® ink temperature management systems which automatically maintains precise ink temperature, controlling viscosity and pH without operator intervention. Each machine is equipped with JB’s VisionMaster® in-press dryer inspection and monitoring system. VisionMaster provides real-time video feed of the print areas and dryer surfaces making it quick and easy for operators to identify if and where sheets, debris or other issues may exist without physically visiting each section. Both machines also have JB ColorCure® COLD UV® systems giving CBC the capability to run a wide range of UV protective coatings and finishes.
“Customers come to us for quality products, high graphic printing and outstanding service,” says Nagy. “They expect us to provide consistent high-quality products, consistent color throughout the order and from order to order. They know when there is an urgent or unusual request, we will find a way to make it happen. The new converting lines together with the JB Machinery product portfolio play into meeting all these goals.”
In addition to offering a wide range of production options, CBC strives to maximize their efficiency while reducing their power consumption. In one project they replaced all their ‘high bay lighting’ with LED equivalents resulting in a 42% reduction in their lighting energy consumption. “We want to run an operation as efficiently as possible,” says Nagy. “That includes reducing our energy consumption, running the machines as fast as we can with minimal waste, while producing outstanding graphics and quality, and automating tasks where possible. The level of technology and automation JB’s products bring to the operation all play a role in maximizing our efficiency as well as our quality. In addition to saving energy, ADC and InKomand lighten the task load on our crews and allow them to focus on other important production tasks.”
He continues, “We build a strong bond and relationship with all our customers. Some of them have been with us from the very start. Some even predate CBC as customers of Seattle Tacoma Box or Pacific Box customers. And we try to develop that same partner-relationship with our vendors like JB Machinery. We’ve worked together on projects since 2011 when we added the first IR dryers to our Apstar. Their team, products, service and support are top-notch.”
These latest investments reinforce CBC’s commitment to continual growth and improvement. “The commitment that CBC’s ownership has to this business is very clear to everyone that works here,” says Nagy. “It’s easy to be optimistic about the future of the business when you see the ongoing growth and investments made in the business. And we’re fortunate to have an experienced and capable team here at CBC that makes it all work.”
What about the future of Commencement Bay Corrugated and parent companies? “We’re definitely not standing still. One thing is for sure about our ownership team, they’re always looking for new opportunities. These recent investments open a lot of potential avenues for future growth,” concludes Nagy.
