 “I don’t do that much work around here anymore. These guys are way ahead of me,” jokes Gene R. Stull (second from right) of his three sons (left to right), Jason, Gene Jr., and Jameson. Below is the new cap that saved the day for soup.   A new, fully automated cell seen here as it was being set up at Stull Technologies was designed in-house to produce food container caps (below) also designed in-house—several million per year, for starters.   CBW Automation systems stack the caps into “logs,” lift and package them, eject the cartons, close them, and seal them for labeling, stretch wrapping, and palletization.  “Our Maguire consistently holds our color concentrate percentage,” says Jason Stull. “We’ve got hot runner molds, so Maguire integrated a Bunting Magnetics separator onto a custom-built stand for us. We’ll eventually run multiple colors.” |
In a cell fully automated by CBW Automation, twin 550-ton all-electric Cincinnati Milacron Powerlines with Xtreem ST controls, each running 2+16 StackTeck stack molds with Moldflow Altanium hot runner controls, produce several thousand parts/min/press/day of a new type of microwave-friendly cap. The cell runs in a family-owned-and-run facility—a facility run by the same family that designed both this new type of cap and the cell that runs them—a family that calls itself “The Comeback Kids.”
We’re talking about Stull Technologies (Somerset, NJ), a company that has designed and produced some of the most legendary caps and closures in the history of packaging. It has put into practice a step-by-step kaizen continuous improvement program to maximize its full-service capabilities and manufacturing efficiencies, as detailed in our January 2003 Plant Tour (for more information, see immnet.com/articles/2003/January/2048). Its commitment to the practical application of advanced technology and to lean manufacturing continues.
“We’re on track. Things are going really well,” says Jason W. Stull, marketing services manager. “Our aggressive growth strategy is paying off for Stull and for our customers. Our sales are showing consistent growth and we’re looking forward to celebrating our 60th anniversary in 2007.
“We’re branding ourselves and are committed to sharing who we are with the world. These days we’re more actively involved in exposing our dedication to designing and developing products, and the advanced manufacturing systems we use to produce them at the lowest possible cost. These are capabilities some of our customers may have been unaware that we have.”
Soup to nuts
Its branding efforts certainly caught the attention of a global company with a legendary brand name, a company that wishes to remain anonymous. Stull designed and developed a patent-pending cap for its microwaveable soups.
“The company came to us for a cost-effective solution to lock the lid onto the container, while maintaining consumer convenience,” Jason Stull explains. “We came up with the current, proprietary design that improves the package’s functionality and its value to the consumer.”
The cell mentioned earlier was designed to produce the new microwaveable soup caps. Jason says the clamp decompression capabilities of the Milacron Powerline presses improve manufacturing efficiencies.
Like most all-electrics, Powerlines can unlock their clamps to “mold touch” at the end of the cooling cycle and overlap most or all of the mold breakaway time during clamp open. However, what sets Powerlines apart is that their clamp decompression can be customized by molders, saving precious cycle seconds with no impact on part quality, Milacron sources say.
Molded lids are ejected onto a turntable where a photo eye gauging part height detects any that are upside-down and triggers an air blast to blow them right-side up, thereby maintaining a fixed distance between the caps and easing further automated handling.
CBW designed all of the cell’s automation. The cell has five robots in all—two horizontals, two verticals, and one punch arm. All of its systems are controlled by CBW’s PC-based Lumerics control, which stores all PM manuals onboard and features fiber-optic communication capabilities for quick remote troubleshooting.
EMI supplied the conveyors for the cell. The gravimetric blender and material handling system is from Maguire Products. An inkjet printer for carton labeling provides the finishing touch.
Organic manufacturing
Jason says Stull has a pipeline full of custom and proprietary projects. Some, like the microwave cap, are “organic” Stull-funded development projects. “Our organic projects require a substantial investment in product development, but yield a better ROI. They help pick up the pace of the rest of the plant and improve our price competitiveness.”
He adds that lean thinking helps to eliminate waste, which drives cost out of their production systems. “It’s how we’re able to bring in newer technologies that can get us to the next level.”
Other confidential organic projects include a patent-pending cap designed to improve both the molding process and the capping process on filling lines. Another is a custom dispensing closure for the hair care industry. Stull also plans to expand its white room into a 100% environmentally controlled cleanroom for pharmaceutical projects.
“We’re constantly peppering our customers with new ideas. We listen to our customers and create solutions for them. Innovation is our key to success. If you sit idle you lose business,” Jason says.
Inspired by his three sons—Jason, Gene Jr., and Jameson—Gene R. Stull, chairman and CEO, says, “You can’t relax. There are major changes going on in the packaging market. We needed to turn off ‘Business 101,’ step outside of the box, and get our minds thinking of things no one’s ever thought of before.”
The Stull family has no intention of sitting idle. Global manufacturing and acquisitions reportedly may be in the cards to add new levels of organic and inorganic capabilities, processes, and customer support. “Our plan is to continue to build our company based on positive family business values and to drive innovation for our customers, rather than being just another ‘me too,’” Stull Sr. says.
| Contact information Stull Technologies (732) 873-5000 | www.stulltech.com |