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Send to KindleValuable relationship shaves time
Duralam receives weekly orders from ASR for multiple brands some with as few as 10 impressions per order. The rollstock for packs of disposable razors is flexo-printed in up to eight colors on 48-ga polyester rollstock laminated to 1.25-mil low-density polyethylene.
The printed rollstock is sent to ASR plants in Knoxville TN and Obregon Mexico where it is placed on Doboy (New Richmond WI) flow wrappers.
In Knoxville the machines employ vibrating bowls that orient the razors. The groups of razors are then transported down a divided belt. In Obregon laborers orient the razors and place them on the belt. The film goes around the different package sizes based on the number of razors in each package. The bag is formed around the razors heat-sealed along the back seam and crimped and cut at each end. The packages are then loaded into boxes. The razors retail from 99¢ to $3.99.
Tangible economics
Though Coppola couldn't quantify savings attributed to ASR's partnership with Duralam he did say it has both tangible and intangible rewards. "The tangible advantage is that by establishing this relationship [with Duralam] by sharing forecasts and volume figures with our printer it allows them to go out and buy their raw materials more efficiently" says Coppola. "What we have been able to do is develop a relationship so that pricing has been stabilized with the increases in our volume and mix."
Coppola adds that Duralam prices films for ASR based on color size and volume. That way the cost of each film will be set regardless of other variables like lead time and changeover.
The partnership with Duralam has also yielded a rebate system for ASR. "There is a volume incentive that says if ASR has a great year has a lot of graphics changes or increases promotional activity then the number of impressions increases. Based on a specific formula Duralam sets up that is related to those factors ASR can receive money back" says Coppola. "When we had five or six vendors this wasn't possible.
"The intangible advantage is the improved quality of the materials we receive" continues Coppola. "The efficiency has allowed for less vendor returns and fewer graphic errors. You may never see those things on the bottom line but it makes life a lot easier."
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