In November 2020, Acme Corrugated Box began what would become the most ambitious expansion project in its more than 100-year history. From the outset, the initiative represented far more than a physical increase in space. It marked a strategic step toward Acme’s future – modernizing processes, integrating advanced automation, strengthening efficiency, and ensuring the company remained competitive in a rapidly evolving marketplace.
By late 2019, Jeremy Cohen, Vice President, General Manager saw the scope and complexity of the expansion becoming clear and formed an expansion team. Together they stepped into a transformative initiative that demanded both strategic vision and operational discipline, an effort that would ultimately redefine Acme’s operational capabilities.
Rising to Challenges
The path to completion was anything but smooth.
Over the course of the project, the team faced a series of obstacles — the onset of COVID-19, material shortages, staffing challenges, and unexpected incidents including a burst pipe that flooded portions of the plant and an electrical fire that halted operations.
Despite these disruptions, the project moved forward because the entire organization rallied behind it. Large-scale initiatives of this kind aren’t carried by one or two individuals; they succeed because every department, every shift, and every team member contributes. That collective resilience became the defining force that pushed the expansion across the finish line.
What the Expansion Has Made Possible
Since the expansion’s completion, Acme has achieved remarkable advancements:
- A state-of-the-art corrugator that has surpassed multiple long-standing production records
- A Hi Rack and automated WIP system that has established a new standard for internal efficiency
- Significant increases in converting output powered by two Isowa Falcons, with a new BWP 50” scheduled for installation in 2026
Click here to view our full collection of before and after photos.
- Total plant square footage before expansion = 209k sqft
- Total plant square footage after expansion = 304k sqft
These upgrades have strengthened Acme’s operational capabilities and positioned the company for continued success.
A Look at the Transformation
These before-and-after photos capture the incredible progress made over the past five years. They illustrate not only the physical evolution of the facility but also the dedication, perseverance, and teamwork that made the transformation possible.
Celebrating a Major Milestone
As Acme reflects on this milestone, it serves as a powerful reminder of what the organization can accomplish when its people move forward together. The progress achieved over the last half-decade is a testament to collective effort by the expansion team.
Here’s to continued growth, innovation, and the next chapter of Acme’s future!
Other posts you might enjoy:
