Extrusion

Background

Master Extrusion was started up with two state of the industry W&H 3-layer blown film lines. Both lines were optimized for collation shrink, frozen food film and sealant web applications. Since 2013, we have consistently added two new W&H lines year over year. Our new extrusion line acquisitions include several high output units as required to supply ColorMasters’ new wide web presses. The product mix of Master Extrusion is organized In a way to support the core competencies of our target market segments.

Total Quality

MasterExtrusion is true state of the industry Total Quality manufacturing facility. The structure has been organized from the ground up using the methods and philosophies of Dr. W. Edwards Deming. In addition, Six Sigma is used as a guiding tool for our quality program. Our testing laboratory uses Mini Tab for statistical analysis of lab data. We use data based decision making in all of our management efforts.

Raw Material Supply

The life blood of a film plant is its raw material supply. In today’s world of hurricanes and weather interruptions, this is of paramount importance. Consequently, the primary and back–up supply positions of our PE resins have been thoroughly planned out and diversified. To help maintain supply we use two 220,000 lbs silos to store our highest use materials instead of a single silo. We have secured direct rail service to our plant utilizing two rail spurs with fourteen unloading stations. As a result of these efforts, not once has a customers been run out of film product causing an interruption to their operations.

Low Cost Producer

MasterExtrusion strives to be the lowest cost film producer in our industry. Our simplified product mix allows us to purchase a minimal number of resins with large quantities of scale. This plan requires us to make few product change overs and allows long run campaigns. As a result, our first pass waste is a third of historical film plants and our hourly output rates are very high. Zero net waste is easily achieved by use of on-line and out of line repelitization units.

Product Design / R&D

MasterExtrusion uses state of the industry testing methods and R&D tools. This includes SPC KISS and SPC DOE design software for computer generated modeling. However, our greatest strength lies in knowledge and experience. This includes an intricate understanding of our customers machinery and application requirements. In a number of cases, we have seen our customers be able to speed up their packaging machines by 25%. Product design has also allowed customer down gauging and/or width reduction by 25%. These significant improvements are the result of the fabulous fabrication on our W&H film lines with automatic gauge control in the +/- 3% range. Our highly trained field engineers provide support to our customers in improving their efficiencies. Our engineers have film making experience which helps with design and innovation relative to fine tuning and optimization of production.

Growth Platform

On a percentage basis, Master Extrusion is the highest annualized growth platform for film making in North America. We currently have major expansion plans underway that will involve revolutionary new film making technologies.

Accomplishments

0 % rejection rate for food safety issues
Best in the industry 0.02% return rate for quality issues
Qualification and commercialization of 12 different film products at a “Who’s Who“ customer base
AMI World Market presentation on the Sustainability of Collation Shrink Films