News Sustainable Biz Eagle Packaging driving sustainability, value into packaging
Order Reprints
Follow @MiBiz
By Nathan Peck | MiBiz
This e-mail address is being protected from spambots. You need JavaScript enabled to view it
ZEELAND — Patrick Patten likes a challenge.
Inside Eagle Packaging Inc.’s Zeeland production facility, Patten and his 19 employees are taking the materials of packaging — cardboard, foams and plastic — and turning them into engineered packaging solutions for some of the largest automotive, office furniture and consumer packaged goods companies in the area.
 |
|
Patrick Patten shows foam protective corners for a furniture manufacturer that incorporate waste materials, such as sawdust, into the compounds. PHOTO: NATHAN PECK |
Patten founded Eagle Packaging in 2003 after working in sales for a number of manufacturers of packaging materials and found that packaging manufacturers’ goals were at times at crosscurrents with his customers. Patten, a member of the Grand Traverse Band of Ottawa and Chippewa Indians, sees opportunities in being a minority-owned business in the contract office furniture and automotive industries.
“There was the sense, where I had worked before, that this is what we pay you to do — this is what you sell. It was not always the right solution,” Patten told MiBiz. “I sensed there was a need for someone who is more of a problem solver. That’s why we’re material neutral. We want to find the best solution whether it is corrugate cardboard, foam, bubble inserts, or plastic wrap.”
The recession hit Eagle Packaging’s business like the rest of its customers, but Patten has seen sales revenues double over the last two years. He expects the growth to continue, projecting 30-percent growth in 2011 and 50-percent growth in 2012, after the company moves from its 25,000-square-foot facility at 441 Roosevelt in Zealand, to a 55,000-square-foot facility later this year.
Patten realized early on that the key to Eagle Packaging’s success would be in staying closely attuned to his customers’ needs. The company has built a reputation for finding innovative solutions to its customers’ difficult packaging problems and is frequently the first phone call that his customers make when looking to ship new products.
“We want to know everything about them. What their parameters are, their goals, their needs, everything,” Patten said. “We’ve become a first call for many of the major manufacturers in West Michigan because we’re so responsive.”
Take the case of a manufacturer of residential washing machines who found shipments to Mexico and Central America were being damaged in transit. In researching the problem, the manufacturer found that most shipping containers were unpacked by hand. Workers would step on the first row of washers, crushing the box and cracking the curved glass lid to the machine. Behind a locked door is the solution — a modified version of their corrugated cardboard “Corrloc Pallets” that will support the weight and prevent the cracked lids.
Another root cause analysis traced damage to Class A finished components to corrugated inserts in the packaging that acted as fine-grit sandpaper for the mirrors. The solution was a polyethylene foam insert that keeps the mirror units from touching and from being scratched in transit.
“We’ve been able to take our customers’ damages in shipping to nearly nil,” Patten said.
Packaging isn’t always thought of as the most innovative field, but Patten challenges that notion. Customers are now bringing new products to Eagle Packaging to come up with novel packaging to ensure that their customers in turn get products safely and cost effectively.
That comes in large part to giving his employees, particularly his quality engineer and two designers, free reign to experiment with new products and techniques in order to bring innovative solutions to customers.
“I allow freedom of creativity. I like it and reward my employees for it. I want free thinkers,” Patten said. “I think that is why we’ve grown — I’ve got great designers and people here.”
Greening his operations has opened up new opportunities for Patten. As customers in the contract office furniture industry look to close their waste loop, Eagle has developed methods to incorporate waste sawdust into foam packaging, a process that is currently in the R&D phase. Other packaging materials, such as the polyethylene inserts, can be reused and reduces the waste stream further.
A furniture manufacturer came to the company with concerns about the fact that dealers in urban centers were having difficulties finding ways to dispose of wooden pallets in cities. The corrugated pallets, in addition to weighing significantly less than traditional pallets (Corrloc pallets weigh 10 lbs. compared to 45 lbs. or more for wooden pallets), can be recycled with other corrugated cardboard and waste paper.
“They can get more product on a truck now, and can then help green their operations,” Patten said. “We’ve built our business model on being a short-run, low volume, quick turnaround manufacturer.”
A gathering of the week’s sustainable business news powered by the editors of MiBiz sent every Tuesday.
Businesses that utilize “green” marketing — claims of environmental benefit or superiority ...
As operational costs continue to rise, many companies have become acutely aware of energy use in th...
