Delivering Innovative and Reusable Solutions for the Food
Delivering Innovative (and Reusable) Solutions for the Food Industry
Corporate Overview l l l l Headquarters - St. Louis, MO Privately-held Company Consolidated Sales over $300 Million U. S Sales Tripled since 2001 Ranked 8 th Largest U. S. Thermoformer Largest Manufacturer of PP Takeout Food Containers Award-Winning Designs l Four Sales Platforms: l Chain Restaurant: QSR, Fast Casual, Fine Dining, Catering l Retail: Supermarkets, Convenience Stores, Mass Merchandisers Packer Processor (food packaged for retail sale) Commercial Distribution-Broadliners, National, Re-D l l Anchor Packaging Confidential Information 2
First 50 years journey Founded in 1963 with a rich heritage of rapid growth, quality and financial stability. At a time when the U. S. thermoforming industry is undergoing dramatic consolidation and isolated Acquired Mt. Vernon Plastics facility and assets bankruptcies, Anchor Packaging remains a successful, privately-held entity with a strong balance sheet. 2013 2012 Acquired Borden Chemical film operation in Argentina 1998 Acquired Microlite division of Amoco Acquired Innovative Plastics Added thermoforming, extrusion & blown film 1998 1963 Anchor founded November 8 th as a converter of plastic film 1985 Second Expansion Paragould, AR facility to accommodate growth Purchased Bon. Faire Division of Placon 1994 Expanded Paragould, AR facility to accommodate growth 1990 1989 1978 2008 Purchased Jonesboro, AR manufacturing/warehousing facility for future expansion New film facility opens in Marmaduke, AR Ground up construction of new plant in Paragould, AR Anchor Packaging Confidential Information
Net Sales Exceed $300 Million 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 E 4
Our locations Corporate Headquarters Ballwin (St. Louis), MO Manufacturing Plant Manufacturing Paragould, AR Marmaduke, AR Jonesboro, AR Distribution Center Manufacturing Plant Paragould, AR San Juan, Argentina
Operations Arkansas − Paragould – Extrusion/Forming ( 310, 000 sq. ft. ) − Jonesboro – Extrusion/Forming (424, 000 sq. ft. ) − Marmaduke – Blown Film ( 260, 000 sq. ft. ) − Paragould – Distribution Center ( 683, 000 sq. ft. ) San Juan, Argentina - Blown Film (130, 000 sq. ft. ) Anchor Packaging Confidential Information 6
Recent Investment In Our Business Paragould plant expansion in 2008 l Significant investment for in-line extrusion/forming and technology l l l 60” PP in-line 50” In-lines - 14; more than any other manufacturer (Additional In-line 2014) 8 Off-line thermoformers; 4 -50”, 3 -40” Extruder: side-by-side, multi-layer sheet for off-lines Trim-in-place for precision flanges (Second Line Q 1 2014) 2 Printing lines 10 Blown film lines - PVC 2 Injection molding lines 2 Lab thermoformers for samples and small production trials Acquired Rock Castle, KY in 2012 and Jonesboro, AR in 2013 Automated bagging/packing lines – 2014 Initiation Anchor Packaging Confidential Information 7
Operations by plant Locations STORAGE & DISTRIBUTION MANUFACTURING Core Mfg. Auto Count & Bag Packaging Silo’s - - 7 - 15 22 - - Marmaduke Plant 260 - - 10 - 1 8 18 14 15 Jonesboro Plant 424 - 3 - - - 3 - 4 13 20 20 Paragould DC 683 - - - 4 - - 5 - - 45 37 1, 819 8 15 10 1 1 7 6 23 53 93 77 130 - - 5 - - 3 - 3 4 Docks 8 C Printing - Storage Blown Film 15 (000 Pallets) Inline Forming 8 (Cars) Offline Forming 310 Rail Siding Square Feet (000) Paragould Plant ARKANSAS AR TOTAL OTHER San Juan, Argentina Anchor Packaging Confidential Information 8
In-Line Extrusion/Forming Anchor Packaging Confidential Information 9
Why Arkansas? 1 hour to the Nation’s Distribution Hub – Memphis St. Louis: Nashville: Atlanta: Dallas: Chicago: Houston: 271 miles 274 miles 448 miles 453 miles 519 miles 577 miles INTERMODAL SERVICES 42 Truck Carriers 17 with local terminals 2 Class One Railroads Anchor Packaging Confidential Information 10
Core Competencies l Thermoforming Rigid Containers – Inline and Offline l Trim-in-Place in addition to Post Trimming l Extrusion – mono-layer and multiple structures l Materials: l Polypropylene (PP, MFPP) l PET, RPET l Flexible Blown Film – PVC l Custom Design Solutions l Stock Products – Over 450 available Anchor Packaging Confidential Information 11
Material Attributes Polypropylene – PP / MFPP – Impact resistance – Heat Resistance, microwavable – High clarity, anti-fog – Weight reduction, mineral fillers – Seal-ability, venting options – Reusable – 3 R’s (Reduce – Reuse – Recycle) l Polyethylene Terephthalate – PET / RPET – Optical clarity – Best choice for cold applications – Rigidity, durability – Anti-fog – Recyclable and post-consumer recycle content l Polyvinyl Chloride – PVC Film - Cutter Box Film - Best cling properties in the Industry - Dri-Gard coating available for outside of box to extend shelf life - Stretch Film (meat, produce) and Shrink Film l Aluminum - Foil rolls and pop-up sheets l Anchor Packaging Confidential Information 12
Quality l Product Specifications (Quality Docket, Drawing, Layout, Packaging, Palletizing) Setup Release Process (verification/QA Lab conf. /Inspection) l Operator and QA Audits (Lab & Line; Specs/Visual/GMP’s) l Zontec SPC Software and Training l l l Lab & Line Operators, supervisors, auditors Containment Protocols (Red Tag and Recall procedures) l Continuous Improvement l l Kaizen activities, Environmental initiatives (Energy cost avoidance/scrap reduction/reuse) 5 S-Lean manufacturing Anchor Packaging Confidential Information 13
Quality Certifications l ISO 9001: 2008 (to 2015 -03 -29) l NSF* l Kosher l GFSI* (in process) *Includes HAACP Plan for critical control points on product safety Anchor Packaging Confidential Information 14
The Process Begins with the Customer l Anchor’s Value Proposition: “Develop innovative packaging solutions that meet the needs of a new product or a solution that fulfills the unmet need of a market segment. ” l Design to meet customer’s desired price point or less l Thorough testing at customer locations Anchor Packaging Confidential Information 15
Responding to Our Customers’ Needs l l 7 Engineers devoted to new designs and tooling to manufacture l Fast turnaround of images, renderings, 3 D models, laser-created samples l 2 CNC machines with dedicated operators 2 Additional design engineers in Asia l Work in tandem with U. S. engineers l Allows round-the-clock product development l In-house SLA/Rapid Prototyping l Dedicated Prototype Production Equipment/ 4 Full-time employees l Capabilities (in-house and offshore) to manufacture tools l On-site design support at customer’s facility available Anchor Packaging Confidential Information 16
Award Winning Designs l FPI/QSR Innovation Award l World Star Packaging Excellence Award l Packaging World - Package of the Year l Ameristar Package Award l Yum Brands Star Supplier– 2010, 2011 Anchor Packaging Confidential Information 17
Anchor Innovation Anchor Packaging Confidential Information 18
Culinary Classics QSR/FPI Foodservice Packaging Award l 1 st polypropylene manufacturer to produce one-piece hinged black base / clear lid, side by side l 8 package options l Anchor Packaging Confidential Information
White Casserole l Classic white “Corningware style” for a take-out package that can go right to the dining room table. l From store to table to dishwasher to cabinet for RE-USE again and again. Anchor Packaging Confidential Information
Crisp Foods Container Patented cross-flow ventilation relieves moisture, food remains crispy. l Retains internal temps meeting health dept. regulations l Independent studies at retailers demonstrated better performance than the leading fried chicken container l Anchor Packaging Confidential Information
KFC Reusable Sides l Anchor adapted its patented ventless-vent technology to provide a unique solution for KFC’s side dishes. l Leading-edge technology allowed cost savings vs. foam l KFC menu items retain their original quality longer in the new containers than in foam (per KFC Test Kitchen) l Increased customer satisfaction with reusable package Anchor Packaging Confidential Information
Sustainability: Initiatives and Strategy Anchor Packaging Confidential Information
Sustainability Efforts World’s largest manufacturer of reusable polypropylene microwavable takeout containers. l Polypropylene (PP) has smallest carbon footprint of all plastics l Anchor Products: l Many PP products contain 40% perpetual resources l PET products made with minimum 10% post-consumer recycled content (RPET) l All made with 50% post-industrial recycle l Reduced amount of material and packaging by 25% in new products through engineering innovation l Reduce and recycle scrap at all Anchor plants (<1% remains) l Anchor does not landfill waste; used in other applications (cutter box core plugs) l R & D is continually researching new technology to increase use of recycled materials and limit use of environmentally sensitive resins Anchor Packaging Confidential Information 24
Carbon Footprint Plastic Resins Anchor Packaging Confidential Information 25
Why Reusable Containers? EPA states: REUSE and REDUCE are preferred methods of waste management l Re-Use saves energy, equipment, and other natural resources l Reusable containers increase sales. Providing reusable polypropylene containers to the consumer has led to increased sales for companies such as Hillshire Farms, Butterball, Healthy Choice and others. l Consumers prefer reusable containers over recyclable or biodegradable. Will reuse containers up to six months Anchor Packaging Confidential Information 26
Benefits of Reusable Polypropylene Containers n n n Heat Tolerant. Safe up to 230ºF. Microwave-safe. Saves energy and time vs. conventional oven. Dishwasher-safe. Saves energy and time. Store to table to dishwasher to cabinet. Maintains Food Taste. No flavor change or plastic odor vs. non-heat tolerant plastics (rigid styrene) Durable and Leak-resistant. Heat and eat right from the container, without cutting, tearing, or breaking. Good for the Environment. Reduction in material and energy consumption and consumer demand for disposable packaging. Visit www. Reuse. Containers. com Anchor Packaging Confidential Information 27
Why Anchor? • • • Exceed our customer’s expectations on product quality and service. Committed to continuous improvement in our manufacturing process to assure you are competitively positioned. Work with you to define the need so the right solution can be put to work on your behalf. Known for our ability to innovate. Consolidate all products so they can be shipped out of our centrally located DC. Value your business and our daily actions put meaning behind these words! Anchor Packaging Confidential Information 28
Restaurant Customers Anchor Packaging Confidential Information
Retail Customers Anchor Packaging Confidential Information
Processor Customers Anchor Packaging Confidential Information 31
Anchor Packaging “We Make it Happen”
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