In the field of industrial manufacturing, achieving efficient and reliable packaging operations is critical. BestPack, a leader in packaging technology, consistently provides innovative solutions tailored to meet the specific needs of its clients.
This whitepaper explores the partnership between BestPack and Johns Manville, focusing on the significant enhancements in packaging automation that resulted from this collaboration.
Johns Manville is a prominent manufacturer and marketer of premium-quality insulation and commercial roofing, along with glass fibers and nonwovens for commercial, industrial, and residential applications. Their operations are wide-ranging and demand high standards for every product component, including packaging.
Before teaming up with BestPack, Johns Manville was up against a real packaging dilemma. Sealing the tops and bottoms of their tall, wobbly cartons was no easy task, especially when dealing with a wide range of insulation sizes for pipes.
Their old systems just couldn’t keep up with the height, weight, and unpredictability of these boxes. It was clear they needed an automated solution that could adapt on the fly to different carton sizes—without someone having to step in and make adjustments.
When Johns Manville partnered with BestPack, they didn’t just get a technology provider—they got a problem-solver. At BestPack, we take pride in making our clients’ lives easier. We understood the challenges Johns Manville faced, and we were ready to handle them.
With our experience, particularly at their sister facility in Louisiana, we were the right choice to eliminate their headaches. We took on the heavy lifting so they could focus on what they do best, knowing we had their packaging needs fully covered.
Johns Manville didn’t just choose BestPack because we had something off the shelf—they chose us because we built something just for them. We knew a standard solution wouldn’t cut it, so we rolled up our sleeves and created the CQD334L—a fully automatic random carton sealer with specialized side belt drives designed to keep those tall, tippy boxes stable.
This model was a direct upgrade from the previous lug drive systems that often damaged packaging and led to product wastage. The new BestPack machine features advanced sidedrive systems, ensuring secure and damage-free sealing that adapts to various carton sizes and conditions, effectively minimizing waste and enhancing package integrity.
The installation and integration of the BestPack system into Johns Manville’s operations were completed within two weeks, with minimal disruption to ongoing processes.
The BestPack machine was specifically customized to handle Johns Manville’s heavier and taller cartons, accommodating boxes over 100 lbs and 36 inches tall without compromising the integrity of the cartons or their contents.
When Johns Manville transitioned to BestPack’s custom solution, the shift was seamless. Their team quickly got up to speed with the new equipment, and the benefits were immediate. The system not only required far less maintenance than what they were used to, but it also elevated their entire packaging operation.
With fewer interruptions and smoother operations, efficiency soared. The precision in tape application improved dramatically, ensuring every carton was sealed securely with a clean, professional finish.
Packaging speeds have been significantly enhanced with the new BestPack system, now reaching up to 12-15 cartons per minute. This improvement is a substantial boost during high-demand cycles, reflecting a marked increase in efficiency over the previous rate of 8-10 cartons per minute.
This smooth integration and boost in performance proved that choosing BestPack was the right move for taking their packaging to the next level.
Despite one incident with heavier boxes, which was promptly resolved by adjusting the air pressure settings, the BestPack equipment has proved to be remarkably reliable. Comparatively, the BestPack carton sealer has significantly outperformed previous systems, with fewer interruptions and reduced maintenance demands.
The financial impact of the BestPack solution is quantifiably strong, with an estimated Return on Investment (ROI) of about 5 years. This is based on significant reductions in excess packaging costs and labor expenditures, proving not just operational efficiency but also cost-effectiveness.
The noticeable reduction in downtime and slashed maintenance costs have been game-changing. BestPack’s reliable technology freed up valuable manpower, allowing staff who were once tied up with constant machine fixes to be reassigned to more productive and impactful roles.
This shift didn’t just streamline operations; it empowered Johns Manville to focus on what truly matters—driving growth and delivering excellence. For BestPack, this is what we strive for in every partnership: creating solutions that don’t just solve problems but open doors to new possibilities and greater success.
At BestPack, innovation isn’t just a buzzword—it’s the backbone of everything we do. Our commitment to customization and continuous improvement means we don’t settle for one-size-fits-all solutions.
Instead, we dive deep into understanding our clients’ unique challenges and needs, creating tailored solutions that not only meet but exceed expectations. This relentless pursuit of better technology and smarter designs keeps us ahead of the curve, ensuring our solutions are always ready to tackle the ever-evolving demands of the packaging industry.
Whether it’s enhancing existing systems or developing entirely new technologies, BestPack’s proactive approach guarantees that our clients stay at the forefront of packaging excellence.
The partnership between Johns Manville and BestPack is more than just a business relationship—it’s a forward-looking collaboration built on trust and shared goals. As Johns Manville continues to evolve, so too will their packaging needs.
With BestPack’s proven flexibility and commitment to innovation, the path ahead is full of promise. Whether it’s refining current processes or expanding into new packaging territories, BestPack stands ready to adapt and grow alongside Johns Manville.
This ongoing collaboration not only ensures that today’s challenges are met with cutting-edge solutions but also that future opportunities are seized with confidence and agility. Together, we’re not just meeting the demands of the present—we’re shaping the possibilities of tomorrow.
The partnership between Johns Manville and BestPack highlights the transformative power of innovative, tailored packaging solutions.
By addressing specific challenges and enhancing operational efficiencies, BestPack didn’t just improve Johns Manville’s packaging processes—they redefined them. A critical part of this success is BestPack’s ongoing commitment to customer excellence, now further strengthened by our brand-new BP360 program.
This comprehensive support initiative provides everything from extended warranties and real-time data insights to AI-powered assistance and exclusive resources, all designed to ensure our clients’ packaging systems run smoothly and efficiently.
With BP360, BestPack isn’t just a technology provider—we’re a partner dedicated to maximizing your uptime, boosting your productivity, and ensuring your long-term success.
This case study not only underscores the value of targeted technological solutions but also reinforces BestPack’s role as a leader in delivering cutting-edge, reliable packaging systems that truly help our clients thrive.
Reach out and see how we can help your business too. You’ll never know without making the first step.
Given the remarkable improvements achieved, Johns Manville confidently endorses BestPack’s solutions to any business aiming to elevate its packaging operations. The success of this partnership highlights BestPack’s unwavering commitment to customer-focused innovation and their ability to deliver solutions that truly make a difference.
With a proven track record of enhancing efficiency and reliability, BestPack is the partner you can trust to take your packaging to the next level—no matter the challenge.
Here’s the result of the system in progress:
