Key Container adds Vanguard SFG Singlefacer

May 1, 2025

Original article reposted from the IPBI Magazine

BW Papersystems is advancing one of its most trusted machines with the introduction of the Vanguard SFG Singlefacer. This next-generation singlefacer integrates the latest automation and process control technologies and is designed to improve board quality, productivity, and operational efficiency. Advanced moisture control systems condition both the liner and medium webs, ensuring optimal bonding across all paper weights and types. Operators can now produce high-quality singleface board at high speed with greater ease. Additionally, the machine’s automated diagnostics and monitoring capabilities provide real-time insights, allowing operators to identify and address potential issues before they impact production.

Key Container’s Experience with the Vanguard SFG

Key Container, a corrugated packaging manufacturer based in South Gate, CA, has been a cornerstone in the industry for over six decades. Today, under the leadership of owner Bob Watts and his son Hunter Watts, Key Container remains dedicated to innovation and efficiency in the corrugated packaging sector. The company prides itself on its advanced manufacturing technology, handling the entire production process from paper to finished boxes. This vertical integration ensures that they can maintain high standards of quality control and meet the diverse needs of its customers.

When the team at Key Container decided to upgrade their singlefacer, they sought a machine that would enhance efficiency, improve board quality, and integrate seamlessly into their existing operations. The Vanguard SFG from BW Papersystems was selected to meet these demands.

From the outset, the installation process was smooth and efficient. Hunter Watts, Sales and Operations Manager, described it as one of the best machine installations they have experienced, with minimal disruptions to production schedules. “It’s pretty much the smoothest one we’ve had,” said Watts. The quick installation meant they were able to resume full production ahead of schedule, reducing downtime and continuing to honor customer commitments.

Following the installation, they immediately noticed improvements in operational efficiency. The Vanguard SFG allows for increased production speeds, reducing the time required to produce board. “We’re running faster. We can turn out more board in less time, and that’s saving us money on labor,” Watts explained.

Before upgrading to the Vanguard SFG, Key Container had struggled with board crushing issues that impacted product quality and led to customer complaints. The advanced automation and precision controls of the new singlefacer have effectively eliminated these problems. “We were getting some crushing complaints before, but since replacing the singlefacer, that issue has been resolved,” Watts said. This has resulted in a noticeable drop in defect rates, leading to fewer reworks and greater customer satisfaction. The Vanguard SFG’s automation capabilities have also streamlined the production process, reducing manual adjustments and improving overall consistency. Watts expressed satisfaction with the machine’s advanced control systems. Watts added, “We wanted something that had a lot more automated controls, more features, and something where we could turn out more quality board with less manual adjustment – and we’ve been able to do that.”

The intuitive user interface allows operators of varying experience levels to efficiently manage production, reducing training time and increasing overall operational effectiveness.

Advanced Automation for Safer, More Efficient Operations

The Vanguard SFG incorporates a suite of automation features designed to enhance productivity, consistency, and safety in corrugating operations. Key features include:

Automation to simplify operation: the automated glue gap control, corrugating roll loading, pressure roll loading, and medium tension control allow operators to run high quality singleface board at maximum machine speeds with minimal manual intervention.
Automation to drive consistent board quality: the moisture control system precisely manages liner and medium preconditioning, ensuring consistent bonding and reducing defects. The system adjusts automatically based on production variables, reducing inconsistencies.
Automation to reduce downtime: advanced diagnostics and real-time monitoring provide alerts for potential issues, minimizing unscheduled downtime. Additional features such as glue level sensing and a glue roll pre-rinse cycle improve operational efficiency and machine cleanliness. The system also allows for predictive maintenance, helping to prevent unplanned outages.

Redefining Singlefacer Technology

As part of BW Papersystems’ ongoing innovation strategy, the Vanguard SFG integrates cutting-edge automation and process control to redefine industry standards. By utilizing intelligent sensors and automated adjustments, the singlefacer is designed to reduce waste, increase energy efficiency, and maintain consistent production quality. Jeff Gafner, P.E., Senior Vice President, highlights BW Papersystems’ commitment to industry innovation. He said, “Through a relentless commitment to innovation, we are reshaping the future for corrugating lines. We are not just meeting industry standards – we are defining them, creating solutions that drive the next generation of operational excellence for our customers and a vibrant future for our team members.”

A Future-ready Solution

The Vanguard SFG represents a step forward in corrugated manufacturing, offering a combination of automation, reliability, and efficiency. With its ability to streamline operations, improve board quality, and reduce downtime, it is designed to meet the evolving demands of the industry. Companies investing in the Vanguard SFG can expect greater consistency, reduced labor costs, and increased throughput, providing them with a competitive edge in the market.

As the industry moves toward greater automation and process optimization, BW Papersystems continues to lead the way with innovative solutions that help manufacturers achieve new levels of efficiency.

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With the acquisition of the ServoPro we have notably reduced the set up time and also increased the productivity of the machine both in quality and quantity.

Luca Lazzaroni, CEO of Icierre Pack, Italy