The Caesarea Plant
Carmel Container System's new
Caesarea plant, representing an investment in excess of $40 million, contains technologically
advanced systems which make it one of the most sophisticated manufacturing facilities of its
type in the world. The plant, situated in the new Caesarea Industrial Park, covers some 90
hectares, with options for expansion in the future. The buildings themselves cover an area
of 35 hectares and incorporate all phases of production starting with the design, planning and
development of packaging systems, continuing with cutting-edge technology in the manufacture
and conveyance of work in process, and including expansive, fully-computerized warehousing
facilities. The two manufacturing facilities (one for corrugation, the other for converting
and finishing) are adjacent to the office building in which the company's management, sales
and marketing, product development and graphic design offices are situated.
The pre-planning and subsequent phases of construction benefited from the participation of
a team of local and internationally recognized experts in the field. Their teamwork resulted
in dramatic cost reductions and shortened the time required for execution of the project by
close to 50% from standard timetables for such a project.
The plant was built using advanced construction methods, and features broad, unsupported expanses.
The roof, of lightweight construction, is translucent above the work areas, thereby eliminating
the need for costly artificial lighting during daylight hours. The various work areas within
the factory area are separated from one another and isolated by means of large sliding metal
doors with automatic locking mechanisms, and fire-resistant walls. The fire fighting system
includes a private water storage facility with a 1,000 cubic meter capacity.
Work flow throughout the factory is facilitated by a completely computerized materials handling system.
The visitor to the factory immediately notes that all materials are automatically transferred from
station to station on an intricate system of roller conveyors; no fork lift trucks are to be seen in
the manufacturing areas.
The production of corrugated sheets is carried out on two totally automated production lines composed of
the most modern and technologically advanced systems available. The lines are fully computerized and
monitored from overhead control rooms. The newer of the two units, designed and constructed specifically
for this plant at a cost of over $8 million, produces corrugated sheets at a speed of 18 kilometers per
hour. The second corrugator was constructed in part from existing units and partly with more advanced new
units in order to yield a highly efficient and modern corrugator.
The conversion of corrugated sheets into finished containers is carried out in an adjacent, similarly
computerized production area which contains, amongst other equipment, several 4-color flexographic printing
presses which are the most modern machines of their type in Israel. Fifteen additional machines are utilized
to carry out the die-cutting, folding and gluing processes. From the time the sheets leave the corrugator until
they enter the finished goods warehouse, no forklift trucks are involved in their conveyance. The entire material
handling function is performed by an automated system of roller conveyors, controlled by computers which keep
track of work in process and ensure the timely arrival of materials at the proper machines throughout the
printing, diecutting, stacking, tying, bundling, palletizing and final inspection stages, all without human
intervention. The new equipment described above makes it possible, for the first time in Israel, to produce
sophisticated containers with four-color process printing under fully automated quality and production control.
The resulting product represents a dramatic improvement in the quality of packaging materials being supplied for
exports as well as to the local market.
The finished goods inventory area covers approximately 7,000 square meters and allows for stacking of pallets
to a height of 4 meters. All pallets are automatically marked with bar codes and every fork lift in use in the
finished goods storage area is equipped with a wireless computer for the efficient storage and recall of each
pallet.
Worker safety, recycling and safeguarding of the environment were prime concerns in the design of the new Caesarea
facility. The planning and construction were carried out under the scrutiny of the Corporation for the Development
of Caesarea in order to ensure that there would be no emissions of noise, dust or other materials outside the
boundaries of the factory. All areas of the factory were designed with safeguards to assure and maintain
environmental quality. Not only did we surpass the most stringent demands; in addition we invested NIS 700,000
in the planting of gardens and development of the surrounding area.
The tanks required for chemicals used in the production of adhesives and for holding fuel oil required for the
production of steam were constructed in a specially protected area on a platform specially designed for containment.
Beneath the entire production floor is a vacuum system which collects all dust and paper scrap and conveys it to
the recycling recovery area. In this area the waste is baled and transferred to our sister company, Amnir Ltd.
(waste paper collection), and thereafter to our parent company, American-Israeli Paper Mills, for recycling into
raw materials which are used to begin the process anew.
An automatic system also recycles the water used in the production process. In the event of failure of local
water sources, the plant can continue to operate for three days on privately stored supplies.
After six years of operation the plant is consistently producing record quantities while the percentage of scrap
generated is being systematically reduced.
In February, 2002 Carmel Container Systems acquired from Aprion Digital (a spin-off of Israel's Scitex Corporation)
one of the world's first wide-format digital inkjet printers for direct printing on corrugated sheets and other
inflexible substrates. In so doing, we established ourselves as one of the pioneers in the corrugated packaging
industry to enter into the field of digital printing.