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April 10, 2012

Rengo Conducts Large-Scale Refurbishment of its Tonegawa Division
Combines Diverse Business with Green Initiatives

Rengo Co., Ltd. (Head Office: Kita-ku, Osaka; President & CEO: Kiyoshi Otsubo) announces that it has completed a major refurbishment of its Tonegawa Division (Bando-shi, Ibaraki Prefecture). The Division, which is one of Rengo’s key divisions, is comprised of three plants involved in paperboard production, printing and converting, and the production of folding cartons including multi-packs, is one of Rengo’s largest facilities by site area. This multi-faceted site, unique even within the Rengo Group, has undergone a large-scale refurbishment.

In addition to producing approximately 320,000 tons of paperboard annually (including containerboard and boxboard), the Division supplies a wide range of products and services in order to meet customers’ diverse packaging needs. This includes the printing of processed paperboard for decorative corrugated packaging, as well as the manufacturing of processed paperboard with a variety of features, such as water-resistant and anti-corrosive properties, and folding cartons, particularly multi-packs.

The refurbishment of the Tonegawa Division was conducted as a project to commemorate the 50th anniversary of the site, which began operation in October 1961. The project’s main initiatives were the establishment of a biomass incineration facility, remodeling of the No. 1 paper machine for boxboard, construction of an automated rack warehouse at the folding carton plant, and a complete rebuild of the main office block. In addition to rationalizing and streamlining operations, the project also aimed to build a production system whereby Rengo’s key environmental concept of “Less Weight, Less Carbon” could be realized, and whereby ideal types of packaging that are lighter and thinner and cause less CO2 emissions could be created.

As a key division of “General Packaging Industry” Rengo, the Tonegawa Division will continue striving to contribute to local communities and to meet its customers’ packaging needs through continual innovation, aiming for packaging manufacturing that is friendly to both people and the environment.

 

Key Aspects of the Refurbishment

1.

Establishment of biomass incineration facility

A biomass incineration facility has been constructed to effectively utilize paper sludge and other waste emitted from the plant’s paper production process as boiler fuel. By efficiently utilizing paper sludge, which had previously been incinerated as waste, it is anticipated that CO2 emissions will be cut by approximately 6,000 tons per year.
2.

Remodeling of the No. 1 paper machine

 

Machines used in the first step in the papermaking process, known as the wire part, have been upgraded, further improving the quality of boxboard (clay coated board), including making it easier to print on.

3. Construction of automated rack warehouse at folding carton plant
 

By automating the shipping of products into and out of the warehouse, the new machinery improves the efficiency and safety of operations, as well as allows inventory control using IT systems.

4. Complete rebuild of main office block
  The new building was designed with a comprehensive focus on environmental-friendliness, including energy-saving measures. In addition to installing solar panels on the roof for the photovoltaic power generating system, the office has been fitted with LED lighting and movement sensors that automatically switch off lights when no-one is present.
5. Effective utilization of natural energy
  Rengo is working to make full use of natural energy. In addition to the main office building, solar panels have also been installed at other sites, and lamps lining onsite roads are powered by miniature wind turbines.

 

Biomass incineration facility

Biomass incineration facility


 

No. 1 paper machine

No. 1 paper machine


Automated rack warehouse for folding cartons

Automated rack warehouse for folding cartons


 

Main office building

Main office building


The photovoltaic power generating system on roof of main office

The photovoltaic power generating system on roof of main office


 

Street lamps powered by wind and solar energy

Street lamps powered by wind and solar energy


 

Overview of the Tonegawa Division

Name

Tonegawa Division, Rengo Co., Ltd.
(paper mill, printing and converting plant, folding carton plant)

Location

5269 Iwai, Bando-shi, Ibaraki Prefecture, Japan
Tel: +81-297-35-2301

Operations commencement

October, 1961

Division General Manager Osamu Nishimura, Managing Executive Officer
Site area 268,122m2
Total floor area

104,474m2

Number of employees Approximately 300
Products Containerboard (linerboard), boxboard (clay coated board), pre-printed containerboard, various types of processed paperboard, bag-in-box containers, multi-packs