June 2013 Spray 29 new production line was validated and producing its first cans in September of 2012. The facility includes a new 200 pieceper minute aerosol can line with a nine-color printing press. “This location was chosen because Montebello Packaging had existing property to expand onto,” explained Zopf. “There are many synergies between making aluminum tubes and aluminum aerosol cans: the economics for manufacturing in Kentucky are good, and this location is fairly central to much of the aluminum can filling operations in North America, making this an ideal location for Montebello’s customers and the aerosol can manufacturing operations.” The Lebanon complex is a total of 220,000 sq. ft, with 100,000 sq. ft. for the aluminum tube plant and 120,000 sq. ft. for the new aluminum aerosol can plant. There are a number of shared roles between the two plants, such as warehousing, shipping and purchasing, and the total number of employees for the two plants is 128. There are six aluminum tubes lines at the tube plant, and one aluminum can line in the new aerosol can plant. This line can produce up to 60 million Always prepared… Montebello Packaging is currently developing an aluminum aerosol can manual for its sales force. It will contain much of the information that customers ask the Montebello sales team including: • Technical specifications for the cans and materials used in manufacturing • Can sizing formulas • Dimensional and volume conversion tools • Internal procedures and policies • Internal and outside industry contacts • Graphic design parameters, capabilities and guides • Promotional materials cans per year, and there is room for up to four more aerosol can production lines to be installed in this plant. Montebello is also opening a new research and development facility to develop new lightweight aluminum containers, new technologies to streamline processes and reduce costs, and new technologies to shape and form aluminum containers. In total, Montebello has five facilities. In addition to the two plants in Lebanon, KY, there is Corporate Headquarters in Hawkesbury, ON. The 100,000 sq. ft. facility is the center of all R&D and central administrative functions and also encompasses the manufacture of aluminum aerosol cans, aluminum tubes, aluminum markers, cigar tubes and other specialty aluminum products. The 187,000 sq. ft. plant in Harrisonburg, VA handles the manufacture of aerosol cans, laminate tubes; aluminum tubes; injection molding for closures and specialty aluminum products. The 60,000 sq. ft. plant in Lachine, Quebec specializes in laminate tube manufacturing operations; digital printing operations for the laminate tube material; product development and engineering; V-Mark automation division and Monfitello contract tube filling operation for food products. According to Zopf, Montebello’s tube filling operation for food products, Monfitello, is currently limited to filling only food products into tubes. “That is not to say Montebello would not be open to exploring expanding the capabilities of this facility to include limited contract filling operations for aerosol if the right opportunity presented itself,” he added. SPRAY
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