Zacpac Goes Operational with New $25m Plant in QLD

Zacpac Goes Operational with New $25m Plant in QLD

Zacpac, the family owned packaging company, has just extended its reach across the east coast through the unveiling of a brand new $25m manufacturing facility stretching over 8,000sqm in Stapylton, near Queensland’s Gold Coast. The ribbon was cut on the factory, which is now operational, while the management offices are still under construction.

The new facility will significantly expand the company’s production of its corrugated packaging, litho laminated packaging, and litho cartons when it is fully operational in early 2015. By the end of this year, the new production hub will employ 30 people. Director John Zac hopes to grow this to more than 100 in the following year, while increasing production and services from northern NSW to North Queensland.

One of the first machines to go into the Stapylton stable, a BCS Autobox automated custom box maker supplied by DES, is now firing out boxes in runs as short as one.
The Autobox can manufacture boxes in any size or shape that the customer requires – from a small cupcake box up to a double sized fridge. It shifts from one style or size to another automatically, and starts producing straight away.

The new production hub will complement the company’s existing distribution warehouse on the Gold Coast and shorten turnaround times for customers based as far north as Cairns. The company has grown by more than 30 percent year on year over the last three years, and is now in the midst of a massive development, thanks to enticing some major multinational clients in the food and beverage, personal care, and wine markets.

John Zac, a company director, said, “The latest expansion is all about living up to new clients’ expectations while maintaining service for our existing customers. Our customers expect us to deliver the most excellent of services, high quality, and the quickest possible turnaround, and we commit to delivering exactly that from order placement to delivery.”

“As we introduce a new machine, we install it and get it up and running. So we are slowly adding the next machine, and the next, and so on, to get production going at the new site. A project like this does not happen overnight. We will begin employing new staff as we add new machinery, and with each new machine we install, we will need more people at the company, thus creating more jobs.”
Zacpac is the recipient of the first full installation of this kind in Australia, and the machine at the Stapylton plant will produce boxes for the whole group.

“The machine suits the company’s focus on shorter runs, which sets them apart from larger competitors who accept only high volume, high output jobs. As well as our big multinational clients, our customers also include mum and dad businesses working out of rental factories, who may only order 150-200 boxes at a time,” added John Zac.

“While our machines are also high speed and high output, we go shopping for specific equipment like the Autobox to serve shorter runs. Even with our high-speed machines we can produce runs of just 250 boxes. Our opposition’s minimum is more like 2500.”

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