What’s new at NewCorr

A Q&A with Vice President and General Manager Dan “Rhett” Bartlett

NewCorr Packaging, a sheet feeder in Northborough, Massachusetts, became affiliated with Schwarz Partners in 2020 and celebrated its 30th anniversary in 2021. Vice President and General Manager Dan “Rhett” Bartlett has been part of NewCorr most of that time, rising through the ranks from his first role as a stacker operator in 1992. In this Q&A, Rhett shares what it’s like to be a successful leader of a successful sheet feeder operation.

Tell us about your history.

NewCorr was formed in 1991 when Hans Hoch went to local entrepreneurs with a proposition: To invest in a company that would supply its partners with quality sheets and great service — something greatly needed at the time. Before NewCorr, it was common for customers to wait weeks for orders to be filled. Today, most orders are ready within 48 hours. The partners put a lot of faith in NewCorr, and we’ve worked hard over the past 30 years to honor that faith.

Who are your customers?

Our six partners are our shareholders and primary customers. Outside sales are less than 4%. All our partners are located within 150 miles of the plant, though there are a few divisions outside of this range. We have a strong working relationship with our partners. We recognize how important they are to our success and how important we are to them. We do whatever it takes to keep them supplied.

Tell us more about what you produce.

We offer several different flue profiles: From tallest to shortest, they are C, B and E. We can combine B and C or B and E, making double-wall. We carry various grades of paper that range from 90 pounds down to 18 pounds, and we routinely run specialty coated or pre-printed paper. Our average order size is 4,500 lineal feet, but we routinely have less than 500 lineal feet orders. In 2021, we shipped 2.14 billion square feet, with an average waste of 6.5%. Currently, we average 9,800 MSF produced per day, with 94% uptime.

Can you tell us a bit about the plant itself?

The first building we chose back in 1990 fell through at the last minute. We scrambled to find an alternative and were lucky to do so on short notice. The building we found is the building where NewCorr is located now. Built in the late 1980s, the original building was 100,000 square feet on rail. We made some modifications, removed some office space and squeezed in the 87-inch double-wall corrugated. In 1998, we added 46,000 square feet to accommodate a second corrugator. We were told no further expansions were possible, but that proved to be untrue. In 2019, we broke ground on a third expansion, adding another 40,000 square feet. Then COVID hit, which greatly impacted the project. Despite those challenges, we got the project done. We received the occupancy permit in 2020.

What about your equipment?

We have a very intricate process where we’re preparing to relocate some components of our oldest matching to our newer ones. That’s been keeping us busy!

Our original corrugator, installed in 1991, is an 87-inch Isowa double-wall machine. Over the years, various components have been replaced; it now has a Isowa wet end with a Fosber dry end. The second corrugator, installed in 1998, is a single-wall machine with an Isowa wet end and a Fobser dry end. The only changes have been adding a JKSP heat transfer system, Kohler water deck and dual high wall LCDs.

In early 2023, we’ll begin replacing the 87-inch corrugator with a 110-inch BHS double-wall machine. Some newer components will be refurbished and moved over to the single-wall line. A Ducker conveyor will combine the two.

What’s the work culture like at NewCorr?

People are the most important part of our company. We believe every person and every position are equal, one no more important than the other. We promote this with our actions. I always say, “Jump in and help wherever and whenever you’re needed.”

People’s opinions matter here. At our weekly meetings, we want to hear people speak up. Like most plants, we talk about safety, staffing, production, waste, maintenance, customer service and scheduling. But our meetings are also a forum where people can share opinions and ideas.

We also like to get together as a company. Every year, we host an all-company outing. For the past few years, we’ve held it at Kimball Farm. It’s a large outdoor venue with zip lines, face painting, a petting zoo, mini-golf, bumper boats, etc. We set up a tent where employees can eat barbecue and ice cream. It’s a great way to learn more about people and interact with families outside of work.

How has NewCorr changed over the years?

As a startup company, we experienced the same growing pains any company does. Through the years, we’ve gained both experience and knowledge. Having many long-term people has benefited us, too. Our partners have enjoyed continued growth and advancements within their own companies, which has allowed us to expand our operation from one corrugator running two shits to two corrugators running 20+ hours per day. We operate at higher levels of efficiency now.

Can you tell us about your own career progression?

Growing up, my brother and I worked for my father, who owned and operated a golf course construction company. I learned how to run multiple pieces of heavy machinery at a young age — long before I had a driver’s license! I also learned about hard work.

When I took a job at NewCorr, during the off-season in February of 1992, it was supposed to be a temporary move. The move has now lasted 30 years. After a few months, I started as a stacker operator and moved to the control room. From 1995-2000, I was a shift supervisor, working first, second and third shifts. From 2000-2018, I served as plant manager. I became vice president and general manager in 2018.

What’s your leadership philosophy?

Henry Ford said,” Don’t find fault. Find a remedy.” That’s the essence of it. I believe in leading with my actions and choosing the right way instead of the easy way. I believe in creating a culture based on hard work, respect and a family-first attitude. I don’t believe any one job is more important than another. We’re all part of a system, and if one part is struggling, we all feel the effects. I encourage everyone to pitch in and help where and when needed, regardless of their role. I wouldn’t ask someone to do something I wouldn’t do myself, and I stress this to our managers.

Tell us about the people at NewCorr.

We’re very fortunate to have so many hard-working people at NewCorr. Many people have contributed to our success over the years. They keep us going.

What’s your relationship with Schwarz Partners?

Schwarz Partners took over the management portion of NewCorr at the end of 2020. Prior to that, we were with a different management company. Since making the transition, we’ve had an opportunity to interact with different people on various levels. We have access to resources for training, human resources and staffing, legal matters and engineering. It’s nice to be able to collaborate. For example, Schwarz engineers Barry Sharesky and Tom Grace have been extremely helpful with our corrugator project. We have lots of work ahead of us, and we’ll be better prepared with their help.

I look forward to strengthening our relationship with each plant, so we can support each other. It’s amazing how similar each plant is — not necessarily the buildings or equipment, but what we contend with on any given day.

What do you see in the future?

Industry-wise and for NewCorr, it’s very favorable. Right now, corrugated is in high demand, and it seems that will be the case in the near future. With the addition of a new corrugator, we’ve increased our capacity and flexibility, and we look forward to growing and supporting the growth of our partners.

What do you do when you’re not at work?

I spend most of my free time with my family. My wife, Kim, and I have three kids: My son Camden is 14, my son Cooper is 12 and my daughter Macie is 8. All are active with school and sports. I coach baseball and I’ve also coached soccer. Camden and I like to play golf, and we all enjoy hiking. In winter, we ski and snowboard.

What advice do you have for others who want to advance in their careers?

If you really want to advance your career, go where the opportunities take you. Even if that’s on second or third shift. Don’t be stuck in a role because you’re comfortable. Put in the effort, continue to learn and you’ll be rewarded.

Have questions about NewCorr? Get in touch with Rhett at rhettb@newcorrpackaging.com.