US-based manufacturer Golden Eagle Extrusions is experiencing strong growth as it benefits from the increasing popularity of flexible packaging for food applications.
The company produces custom film laminations, coextruded films and bags, and specialty lidding films, among other products. It turned to UK manufacturer Ashe Converting Equipment for slitting and rewinding of its laminated films, in a partnership that began nearly 13 years ago and which has resulted in four installations of two different Ashe slitter models.
Market leader
Golden Eagle Extrusions was founded in Cincinnati, Ohio, in 1978 by Paul Eagle, With a degree in chemistry, he initially operated out of his basement – and then his garage – creating formulations for food protection and producing films and bags for fresh-cut produce.
Rapid expansion and a move to a state-of-the-art facility led the company to become a market leader in films for the food packaging market. Today, it produces custom film laminations, coextruded films and bags, specialty lidding films, hot needle perforated films, and custom print.
Food packaging makes up nearly 90 percent of the company’s business, with industrial applications – such as bulk packaging for corrugated piping, and protective packaging for goods stored outside – taking the remainder.
‘The move from rigid packaging to flexible packaging such as stand-up pouches has been a huge market trend in recent years,’ says Chad Weikert, who joined Golden Eagle in 2000 and currently serves as CEO. ‘They offer better preservation for your product, take up less space and are lighter. Flexible packaging continues to grow at a strong rate and we are seeing more and more of it in supermarkets.’
Golden Eagle is SQF (Safe Quality Food) certified. ‘We had an unannounced audit early this year and scored 100 percent – we’re very proud about that,’ says Weikert. ‘Being SQF-certified allows us to expand our footprint in the flexible packaging industry, by servicing a greater variety and number of global and elite brands.’
Capabilities
Around 16 years ago, Golden Eagle moved into laminating and converting. ‘It was a natural step for us in terms of adding capabilities,’ explains Weikert.
The company installed a 60in Nordmeccanica Super Simplex SL in 2010 and a second in 2020. For slitting machinery, it turned to UK-based manufacturer Ashe Converting Equipment.
‘We did a great deal of research on slitters and went to a lot of trade shows,’ recalls Weikert. ‘Ashe was the outstanding candidate. Service is key, particularly when dealing with a foreign company, but Ashe’s US subsidiary could supply parts and technical support. I called a couple of companies who I knew used Ashe’s equipment – no one had anything other than positives to report.
‘We wanted to have machines with longevity, and this was a key point about Ashe’s equipment – these machines last. They also offer a variety of equipment, so we could start with a lower-cost machine. We liked that they offer a great deal of customization: you can design what you want in the machine.’
Golden Eagle installed an Onyx slitter from Ashe Converting in 2013, the UK manufacturer’s entry-level system, and then a second three years later. In 2019, seeing strong growth and increasing opportunities for its laminated and converted films, it added a Diamond slitter, which contains more advanced features resulting in less machine downtime. A second Diamond – Golden Eagle’s fourth slitter from Ashe – was installed in 2022.
The transition between the two machines was seamless, according to Weikert. ‘If you can run one model, you can run them all. We move our operators around a lot, so it’s great that anyone can run any of the slitters. That’s not normal among many slitter models – an upgraded machine sometimes requires a steep learning curve. But with Ashe, it’s all the same operating system.’
‘Golden Eagle is a key customer of ours. They produce high-quality products and it’s a privilege to do business with them,’ says Matthew Godbold, sales director for wide web machinery at Ashe Converting Equipment. ‘We have a large number of installations in the US across all our machine ranges. They are serviced through our subsidiary in Vermont where we have service technicians and spare parts available.’
Growth
While the bulk of Golden Eagle’s business continues to be coextruded films, its fastest-growing sector is specialty lidding films. ‘We made it our mission to develop a one-size-fits-all lidding film,’ says Weikert. ‘As food processors moved towards ready-made meals, the market shifted to packaging with lidding films, but there wasn’t a supplier which could produce a film to adequately supply the market. Previously, the film had to match the substrate of the tray.’
Golden Eagle’s universal seal lidding films can adhere to all types of trays and cups, no matter the substrate. Available in clear, white, metalized, foil and also in retortable form, the lidding films can be printed, microwaved, and are available with customized peelability levels. Depending on the application, the company can incorporate micro-perforations, macro-perforations, slit vents, anti-fog and high-clarity additives.
‘Our lidding production is growing every year. It hasn’t overtaken the coextruded side yet, but it’s our fastest-growing sector,’ says Weikert.
Weikert says the US flexible packaging market has been steady this year, despite tariffs causing some uncertainty. ‘There has been less purchasing of equipment because of the fluctuations, but the market has been settling down. Reshoring has been good for us – companies who were previously importing their packaging materials have come to us instead.’
Laser-perforation technology is a potential next area of investment for Golden Eagle Extrusions. ‘It would replace our micro-perforation equipment as it is faster and easier to control thanks to its automation,’ says Weikert. ‘We are not actively considering more slitting and rewinding equipment, though I wouldn’t be surprised if next year we were looking to buy. We would 100 percent buy another Ashe machine.’
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