From a Horse and Wagon Breaking Down Boxes

Welcome to Breaking Down Boxes. We have compelling conversations with entrepreneurs in the packaging space.
In this episode we talk with Bob Cohen, President, Acme Corrugated Box.
Bob Cohen’s family went from selling rags to selling used boxes to creating an innovative manufacturing company. With humility, Cohen shares his company’s story of growth and how he and his wife chose to give back to the community that supported them.
Spurred on by the tight market in the 1970s, Cohen went from being a distributor to a converter, starting with a used letterpress. Following his instincts, Cohen continued to grow the company and eventually brought his three sons into the family company.
About Bob
My name is Burton (Bob) R. Cohen, and I have been involved with my family business since 1969 after a short stint in the Army Reserves. I graduated from Central High School in Philadelphia and Penn State University, majoring in History (Bachelor of Arts). When I joined the company, we had five employees. We distributed corrugated packaging in the local market, and we generated annual revenues of about two hundred and fifty thousand dollars. In 1973, we purchased the first converting equipment, allowing us to produce corrugated packaging ourselves. Our start was primitive, but somehow, we survived in a market with better-equipped and more seasoned competitors. In 1980, the company moved from Philadelphia to the Bensalem area (a Philadelphia suburb). There, we occupied a 60,000 square feet facility, which allowed us to expand our manufacturing capability and add a larger workforce. We prospered there until the early 2000s and in 2001, we were given the opportunity to further integrate our manufacturing operation with the addition of corrugating capacity (2 Narrow Width Agnati Corrugators). This equipment acquisition necessitated our move to our present location in Hatboro. The new building has 234,000 square feet of manufacturing space. Looking around, we initially felt, “How will we ever fill this space!” We filled it a lot quicker than expected.
We had seen steady growth since the major recession of 2009, essentially increasing the sales volume by 75% by 2016. We continued to add converting lines as our business grew. Between 2016 and 2019, we had increased sales by 57%. We also added four additional converting lines in that same timeframe prior to the Pandemic. As our volume increased, it became apparent that we needed far more space and more converting lines. With a focus on our clients and their growing demands, we investigated how an expansion could be executed while the economy was in the throes of the Pandemic. Believing there is no going backward in business, we took the plunge. The plans drawn up would make us the most progressive and best-equipped independent converter in the Northeast region. So, in November of 2020, we began construction. We added 80,000 square feet (with heights of 40’”& 60’ to accommodate roll stock and the WIP system) and numerous new machinery including a 110” Fosber 1500 ft/min three stage corrugator, a Warak high rack WIP system developed in Europe, A Warak roll delivery system, full conveyorization of the entire facility (WSA & Ducker), a new waste and starch system, a dust collection system, the movement of entire departments within the facility and the addition of two new converting lines. The project was complete in April of 2023. At present, we employ 250 staff members, and presently our revenues are almost 2 times as great as our 2016 revenue had been.
Our Management Team includes our General Manager, Jeremy Cohen, with 23 years of converting and industrial engineering experience, our Vice President of Finance, David Platt, 34+ years of corporate financial reporting responsibility, our Human Resources Manager- Heidi Morrison, 37+ years in Employee Relations, Operations Manager, Joseph Hodges, 26+ years of production...