SUN Automation’s ongoing evolution 

Over the past 18 months, SUN Automation (SUN) has been undergoing a significant transformation, making strategic investments to improve efficiency and productivity. A major part of this effort has been optimizing its facilities. The company recently expanded its distribution center, integrating advanced Kardex Remstar vertical lift modules to streamline inventory management. “These machines operate like two-story vending machines, retrieving inventory much faster than humans could,” explains Pat Carner, Senior Vice President of Operations. By automating these processes, SUN has significantly reduced order fulfillment time while allowing its team to develop new skills rather than replacing jobs. 

“Two machines were implemented two years ago, and we are currently incorporating two more as we speak,” says Carner. “In addition, we also moved all the racking, including the cantilever, pallet racks, and about $20 million worth of stock inventory. It’s very important for us to manage all this while continuing operations, building machines and servicing our customers, so that they don’t experience any disruption at all. We did a study of how many steps it takes versus this automated element. With just one sales order, it saved over 30 minutes. One of the benefits, contrary to the common fear that it will replace human jobs, is that you can achieve more with the same team of people, and they also acquire new skills.” 

Another major development is the launch of SUN’s heavy-duty rotary die cutter. “We got some feedback that customers weren’t able to make what they wanted with the old version because it wasn’t beefy enough. We believe we now have one of the most robust units in the industry,” says Carner. Several units have already been delivered, reinforcing SUN’s commitment to responding to customer needs with innovative solutions. 

As the company celebrates its 40th anniversary, Carner attributes SUN’s longevity to its 100 percent employee-owned structure. “Our competitive advantage comes from our agility and adaptability,” she says. With a workforce of just around 150 employees, the company can pivot quickly to meet customer demands in ways that larger corporations often cannot. “Because we are all owners, we manage money as if it’s our own – because it is,” she adds. This approach has allowed SUN to remain debt-free, enabling reinvestment in technology, customer service, and product development. “It makes a remarkable difference in how employees approach solving a problem because they know that any savings can be reinvested. For example, when we bought this building, we managed to pay the mortgage in about half the time we could have. Because of decisions like this that play out across the business, we are debt-free. There aren’t many companies that can say that.”

Vital relationships 

SUN’s commitment to customer relationships is another key differentiator. The company goes beyond contractual obligations, ensuring long-term partnerships by addressing issues proactively. “If it’s the right thing to do, we’ll fix it – whether it’s under warranty or not,” Carner emphasizes. “We also view our customers and our suppliers as partners, in the same way as our employees. These are all vitally important relationships that should benefit everyone involved. This approach facilitates our excellent levels of service. Our customers tell us they really value this. It sets us apart from the bigger, more bureaucratic organizations. We can make decisions quickly because we are all owners.” 

Looking ahead, the company is investing in automation and digital label printing, collaborating with Domino in the UK. SUN’s smart system, Helios, enhances this process by using machine learning to provide predictive maintenance and operational insights. “Helios is machine-agnostic, which our customers love. Instead of managing multiple systems, they can rely on one,” she notes. The subscription-based service has been well received, further cementing SUN’s role in advancing IIoT solutions for the corrugated industry. 

With machine orders booked through mid-2026 and ongoing advancements in rotary die-cutting technology, SUN’s next five years promise even more exciting innovations. The company is exploring ways to replace traditional gear-driven mechanisms with servo motors, a development that could significantly enhance efficiency. As SUN continues to evolve, its dedication to innovation, employee ownership, and customer service remains at the core of its success.  

www.sunautomation.com