Rebel Conversion | Nonwovens industry
655 N. Delora Woods Blvd., Saukville, WI
With the ability to convert 2.1 billion square meters per year into wipes, Rebel Converting is a force in the coreless roll/box wipes industry. As a contract manufacturer, Rebel partners with its customers in the retail, healthcare and business-to-business segments to maximize the opportunities that exist in today’s market. “With the ‘hangover’ the wipes industry has been experiencing and post-Covid demand plummeting, Rebel is doing the exact opposite of what many others in the industry are doing by adding extra capacity and innovative new packaging options,” says Scott Meiller, COO’s Rebel Conversion. “The aspect of sustainability and the overall carbon footprint is critical to the future of our industry. That said, Rebel Converting has invested heavily in two complete injection molding cells, each with a 400 ton press, pick-and-place robotics to create fully digital in-mold labels.
Rebel’s X-Treme cartridges have been specifically designed for “hard-to-hold solutions” (such as solvent-based solutions), and they are also designed for customers who wish to reuse their cartridges. “In either case, traditional blow-molded canisters can’t withstand the pounding that X-Treme can,” says Meiller. “These HDPE canister “Sherman tanks” are extremely durable and can be used multiple times with Rebel refills.” Rebel refills are box-gusseted pouches containing pre-moistened wipes perforated with a micro-perforated, tear-off notch for convenience for consumers. Rebel claims its refills take up up to 99% less landfill space and use 96% less plastic.
The company notes another advantage of its X-Treme cartridges in the use of high resolution digital printing which allows Rebel to print any design, graphics and wording with “four times the resolution of a People magazine. Since each label is printed individually, labels can be numbered sequentially, have different sets of numbers, or be printed with unique images. Artwork changes are quick and cost effective, with no delays. Fully digital technology allows Rebel to provide customers with sample boxes identical to those in a final production run. It becomes easy to prototype canisters for customers to test new products in the market, various brands and label designs. Since the labels are molded – fused directly into the cartridge, they provide maximum durability – again important for reuse.
“At Rebel, where our motto is ‘YOUR wipes business is OUR business’, most of our customers (certainly not all – heck, everyone needs a second source) don’t produce wipes, it’s so it’s our job to make sure we’re maximizing the opportunities for those customers in their wipes offerings,” says Mike Kryshak, CEO.
Rebel has two facilities, each with identical equipment, where all have undergone extensive custom upgrades that give customers the assurance of production redundancy.
The company’s offerings include wet and dry wipes, alcohol-based and other solutions, fill-it-yourself wipes, unique folded box options, and small to “huge” containers. “When it comes to bent rolls, we pretty much invented them,” Kryshak explains. “Want a bigger towel without a bigger box, bucket or refill pouch? We fold the napkin in half and puncture it. All our coilers are equipped with our own folding plows. So whether you need 10,000 or millions of square meters of fabric converted into folded rolls, we have the capacity.
On unfolded rolls, Rebel performs high counts such as standard 1200, 1500, 2000 and even more.
Rebel’s quality and customer satisfaction is a main pursuit. For example, on high number reels, the focus is on more than cost, but also on value. End users pull out individual towels instead of boring multiple clumps. Proprietary technology ensures consistency from the first towel to the last.
The company prides itself on keeping the decision-making process simple, with no chain of command or private equity owner hurdles. Continuing to grow and deliver new market-driven designs to the wipes industry, Rebel Converting is committed to maintaining its leadership role.