API Foils Inc. has found ways to consolidate its operations to improve efficiency when it moved 18 workers from its distribution and processing facility in Lenexa to Lawrence.

“There were too many steps in the old process,” API spokesman Bruce Ackerman said. “This is a step-reduction project. There were too many people driving back and forth from Lenexa to Lawrence.”

Joe Souders, engineering and quality assurance manager at API Foils Inc., says API's move from Lenexa to Lawrence went smoothly.

Ackerman said the company, which manufactures hot stamping foil used in a variety of packaging and greeting cards, decided to expand to Lawrence because the company owns the East Hills plant. It leases the Lenexa building. It also was easier to move its distribution operations than its manufacturing equipment.

The move from Lenexa to Lawrence was completed in September. Joe Souders, engineering and quality assurance manager at API, said the move went smoothly.

“There was an outstanding effort put forth by the employees,” Souders said. “One reason this move went so well was because of the work done by our in house personnel.”

Warehouse, sales, marketing and information technology jobs were created because of API’s move to Lawrence. API officials said say they had 40 employees in the production and 38 in administration and customer service. Some of the positions were vacated by employees unwilling to make the move or commute from Lenexa. These positions were filled in large part by local residents.

Souders said consolidating facilities had greatly increased API’s ability to respond to the market. By housing distribution and manufacturing divisions under the same roof, lead time for production in Lawrence has been reduced by one day. This approach also allowed API to cut the cost of over the road shipping.

“Approximately 60-70 percent of the manufactured material that used to arrive on trucks from our Lenexa plant, now comes on a pallet from across the hall,” Souders said. “The company that used to move materials for us did a great job, but operating like this is better in almost every way.”

Souders indicated the future of API Foils Inc. in Lawrence was bright.

“Our busiest time of year is the summer when companies are ordering tons of foil for Christmas packaging, wrapping paper and cards,” Souders said.

Souders remembered a few years back when he recognized a bit of foil from an order they had just filled.

“I realized it was the little label from our shampoo bottle at home,” he said. “This stuff is everywhere and you don’t even realize it.”