SunDance Expands Orlando Campus Amid Surging Packaging Demand

ORLANDO, Fla. – January 30, 2026 – SunDance, a leading marketing, printing, and packaging solutions provider, today announced a significant expansion of its manufacturing capabilities with the addition of a new production facility. The move, effective in 2026, is a direct response to sustained client demand and aims to strategically enhance the company's service delivery for its national and Fortune 500 clientele.

The expansion consolidates the company's operations into a cohesive campus, with three distinct buildings located within walking distance of each other. This latest addition will house the company's folding carton, finishing, and mailing departments, along with much-needed office and meeting space.

"Adding this new production facility enables us to structure our operations and services more strategically," said JohnHenry Ruggieri, President of SunDance. "The newest building houses our folding carton, finishing, and mailing functions and adds some much-needed office and meeting space. All three buildings are within a quick walk of each other, so we essentially have three plants under one roof."

Riding a Wave of Market Demand

SunDance's expansion is not happening in a vacuum. It mirrors powerful trends across the global printing and packaging industries, which are experiencing robust growth. The global packaging market, valued at over USD 1.2 trillion in 2024, is projected to climb steadily, driven by the relentless expansion of e-commerce and a seismic shift in consumer and regulatory preference towards sustainable materials.

The folding carton market, a key focus for SunDance's new facility, is a particularly bright spot. Forecasts show this sector growing at a compound annual growth rate (CAGR) of over 4%, fueled by a market-wide pivot away from single-use plastics. As brands seek biodegradable and fiber-based alternatives to meet their environmental goals, the demand for high-quality, recyclable paperboard cartons has skyrocketed.

Simultaneously, the direct mail industry is demonstrating remarkable resilience and innovation. Far from being obsolete, direct mail volume is on the rise, with marketing executives increasing their investment in the channel. Modern direct mail campaigns leverage hyper-personalization and integration with digital platforms, making it a high-performing complement to online strategies. SunDance's decision to bolster its mailing operations positions it to capitalize on this resurgence, offering clients a full spectrum of physical and digital marketing tools.

A Strategic Investment in Technology and Efficiency

At the heart of the new facility is a significant investment in state-of-the-art technology designed to boost efficiency, quality, and capacity. The plant will be equipped with the newest generation of Heidelberg commercial printers, a brand synonymous with precision, automation, and high-speed output in the printing industry. These advanced presses allow for faster job setup, reduced material waste, and impeccable color consistency, enabling SunDance to handle more complex projects with shorter turnaround times.

A cornerstone of the new folding carton operation is the integration of an advanced inline camera inspection system. This technology is critical for ensuring flawless quality in high-volume packaging production. The system performs a 100% inspection of every carton as it moves through the production line at full speed, instantly identifying and flagging any defects, from minute color variations to registration errors. This automated quality control not only prevents defective products from reaching clients but also dramatically reduces waste and increases overall throughput, aligning with modern "smart factory" principles.

This technological leap is part of a broader strategic reorganization of the company's physical footprint. While the new building focuses on folding cartons, finishing, and mailing, one of the existing facilities will continue to serve as the dedicated large format printing plant, producing everything from banners and trade show booths to custom wall wraps. The original SunDance building remains the company headquarters and the hub for its flexible packaging and commercial printing operations. This intelligent division of labor across the campus is designed to optimize workflows and create centers of excellence for each service line.

Bolstering a Regional Manufacturing Hub

SunDance's growth contributes to a larger narrative of manufacturing resurgence in the Southeastern United States. The region has become a "mecca for smart manufacturing," attracting significant investment due to a skilled workforce, strategic infrastructure, and a business-friendly climate. As a key player in Florida's robust manufacturing landscape, SunDance's expansion reinforces the area's economic vitality.

The move not only signifies the company's health but also its role as a vital regional partner with a national reach. By expanding its capacity and technological prowess in Orlando, SunDance is better equipped to serve its diverse client base, which includes numerous Fortune 500 companies. This ability to provide world-class services from a regional base highlights a successful blend of local roots and broad market influence. The expansion strengthens the local supply chain and underscores the region's capacity to support large-scale, high-tech manufacturing operations.

A Deepening Commitment to Sustainability

This expansion also deepens SunDance's long-standing commitment to environmental stewardship. The company holds the distinction of being certified as the first offset Sustainable Green Printer in Florida, a credential that requires rigorous adherence to sustainability best practices. This certification, likely from the Sustainable Green Printing Partnership (SGP), involves comprehensive audits of waste reduction, energy efficiency, and responsible chemical management.

The investment in a new facility and cutting-edge equipment inherently supports these green initiatives. Modern printers like the new Heidelbergs are engineered for greater energy efficiency and reduced material waste compared to older models. Likewise, the inline quality control systems minimize spoilage, conserving resources and reducing the carbon footprint associated with remanufacturing.

Furthermore, the strategic focus on the folding carton market directly aligns with the global push for sustainability. By expanding its capacity to produce paper-based packaging, SunDance is actively helping its clients transition away from less-desirable plastic alternatives. This positions the company not just as a service provider, but as a partner in achieving corporate social responsibility goals, a crucial differentiator in today's environmentally conscious marketplace. The expansion allows SunDance to more effectively meet the surging demand for eco-friendly solutions, solidifying its reputation as a leader in sustainable printing and packaging.