Full article appeared in May 2000 issue of International Paper Board Industry
- edited for website by Robin A. Sommers, Engineering Manager

In September 1982, John Donahue and his wife, Maureen, founded Donahue and Associates International, Inc. (DAII) in Cincinnati, Ohio. It was an action motivated by John's experiences as a corporate engineer at General Box and as Director of Engineering for Mead Container. He realized he could substantially improve the corrugated packaging industry's steam system procedures and technologies. An engineering graduate of the US Merchant Marine Academy, John had proven and remained convinced that steam system improvements would not only result in more efficient production, but would enhance quality. With Maureen's support and consul, and the commitment to never waver from their area of expertise, DAII forged ahead.

Customers are the ultimate judges of their suppliers' core competence. The core competency of a company is identified by its ability to make a significant contribution to its customers. Today, with the experience of more than 180 corrugator steam projects behind them, John, Maureen, and son, Michael, a mechanical engineer from Purdue University, have not only proven their proficiency, they have successfully positioned DAII as the premier steam system provider to the corrugated industry.

During his company's early days, John recognized that inconsistent heat in a corrugator steam system was a large factor in producing warped board. That fact led John on a mission to improve steam system temperature, control and efficiency. At the time, the fuel crunch compounded the problem. Donahue's first design idea was to incorporate a high pressure condensate receiver. This vessel accepts condensate returning from the corrugator maintaining its high energy content. The hot condensate is reused as boiler feedwater. Corrugator plants previously blew the condensate out through the roof. Considered revolutionary at the time, the maiden Donahue Steam System was the first of several generations.

John next began to identify flaws in stock steam traps. Again, he was determined to remedy and improve existing technology. In 1984 he unveiled the Donahue Steam Trap. It was eagerly accepted by the industry and has evolved into the recognized industry standard.

By the mid-1980's advancements in corrugated substrates heightened the need to control paper temperatures throughout the corrugating process. Donahue responded by designing a system that permitted the operators to independently control temperature in each section of the doublefacer. That technology is now applied to the singlefacer as well, resulting in the ability to control paper temperature along the entire corrugator.

Today the principle activities of Donahue and Associates International, Inc. fall into three categories: 1) Installing steam systems for new corrugators. 2) Providing new or updated systems for existing corrugators. 3) Providing service, maintenance and problem solving solutions for existing steam systems.

A new Donahue Steam System for a new corrugator is a large project. DAII is involved from the outset and maintains responsibility for the design and installation of the whole steam system. This includes laying out the boiler room, equipment to support the boiler, fuel, chemical and water systems, the steam distribution system and the condensate return system. Following the installation, DAII oversees commencement, fine-tuning and training.

Older steam systems falter for a myriad of reasons. Prior to offering a remedy, DAII conducts a thorough steam system survey. The survey provides a detailed snapshot of the existing conditions. Photos help illustrate problem areas. A survey is often conducted as a troubleshooting tool or to prepare for an upgrade.

In 1999 DAII incorporated the Donahue Boiler Room Safety Audit as a new service. The safety audit consolidates a complete boiler room evaluation into a comprehensive assessment report. Existing and potential problems are identified and presented with suggested solutions.

The extraordinary successes achieved by DAII are directly attributed to its people -their steam system expertise, understanding of the corrugating process, and focus on continuous product improvement.

DAII recently initiated programs addressing service, maintenance and training services. Their professional staff now includes an applications engineer whose sole focus is service - performing system checks, providing guidance and training and maintaining long-term relationships with existing customers. It is this kind of commitment to the industry that has virtually made corrugator steam systems and Donahue and Associates International, Inc. synonymous.