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The two-sided tape applying machine

Thu, 09 Feb 2012 10:07:51 GMT

Ansder Co., Ltd., founded in 2003 and a leading manufacturer of cosmetic assembly equipment in Taiwan, has released a high-speed “Two-sided tape applying machine” for attaching aluminum godets on compacts automatically. The new innovation brings practical benefits to cosmetic producers.

The base and case of machine are made of aluminum and stainless material. Ansder uses motor and cylinders that are made in Japan or by Japanese brand manufacturers in Taiwan, ensuring the machines work more accurately, with more stability, and more smoothly, so as to increase output and decrease the damage rate. PLC is taken according to Euroupean and Japanese specifications. Generally, Ansder uses a variety of global brands for the primary optional parts in order to have users incorporate local material urgently with less mechanical downtime.

Traditionally, workers have needed to cut, remove, and then attach two sided tape on the bases of compacts step by step. It seems a simple task but takes time. How many workers and how much time are needed to complete one million pieces? This machine is designed as a double station to expand output twice over. Each station can be operated individually. Therefore, users can have a single station or double station online, and can achieve outputs of 2,400/hr, 2 pieces at a time. High speeds, stable, and 24-hour operation are the machines best features.

''It is an amazing machine. We make it work 24 hours a day and it seldom has to stop”, said the machine's first user in Brazil. Ansder is confident in the design that brings a variety of benefits to those users that have a need for high output. The company offers a variety of solutions, and Ansder's elite R&D team also creates many other automatic machinery for cosmetic packaging assembly.

Packsys’ LTR2, a new era in side-seaming technology

Thu, 26 Jan 2012 11:13:39 GMT

Packsys Global, a world leader manufacturer of specialized equipment for packaging, has introduced the new LTR2 side-seamer, the only side-seamer in the world operating with a closed control loop, leading to exceptional process stability. With five years of success in legendary high quality seam technology brought by the LTR side-seamer, now is time for the LTR2, carrying over all the advantages of LTR including INVISEAM®. Among the innovations in the LTR2 are the possibilities for quickly changing the size over capability, as well as the next step in side-seam stability, the “A4S” system.

The size part change can be over in 10 minutes. Complete unit can be prepared off line and brought to the machine and exchanged via trolley. Trolley accommodates all size parts (i.e. forming belt, blade take up, etc.) and serves for maintenance and storage.

The new active side seam stability system “A4S”, is a closed loop system: additional sensors do continuously measure the laminate position and give feedback and instructions to machine and web guide controller.

Some of the advantages of the LTR2 are that guarantees stable and consistent seam quality; no additional skills are required to run Inviseam tube quality; and there isn’t any reduction in production ef?ciency for Inviseam as it detects abnormalities and adjusts, rejects, or stops the machine immediately.

It is also an energy efficient machine, since it uses a waterless system for tube ovality prevention. The new LTR2 is able to save up to 40% in air and water and electrical consumption. It also features an automatic splicing of web roll.

All of this advantages result in less waste, less operator influence... and more output!

Technical details:

Diameter range 19 – 63.5 mm
Body lenght 60 – 240 mm
Max. linear speed 36m / minute
Maximal cuts per minute 150

PACKstory: The Heavy Base Bottle

Wed, 01 Feb 2012 11:43:16 GMT

The technical aspects of the packaging industry normally remain hidden from the average consumer. There are, however, a multitude of issues that result in consumer acceptance or refusal, such as the much-valued heft of a product. Consumers prefer packaging that's sturdy and capable of resisting day to day use, and one of the best tests for this is the product's weight in the hand and its resistance to squeezing. Traditionally, varieties of plastic have fallen short with regard to heft when compared to glass or metal.

To change this perception, as well as offer other advantages , Pin Mao has developed what it terms the Heavy Base Bottle. The company's new product design features an exceptionally thick-walled bottom that gives the bottle extraordinary stability and an excellent, balanced weight. AND it's made of plastic.

Thanks to the added weight, the bottles look and feel like glass, but are actually made of high quality, blow moulded Polyethylene Terephthalate, more commonly known as PET. The gorgeous, elegant look of the bottles is augmented by the crystal clear clarity of the material, creating a piece of packaging that satisfies the consumer's need for a dense and sturdy bottle that's also visually appealing, not to mention the fact that PET is highly recyclable .

For companies, making the switch to PET packaging provides a number of benefits, apart from end consumer satisfaction. First and foremost, the bottles are generally less expensive than comparable, weighted glass bottles. Also, the bottles don't require any special retooling or complex machine recalibration, so they can be installed on existing lines almost immediately. The bottles are also thick enough to withstand normal fill pressures, so lines can run at the same speeds they normally do.

With a product that satisfies both consumers and companies, Pin Mao's Heavy Base Bottles are the ideal solution for reducing costs while keeping lines running.

Graham Packaging gains BRC-IoP accreditation

Wed, 08 Feb 2012 14:49:14 GMT

The New Year was a double celebration for the Graham Packaging Etten-Leur team, when the company heard they had received the "A" status BRC-IoP, which is the highest possible rating for the Quality Management System for the factory.

The entire team at Graham Packaging Etten-Leur worked very hard during the course of last year to achieve this industry honour. Plant Manager, Roeland Marijnissen said, "This is a milestone for the group and we are delighted that the efforts put in by the whole team have been acknowledged by the industry body. It gives our customers a greater degree of security knowing that the Etten-Leur facility is working to the highest industry standards, which sets us apart as the number one supplier in Europe."

Graham Packaging Europe has become a leading supplier to all the major Blue Chip Drinks, Food, Dairy and Pharmaceutical groups throughout Europe together with a growing number of Independent smaller customers, where the products produced by Graham Packaging have helped them develop their brands.

At Etten-Leur a huge number of stock and custom PET bottles are produced, which is supported by a full in-house design team that can create innovative and eye catching bottle designs, all covered by the BRC IoP accreditation.

Petainer develops 'greenest ever' refillable bottle

Wed, 08 Feb 2012 13:59:47 GMT

Specialist plastics packaging technology business Petainer has developed its 'greenest ever' refillable bottle. Thus, Petainer improves the sustainability of what is already one of the most environmentally-friendly forms of beverage packaging.

The new bottle is manufactured using more than 25 per cent post-consumer 'one-way' recycled PET (PolyEthylene Terephthalate) plastic but has the same performance characteristics as a refillable bottle made entirely from virgin material.

Nigel Pritchard, group chief executive of Petainer, said: "This is a very exciting development. Refillable bottles are already the beverage packing system with one of the lowest environmental footprints. This massive advance in the use of recycled material makes refillable bottles even more 'eco-nomic'. They are 'eco-friendly' because they use up to 90 per cent less virgin material per filling.

They are also economic in the traditional sense because the environmental benefits translate into lower costs. As the cost of PET resins inexorably increases, the economics of refillable bottles using recycled material become even more compelling.

We believe these new containers have a good claim to be considered one of the world's most sustainable forms of beverage packaging".

Petainer is now working with bottled water companies, carbonated drinks producers and brewers across Europe to put its new 'greener' refillable bottles into use.

Research has demonstrated that refillable bottles - which are returned to the retailer by the consumer once emptied, then sent to the beverage manufacturer for washing and refilling - have a lower carbon footprint than one-way bottles that are thrown away after use. This is the case even if one-way bottles are recovered for materials recycling.

Petainer, which manufactures both refillable and one-way bottles in PET, is a leader in the use of recycled materials in both types of bottle. It has demonstrated that one-way bottles can be manufactured from 100 per cent recycled material.

Petainer's latest developments in manufacturing technology allow more than 25 per cent of post-consumer waste from used PET bottles to be included in refillable bottles. The company is now working on improving the use of post-consumer recyclate even further.

The 'greener' bottle's performance is identical to the performance of conventional refillable bottles. It gives the same number of 'round trips', has the same top-load strength which allows it to be stacked in the same way as other refillable bottles, and provides the same level of retention of CO2 in carbonated soft drinks.

The technology can be applied both to bottles manufactured in Petainer's own plants in Sweden and the Czech Republic and also to bottles blown from Petainer-supplied preforms.

Nigel Pritchard added: "This bottle-to-bottle recycling, added to the existing environmental and economic benefits of refillable bottles, makes a strong case for fillers and brewers to consider switching to refillable bottles. We are already seeing a number of customers and countries considering the introduction of refillables."

A company using one-way bottles can spend around four to five times as much on packaging as a company that bottles the same quantity of beverage in refillable bottles, which it needs to replace only once in every 20 trips.

The total PET used per filling is 90 per cent lower for the refillable container, which is improved even further with this development in the use of post-consumer recyclate.

Sunrise Packaging launches new website

Wed, 08 Feb 2012 12:08:52 GMT

Companies surfing the web for custom packaging can now find a perfect place to browse innovative packaging solutions at Sunpac.com. Owned by Sunrise Packaging, the website has received quite a makeover in order to better serve its customers in the business-to-business market.

The Twin Cities packaging manufacturer continues to experience significant growth in sales as well as web traffic and wanted their main source of obtaining new business to reflect that. The new look website launched just in time to celebrate the 30th Anniversary of the company.

Upon first glance their customers will notice a cleaner, more modern look than the previous version of the site. By browsing through the site, they will also notice the addition new products and updated product images that showcase the variety of creative custom packaging solutions Sunrise Packaging offers. Sunrise Packaging continues to make creative packaging based on customer needs and expand their products lines. For example, their Flash Pad, was released last year to address the rise in demand for unique custom USB flash drive packaging.

Improved navigation was also applied to Sunpack.com to give an enhanced experience for the wide variety of clients and industries that Sunrise serves. The biggest change is the menu that now runs along the top of the website as well as the footer that allows for better accessibility to the company's most visited pages.

As Sunrise Packaging continues to find innovative ways to manufacture packaging, they will anticipate more growth and continue to add great talent. The newly designed website encompasses the spirit of growth and change that the company has welcomed in recent years and will continue to welcome in years to come.

IPS presents Micropast at Anuga FoodTec 2012

Wed, 08 Feb 2012 11:05:07 GMT

IPS International Packaging Systems and Creative New Food GmbH are joining forces to present Micropast® at Anuga FoodTec 2012. This innovative pasteurization method is rapid, gentle, energy saving, and both cooks and preserves ready meals and menu components in a single step process. A ‘best-before’ date of up to 90 days for both complete ready meals and menu components can be achieved in less than ten minutes with minimum thermal stress.

Combining microwave technology and steam pressure cooking, Micropast offers an optimal method for pasteurization of sensitive products. Consumer tests have shown that foods prepared using Micropast technology can be difficult to distinguish from similar freshly prepared foods. The DLG German Agricultural Society (Deutsche Landwirtschafts-Gesellschaft) has recognised this quality leap in the process technology for preserving foodstuffs and will present Micropast with a gold medal at the upcoming International FoodTec award ceremony. Visitors can find out more about the wealth of possibilities Micropast offers at Stand E049 in Hall 10.1. As usual, IPS is also represented at the joint stand with Gerhard Schubert GmbH (Hall 6.1, Stand A066/B069).

The Micropast process starts with filling a standard tray with menu components. The tray is then sealed with the lid film, which has a small opening. The sealed packages then pass through a microwave tunnel where menu components are rapidly heated by microwave and generate steam. Unlike conventional microwave technology, there are no cold/hot spots as the steam pressure ensures a uniform temperature distribution. The core temperatures inside the product quickly rise to 90 to 95 degrees Celsius, cooking and pasteurizing the tray contents.

The overpressure acts as counter pressure and prevents the cells in the food from bursting during heating. No liquid is released from the ingredients and they retain their texture. Immediately after passing through the microwave tunnel oven, the steam is removed by a gas injection process. The surface temperature of the food drops by 10 to 15 degrees Celsius. This prevents the generation of a vacuum during cooling. The process solves several problems: no liquid is released from the food, while the product is not damaged by crushing. The food products maintain their texture and colour intensity. Thanks to the gentle processing, consumers are presented with high-quality products at the point of sale.

Oystar expands its facilities in India

Tue, 07 Feb 2012 15:57:09 GMT

Packaging machine manufacturer Oystar continues to expand its business in Asian markets. The site in Pune, India, has been upgraded and 30 additional employees have been added.

Thanks to a steadily growing order situation, Hassia Packaging Pvt. Ltd. – a 100% subsidiary of the Oystar Group in India – has doubled its capacities to what is now a 4,033 m² large surface used for production and administration. With that, the site in Pune is capable of building 20 machines per month.

Sales have increased by 45 percent in this past year alone. As part of this growth, 30 additional employees have been hired and now the site in Pune now employs a total of 100 employees.

Hassia Packaging Pvt. Ltd. manufactures packaging machines for the food and chemical industries. This includes FS machines for filling and sealing preformed cups as well as machines with volume and weight filling systems for placing products into pouches, glass, cups and cans. The filling amounts range between 25 g and 50 kg. Customers primarily consist of international big corporations as well as small and medium-sized companies that manufacture their products in emerging markets.

Rexam Fusion bottle wins top prize in LSA Innovation Award

Tue, 07 Feb 2012 15:37:38 GMT

The new Chamane natural energy drink, packaged in Rexam Beverage Can’s Fusion bottle, recently won an award at France’s prestigious LSA Innovation Awards 2011 hosted in Paris. The event rewards industry professionals for innovative products and concepts.

The new drink won the top prize in the ‘alcohol free beverages’ category. Rexam worked closely with Deveurop SAS to develop the Fusion bottle for their new Chamane natural energy drink and help it really stand out from its competitors in the energy drinks market.

Composed from 100% natural ingredients, Chamane is targeted at working adults who want a natural alternative to traditional energy drinks. Deveurop SAS chose to package Chamane in Rexam’s 250ml Fusion bottle, with a ROPP closure, to represent and enhance the health benefits and qualities of the drink.

Rexam’s Fusion bottle is a breakthrough innovation in the market and uses drawn wall and ironed technology to create a lightweight and sophisticated aluminium bottle that keeps the drink inside fresh and chills faster than other packaging - offering faster ultimate refreshment for the consumer.

The bottle is 100% recyclable and infinitely so with no loss of quality, embodying Chamane’s vision of natural energy and its commitment to a healthier planet.

Stéphane Lacourt, CEO and Founder of Deveurop SAS, said: “The Fusion bottle perfectly complements the Chamane drink and the LSA Innovation Awards judges saw it as a key component of our winning product. Rexam’s unique graphic design and printing techniques allowed to us to have fun with the packaging and really put Chamane in a different league from other energy drinks.

The Fusion bottle has enabled us to position our new product on the market as a premium, high quality energy drink, which has resulted in a great number of impulse buys and a high level of repeat purchases. We have found the ROPP closure option to be a particular asset to our product as this ensures the bottle is safe for the consumer to open, with the added benefit of being resealable”.

Galactika Group leads the Russian dairy market with Tetra Top packaging and Tetra PlantMaster

Tue, 07 Feb 2012 15:02:49 GMT

As one of the largest producers in Russia’s highly competitive dairy industry, Galactika Group is continually challenged not only to operate efficiently and produce high-quality products, but to find new ways to attract customers. Doing so requires a complex mix of production efficiency, product quality, consumer safety and convenience, and appealing packaging and branding. To bring all these factors together, Galactika looked to Tetra Pak.

Galactika Group is a modern Russian success story, producing a wide range of milk, sour milk and yogurt products, including the popular Bolshaya Kruzhka, Milk Time, Tom and Jerry and Sudarynya brands. Over 1,000 employees deliver high-quality products that are sold in more than 8,000 retail and wholesale companies in Russia and range of CIS countries.

Galactika Group is among the first companies in Europe to adopt Tetra Pak’s Tetra PlantMaster™ automation solution, which combines optimum efficiency with uncompromising quality and safety. Automating the entire production process, from the moment raw ingredients come into the factory to the moment the finished product leaves it, Tetra PlantMaster gives Galactika complete control, providing real-time information about the volume of product being processed, the number of packages produced, the efficiency of specific machines and overall production performance.

Today, the only manual process left in the factory is the physical attachment of the hose used to fill milk tankers — just 40 employees per shift are needed to run the entire operation, cutting down on the potential for human error.

As consumers lead ever-busier lives, packaging convenience can influence their purchasing decisions. So, in addition to its investment in high-tech processing solutions, Galactika sets its products apart with innovative packaging.

Galactika has chosen Tetra Pak’s Tetra Top® packaging solution for its pasteurized and sour milk products. Tetra Top is a roll-fed packaging solution with a carton sleeve and an injection moulded top, which is sealed, to the package, in a single process. It offers many advantages, including bottle-style convenience, rounded corners for good grip, One Step Opening (OSO) re-closable caps with wider openings — ideal for easy pouring of thicker products — and the positive environmental profile of a wood-fibre based package. With a 100 per cent printable carton sleeve, it also brings new marketing design options over packaging alternatives.

“We decided to switch to Tetra Top in 2008 because it has the shape, convenience and safety features that appeal to consumers and the branding opportunities, production flexibility and efficiency that we need,” said Anatoly Sirotinin. “It’s a solution that drives both profitability and consumer trust, which favours the expansion of our product range.”

Galactika is taking advantage of the flexibility of the Tetra Top range, selling premium, vitamin-enriched sour milk and whey-based beverages in 200, 250, 330, 500 and 750 ml packages. This allows them to target products at specific audiences and expand the product portfolio. Tetra Top also played an important role in the major rebranding of the company’s Bolshaya Kruzhka drinking yoghurt range in 2010.

The decision is paying off: Products in Tetra Top packages constitute about 20 per cent of the company’s overall sales volume. The Bolshaya Kruzhka brand sales volume has grown between 70 and 80per cent in just two years, with almost half of it sold in Tetra Top package.

Galactika uses the Tetra Top TT/3 XH IC (Extended Hygiene & Integrated Capping) filling line for Tetra Top-packaged products. It applies OSO caps inside the machine, reducing floor-space requirements by up to 20 per cent. It also brings flexibility, simultaneously filling different products and delivering a 9,000 package per hour two-line filling capacity.

Partnership with Tetra Pak has notched up a number of notable technological achievements for Galactika: it was one of the first companies in Russia to invest in the TT/3 XH IC; delivered the world’s first Tetra Pak Carton Bottle Mini 250 ml packaging format; and installed the first OSO system in the country.

Galactika’s integrated approach to the latest Tetra Pak processing and packaging solutions is central to its growth strategy. “We are investing in Tetra Pak solutions because they deliver what we need to compete effectively in today’s markets,” said Anatoly Sirotinin. “Tetra Pak’s innovation, cooperation and originality bring us quality, efficiency and differentiation.”

The new S-ratchet for trigger sprayers

Tue, 07 Feb 2012 11:16:39 GMT

Arminak & Associates, a leading California-based packaging and dispensing supplier, has introduced the new 28mm S-Ratchet closure for its trigger sprayer lines. The trigger sprayers using S-Ratchet closures are generally applied in the automotive, home and garden, and industrial product packaging sectors - basically anywhere a non-removable sprayer may be necessary for security.

Ratchet closures are designed to make the sprayer non-removable and prevent the closure from coming off bottles during shipping, as well as to avoid children accidentally unlocking the closure and spilling out hazardous or caustic products. Traditional ratchet closures can be troublesome on filling lines when the ratchet serrations are engaged before the threads. It might not only cause sprayer misalignment before the closures are torqued on the bottles, but also possibly can slow down or even stop the filling line.

Arminak developed this S-Ratchet Closure with about a quarter of a turn of thread engagement before the ratchet serrations start to engage. This will help the sprayer level and stay on the bottle before it is fully installed. This S-Ratchet can be offered on a wide array of Arminak’s trigger sprayers and available with different outputs, spray patterns and shroud options.

Arminak is continuously researching and developing new technologies in order to meet ever changing market trends.

New plastic tube packaging for Bimbo's "Cajeta"

Mon, 06 Feb 2012 15:51:28 GMT

La Cazadora has leapt into the food market, producing the first tube container ever for "Cajeta", a type of caramel for one of Mexico's most recognized food brands. The packaging concept, a novel one on Mexico, required special considerations for decoration and compatibility.

Grupo Bimbo, in its constant drive to innovate, has confided in La Cazadora to develop the first container for Cajeta Coronado in plastic tube package, containing 200g of product.

The package manufacturing process required special care, beginning with the art analysis, including digital prepress and its adaptation for printing in a dry offset process, as the design integrates photography and traditional elements of the brand name printed in a full colour selection.

Grupo Bimbo was captivated by La Cazadora's commitment to production excellence, as the ISO 9001:2008 certified company adheres to the highest quality standards for the manufacture of plastic squeezable tubes.

"This project is very important for us not only to consolidate relations with Bimbo but also to open a niche in the plastic tubes market for the food industry," commented La Cazadora’s General Manager, and a leader in the manufacture of plastic squeezable tubes nationwide.

Filling and padding according to the ESD norm

Mon, 06 Feb 2012 12:05:08 GMT

Storopack is a specialist in the field of protective packaging. Its product portfolio encompasses both customised and flexible packaging systems and their integration into customer packaging processes. The services provided by the internationally active company group based in Metzingen (Germany) are performed by the two divisions moulding and packaging.

The packaging division offers flexible protective packaging systems encompassing air cushions (Airplus), paper pads (Paperplus®), PUR-foam-in-place packaging systems (Foamplus®) and loose fill (Pelaspan® and Pelaspan® bio) packaging materials. It supplies demand-driven equipment solutions covering everything from single workstations through to the design and implementation of packaging lines integrated into a company’s intralogistics and equipped with manual, semi- and fully automated infeed packaging systems. Specialised application engineers of Storopack ensure that the entire work flow takes place in keeping with economic and ergonomic principles in order to constantly improve the customers’ protective packaging process. The packaging division is represented by locations in North America, Europe and Asia. The products are available through dealers in over 40 countries.

The air-cushioning materials Airplus and Foamplus foam padding from Storopack are now available in an ESD film version for the protective packaging of electronic components. The film complies with the requirements of DIN EN 61340-5-1 for electrostatic dissipating materials. It has been developed by Storopack and is now manufactured from several of its production sites. The on-demand protective packaging systems are a practical alternative to normal ready-to-use packaging, such as foam cushions and bubble wrap films.

The more complex and more miniaturized active electronic components become, the more sensitive they are to electrostatic discharge (ESD). High potential differences arise when two surfaces rub together, e.g. built up simply by walking over a carpet or when handling packaging.

Thermo Fisher Scientific announces new Versa Warehouse in-line scale control

Fri, 03 Feb 2012 10:18:35 GMT

Thermo Fisher Scientific Inc., the world leader in serving science, has announced its new Thermo Scientific Versa Warehouse in-line scale control for demanding distribution warehouse environments. The company will showcase its upgraded capability at MODEX, February 6-9, 2012, at the Georgia World Congress Center, Atlanta, booth 2806.

The Versa Warehouse control can weigh each package more than 100 times as it travels across the scale. This ensures that companies get extremely accurate weight data without compromising line speeds of more than 500 feet per minute. The new software employs unique algorithms designed for variable package dimensions and weight. This dramatically increases accuracy when weighing packages with variable attributes.

“With cost management being an ongoing priority, the Versa Warehouse’s ability to offer both accuracy and speed gives distribution warehouse managers another tool to better manage postage and other freight-related expenses,” said Greg Bredahl, business development manager, Thermo Fisher Scientific.

Suitable for line speeds of up to 100 packages per minute, the control’s upgraded software also offers industry-leading calibration and diagnostics. A built-in oscilloscope (with waveforms displayed on the control panel) simplifies calibration because the operator can see a visual representation of the weight. A color touch screen features a user-friendly interface to simplify set-up and modify performance variables.

The new control will now be offered on the entire line of scales branded under the Thermo Scientific name. It can also be retrofitted onto units already in the field.

The Versa Warehouse in-line scale control can provide accurate measurement for a variety of package types (corrugated cases, padded mailers, envelopes, totes, etc.) up to 110 pounds. The rugged design ensures reliability and maintenance-free operation. It is virtually damage-proof, with overload protection up to 1,000 pounds.

“More than 55 years of experience and expertise backs Thermo Scientific in-line scale product line. This helps set apart the performance, accuracy and durability of its equipment from competitive alternatives,” added Bredahl.

Multilayer packaging films innovations at Specialty Packaging Films conference

Thu, 02 Feb 2012 15:48:07 GMT

Specialty films are being developed to provide appropriate barrier and protective properties and the latest innovations were highlighted at the annual AMI international conference on Multilayer Packaging Films 2011, held in Cologne in October. The flexible packaging market in Europe is valued at around 20 billion Euros by Andrew Reynolds, the Research Director at Applied Market Information. There is room for growth to replace rigid packaging and reduce weight, as per the new YES pack from Kraft, which is replacing a bottle. There is increasing globalisation in this market as both food and packaging companies expand their geographical footprint. The focus for packaging is both on consumer appeal and product differentiation, and on improving sustainability in the supply chain.

The leading brand owner, Procter & Gamble, is constantly looking for superior innovation combining the needs of the consumer with leading technology from the supply chain. The company had 80 billion dollars of sales in 2010 and spends more than 700 million dollars on packaging films. There are more than 500 packaging researchers, aiming to improve sustainability and fast track new products. P&G is famous for its FMOT – First Moment of Truth- thinking, which is the point when a consumer sees a product and makes a decision to purchase. The development process can be reverse engineered from that starting place and needs to consider factors such as decorative effects, pack differentiation, affordable functionality and a good consumer experience in use. The five sustainability mantras are: reduce, reuse, recycle, remove and replace. Procter & Gamble is looking to build relationships with packaging suppliers who have a global reach and can speed up cost-effective packaging development.

The film producer RKW processes around 350,000 tonnes of PE and PP per year at 21 sites and co-extrudes up to 7-layer films. The company is conscious of the carbon footprint of its products and materials and is looking at improving sustainability. For example, a highly mineral-filled polyolefin wrapper can replace an aluminium laminate and reduce the carbon footprint by 35-60%. The company has many new products including laminate PP films for retortable pouches that are heat stable to 125C for 45 minutes.

Dow is producing sealing layer materials to improve film seal integrity, thus reducing food waste. In a 2009 study conducted by WRAP and the University of Lincoln it was found that around 8% of packages failed in the supply chain. Three factors should be considered in VFFS performance: heat seal, hot tack and caulkability.

A new laminating product range has been developed for bio-based films from renewable raw materials, based on low viscosity, solvent-free PUR. Polybutene products from LyondellBasell are used in peal-seal films and to modify the seal initiation temperature in BOPP and COPP from 115C down to 75C. In multilayers the PB-1 is blended with PE depending on the final requirements. There is a new family of C4 Koattro resins developed for PP modification and in pilot production in Italy.

In terms of manufacturing technology, Reifenhauser Extrusion is a leader in extrusion equipment. The company sees demand for high flexibility, short product changeover time, ultra-tight tolerances, and energy saving. The trend is for wider lines over 5 m in Asia rather than Europe or the USA, and for 5- and 7-layer lines over 3m wide for high barrier film. Cast coextrusion is used to reduce the thickness of expensive layers like EVOH, and allows a wide range of film thickness on the same die. The end use markets for barrier films include liquid packaging and MAP packs for meat, fish and cheese. The level of barrier required varies with the product, for example fresh fruit and vegetables tolerate a water vapour transmission rate (WVTR) of 10-3000 whereas baby food and dried coffee need a much higher seal of 0.7-3 and similarly for the oxygen transmission rate (OTR). A typical 5-layer barrier might include outer layers of LDPE around EVOH in an adhesive /tie layer sandwich. As one example, an extrusion coated bread pack comprised OPET at 12 microns, LLDPE at 21 microns, tie layer 3 microns, EVOH 3 microns, tie layer 3 microns and an outer LLDPE layer at 20 microns.

Biaxially oriented films are found in barrier applications from MAP to vacuum skin packaging. Multiple bubble systems are used to produce many of these films from shrink bag and film to lidding films and GAP Srl provides systems for this. In a three-bubble line the plastic is extruded through a circular die and immediately water quenched; the resulting tube is then re-heated and blown and at this point the non-contact orientation occurs; the second bubble is air cooled and flattened, then a third bubble is annealed in ovens. Orientation improves mechanical properties, enhances impermeability, dimensional stability and gives a gloss effect.

The layer thickness in barrier films ranges from 25 microns down to 1440 Angstroms. Extrusion Dies Industries is involved in microlayer production and studied the gauge required to achieve the right properties. For example, the oxygen permeability of EVOH is around 10 cc/m2.day.atm at 4 microns thick and down to 1.4 at 25 microns thickness. Oxygen barrier properties also improve with a higher level of crystallinity, which in turn is affected by cooling rate, orientation and annealing,

Polyamide is often used for its barrier properties, for example in gas flushed barrier laminates for Dairy Crest resealable cheese packs. Ube has capacity to produce over 155 kT per year of PA at sites in Asia and Europe and copolymers of PA6 and 6,6 are produced for film use. They are found in applications such as shrink bags, for example in 7-layers with EVOH, PE and tie layers at a total thickness of 50 microns, or with a PET in a 9-layer structure. The 7-layer film tested by Ube has good puncture resistance, which is important for wrapping products with sharp edges like bones in meat. Another grade of PA, Terpalex, which has a much higher CO2 transmission rate, is used for packaging items that need to “breathe” like respiring cheese. These types of films are replacing PVDC-based bags and are around 40% lower gauge.

There are new metallocene polyolefins available from TOTAL PETROCHEMICALS. The company is focusing research on sustainability, which includes PLA (bioplastics) and renewable feedstocks. The metallocene technology uses less energy in production. The ultimate goal is a film material that is highly transparent and stiff with good tear resistance for applications like bread bags, magazine packaging and lamination film. A Lumicene coextruded structure can provide the necessary properties. This metallocene polymer can also be used in each layer in a PE/PP combination for interlayer adhesion without a tie layer, optimising the optical performance. A new Supertough material is in development, which would allow more downgauging.

MAH-modified polyolefin is extrudable adhesive, and is supplied by companies such as Yparex. The MAH reacts with the hydroxyl group of minerals, glass and EVOH, and with the amine group of polyamide. During the K show in 2010 an Yparex resin was run in a 16-layer demonstration film by Windmoeller and Hoelscher. PP based Yparex grades have higher heat resistance, so are suitable for applications such as hot fill. In three-bubble film lines the adhesion time is very limited as the film is quenched after exiting the die and there is a high level of stretching, so appropriate adhesive has been developed. A new player has come into the tie-layer resin marketplace: Industrie Polieco MPB Srl of Italy. The company grafts MAH onto LLDPE and has compounds and resins for blown and cast film extrusion, EVOH and PA.

Quality control of multilayer film is under investigation. There are a variety of possible defects including insects, gels, black specs, contamination, die lines, oil stains, holes and fish eyes. 40% of defects originate during pellet transport, 25% in the resin (either the recipe or contamination) and 15% of problems arise during processing. OCS Optical Control Systems is developing technology for monitoring defects and feeding the results back into the production process including the raw material supply system, according to the specification for each film type, from optical sheets to food films.

One area where quality control is critical is in the pharmaceutical industry. Amcor Flexibles works in this sector and produces active pharma packaging with a desiccant. The outer film layer is OPA at 25 microns, the next layer is aluminium at 45 microns and the inner layer is PE. Dessicant particles can be incorporated into the inner layer to inhibit cross diffusion and keep moisture to a minimum in cold form blisters. Calcium oxide is the active component and it is blended into a mineral-filled, blue PE masterbatch, which is then coated onto aluminium foil. Formpack Dessiflex has been shown to keep the blister cavity dry for more than 5 years at 40C/75% r.h.

The environment and sustainability are the hottest topics in the packaging industry. Innovia has been at the forefront of developing barrier films from renewable sources. The NatureFlex range comprises a transparent cellulose film with barrier coatings, and the wood pulp feedstock is from managed forests and not from food crops, which means that the product content is 94% renewable carbon. This film has excellent twist properties, provides an aroma barrier and is heat resistant to 200C. It is used in Quality Street (Nestle chocolate) wrappers in rainbow colours and is being tested for barrier properties in paper laminates. It has recently been tested and found to be a good barrier to mineral oil, which has been the subject of recent food safety research.

One supplier of bioplastics in Europe, FKuR Kunststoff has also looked at combining bioplastics with other materials, including the use of coextrusion. There are two types of bioplastics: biodegradable (fossil or renewable carbon source) and biobased (renewable carbon source). The biodegradable materials can be difficult to process on conventional equipment, so they are compounded to improve properties. The company’s Bio-Flex range comprises PLA and co-polyester and can be incorporated in a 3-layer film that can be processed on conventional LLDPE blown-film extruders and contains 60-80% renewable carbon.

Another innovation in the retail industry is the development of smart packaging. The Fraunhofer Research Institution for Modular Solid-State Technologies is studying sensor technology and has developed a colour-changing film, which can be integrated into packaging and detects amines from decaying food such as fish and meat, changing colour from yellow to blue. When the blue colour is very evident, the food is not safe to eat.

The specialty packaging films industry continues to grow and expand in complexity, with new materials, new barrier testing and quality control. AMI has scheduled the next conference on Multilayer Packaging Films 2012 to highlight the latest trends; the dates are 16-18th October 2012 at the Maritim Hotel in Cologne, Germany.

Chesapeake joins Pan-European sustainability project

Thu, 02 Feb 2012 14:56:25 GMT

Chesapeake, a leading manufacturer of consumer packaging, is contributing to a pan-European project that aims to revolutionize paper packaging. The project, coordinated by the UK’s Sheffield Hallam University, has secured EU funding in-excess of 3 million euros (£2.5m) and is expected to result in the development of ‘NEWGENPACK’ - the next generation of environmentally friendly paper packaging.

Experts from across Europe are pooling ideas and resources to ‘change the face of paper packaging’ and create innovative sustainable packaging with enhanced properties.

Carol Hammond, Head of R&D at Chesapeake, who is one of the research partners, declared that the expertise bought together for the project has the potential to create a new generation of packaging.

“Cardboard products are inherently made from a very sustainable material. If it is enhanced with greater functionality, such as barrier properties to prevent moisture loss or has increased shape flexibility, its use can be extended to a greater number of market applications”, she said. “The team of experts is focused on developing the next generation of environmentally-friendly products that could change the face of paper packaging.”

The group, with specialists from Sweden, Poland, Spain, France, Germany, Italy, Denmark, the Netherlands and the UK, said it will focus on the development of new packaging that is both sustainable and economically viable. The participants are carrying out top level, individual research projects to advance in three major fields: next generation packaging composites; cellulose fibre based active packaging and the effect of packaging production on the environment, the economy and society as a whole.

The initiative has the brief to foster the next generation of research experts equipped with the know-how and multi-disciplinary skills to develop future sustainable packaging solutions.

Project coordinator, Professor Chris Breen, of the University’s Materials and Engineering Research Institute, said: “Currently very few researchers are trained to deal with such a broad variety of disciplines, and are therefore insufficiently prepared to assist with the commercial challenges of delivering sustainable packages that are both economically viable and environmentally fit for purpose.”

He added the training aspect of the project was a major part to create the experts, “who will drive continuing progress in sustainable packaging.”

Plasticum introduces Spray Cap Jill

Thu, 02 Feb 2012 10:42:54 GMT

Plasticum extends its range of horizontal spray caps with Jill. This elegant spray cap has been especially designed for female cosmetic applications. Jill is fitted with Plasticum’s patented Integrated Spray technology, integrating the actuator and insert. This technology allows different orifices and channel designs to generate many spray patterns with a one-piece spray cap. Jill will be presented at the Aerosol & Dispensing Forum in Paris where Plasticum exhibits at stand C12.

Jill has an exclusive appearance and is perfectly suitable for personal care applications, such as deodorants, body sprays and hair sprays. The Integrated Spray technology offers flexibility to handle various formulations and to obtain different spray patterns, depending on the required effect. A complete product range can be covered with this functional design. The first launch in the series has a diameter of 52 mm.

Jill has a high gloss surface finish that complements the stylish look. Also translucent materials, metallic or pearl effects give the cap a glamorous image. This horizontal spray cap has a clearly marked finger recess area that offers a light and convenient actuation of the spray, supported by the solid hinge that is situated on the push side. The fixed and flared stem fit offers the advantage of easy positioning during assembly. The compact and integrated design guarantees an economical choice.

The polypropylene spray cap exists of only one piece and is manufactured in one single moulding shot. The actuator and insert are fully integrated, so there is no need for additional assembly. This makes the manufacturing process simple and efficient, while the Jill can be recycled easily. All products are produced in a clean and well equipped production environment honouring operational excellence.

Samples from the pilot tool are already available. The final products will be launched in the second quarter of this year. Customers already showed serious interest for their personal care brands.

Bombay Sapphire 250th Anniversary Limited Edition wins Mobius Award

Thu, 02 Feb 2012 09:51:53 GMT

Bombay Sapphire 250th Anniversary Limited Edition, designed by Webb deVlam, took First Place in the Mobius Awards Package Design-Food, Beverages category. This year the Mobius Awards attracted entries from 21 countries. The international judging panel awarded points for effectiveness and creativity.

Congratulating Webb deVlam, Lee Gluckman, Chairman of the Mobius Awards said, ‘The international panel of judges were impressed by the special limited edition bottle and each judge took the time to view the accompanying explanatory video. I found it impressive that a distiller would go to all the trouble of creating such a special bottle. It’s a lovely clean design that carries forward the top quality image of the product.’

Bombay Sapphire Limited Edition bottle was introduced in 2010 to mark the 250th anniversary of the gin’s unique secret recipe and only 500 have been made. The design demonstrates and communicates the underlying sense of the ‘soul of the brand’ using intriguing visual effects to impart the prestige proposition. Webb deVlam’s design director Dominic Burke summarises the concept for the Limited Edition as ‘the window to the soul’ and took this as the direction for the design development. The result was a limited edition bottle, blown and hand crafted in high quality crystal and set with crystal stones, in a bespoke gift box accompanied with a signed booklet to explain the process and authenticate the bottle number.

Webb deVlam employed new experimental processes and adapted technologies from other industries such as the 3D laser etching that highlights the botanical ingredients. Garrard the jeweller’s creative director, Stephen Webster devised the concept for the crystal encrusted stopper which Webb deVlam brought to fruition.

John Burke, Global Category Director for Bombay Sapphire commented "We are incredibly pleased that the Bombay Sapphire 250th Limited Edition Bottle has been recognised by the Mobius Awards. The Limited Edition Bottle uses a juxtaposition of traditional artisan handcrafted skills, combined with the modern laser etching technology - this compliments Bombay Sapphire's brand heritage, created using 10 hand selected exotic botanicals alongside its signature Vapour Infusion distillation process."

“Bombay Sapphire is recognised as a global brand, and the Limited Edition serves to emphasise its prestigious reputation. We are absolutely delighted that so many awards are acknowledging both the design and the expertise that went into creating the Limited Edition,” says Dominic Burke.

Mobius Awards is one of the world’s oldest independent international advertising competitions. It was established in 1971 in Chicago by J.W. Anderson as part of the U.S. Television and Radio Commercials Festival.

“The Polyfoil PET tube offers high resistance and better oxygen protection” assures Neopac's Dr. Philippe Kern

Wed, 01 Feb 2012 15:45:00 GMT

The Polyfoil tube is now available in PET. Dr. Philippe Kern, Head of Material Development, is presenting the latest Neopac developments at the PCD Congress. WEBpackaging here presents all about this new tube in this reprinted interview.

Philippe, why has Neopac developed a new PET tube?

To date, Neopac has produced Polyfoil® PE or Polyfoil® PP tubes that already possess good barrier properties. The Polyfoil PET tube offers the best oxygen barrier of all the Neopac tubes and is particularly impressive because of its high level of resistance against aggressive products. The product only comes into contact with PET materials. The composition of the layers is PET/Aluminium/PET, with the shoulder of the tube made from PET Copolymer. A PET tube does not diffuse any components into the product and similarly does not absorb any of the product’s components. This means that the product does not lose any active substance or aroma.

What are the possible applications for a PET tube?

In the cosmetic sector, the PET tube protects products with rapidly oxidising ingredients such as vitamin A (retinol) and vitamin C. These tubes are ideal for storing aggressive substances such as peroxide and ammonias as well as essential oils. The active substance concentration in the product is preserved long-term because the active substance does not evaporate outside or inside the packaging.

Polyfoil PET has very thin walls, just 0.35 mm thick. It is nevertheless stable and effective. The tube can be gamma-sterilised without any changes to the material properties. All materials comply with pharmaceutical guidelines.

Barriers are all very well, but what about cosmetic decoration?

The Polyfoil PET tube also offers new options in this respect. Novel coloured pigments are available for the outer layer, which could not be previously incorporated in either PE or PP. Firstly, a highly transparent tube shoulder is possible. Our clients can make a real statement when they use our PET tubes for their products.

How easy is it to produce a PET tube?

PET is processed differently from PE or PP. PET must be dried thoroughly in advance. The material is much more liquid then PE or PP on heating. This makes the production process difficult, especially for the tube shoulder, and called for a new process to be developed.

And how expensive is the new Polyfoil PET tube?

The PET material is more expensive than the PP and PE materials we processed. We are convinced that the afore-mentioned advantages of this tube outweigh any additional costs.

When will the PET tube prototypes be available?

The prototypes for 10 to 125 ml are available now. Interested customers can already carry out initial tolerance and stability tests.

Clariant supports Indian push for innovative plastic products

Wed, 01 Feb 2012 14:59:04 GMT

Clariant supports Indian plastic sectors in their effort to create innovative, safer, more environmentally-compatible products at PlastIndia 2012. The specialty chemicals and master batches expert will showcase its broad portfolio of high-quality, cost-effective pigments, and performance additives and master batches at Booth 7F-R1.

Developed with a focus on sustainability, Clariant introduces its new and established processing aids and performance-boosters to the Indian market. The innovations combine sustainable solutions with cost-efficient processing, and advanced functionality and aesthetic possibilities to meet the challenges of a wide range of segments. These include food and cosmetics packaging, electronic and electrical, infrastructure, agriculture, and medical and pharmaceutical.

New to India’s plastics community at PlastIndia 2012 are:

Clariant’s new generation of sustainable lubricant for PVC processing based on renewable resources. Licocare™ SBW11 TP improves efficiency and product consistency in calcium/zinc- (Ca/Zn) and tin (Sn)-stabilized PVC film and extrusion applications, and in injection molding.
New colors and effects: organic pigments with good dispersibility offering high color strength and bright shades to replace inorganic pigments and support design creativity. Part of Clariant’s overall commitment to provide safer products for a cost effective coloration of plastics.
MEVOPUR® color and performance masterbatches and additives for medical devices and pharmaceutical packaging.
The sector-dedicated range offers cutting-edge functionality and processing improvements supported by a Controlled, Consistent, Compliant approach to help the medical and pharmaceutical sector meet regulatory challenges and minimize risk in product development.
HYDROCEROL® chemical foaming agents offering weight reduction and raw material savings, in addition to cost-efficient production of stable, high performance parts used for example in automotive, and machine housing applications.

Further products providing added-value in terms of performance, effects, sustainability and smart cost saving include Clariant’s pioneering low dosage, non-halogenated Exolit® OP fire retardancy range, which has defined a new standard for demanding and innovation E&E applications around the world. This will be showcased alongside colors and additives for PET bottles, UV stabilizers for improved product and processing control of engineering plastics used in automotive parts and agricultural films.

“Product quality has become a must as India’s plastics processors work more closely with multinational companies. At PlastIndia 2012 we will aim to highlight how Clariant’s innovations combine the assurance of advanced performance with cost-saving processing efficiency and product safety to support the trend, across all markets in the region, towards high quality, more sustainable products,” comments Mr. Sahadeo Patil, Head -Masterbatches, Clariant Chemicals (India) Limited.