AIP March 2014 eNewsletter

AIP NEWSLETTER MARCH 2014

Join the AIP on

AIP EDUCATION DIRECTOR HEADS TO INDONESIA

T

he AIP in conjunction with the Indonesian Packaging Federation and the World Packaging Organisation (WPO) will run packaging workshops and a training course at the Swiss Belhotel Seminyak, Bali, Indonesia from March 5-8. The event comprises two parallel workshops with class discussions from March 5-7 and on March 8 a visit to the Food, Hotel & Tourism Expo in Bali Nusa Dua Convention Centre.

The workshops aim to equip participants with greater in-depth knowledge to tackle the challenges facing the packaging industry today and prepare for the competitive advantages towards the coming up Asean Economic Community market opportunities.

The packaging training course will help to strengthen participants in packaging capabilities, providing a level of insight and understanding of the packaging industry that adds real and measurable value to careers and businesses.

Packaging Workshop A has a focus on paper board, rigid plastic packaging & labels while Packaging Workshop B locks on to flexible packaging, tubes and paper board packaging. The packaging training course focuses on packaging technology and will be run by the AIP.

JOIN THE AIP LINKED IN GROUP TODAY

NEW MEMBERS The AIP would like to welcome the following new Members...

Elma Collins Dylan Fisher Stephen Flaherty Hournaz Meshgi Karen Roberts Thomson

Associate Associate Associate Associate Member

VIC NSW VIC NSW NZ

The AIP recognises the changing role of social media as an additional means of reaching our members, sponsors, and industry contacts across Australasia as an international group. The AIP has a Linked in Group and we invite you to join your peers who have already connected.

Linkedin: Australian Institute of Packaging.

BUILD YOUR PACKAGING CAREER ON FIRM FOUNDATIONS WITH THE AIP The Australian Institute of Packaging (AIP) is at the forefront of packaging training and education in Australasia; helping to shape the careers of generations of packaging professionals - from packaging technologists to international packaging business leaders along with a host of people in associated disciplines - sales and marketing, purchasing, production and environment.

MAKE 2014 THE YEAR YOU INVEST IN YOUR CAREER.

PH: +61 7 3278 4490

educate@aipack.com.au

www.aipack.com.au

AIP National Office 34 Lawson Street Oxley QLD 4075 Australia  +61 7 3278 4490  +61 7 3009 9916  info@aipack.com.au  www.aipack.com.au

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POSITION AVAILABLE WITH SIMPLOT

PACKAGING DEVELOPMENT OFFICER Job no: Work type: Location:

492513 Full time Melbourne Metro

An exciting opportunity currently exists for an energetic and detailed individual to join our Packaging team as Packaging Development Officer. Based at our Mentone head office and reporting into the Packaging Development Manager, this role will be responsible for gathering, maintaining and controlling packaging specifications data as well as providing general support for products utilising existing packaging formats.

Additional responsibilities include but are not limited to: • To support product development projects that have pre-defined packaging development requirements by supplying required packaging dielines, specifications, suppliers details, lead times and key manufacturing contacts • Delivery of packaging specification data for Supply Chain, Quality and Innovation and Marketing.

• Liaise with packaging suppliers to ensure provision of required specification data.

• Assist Packaging Development Manager and Packaging Technologist with specification provision.

To be successful in this role you will ideally have demonstrated experience in a similar role. You consider your attention to detail as a real strength and have a continuous improvement mindset looking to identify opportunities to build on current processes. Your strong communication skills allow you to build strong crossfunctional relationships to achieve outcomes. Lastly you are a team player that enjoys working within a high achieving positive environment.

If this sounds like you, then apply online – click here.

AIP PARTNERS

Find out how your company can become a partner of the AIP by emailing info@aipack.com.au

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AIP NEWSLETTER MARCH 2014

DON’T MISS OUT ON THE LATEST AIP ACTIVITIES FOR 2014

ALL MEMBERS ARE INVITED TO ATTEND ANY EVENTS ACROSS AUSTRALIA & NEW ZEALAND

To register to attend any of the events simply email info@aipack.com.au or visit the events page on www.aipack.com.au

NZ

AIP FRUCOR SITE VISIT When: Where: Time:

Wednesday 5th of March Frucor Beverages, Auckland 10.00 am Splitting into two groups a personalised packaging touch will be applied to the visit.

AIP Members will ‘walk the line’ to view noncarbonated beverage lines PET filling lines, can lines, and a PET blow fill line. The visit will be interactive and will talk about what it takes to make Frucor manufacturing effective in supporting the packaging aspirations of it marketing team/s. Be prepared to walk, talk, get hot and sticky in the juice environment of Frucor Beverages Ltd.

QLD

AIP TECHNICAL LOUNGE THE STATE OF THE FOOD & BEVERAGE INDUSTRY REPORT BY AFGC When: Where: Time: Speaker:

Wednesday the 5th of March Queensland Cricketers Club 10.00 am Tanya Barden Director, Sustainability, Trade and Innovation Australian Food and Grocery Council The food, beverage and grocery manufacturing industry is under pressure from a range of factors including rising costs, retail price deflation, a high Australian dollar, low consumer confidence and weak economic growth. Yet despite the challenges, the industry has remained resilient compared to other manufacturing sectors.

VIC

MONDELĒZ INTERNATIONAL SITE VISIT When: Where: Time:

Wednesday 12th of March Mondelēz International Ringwood Food Innovation Centre, VIC 10.00 am All AIP Attendees have the opportunity to take a tour through the new Food Innovation Centre at Mondelēz International. Facilities included in the tour include the Design & 3D printing Lab, Virtual Store, Sensorium and Table-top Knowledge mapping room.

NSW

AIP PARMALAT SITE VISIT When: Where: Time:

Wednesday 26th of March Parmalat Lidcombe, NSW 10.00 am The Paramalat site visit is designed for AIP Members to gain an understanding of how white and flavoured milk is manufactured from processing to distribution.

EXCLUSIVE WOOLWORTHS IN-STORE & IN-DC SHELF-FRIENDLY PACKAGING (SFP) TRAINING AMBIENT & CHILLED HANDS-ON TRAINING LIMITED SPOTS! The AIP is pleased to announce that it is continuing its innovative initiative with Woolworths for the third time by offering exclusive and intensive in-store Shelf-Friendly Packaging training. In addition, off the back of feedback from the attendees at the last series of training a second day will be offered for In-DC Training. This intensive training is unique to the AIP and is led by a trainer from IGD in the UK. This training will be open to everyone in the industry, members and non-members alike. Limited spots will be available for each date.

Endorsed and sponsored in kind by

NSW IN-STORE SHELF-FRIENDLY PACKAGING NSW IN-DC SHELF-FRIENDLY PACKAGING QLD IN-STORE SHELF-FRIENDLY PACKAGING QLD IN-DC SHELF-FRIENDLY PACKAGING VIC IN-DC SHELF-FRIENDLY PACKAGING VIC IN-STORE SHELF-FRIENDLY PACKAGING

When: When: When: When: When: When:

Tuesday the 18th of March Wednesday the 19th of March Monday the 24th of March Tuesday the 25th of March Thursday the 27th of March Friday the 28th of March

AIP NEWSLETTER MARCH 2014

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DON’T MISS OUT ON THE LATEST AIP ACTIVITIES FOR 2014 ALL MEMBERS ARE INVITED TO ATTEND ANY EVENTS ACROSS AUSTRALIA & NEW ZEALAND To register to attend any of the events simply email info@aipack.com.au or visit the events page on www.aipack.com.au

VIC

SPC ARDMONA SITE VISIT LIMITED SPOTS! When: Where: Time:

Wednesday 2nd of April SPC Ardmona, VIC 10.00 am

INTELLECTUAL PROPERTY, PACKAGING AND LABELLING (LEGAL) HALF-DAY TRAINING COURSE

NSW

When: Wednesday the 14th of May Where: Oatlands Golf Course Club House Time: 10.00 am Presenter: Sharon Givoni This half-day training course will provide attendees an overview of important considerations relating to packaging, labelling and Intellectual Property laws.

AIP NATIONAL CONFERENCE

NSW

When: Tuesday 17th and Wednesday the 18th of June

Packaging & Processing Week Where: Sofitel Wentworth

61-101 Phillip Street

Sydney NSW 2000 What: The biennial AIP National Conference is the largest packaging conference of its kind in Australia and New Zealand. Run by industry for industry. The AIP National Conference has been leading the way in professional and personal development for decades.

LABELLING & MATCHING THE LABEL WITH THE PACKAGE HALF-DAY TRAINING COURSE

VIC

When: Wednesday the 23rd of July NEW Where: UPM Raflatac, Braeside, VIC COURSE Time: 10.00 am AIP TECHNICAL DINNER Presenter: Carol Lawrence FAIP Environment & Sustainability Specialist

UPM Raflatac Oceania When: Wednesday the 14th of May How do you select the right type of label to suit Where: Oatlands Golf Course Club House the package and carry the product branding Speakers: Gwen Blake from the filling and labelling line right through Managing Director, Boxer & Co to the consumer?

There are a plethora of considerations for packaging designers to bear in mind to ensure Self-adhesive labelling has evolved as the most they adhere to legalities and keep themselves widely used method of product decoration, and their clients out of deep water. being innovative and versatile for such a wide Sharon Givoni variety of packages. This half-day training Principal Solicitor, Sharon Givoni Consulting course is designed to give a comprehensive There are many questions and misconceptions guide to labelling and how to navigate through that people in the packaging industry have the myriad of options available for each style about how they can protect their intellectual of packaging. property, whether it is your brand, the shape, the way it folds and even the colour (Tiffany’s COME & SEE THE AIP ON STAND 2037 blue box being a classic example).

NSW

INTRODUCTION TO EXTRUSION BLOW MOULDING HALF-DAY TRAINING COURSE

QLD

Wednesday the 28th of May When: Where: Mt Ommaney Hotel Time: 10.00 am Presenter: Stephen Barter MAIP Extrusion Blow Moulding is a challenging and complex process. The Extrusion Blow Moulding process is capable of delivering a wide range of Plastic Bottles and Hollow Plastic parts to suit almost any Rigid Packaging and Industrial application.

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AIP NEWSLETTER MARCH 2014

FOODTECH PACKTECH

When: Where:

Time:

NZ

23rd to 25th of September ASB Showgrounds Auckland, New Zealand 9.00 am

Foodtech Packtech is the most important trade event for the New Zealand Food Technology and Packaging Technology industries.

This biennial event gives you the opportunity to come face-to-face with the experts behind the key innovations entering the New Zealand market. www.foodtechpacktech.co.nz

DON’T MISS OUT ON THE LATEST INDUSTRY EVENTS FOR 2014

ALL MEMBERS ARE INVITED TO ATTEND ANY EVENTS ACROSS AUSTRALIA & NEW ZEALAND

To register to attend any of the events simply email info@aipack.com.au or visit the events page on www.aipack.com.au

INDUSTRY EVENTS PROFESSIONAL WORKSHOP ON PLASTIC PACKAGING AND SHELF LIFE

When: 26th to the 27th of March Where: Riverside Hotel, Brisbane Presenter: Dr Gordon Robertson FAIP Time: 10.00 am Decisions about which polymer to chose or what the effect on shelf life will be if a change is made in package dimensions or polymer type are often based on trial and error or intuition. This workshop is an attempt to fill that gap with respect to plastic packaging by discussing the basic principles behind deteriorative reactions in foods, indices of failure, polymer selection and shelf life.

When: 8th to 14th May 2014 Where: Dusselldorf, Germany

2,700 exhibitors from more than 60 countries will present their latest ideas, innovate concepts and technological visions at interpack. - not only in equipment and machinery for packaging and processing, but also in production tools for packaging materials, materials themselves, and services for the entire industry. www.interpack.com

www.gordonlrobertson.com

PACK A PALLET APP

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ack a Pallet is a great App for both iOS and Android platforms, to quickly and easily optimise a pallet load of product onto a standard Australian 1165 x 1165mm pallet. The results provide Australian pallet patterns and will identify the number of packs on the pallet deck as well as the number high, based on the load height that the user requires. The load height entered, always includes the height of the pallet.

needing to access a pallet pattern for printing onto their shippers, particularly when they are not at their desk, will find this economical App to be a great tool.

Price is just $15.99. Our next development will be 1200 x 1000mm export pallet size for both platforms.

Pack a Pallet is supported by very experienced technicians from the packaging industry. See www. aussiepacknship.com.au for PC programs of higher capability and also for any other packaging related support. Following is typical of the feedback we are receiving for this new App:

Next enter the external length, width and depth of the shipper. Note, minimum length and width dimensions calculated are 200mm x 150mm. The iOS App also produces a 3D image that can be manipulated by hand.

Unfortunately the Android platform does not provide this facility. The best solution can be selected, then a pdf file produced to print, save, email or message.

“

App. Also anyone involved in preparing a presentation for supply to Aldi, Coles or Woolworths and anyone

For further information please contact boxologist.ron@gmail.com

Just wanted to let you know how much I have been using your app and how much easier it has made things for me. It’s fantastic.

Every sales person in the box industry needs this simple Tania Schwede, Oceanic Agencies.

”

PACK A PALLET APP NOW AVAILABLE! PACK A PALLET is great iOS app to quickly and easily optimise a pallet load of product onto a standard 1165 x 1165 pallet. The results provide Australian pallet patterns and will identify the number of packs on the pallet deck as well as the number high.

GENERATE A PDF FOR PRINTING OR FORWARDING. Very soon the android version will be available Price $15.99 https://itunes.apple.com/au/app/pack-a-pallet/id735917888?mt=8 Our next development will be 1200 x 1000 pallet size for both platforms.

Pack a Pallet is supported by experienced technicians from the packaging industry.

See www.aussiepacknship.com.au for PC programs of higher capability.

AIP NEWSLETTER MARCH 2014

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MARK THESE DATES IN YOUR DIARY

2014 AIP NATIONAL CONFERENCE: PACKAGING & INNOVATION EXCELLENCE TUESDAY 17TH AND WEDNESDAY THE 18TH OF JUNE PACKAGING & PROCESSING WEEK Sofitel Wentworth, 61-101 Phillip Street, SYDNEY NSW 2000

Designed for everyone, from packaging designers, technologists and engineers to sales and marketing people. The biennial AIP National Conference is the largest packaging conference of its kind in Australia and New Zealand. Run by industry for industry. The AIP National Conference has been leading the way in professional and personal development for decades. With speakers already confirmed from Mondelēz International, Kimberly Clark, Campbell Arnotts, LION, Sunrice, Coca-Cola, Nestlē, Diageo, Simplot, OI and Amcor Flexibles, to name just a few the 2014 AIP National Conference will be the only place to be on the 17th and 18th of June.

PROUDLY SPONSORED BY

PACKAGING

+ PROCESSING

30TH ANNIVERSARY

OWNED AND PRESENTED BY THE APPMA

new age business

ASIA PACIFIC PACKAGING

CO.PTY.LTD.

MEDIA PARTNERS

ASIA PACIFIC PACKAGING

PH: +61 7 3278 4490

info@aipack.com.au

www.aipack.com.au

2014 APPMA SCHOLARSHIP NOW OPEN comprehensive, and provides an opportunity to study the principles of packaging, packaging materials and packaging processes.

According to Mark Dingley, Chairman of the APPMA, the Annual Scholarship Program is a unique opportunity for a packaging engineer to attain a Diploma in Packaging Technology and further their education in the packaging industry.

2013 Winner: Jamie Schellebeck MAIP

T

he Australian Packaging and Processing Machinery Association (APPMA), in conjunction with the Australian Institute of Packaging (AIP), are pleased to announce that submissions are now open for the sixth annual scholarship program which will enable a packaging engineer the opportunity to complete a Diploma in Packaging Technology to the value of over $9000.

The Diploma in Packaging Technology is an internationally recognised Level 5 foundation qualification that will prepare students to take responsibility for packaging operations at any level through the supply chain. The qualification is

“The APPMA has been offering this educational program now for six years and we have been very pleased with the calibre of winners; all of whom are busy completing their Diplomas as we speak,” Mr Dingley said.

Jamie Schellebeck MAIP, who was 2013 scholarship winner, is a Packaging Engineer at Amcor Fibre Packaging.

“Winning the scholarship in 2013 was a wonderful opportunity for me and I am eager to gain more technical expertise in the packaging industry by undertaking the Diploma in Packaging Technology. I look forward to graduating from the course in a few years.” Mr Schelleback said.

Mr Ralph Moyle, MAIP, National President of the AIP, added that the AIP is at the forefront of packaging

training and education in Australasia; helping to shape the careers of generations of packaging professionals - from packaging technologists to international packaging business leaders along with a host of people in associated disciplines - sales and marketing, purchasing, production and environment.

“The Diploma in Packaging Technology is an internationally recognised Degree that will provide exemplary skills to graduates and we commend the APPMA for their longterm commitment to educational growth within the packaging industry.

We encourage all packaging engineers in Australia to apply.” Mr Moyle said.

Application forms are now available for the APPMA 2014 Scholarship program and can be accessed by emailing appma@appma.com.au or info@aipack.com.au or visiting either www.appma.com.au or www.aipack. com.au Submissions must be received by Close of Business on Friday the 11th of April with the 2014 winner being announced as a part of Packaging & Processing Week which will be held alongside the AIP National Conference on Tuesday the 17th and Wednesday the 18th of June at the Sofitel Sydney.

APPLICATIONS CLOSE 11TH OF APRIL CLICK HERE FOR AN APPLICATION FORM

2012 Winner: Anna Roland

2011 Winner: Jude Van der Zalm

2010 Winner: Natalie Quarrell

2009 winner: Rebecca Du

AIP NEWSLETTER MARCH 2014

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STRIPES SPACE SAVE STRIFE! Written by Michael B Halley FAIP

T

he Australian Football team Collingwood has traditionally turned out in white and black striped guernseys, but now also have an alternative stripe. Fine for promotional purposes but if the dark and white stripes on a barcode are not correct strife will follow.

As Sean Carter Product Manager Advanced Industrial Sensors at Sick Pty Ltd stated “there is nothing more exasperating than a barcode that cannot be read”. He then explained that the solutions are quite simple and that a few minutes of investigation can save the cost of a call out by a specialised technician.

Sean has identified seven deadly sins of barcodes. The first is the most often discovered failure. At the end of every barcode is a white space that is called the quiet zone. This is akin to the full stops and the spaces in a body of text.

Without the quiet zone the barcode is not readable to the scanner.

There are technical considerations in the production of barcodes but generally speaking they may only vary within certain limits.

Printing must ensure clarity and contrast with all the bars vertical and straight in a contrasting colour. Red printed barcodes are unable to be read as the most code readers show red as blank. Also the print immediately around the edges of the quiet zones such as vertical lines and text can cause strife. Shrinking the barcode size has a limit because it can make the resolution unreadable.

Keep the scanning area free from dust and vapours and have the barcode sufficiently illuminated. Additionally don’t place the label behind reflective plastic. Poor printing will result in missing bars or bleeding that will cause no reads.

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There are several types of barcode readers so it is vital that the label and the scanner are matched. Positioning of the scanner is also critical and there are many variables to be considered but, where scanning distances vary, auto focus technology can be a saviour. Using the right scanner for the right code should not need to be explained but there are new technologies coming on stream all the time and not all scanners read all codes.

Technological advances help to overcome most problems however some human faults cannot be overcome. We were left to consider an example where the barcode content and the printed numerals were completely different – a simple design error that hadn’t been picked up and caused issues that took ages to solve.

Sean was followed by Steven Petinakis of CSIRO who could well have an application for a barcode to display his title which is: - Project Leader Biopolymer/composites Future Manufacturing National Research Flagship.

Advice that his name was a Greek word for rooster was forthcoming but far from being a feather duster Steven was ‘cock-a-hoop’. He explained in much technical detail the development of an expanded foamed product not from polystyrene (EPS) but from the environmentally more acceptable Poly (lactic acid) (PLA).

The product concept and development was conducted in association with the industry partner RMAX, an Australian company, which was funded by a grant from the Victorian Government.

RMAX promotes itself thus: - The RMAX products are seen across an expanse of industries – from home insulation to cold chain solutions, agriculture to aerospace. From white goods to wave riding! From artistic to

AIP NEWSLETTER MARCH 2014

zany! When it comes to rigid cellular plastic foams no one does it better, more consistently and more professionally than RMAX. Quite understandable how a company with those credentials collaborated with the CSIRO’s Future Manufacturing Flagship to develop a more sustainable alternative to EPS. It is acknowledged that although EPS can be recycled there are a number of shortcomings including regulations about disposal of waste and high landfill costs.

Expanded PLA overcomes most of these concerns as it is biodegradable and compostable with the feedstock derived from renewable sources. The foaming agent is liquid carbon dioxide (CO2) giving a cell structure almost indescribable from EPS. The foamed material will degrade within accepted time frames and does so completely unlike some other materials promoted as compostable that only degrade partially. Steven explained that the foamed material degrades quicker than unfoamed beads due to a more homogeneous and very low density open cell structure.

CSIRO have now patented a process for producing very low density foams in a manner analogous to current polystyrene processes. Questioning by members revealed that considerations of possible limitations are well in hand.

Tony Seers Managing Director of Seeplas the exclusive Australian Agent for NatureWorks rounded off a varied but most informative evening with visual aids, backed up by innate knowledge about the opportunities to achieve Zero Waste.

The 2012 London Olympics provided 14 billion take away meals in compostable containers. This was contained in 120 million pieces of ecofriendly packaging, collected on site and

STRIPES SPACE SAVE STRIFE! cont’d Written by Michael B Halley FAIP then transported to a composting area.

In nine weeks it was ready to fertilise crops that can be converted into new packaging. This closed loop helped to divert an estimated 850 tonnes of material from landfill.

Over in the USA there is a Green Sports Alliance comprising of 190 teams of all persuasions that has similar targets as the London Olympics but with much more hype and incentives. We viewed a video about the Portland Trail Blazers and how they approached the issue and the manner in which they changed consumer attitudes over as little as two months.

The zero waste attitudes soon spread beyond the walls of the sports stadium and recycling extended into the general population.

The Blazers invested $560,000 in operations improvements around the stadium. By 2011 the team had recouped $411,000 in energy savings, $165,000 in water savings and $260,000 in waste diversion savings, for a total of $836,000.

Tony explained that a venue that first baulked at the higher cost of compostable drink cups were convinced that the cost to send the alternative to landfill made the eco-friendly cups the most economical.

educating vendors and patrons about proper disposal of materials, so that eventually zero waste is sent to the landfill. In 2013, Waste Management’s goal is to divert 100 percent of tournament waste away from landfills and into recycling and composting facilities.

Many questions were posed and answered by the three presenters who were then presented with a plaque and gift by Michael Grima on behalf of AIP and SPE that jointly brought the program to fruition.

As Collingwood are already barcoded and the entry to the ground where they play are already controlled it would Since 2008 over US$600,000 worth seem that they and the AFL could well of savings have been realised by simply composting food contaminated waste. For the second year at the 2013 become the catalyst for a zero waste Studies of consumer behavior led to the Waste Management Phoenix Open Golf sports event in Australia. It is certain establishment of the first electric car tournament was targeting zero waste. that a closed venue will be the catalyst consumer attitudes. controlling for changing rechargeINDEPENDENT facility at a sports groundMEASUREMENT and The initiative is aimed OFatPACKAGING PERFORMANCE materials brought into the event and undercover secure bicycle parking.

INDEPENDENT MEASUREMENT OF PACKAGING PERFORMANCE

Permeability testing - oxygen transmission and water vapour transmission.

Analysis to determine what types of plastic materials are present in a sample, including structures of multilayered packaging.

Mechanical testing of plastic films – tensile strength and related properties, tear resistance, puncture dart impact and transmission. others.

Permeability testing - resistance, oxygen transmission andresistance water vapour Plus many tests.what types of plastic materials are present in a sample, Analysis to other determine including structures of multilayered packaging.

Mechanical testing of plastic films – tensile strength and related properties, Australia 1300 tear GunnLab resistance, puncture resistance, dart impact resistanceNew and Zealand others. 0800 GunnLab Plus many other tests.

Email: bruce@gunnlab.com.au

www.gunnlab.com.au

Australia 1300 GunnLab New Zealand 0800 GunnLab Email: bruce@gunnlab.com.au

AIP NEWSLETTER MARCH 2014

www.gunnlab.com.au

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January-February 2014

tech speak

www.packagingnews.com.au

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Preventing pallets from blowing their stacks RETAILER REQUIREMENTS Australia’s two major retailers, Coles and Woolworths, provide their requirements for trade stack optimisation on their websites. For detailed information on their needs, go to: ■ Coles: www.supplierportal.coles.com.au ■ Woolworths: www.wowlink.com.au

poorly stacked pallets can prevent goods from being transported in acceptable condition.

Stacking primary packs onto pallets is a task that requires careful attention to stack geometries. Ron Mines looks at the potential pitfalls involved and suggests solutions.

E

ffEcTIvE optimisation of primary packs into trade unit packs which are then stacked on pallets often provides much-needed savings for FMCG and other suppliers of packaged goods.

To achieve such optimisation, suppliers first need to understand the requirements of their customers.

Retailers commonly state their requirements for pallet deck usage, which generally include ‘no overhang’ and maximum height. Such requirements are often linked to the weight of the trade unit.

The next step for suppliers is to evaluate current packaging and pallet loading to determine whether there is any opportunity to better use the pallet deck and cubic volume for the load.

I often find that the parameters allowed by the customers are not being fully utilised.

For example, load stack heights set below the requirements or not fully utilising the pallet deck or weight allowance.

PALLET PITfALLS Caution is required when attempting to optimise these values. Trade unit dimensions and

other characteristics can affect the ability of human or automated palletisers to achieve certain pallet patterns without creating unpackable patterns or inadvertent overhang.

Common pitfalls include trying to use too much of the pallet deck. This becomes more problematic the more trade units there are per layer.

Consideration also needs to be given to the physical variations in pallet deck dimensions that occur commonly due to age, wear, damage and fabrication variations.

Understanding the nature of the product and the packaging assists with determining whether load security can be enhanced by column stacking or alternating layers.

WEIghINg ThE coSTS Cost savings can be achieved when the weight of the load on the bottom layer of trade units is evaluated.

Further considerations often revolve around other methods of unitising the load, such as slip sheets, and the means of transporting the product to the customer, including alternative storage conditions.

Optimising the volume on the mode of

transport can be of benefit. This includes limitations of truck deck and volume, as well as shipping container deck, volume and whether the shipping container is hand-loaded or pallet-loaded.

gET WITh ThE PRogRAM Palletising optimisation programs make this work quick and effective, providing for manipulation of the output to achieve cost savings through investigation of current or planned new packs.

Every FMCG business has differing needs and opportunities for improvement.

With some focused training, users of these programs usually find many opportunities for savings.

Often these savings are found to be substantial, proving to be just what coststressed suppliers need to keep them competitive and profitable.

Technology is making this task easier.

Now pallet configurations can be accessed quickly and cheaply, in the field, using a mobile phone or tablet.

A word of advice: when you determine new pallet load configurations, be sure to upload that information to your customer’s website, to avoid complications and delays when delivering the next consignment. ■

*Ron Mines FAIP, known as the "Boxologist", is a consultant to the box and packaging industry. His 40plus years of experience and close involvement in the industry provides considerable credibility among his peers.

THIS ARTICLE WAS RE-PRODUCED WITH PERMISSION FROM PKN PACKAGING NEWS

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AIP NEWSLETTER MARCH 2014

The real

art and science of

packaging

Australian inhibitor’s breakthrough development in barrier material for protecting valuable art works has already won two major industry accolades. Professor Harry Lovell takes a look at the technology behind the innovation.

A

t the 2013 Australian Packaging De-

sign Awards, run by the Packaging Council of Australia (PCA), Australian Inhibitor demonstrated its capacity for innovation with the introduction of Preservation Foil – a new barrier material developed specifically for the protection and packaging of art works and historical artefacts, winning the gold award in the Industrial category. The company was also recently notified that Preservation Foil had won a gold award in the World Packaging Organisation’s 2013-2014 Worldstar Awards to be presented at interpack in 2014.

This innovation has its roots in another Australian Inhibitor success story. It was developed from knowledge gained in the manufacture of the highly successful military-approved VCI Ferro Foil – a plastic/foil laminate incorporating a vapour phase inhibitor designed for the storage of military equipment from handguns to tanks, which was awarded gold in the 2011 PCA Awards.

PreservAtion of Precious cArgo Building on this foundation, the new Preservation Foil demonstrates the company’s innovative ability to respond to an important need in the art world. Initially the new material has been designed specifically for the packaging of valuable paintings and is being used by the National Gallery in two states.

The packaging of valuable art works is not something which is necessarily constrained by cost. In terms of monetary value, the recent sale in November 2013 of three pictures for the sum of $125 million

With effective control of the atmosphere within the pack, the physical protection provided by Preservation foil is reflected in the innovative engineering of the plastic laminate.”

provides some quantification of the value of significant art works, but even these pale into insignificance when one looks at the works of Cézanne, Picasso, Titian – valued in excess of $100 million. Leonardo Da Vinci’s Mona Lisa tops the list at just under $300,000,000!

Transporting these rare and valuable paintings around the globe to exhibitions demands the maximum protection during travel, handling and intermediate storage. This movement of valuable art works has grown steadily over the last decade as the financial returns have been worthwhile both to the host gallery and the owners of the pictures.

The new barrier material is a multi-layer structure which is water vapour-proof, greaseproof, flexible and heat sealable. The material is used to form a tailored bag for each piece of art which can be supported by an internal rigid frame if so required.

AtmosPHeric controL The bag is fitted with two one-way valves.

One valve is used for nitrogen gas flushing while the second valve is attached to

THIS ARTICLE WAS RE-PRODUCED WITH PERMISSION FROM PACKAGING NEWS PKN

AIP NEWSLETTER MARCH 2014

11

PreservAtion foiL’s muLtiLAyer bArrier mAteriAL is comPrised of: ■ Three layer co-extruded oriented polypropylene ■ 19µm extrusion layer ■ Foil ■ 19µm extrusion layer ■ LD/LLDPE film, three layer co-extruded

LEFT: Les Amy, general manager – research, design and development at Australian Inhibitor, with doyen of the Australian packaging industry, Professor Harry Lovell.

BELOW, LEFT TO RIGHT: Australian Inhibitor’s R&D laboratory manager, David Lade, carries out (1) a foil weight test, (2) a foil gauge test, and (3) a lab corrosion test.

an oxygen flow meter. This is a vital stage which ensures that the gallery standard of a 0.3 per cent anoxic oxygen level is achieved. (The “anoxic” state is simply an environment without oxygen, which is lethal for micro-organisms and insects. It is not to be confused with anaerobic conditions in which micro-organisms derive their oxygen through cellular respiration.) There are also side benefits with the removal of oxygen, namely the prevention of colour fading through oxidation. A humidity indicator can also be incorporated. If required, the bags can include a clear visual panel for the identification of the contents.

With effective control of the atmosphere within the pack, the physical protection provided by Preservation Foil is reflected in the innovative engineering of the plastic laminate. A high degree of physical protection is paramount. Thus the demands on the material are substantial; it must be strong yet flexible within defined limits,

6.2

kilo-newtons per metre: Preservation foil’s tensile strength

1

2

impervious, sealable and capable of holding a positive pressure. This is achieved by a multi-layer barrier material comprised of: • Three-layer co-extruded oriented polypropylene • 19µm extrusion layer • Foil • 19µm extrusion layer • LD/LLDPE film, three layer co-extruded The tensile strength is 6.2 kilo-newtons per metre and its external slip coefficient is 0.385. (Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting [ASTM 1894]). The material has a nominal yield of 5405 square metres per tonne.

The recommended sealing temperature range is 195°C-220°C. A bead profile 6mm wide ensures the highest integrity of the seal. This has resulted from the installation

by Australian Inhibitor of a custom-designed, 16.5 metre, stainless steel continuous sealing system. Certified as meeting Military Specification Defence 1000c, the new system meets the highest standards in seal integrity.

The inflated pack, with its composite material protection and cushioning provided by the anoxic atmosphere coupled to its structural design, flexes without distortion.

It offers maximum cushioning area and also

3 results in neat uniform packs, thus facilitating further packaging into larger units. The fact that the material can be tailored to meet specific requirements means that it has an infinitely large market, including the scientific and medical sectors.

stAnding uP to insPection Ancillary factors which have to be considered concern air transportation and transfer through border inspection services. The ability to control the internal pressure is an essential feature with respect to air transportation, and the ability of the design to accommodate these requirements within current practice. A typical example is that of the Boeing 767 cruising at an altitude of 39,000 feet with the cabin pressurised to an altitude of 6,900 feet.

The Australian Quarantine and Inspection Service should be facilitated by the new pack design making inspection easier.

Specialist packaging is a challenging area and while the physical geometry of items can be difficult to accommodate, Preservation Foil has the potential to ameliorate this problem.

This is an innovative development built on past experience and a proven record in the demanding area of defence and will doubtless open up new markets for the Australian Inhibitor company. ■

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AIP NEWSLETTER MARCH 2014

The expert behind the innovation no stranger to award-winning design success is Les Amy, general manager of research, design and development at Australian inhibitor, who was instrumental in bringing the company’s latest innovation to market.

L

es Amy has been actively involved in the

packaging industry for over 35 years, and during this time has been a member of numerous industry associations in a professional capacity, including a stint serving on the board of the Australian Institute of Packaging (from 1997-2000).

A designer to the core, Les Amy enjoys all aspects of industrial design and development of speciality papers, films, foils and laminates; taking the idea from conception and research through to end trade mark and patent approval.

He began his career in the printing industry with Leigh Mardon where his role covered designing folding board, art work preparation, and developing print separations for printing/ cartoning machinery.

Subsequently he joined MPI to develop sales of capital equipment, including brand names such as Automac, Roure, Arenco, Jacob White, MAF Rejafix, Ratcliffe, and IWKA. In 1979 he took over Eckersley, Amy & Davids (originally just Eckersley Pty Ltd), which manufactured heat sealing and shrink wrapping equipment. His persistence in developing machinery to world class standards paid off when, in 1983, he won the prestigious Australian Design Award (presented by the Design Council of Australia) for his achievements.

His next step was to join packaging giant Visy Board’s packaging systems division where he was involved in sales and marketing of specialised corrugated machinery to back up the pre-print and corrugated board divisions.

From paper and board he moved into plastics, joining Ruskin Plastics where he was charged with the task of developing vapour corrosion inhibitor (VCI) products and alternative resin constructions.

This expertise served him well when, in 2000, he joined Australian Inhibitor, a paper-coating company which specialised in VCI chemicals employed to prevent rust and corrosion of metal components and alloys used in the engineering, automotive and related industries.

Dramatic challenges facing the engineering industries, specifically tin plate production, necessitated the rapid move towards plastics and the integration of VCIs into both flexible and rigid plastic products.

AWArds & AccoLAdes Australian Design Award 1983 Presented by Design Council of Australia for development of specialised plastics capital equipment.

Les Amy accepts his award to loud applause at the 2013 Packaging Design Awards.

Australian Packaging Awards 2005 – nominee Designed VCI wheel protector for Holden HSV Monaro export, nominated for Cryovac Technical Innovation Award by Packaging Council of Australia.

Australian Packaging Awards 2006 Gold Technical Innovation – Export Award; Silver Industrial Packaging – Export Award for export engine covers for Saab, Opel, Alpha, Isuzu (Holden Australia).

Australian Packaging Design Awards 2011 Gold Industrial Packaging Award for VCI Ferro Foil; Silver Innovation Award for VCI Ferro Foil. Product is employed to wrap expensive military hardware (truck assemblies, guns) and used at military establishments Australia-wide.

Australian Packaging Design Awards 2013 Gold Industrial Packaging Award for nine-layer foil product (Preservation Foil) for the protection of art works of national interest.

World Packaging Organisation Awards 2013-2014 World Packaging Organisation World Star Award for Preservation Foil.

Competed against 249 packaging submissions from 35 countries.

Award to be presented at interpack 2014, in Dusseldorf, Germany.

ABOVE: A rectifier filled with electronics packed in VCI Ferro Foil, a good example of sound packaging for static storage of a very large item.

BELOW RIGHT: The 2011 award-winning VCI Ferro Foil has applications in military gun and tank packaging as well as for other large-scale vehicles like this CAT Transporter.

Under Amy’s guidance, the Australian Inhibitor team’s rigorous laboratory development of co-extruded VCI rigid plastics saw the company establish a firm reputation for excellence with the automotive industry, and garner numerous industrial packaging awards. ■

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13

Blow moulding basics T

he strength and success of a bottle design is a direct descendant of the bottle shape. The shape - which includes the corners, handles, the neck and panels - governs both the physical performance in filling and the degree of difficulty in moulding; the two are delicately connected and cannot be separated.

Below are some useful pointers and guidelines regarding blow moulding:

Shrinkage One of the important facts about mould-

Stephen Barter from ing plastic is it shrinks as it cools; the longer it takes to cool the more it shrinks. the Australian Institute The mould acts as a heat transfer mechaof Packaging sheds nism removing the heat from the plastic light on the best ways to at 190 degree celsius down to less than 70 approach blow moulding degree celsius, at which point the plastic is a solid and no longer liquid. and the influence it can Variabilities have on a package’s As the plastic takes the shape of the mould, effectiveness. the plastic becomes variable throughout the bottle, thicker cross sections shrink more than thinner sections inducing stress within bottle features and creating issues like buckled label panels. The best method to reduce this effect is to design contours to reduce thicker sections.

Function Features can be added to the shape to improve mouldability and function and do

not detract from the appearance. Features like corners act as hinge points for slumping and topload weakness. Using variable radii in corners will increase structural strength; fixed radii will reduce structural strength.

Bottle components

Neck - orientating the thread start over the part line (opposite the handle) will improve the capping process, the bottle is able to handle downward pressure from the capper when the thread start of the cap lands on top of the thread start of the bottle. In these conditions the bottle is able to bounce back after being hammered by the capper.

Shoulder - making the bottle strong through the shoulder by keeping surfaces in the form of an upside down funnel and compound radii allows the top load to be dispersed down through the bottle into the base. Compound curves reduce plastic and ovality in the neck finish, especially on oval shaped bottles.

Handles - the closer to square or round for the handle crossection the easier the handle will be to mould. As the depth of the handle increases in relation to the handle width the risk of webbing increases, a major quality complaint.

This rule applies to blending the handle out into the bottle; avoid blending the handle by increasing the depth of the handle, only without increasing the width in similar ratios.

Panel features 2D or conical curves in label panels make labelling easy. 3D curves in panels will lead to the labels lifting and bubbling. The reason for a conical shape in particular is the increase in the bottle topload strength.

Bulging in the panel is difficult to control, especially with thin walled bottles. Start the design with bulge in the shape and work back by changing only the label panel back to a 2D curve.

Imagine the bottle shape you have in mind and then partially blow up a balloon inside this bottle shape. Take particular note of the corner radii and then factor these into the shape of the bottle. These will not only improve slump resistance, it will also make the bottle easier to mould.

Base corners Base controls the topload strength and stability of the bottle. Using a simple radius in the base corner will result in poor topload, slump resistance, base rock as well as difficult moulding. Compound curves are essential here.

It is paramount the bottle designer is aware that most design flaws cannot be ‘processed out’ by the moulder. An over-confident moulder can underestimate these details, adding substantial costs to new projects and the finished bottle weight - costs that may be carried for the life of the bottle. F

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PACKAGING

27

Packaging for product life extension – active and smart packaging

By Pierre Pienaar, education coordinator, Australian Institute of Packaging (AIP)

Those involved in food and beverage packaging know well that consumers and brand owners both are demanding increased shelf life from products. The modern food industry has developed and expanded because of its ability to deliver a wide variety of high quality food products to consumers on a nationwide and worldwide basis.

This feat has been accomplished by building stability into the products through process-

• Modify the immediate environment (MAP) Initially extending the shelf life of products

the consumer of the state or freshness of the product.

ing, packaging, and additives that enable foods to remain fresh and wholesome

was a supply chain issue but it is now a consumer concern, because freshness coupled

• Time temperature indicators • Leak or gas indicators

throughout the distribution process.

The terms active packaging and smart pack-

with sustainable packaging has become an important buying factor.

• Freshness indicators

aging refer to packaging systems used with foods, pharmaceuticals, and several other

Consumer demands for convenience have created new innovations in the food prod-

Nanotechnology One of the fastest growing areas is the ap-

types of products. They help extend shelf life, monitor freshness, display information

uct development and packaging industries.

The widespread desire for products to use

plication of nanotechnology in packaging materials. As the food market has expanded

your consumer market, successfully engage them, and as a result increase your profits.

on quality, improve safety, and improve convenience.

in the microwave oven has added further to the effort. Consumers are demanding more

to a worldwide marketplace, it is requiring a longer shelf life. New materials incorporat-

With the daily challenges of preserving product and minimising losses, growers, packers,

Recently this has been updated to include intelligent functions (sensing, detecting,

sustainable packaging solutions that also perform shelf life-extensions, whilst brand

ing nano-particles have been able to reduce and in some cases eliminate the transmission

shippers and retailers of produce now have new packaging options that allow them to

recording, tracing, communicating and applying scientific logic) in order to extend

owners understand the commercial advantages that active packaging technology can

of oxygen, and in addition have blocked the transmission of moisture from the product.

dramatically increase shelf life.

Various packaging technologies can help

shelf life, enhance safety, improve quality, provide information and warn about possible issues.

deliver to their products.

In the supply chain more work is being done on oxygen scavengers, moisture absorbers

Packaging today not only has to be multi-functional by meeting the design requirements now, with the added pressure

food handlers remain competitive by reducing spoilage and delivering consistent quality products on every shipment. Inno-

There is a commercial need to allow products to stay fresh on a retailer’s shelf for longer. This extension of shelf life is aimed at slowing down the deterioration of the product using a range of processes. Each of the processes is interdependent on packaging to preserve the product in a suspended state.

The principal mechanisms involved in the deterioration of processed foods are: 1. Microbiological spoilage sometimes accompanied by pathogen or germ development 2. Chemical and enzymatic activity causing the breakdown of colour, odour, flavour, and texture changes 3. Moisture or other vapour migration which produces changes in texture, water activity and flavour

and barrier films that will enhance the shelf life of products. Consumers want packaging that keeps products clean, ready for eating, with longer shelf life, product security and value for money. This remains a big ask, but if success is to be achieved, packaging technologists need to rise to these demands.

towards sustainable packaging, it has to be environmentally friendly in the effort to reduce our carbon footprint. This event will provide you with a sound understanding of how and why product innovation for labeling and packaging is the crux of your business and how to strategically tap into

vations in packaging for extending shelf life will be a key driver over the next few years for manufacturers. Enhanced technical knowledge and input by packaging technologists and packaging engineers through improved performance qualities of materials will be required to fuel market growth.

Therefore to enhance shelf life the focus

packaging materials which help to extend

ought to be on: • Reducing microbial activity • Increasing the acidity

and protect shelf life there is also a complimentary group of devices which monitor the products in the packs. These include

• Addition of additives

time temperature indicators, leak and gas

• Reducing water activity

indicators which provide an indication to

Smart packaging In conjunction with the developments in

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Active packaging There is a range of active packaging techniques which are available; the broad categories are: • Absorbers/removers • Release systems • Self heating/cooling • Selective permeation

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February 2014

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AIP NEWSLETTER MARCH 2014

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MAKE 2014 THE YEAR YOU INVEST IN YOUR CAREER

The Australian Institute of Packaging (AIP) is at the forefront of packaging training and education in Australasia; helping to shape the careers of generations of packaging professionals - from packaging technologists to international packaging business leaders along with a host of people in associated disciplines - sales and marketing, purchasing, production and environment.

DIPLOMA IN PACKAGING TECHNOLOGY The Diploma in Packaging Technology is an internationally recognised Level 5 foundation qualification that prepares students to take responsibility for packaging operations at any level through the supply chain and can also lead to higher level study.

CERTIFICATE IN PACKAGING The Certificate in Packaging is an internationally recognised Level 3 qualification designed to meet the training needs of a wide variety of personnel in packaging, from the new entrant looking for a great start, to design, production, management, sales, marketing or purchasing staff looking to deepen their packaging knowledge.

BUILD YOUR PACKAGING CAREER ON FIRM FOUNDATIONS WITH THE AIP. PH: +61 7 3278 4490

educate@aipack.com.au

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