Giró Magazine, February 2018

FEBRUARY 2018

ENG

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Giró Magazine GIRO GROUP PUBLICATION WITH THE LATEST NOVELTIES Hall 10.2. Stand B-04

Fruitlogistica 2018: Giró new products Giró will be participating as an exhibitor at another edition of Fruitlogistica, the world’s leading trade fair for fresh produce.

This year, Giró will offer the most spacious stand in the history of Fruitlogistica exhibitions with an area of 144 sqm where the different novelties and packaging solutions will be shown.

These are some of the main novelties presented in this edition.

Handle Bag and Window Compact

New concepts in clipped net packaging

GirBagger: the world’s most versatile and sold machine

The accuracy of dynamic weighers

New packaging proposals that do not require large investments. That’s right, with a simple adaptation or upgrade, GirBagger machines allow new and attractive packs. Discover the Handle Bag and Window Compact on pages 2 and 3.

We introduce new concepts to give more attractiveness and sales impact in our Clip2Clip packaging range. A new generation of proposals revolutionizing the clipped bags to make exciting promotional activities. See it on pages 4 and 5.

Our GirBagger remains a benchmark in the net packaging market.

More than 2,600 units sold prove the success of a machine capable of performing up to 10 different types of net bags.

Find out on pages 6 and 7.

Giró dynamic weighing range is the most precise in the market thanks to its combination capability.

Now, to the well known PDG-4, the new Exact 100 is added. The citrus weigher world’s most accurate. Learn more on pages 8 and 9.

End-to-end Giró’s multi-produce bagging line

Giró net bags: the most sustainable on the market

On pages 10 and 11 we show a solution to a typical case: to set-up a complete weighing and bagging line for a multi-produce.

Since the fruit is ready for sale to the palletizer, Giró has one of the best proposals in the market to carry out the weighing, the net bag packaging and, finally, the automatic box filling.

Concerned about the environment?

We also, and very much so. The Giró packaging proposals are the most sustainable in the market. Any of our solutions offers, in addition to a 100% recyclable product, the best content / packaging weight ratio that can be found in supermarkets.

All with weight control devices that ensure the quality of the product delivered at the supermarket.

Thanks to the GirControl, the line can be monitored in real time and all the production indicators can be known to be analyzed in an agile and precise way.

Our packagings allow 1 kg of content weight with only 1.8 g of plastic material. An unbeatable system that provides an unbeatable carbon footprint.

There is no packaging system in the usual food products that improves our sustainability. More information on page 12.

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FEBRUARY 2018

Handle Bag & Horizontal Bag styles Girรณ expands the range of horizontal net bags with the new launch of the Handle Bag, which is added to the Window Compact packaging style.

A new concept that allows to increase the creative packaging offer made with the GirBagger machines.

Both packaging styles (Window Compact & Handle Bag) are ideal for horizontal display at the point of sales and for formats from 300 g to 1 kg or 1.5 kg.

Window Compact Window Compact is a package intended for horizontal display at the point of sales.

It is ideal for sizes from 0.3 to 1 Kg and especially suitable for small and mid-caliber fruit.

It is a very compact package which optimizes package size according to the content.

To make this pack it is necessary to use a GirBagger UB-50, UB-60 or UB-65 equipped with an optional accessory for making the Window Compact.

It is also based on Ultrabag style but reducing the length of the package and using a film with window. The recommended window dimensions are 140x60 mm or 130x60 mm depending on the size of the bag.

Both sides of the film must have a width of 145 mm and a recommended thickness of 320 gg.

The Window Compact bag can be made with tubular knitted or extruded net from Girรณ.

Window Compact bag. Ideal for packs from 300 grams to 1 kg and horizontal display at the point of sale

Handle Bag On the other hand, the Handle Bag is also a packaging system with a horizontal presentation.

The Handle Bag is a very attractive bag that provides a good communication surface and excellent visibility of the contained product.

The upper side film is used as a handle for an easy transport and grip, welded

by its ends with a greater width (145 mm) that allows the closure of the bag on both sides.

The lower side film is welded longitudinally along the entire length of the bag.

In order to make the Handle Bag it is necessary to use a GirBagger UB50, UB60 or UB65 equipped with a Win-

The upper film performs like a handle

dow Compact kit and also a Handle Bag kit. Therefore, the machine that makes the Handle Bag can also make the Window Compact.

The Handle Bag is ideal for formats from 0.5 kg to 1.5 kg., considering that these sizes are those that offer a better aesthetic and functional balance to the bag.

Handle Bag: Recommended for formats from 0.5 kg to 1.5 kg. The upper side film configures an attractive and comfortable carrying handle.

To make this pack it is necessary to use a Fashioned Girfilm on the upper side -which performs the handle function- with a 145 mm width at the end of the film and recommended thickness of 320 gg. For the lower side, it is necessary to use standard Girfilm of 145 mm width and recommended thickness of 320 gg. It is possible to make the Handle Bag with knitted or extruded tubular net from Girรณ.

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Window Compact made by GirBagger

Some Window Compact packaging samples with potatoes, avocados or apples. An excellent package for horizontal display, very attractive and compact size. The presentation in boxes is an interesting and attractive proposal to display the bags with orderly manner and high content visibility.

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Handle Bag Packaging styles

The Handle Bag is excellent to merchandise due to the horizontal orientation exposure at the point of sale, where the bags appear ordered and with a great visual impact.

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New clipped The most versatile clipped

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p i l C

p i l C

Most eye-catching clipped bag Back in 2016, a new concept was introduced by Giró in the marketplace in order to enhance the look-and-feel of mesh clipped bags: “Clip2Clip”.

All C2C variant labels that are shown at Fruitlogistica 2018 can be produced with all homologated sizes, ranging from 40 to 98mm width and from 160 to 292mm By attaching a bigger label clipped at length. each end of the bag, meaning from clip to clip (and so, where its name comes C2C Fashioned from), there outcomes a more compelling tag system to display messages, First of new Giró proposals is the images and promotions. production of labels with different shapes, so-called Fashioned. This eaGiró takes one step ahead and offers ses the adaption of label shape either Clip2Clip labelling, acknowledged to the printed message or image on as C2C in its abbreviated form, de- it. By doing this, the label integrates ploying variants that deliver multiple the bag in a really astonishing visual creative options to packaging in order effect. to improve their appearance at the supermarket and to help foster sales.

The C2C Fashioned labels may be produced in multiple die cut shapes tracing either a picture, or a logotype or an

artwork contour. The only limitation there might be is a sharp finish of the label causing wrinkles or jamming on the guiding systems of the clipping head. Recommendation is to finish labels with rounded shapes and soft edges in order to avoid labelling conflicts when it comes to the bagging machinery. The use of C2C Fashioned delivers an outstanding look-and-feel to the packaging that still surprises consumers.

C2C Paper Another breaking new for the Clip2Clip bagging style is the possibility of creating labels with paper lamination.

C2C Paper labels are coated with an external paper layer that delivers a more vintage finish.

C2C Paper labels include an inner Poly-Ethylene layer that affords the optimum resistance conditions to a clipped bag. This Poly-Ethylene layer grants a superior tear and traction resistance, which are the necessary properties to ensure a robust and resistant packaging.

Clip2Clip Paper packaging

Clip2Clip Fashioned packaging

C2C Collectible Last new-coming on the Clip2Clip bagging style are the C2C Collectible.

As to the present, all packs produced under the same batch are exactly the same as long as they are coming from a continuous consumable material, either a film or a label, that are fed into the bagging machine by means of a reel.

Thanks to a brand new printing technology available at Giró, label reels may be offered in a way that every single label is different from the previous printed one. By creating packaging with singular printed labels, Giró opens the possibility to address marketing activity or promotion at the point of sales, bond to the packaging label.

A potential idea is the creation of collectible labels whereby consumers attempt to gather a line-up of football players, celebrities or whatever playful idea that may foster the sales of the packed product.

* Clip2Clip (and its logotype) is a GIRO registered trademark

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packaging concepts systems in the marketplace

Clip2Clip Fashioned

Clip2Clip Collectibles

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GirBagger: 10 packaging

The world’s most versatile packaging m A machine for all needs With more than 2,600 units sold worldwide GirBagger machine is probably the most recognized in the horticultural packaging business. A range of machines that has evolved over the 10 years since its introduction into the market and is now an undisputed leader. GirBagger is a versatile machine in many ways: • It is versatile because thanks to different versions, allows adequate treatment for many types of products such as potatoes, onions, oranges, tangerines, kiwis, avocados, lemons,

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apples or peaches Another machine versatility is the ability to incorporate and interconnect many elements or devices that improve the quality of packaging plant, such as intelligent recognition system supplies (SCS), interconnection with GirControl Plus, the ability to add a checkweigher CHW-G30 or adapt integrated Spotless film centering system without visible mark And is especially versatile for the possibility of up to 10 different variants of bags.

No other machine on the market with this versatility. Its flexibility is highly appreciated by packers and producers because it allows them to optimize their investment in machinery, due to the cost of it but also for the floor area saving. The range of packages and variants makes this machine, provides a great productivity in any packaging plant.

But that’s not all. One of the great features of the GirBagger machine is its ability to grow according to your needs. It is not necessary to start with the most equipped and expensive model but any model can be complemented in the future to be modified to the requirements of packaging.

And do not forget something very important: no other machine on the market offers the quality of the package you get with GirBagger.

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Girplus An economic and eco-

logical packaging with high visibility to show the fruit at its best. Ideal for bags between 1-3 kg

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BEST SELLER

2600 UNITS

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Window Compact

Something different. Thanks to a simple kit, GirBagger machine can make the Window Compact bag. An horizontal package ideal for small caliber fruits and bag sizes from 300 g and 1 kg. Extremely compact.

Handle Bag

Adding a Handle Ba is possible to make th tal bag with high vis Ideal for 500 g to 1,5

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g styles with one machine

makes up to 10 different netbag styles 4

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Girsac Fashioned

A new style that brings originality and appeal to Girsac through the use of a shaped film with the desired design to enhance the image and creativity.

Girsac This world famous package

incorporates a printed film longitudinally not welded to the bag that allows its grip.

Suitable for formats up to 4 kg

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Ultrabag

An elegant, ergonomic, durable and great printed surface to communicate the best properties of the product inside the package. Ideal for any fruit and format up to 5 kg.

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ag to the GirBagger it his pack.. An horizonsibility and ergonomy.

5 kg. Compact size.

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Window Ultrabag

A touch of uniqueness to the traditional bag. A window to see the content can be done with the most convenient shape and size.

MiniBag A package for small formats

(100 g to 500 g) ideal to give a high class appearance to small products (garlic, shallots, clementines) offering a wide communication area.

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Girplusac An interesting way

to make a package with a good balance between visibility and communication skills: half Girplus, half Girsac.

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Ultrabag Fashioned

A touch of class to a great added value package giving a 3D effect to the printed and longitudinally welded film.

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FEBRUARY 2018

Dynamic weighers: the New EXACT 100, the big Dynamic weighing or Static weighing system?

Most automatic fruit weighers, and particularly of citrus, are based on a rather simple principle. There are multiple buckets filled with small amounts of fruit (one or a few units).

Every bucket with its contents is individually weighted and after knowing all the individual bucket weights is carried out a combinatorial operation to find the target weight (the package you want to be obtained) by adding several buckets.

Conceptually, a static weigher consists of a number of feeding channels (usually between 8 and 16) with a bucket associated to every channel.

The buckets are static, there is not moving, and also static weighted .

The fruit to be weighted is moved through the vibrating channel and introduced into the corresponding bucket. Once the bucket is filled it needs to be stabilized and finally weighted through load cells. It is obtained one weight measurement per bucket.

Static weigher bucket system: feeding channels, weighing buckets and output belts

Subsequently a microprocessor takes care of combinations between these ‘n’ buckets (remember, usually between 8 and 16) for all the possible combinations, or sums of weights of buckets, and choose the one that best sum approaches the target weight.

How does a dynamic weighing?

The difference is that there are several carousels (usually 3 or 4) each formed by several buckets (15 to 30). These carousels are continuous-

ly rotating and a feeding system fills the buckets with one or a few pieces of fruit. The buckets with fruit inside are continuously on the go. For each carousel there is a load cell and the buckets are dynamically weighed, one by one, as they pass through the weighing zone were the load cell is located.

Carousel and buckets system of a dynamic weigher

A microprocessor is responsible to calculate all the combinatorial possibilities with the buckets (in this case may be more than 100), to reach the target weight.

It is evident that the combinatorial capacity of a dynamic weigher is higher due to the higher number of buckets to combine.

So dynamic weigher is recommended rather than a static? The answer is not universal. If a machine is required for fruit very accurately calibrated, the answer is yes. A dynamic weighing is ideal for working with citrus because usually the product is distributed very calibrated. But a static weigher is perfectly valid for less demanding product calibration (e.g. potatoes or other vegetables).

The advantage of a static weigher is its less mechanical complexity (no moving parts) and a lower cost for equal productivity.

A dynamic weigher is usually more expensive than a static offering the same ‘output’. If there is no need to handle a very calibrated produce it is not needed to invest in a dynamic weigher.

A dynamic weigher saves 6 g of fruit in every dump, which means 12 Tons of fruit per year

PDG-4 The PDG-4 is a “classic” in the world the intuitive icons of dynamic weighing. It is the fourth • Easy access for cleaning and generation of the best seller dynammaintenance ic weighers worldwide. It is an advanced machine that incorporates a number of advantages and benefits that will probably make the weigher for citrus best price / performance ratio in the market.

• 60 bpm consistently (based on 1 kg of fruit with enough combinational caliber) Feeding system with rollers to have good • Excellent citrus handling fruit ‘lamination’ and brushes to achieve proper product dosage.

• Fully compatible GirControl Plus connectivity providing productivity data and failure ratios in remote way • Fruit feeding without elevator need • 4 output conveyors to easily allow up to 4 baggers • Compact layout even installing up to 4 packaging machines.

4 bidirectional output belts to feed up to 4 • Color touch panel with a extremebagging machines ly easy user interface thanks to

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world’s most accurate brother of the known PDG-4 Exact 100: The best citrus weigher in the world Giró launched the new citrus weigher Exact 100 in late 2016. A machine with an innovative design appointed to be the best citrus weigher manufactured ever.

Giró’s engineering team invested more than 5 years of research and development to achieve an outstanding product which will become a breakthrough in the fruit processing business.

bucket feeding can be done at high speed allowing to fill up to 48 pieces per second in the 8 buckets.

The high capacity buckets are driven trough different carousels with a precise continuos movement. The completely new driving system is smooth and free of undesired vibrations.

Also, a unique design of the load cells system do the weight measurement Exact 100 is a high productivity and achieving an accuracy of half gram per extremely accurate dynamic weigher. bucket, an unprecedented milestone in A new and smart mechanical driving weighing fruit. system together with a sophisticated algorithm are responsible to achieve Up to 100 bpm the better bucket feeding according to the fruit caliber and target weight. A High accuracy (<10 g) well balanced bucket feeding is very important to have the proper combinational possibilities to find the target Thanks to this set of new developments (do not forget this machine has weight.

An innovative system based on ro- 6 different patents protecting different botic fingers gives the right and pre- technological improvements) it’s poscise dose of fruit to each bucket. This sible to achieve a high accuracy of 10 grams per dump at high output of 100 bpm of 1 kg.

Feeding channels to the buckets and robotic fingers

Exact 100 is a very versatile machine because it has 4 bidirectional output belts that enable to feed a multitude of packaging machines. An optimal configuration is to install four GirBagger machines or in a multi-format implementation, can feed 3 GirBagger and 2 clipping machines like CA-9s or CA-10.

Exact 100 weighing head. Should be installed in a upper position together with a platform and elevator.

Also the discharge system must be added.

Easy maintenance Another important aspect where Giró engineers take care in designing the Exact 100 is its easy maintenance and cleaning. In addition to employing robust and reliable mechanical systems and easy accessibility to the components that may require maintenance, it has also designed for a simple and effective cleaning. The buckets can be easily removed by using one hand.

Cleaning-Sanitizing machine: Cabinet with the buckets trolley inside

The 68 buckets of Exact 100 can be easily removed using only one hand

Packaging line example with a Exact 100 (on platform) and three GirBagger machines

Together with the Exact 100 an automatic washer-sanitizing machine will be launched. This washer is ideal not only for cleaning but also sanitizing the buckets. Also it supports the PDG4 buckets or other elements such as conveyor belts.

Top view of the Exact 100 buckets carousel

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End-to-end Giró’s The highest versatility No matters whatever the challenge is but GIRÓ is able to deliver the best solution to the customer when it comes to packaging systems. This actual case study shows how to cope with a high demanding project for handling a wide range of commodities such as avocados, oranges, lemons, grape fruit and limes through a single line.

tility and productivity rates in order to accommodate his business demands.

The line had to enable fruit inspection, weighing, counting and bagging in different styles such as Ultrabag, Girsac and Clip2Clip. On top of those requirements, strict quality assurance protocols from market retailers, compelled to add check weighing devices as well as automatic boxing at the end This full-line solution showcases of the line.

GIRÓ’s complete offering outside grading and palletizing.

In order to fulfill those requirements GIRÓ is to afford a comprehensive Amongst other requests, the customer was expecting a high degree of versa-

line including: PDC500 buffer integrated with an inspection table, dynamic weigher PDG4L, three GirBaggers UB-60 with thermal transfer printer E300TT, one clipper CA-10, two standalone checkweighers CHWS60, one automatic box filling system GBF-100 with a de-stacker and box rejection system.

able to control the performance at every step of the line, viewing real-time machinery alarms, and having access to comprehensive service and output reports The whole system is to achieve an output of 7,200 kg/hour circa and had to fit in a 86 sqm corner in the packing shed.

Every single machine is fully monitored by the GirControl system (on site One of the most renowned weighor remotely) for which the customer is er systems from GIRÓ’s line up is

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PDC500 Fruit buffer integrated with an inspection table

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PDG4L Dynamic Weigher

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GirBagger UB-60: up to 10 different bagging styles

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CA-10 Clipping machine to make Clip2Clip or Wineglass netbags

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CHW-S60 Check weighing unit

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GBF-100 Box filling machine

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Box de-stacker and filling device for GBF-100

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Box check weighing and rejection system

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bagging line for multi-produce handling PDG4L that delivers a weighing accuracy of 6 g / 3000 g Ultrabag Oranges at a 48 bags/minute rate, and is able to weigh up to 78 bags/minute on 500 g target weight. PDG4L dynamic system handles lemons as well as oranges and avocados, in a triple weighing mode (fast or accurate) and count-totarget mode. PDG4L has the ability to interface with 4 different bagging systems benefiting from its 4 exit belts, which makes a very versatile and compact layout.

GIRÓ flagship bagging equipment socalled GirBagger UB-60 is included in the line, as this unit’s outstanding versatility performs 7 thermal sealed bag styles (up to 10 with a very simple and inexpensive upgrade kit). The system

combines three GirBagger units in order to deliver a maximum output of 75 bags/minute (5-count or 500 g lemon bags). This bag flow is consistently guided through a conveyor framework that is controlled by a “smart traffic” system leading the bags onto a couple of checkweigher CHW-S60 units.

the whole line.

different elements: GBF-100 box filler machine, 9 unit crate de-stacker and box rejection system. This is a very strategic decision at customer side and involves head count reduction. The automated box filling system ensures a non-stop workflow at the end of the line, so that no operator is needed except for the consumable refilling of the line. (outside operators set at the inspection table). One headcount can control the whole line. In the best bag flow condition through the line, we would be able to fill boxes at the rate of 10 per minute. For instance, 4 Ultrabag Oranges 3 kg per cardboard box, 12 kg per box, meaning 7,200 kg per hour. The de-stacker system enables to feed the box filler automatically with a 9 unit empty box stack, one by one.

Because quality matters, our customers aim to secure the right weight on their produce deliveries, and so checkweigher systems become crucial.

GIRÓ consistenly include two checkweighers CHW-S60 in order to secure accurate weight readings on every sinAlternatively, this specific layout gle bag, with a resolution of +/- 0.5 g takes on board hi-end clipping equip- at 60 bags/minute rate. ment such as CA-10, in order to perform either wineglass clipped bags or The CHW-S60 standalone system is to Clip2Clip style bags. The line is ready be set in the conveyor collection line, for this 2 clipped bag styles thanks to including a 10 inch display that shows the Clip2Clip labelling module which the histogram of weight readings beis a state of the art clipping systems tween upper and lower weight threshcurrently. CA-10 is the first-ever ma- olds, as well as number of rejected chine that automates mesh tube load- bags. ing, which favors cost effectiveness to At the very last steps of the line, right before the palletizing, customers may On top, the box rejection system, meadecide go for a manual crating or au- sures the box weight in a very last tomated. GIRÓ proposal consists of 3 checkpoint and let the box go ahead if the weight sits between the right weight limits.

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In conclusion, GIRÓ focuses on value added solutions to our customers that ensure the right return on investment and quality outcomes.

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Giró net packages The most sustainable on the supermarket At all the stages in the supply chain, from production to the consumer, there is a big concern for ecological efficiency, sustainability and the environment. Packaging materials are one of the biggest concerns given that indiscriminate, inefficient and without control mechanisms can be an important pollutant and environmental degradation agent.

Giró, as a leading business group in horticultural packaging, has always been concerned and involved in offering efficient and sustainable solutions. We can ensure that Giró net bags are the most efficient and sustainable that can be found among consumer products.

To evaluate the efficiency of a packaging in terms of its sustainability and respect for the environment, different criteria must be taken into account:

the convenience of using agricultural crops to be used for the production of raw materials (there are food deficits in many countries) or the possibility of contaminating plastic or organic waste The materials if the consumer doubts the packaging First, the packaging must be made composition. with materials that have a minimum environmental impact when disposed Carbon footprint of. In this sense there are two clear Another important aspect to evaluate options: use recyclable materials or the sustainability of a pack is its “caruse biodegradable / compostable ma- bon footprint”. The carbon footprint terials. Giró is constantly researching is a measure of the environmental imin this field and, for the moment, the pact caused by a product, service or best solution is the use of polyolefin even a process. The carbon footprint derived plastics, raw materials that measures - in a fairly complex calcuare 100% recyclable and offer an ex- lation - the emission of greenhouse gacellent performance, weight and price ses that this product or service causes ratio. throughout its production chain and The use of compostable materials was life cycle to its destruction, both dialso an option proposed by Giró and rectly and indirectly. we were the first company to certify For a packaging, the calculation of the a packaging of compostable mesh. carbon footprint consists of analyzing However, these materials, in addition the emission of gases (or their equivato having a higher cost, have lower lent) in the process of extracting the performance in terms of strength and raw materials that made it, its design weldability, which requires using and transformation, packaging, transmore material to achieve a similar re- port, distribution and recycling. sult. On the other hand there is some It is a very interesting concept because confusion and controversy regarding it not only takes into account the re-

cyclability or reuse of the packaging the energy consumed in the trucks, the but many other aspects that impact on transport of the recycling containers, the environment. etc. And all these elements in the life cycle consume energy that, directly or To understand the concept well let’s indirectly, end up emitting greenhouse take a very simple example: is a glass gases. bottle more ecological than a plastic one? A priori it may seem that glass is The Giró net packaging a more recyclable material than plastic Without a doubt, the most sustainable and we might even think that the glass packaging system that can be found in bottle is reusable once it has been was- supermarkets around the world is the hed.

Giró net packaging.

However, a 1.5 liter PET plastic water bottle weighs 35 g. Therefore, to Depending on the type of packaging contain 1.5 kg of water, 35 g of pac- (using Girfilm with greater or lesser kaging are needed, that is, 2.3% of the width or thickness) and the size of the total weight is packaging. On the other packaging (kg of content), our packahand, if the bottle is made of glass, to ging represents only between 0.18% transport 1.0 l of liquid, 410 g of pac- and 1.03% of the weight of the conkaging are needed, therefore 29% of tents. Compared with liquid contaithe total weight is container. ners, Giró mesh containers are betA 12 ton truck that transports liquid ween 2.3 and 30 times more efficient. moves 276 kg of plastic in one case or 3,480 kg of glass.

There is no other type of packaging that meets this sustainable relationThe effect is spectacular: every 2 ship and with so little environmental trucks of liquid in PET equals 3 trucks impact due to its carbon footprint, of liquid in glass bottles. This same without forgetting that the Giró net proportion is also applicable in the bags are made 100% with recyclable space occupied at the point of sale, materials.

This chart shows the weight of different types of packaging needed to contain 1 kg of product. In each type the usual range of values is indicated, taking into account that the packaing size and possible variants can significantly affect the weight of the pack to contain 1 kg of product.