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Modern Packaging & Design

May-June 2011


EDITORIAL

The quest for ‘quality’

P

ackaging, perhaps, is one of the select sectors witnessing tremendous changes (and challenges) in terms of new materials, new production technologies, new users and thus, new end-products. All these are adding to the growing demand for the right packaging material and technologies, with the right quality and right price. Apart from specialisation and sophistication, eco-consciousness is gaining a wider footprint, especially in packaged foods & medicines. Quality control, quality assurance and quality improvement, which form the three key pillars of quality management, are not only meant to drive product quality, but also to ensure an effective way for achieving it. In this context, the customer–supplier interface should extend beyond the immediate customers and suppliers to unlock the hidden potential. Biological food safety hazards, though mainly linked to food manufacturing processes and not much to packaging materials, can be included in a hazard analysis. Quality issues, in fact, encompass mould, product leakage, transferable ink, etc. Hence, as a preventive measure, it becomes imperative to test the containers, cartons and other packages with the ingredients and food products to be packed in them and ascertain the possibility of any reactions thereof. Besides conducting regular process audits by an independent team to make quality built into the products, food manufacturers and

packagers need to follow a hazard-based analysis ecosystem, towards proactively tackling potential food safety issues. It is encouraging to see the implementation of such formalised programmes by packaging suppliers along with their respective manufacturers to identify and avoid potential hazards. Turn to ‘Sector Watch’ for some of the latest insights into this value-added approach on enhancing packaging quality. This said, packaging printing can play a differentiating role in the all-important journey of a product to a brand, particularly in the current era of intensifying competition on supermarket shelves. As the application of various high-end printing and graphics technologies grows, the Indian packaging sector seems set to tap the growth opportunities not just in the domestic market but globally too. Take a look at ‘Market Trends’ for a detailed perspective. With Interpack 2011 – the world’s leading business platform for the packaging domain – round the corner, the rising influence of emerging economies on the global map is even more visible. The ‘Curtain Raiser’ presents a sneak peek into this mega show. Read on…

Editorial Advisory Board P V Narayanan

Chairman Cognizance Packaging

M K Banerjee

Director - Creativity & Innovations (Global) Essel Propack Ltd

R Krishnamurthy

Director-Marketing & Operations Orient Press Ltd

S Das

Managing Director Nordson India Pvt Ltd

Manas R Bastia

Editor manas@infomedia18.in

Editor Manas R Bastia Senior Features Writer Beverley Lewis Features Writer Annabel Dsouza Correspondent Anwesh Koley (Delhi) Copy Editor Swati Sharma Edit Associate - Products Paskaline Sebastian Chief Photographer Mexy Xavier Photographer Neha Mithbawkar, Joshua Navalkar Design Sharad Bharekar Production Pravin Koyande, Dnyaneshwar Goythale, Vikas Bobhate, Ravikumar Potdar, Ravi Salian, Sanjay Shelar, Lovey Fernandes, Pukha Dhawan, Varsha Nawathe, Abhay Borkar, Akshata Rane Marketing & Branding Jagruti Shah, Ganesh Mahale CEO-Publishing Sandeep Khosla Associate Vice President Sudhanva Jategaonkar

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Modern Packaging & Design May-June 2011

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Editor: Manas R Bastia

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CONTENTS

Design Innovation

36

22

The latest in product designs and innovations

24 26

Mohan Joshi, Country President, Schott Glass India Debdeep Kole, Director, Koley Converting Machinery (P) Ltd

Leaders Speak

Facility Visit 28

Hindustan National Glass & Industries Pvt Ltd: Driving the sustainability index

32

Quality standards in packaging: Raising food safety and hygiene value

Sector Watch

32

Market Trends 36

Printing & graphics in packaging: Combining creativity with technology

Packaging Perspectives 40

Food packaging: Convenience, creativity and consistency P V Narayanan, Chairman, Cognizance Packaging

Packaging Printing 44

40

Colour calibration: Synchronising the shades Bhargav Mistry, Managing Director, Grafica Flextronica

Industry Update 48

Checkweighing: Profit boost with innovative feedback control Gunter Schilpp, Head, Product Management, Mettler Toledo Garvens

Policy Matters 52

Design dynamics in MSMEs: Gaining competitive edge through innovation Jitendra Rajput, Co-ordinator, Design Clinic Scheme, National Institute of Design

44

Curtain Raiser 55 60

• InterPack 2011 • In the news

Cover Design: Sharad Bharekar

REGUL AR SECTIONS Editorial............................ 3 National News.................. 6 World News.................... 12

Book Shelf ...................... 68 Product Update Update............... 68

Tech Updates .................. 18

Product Index.................. 83

Events Calendar.............. 62

Advertisers’ List ............... 84

6th ary rs Annive

Details on page no.62

Highlights of Next Edition Sector Watch : Packaging Security Market Trends : Innovative Packaging Designs

And much more... Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise

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Modern Packaging & Design May-June 2011


NATIONAL NEWS

Nichrome collaborates with Spanish technology manufacturer for innovative packaging solutions

pack, spout (cap) pack. This increases efficiency and ease of operation. Nichrome India has ventured into a technical collaboration with TOTPACK from Spain. In this regard, the company will use the most advanced Spanish technology to manufacture and sell HFFS machines domestically and internationally at an Indian price. Under this technology licensing arrangement, TOTPACK will support Nichrome with its experience and specialty of HFFS technology transfer and upgradation. The machines will be manufactured in simplex and duplex constructions for products like cosmetics, pharmaceutical powders, juice concentrates, etc. With this technology, the company will be able to offer machines for Doypack style stand-up pouches with spout, zipper and straw attachments. Harish Joshi, Managing Director, Nichrome India Ltd, said, “With this collaboration, Nichrome envisages a breakthrough in new market segments like cosmetics, personal care, food, neutraceuticals and Over-TheCounter (OTC) pharma products.”

Rajasthan Ventures invests in PR packaging

Rajoo supplies film line to Polypack flexible packaging

The line installed is equipped with 2 x 50 mm and 1 x 60 mm grooved feed barrier extruders. In addition to other film products, the machine is designed to produce 37.5 micron film with 1,500 mm lay-flat width and output of 250 kg per hour. The sale was facilitated by Trade Polymerz, Rajoo’s agent in Pakistan. Rajoo is aggressively promoting its brand in the South Asian Association for Regional Cooperation Countries, Sri Lanka, Bangladesh and Nepal.

Rajasthan Venture Capital Fund, a state-run venture capital fund based out of Jaipur, has invested `15 crore in the second round of funding of PR Packaging Ltd (PRP), a packaging company located in Faridabad. PR Packaging produces high-quality folding cartons like printed mono cartons, fluted boxes, pouches, brochures, leaflets, etc. Girish Gupta, CEO, Rajasthan Ventures, said, “PRP is serving to best-known brands in electronics, pharmaceuticals, cosmetics, automobile industries and food chains. The company is well-positioned in northern India and is planning to foray in flexi tube packaging, as well as seamless and laminated tubes.” The funds will be used to widen its customer base by enhancing its capacity, exploring new packaging opportunities, widening its product portfolio and consolidating its position, and thus become the preferred vendor to all its clients. The Indian packaging industry is expected to grow to `82,500 crore by 2015 from the current `65,000 crore, according to the Indian Institute of Packaging (IIP). At present, India stands at the 11th position in the world packaging industry, which is $550 billion, and with the rising consumer demand and new technologies, it is expected to grow at 18-20 per cent from the current 15 per cent, the industry body added.

Health concerns to boost demand of packaged juice segment

of 7.8 per cent over 2009-14, as per the analysis. In terms of volume sales, the category displayed a healthy 15 per cent Compounded Annual Growth Rate (CAGR) during 2004–09, reflecting the growing demand among Indian consumers. Varun Kumar, Senior Analyst, Consumer Markets, Datamonitor, said, ‘’Offerings in the Indian juice market have come a long way, from juice prepared by street vendors, via India’s

first popular drink, Frooti, to Tetra Pak fruit juices. A major inhibitor to this category was a cultural aversion to packaged food & beverages, but consumers are slowly progressing towards branded fruit juices, primarily due to growing health consciousness.”

(L-R): Vaibhav Modak, Executive Director, & Harish Joshi, MD, Nichrome India (Ltd) with Joaquim Miro, CEO, TOTPACK Spain

Nichrome India Ltd, the pioneer of vertical form-fill-seal machines in India, is all set to cater to the requirements of packaging industry by offering special machinery with re-closability and pourability features for packaged products. The machinery typically known as Horizontal Form-Fill-Seal (HFFS) machines is highly automated and offers a variety of pouch formats like stand up pack (Doypack), zipper

India’s Rajoo Engineers has anounced that it is the first Indian company to supply a three-layer blown film line to Polypack, a Lahore-based customised extruder. Polypack is a major flexible packaging supplier in Pakistan, with products like shrink film, milk pouches and lamination-grade film. Sunil Jain, President, Rajoo Engineers, said that the sale provides the company significant entry to the Pakistan market.

The beverage packaging segment is likely to get a boost, as larger number of Indians choose packaged fruit juices. Rising health consciousness, disposable incomes and urbanisation is driving the growth of the packaged juices in India, according to research firm Datamonitor. The Indian packaged juice segment is expected to display a growth rate

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Modern Packaging & Design May-June 2011


NATIONAL NEWS

Convertec installs first Braillemaker One in India

Manjushree Technopack awarded ‘Best Supplier Performance Gold Award’ Bangalore-based packaging major, Manjushree Technopack Ltd, was recently presented with the ‘Best Supplier Performance Gold Award’ by Hindustan Coca Cola Beverages Ltd (HCCB), the bottling arm of Coca Cola India, at the recently conducted ‘Second Strategic Supplier Summit’, in New Delhi. The award was presented to Vimal Kedia, Managing Director, Manjushree Technopack Ltd, by Patrick Yadauga, Senior Vice President - Supply Chain Coca-Cola, India. Also, present were T Krishnakumar, (CEO, Hindustan Coca Cola Beverages Pvt Ltd), Asim Parekh (VP Technical, Coca Cola India) and Atul Singh (President, India and South West Asia Business Unit, The Coca-Cola Company).

(L-R): Vimal Kedia, Managing Director, Manjushree Technopack Ltd, receiving the ‘Best Supplier Performance Gold Award’ from Patrick Yadauga, Senior Vice President - Supply Chain, Coca-Cola, India.

Manjushree Technopack is among the leading rigid packaging manufacturers offering total packaging solutions under one roof, right from Concept to Design, R&D, Tooling and Commercialisation of the package. Manjushree has been a preferred supplier for HCCB for over three years.

Paper prices up on buoyant demand Rising costs of raw materials such as coal and furnace oil have resulted in rising costs. Riding on buoyant demand, paper companies such as Bilt, West Coast and JK Paper have increased the prices of writing, printing and packaging paper by about three per cent from April 2011. This is the first increase in the current financial year. In the last financial year, companies had increased prices thrice. High paper prices are eating into box manufacturers’ margins. Prices of kraft paper, used for making corrugated boxes for packaging, have risen by 20 per cent from Rs 24 per kg to Rs 29 per kg. Also, the import duty on kraft paper is 10 per cent at present, which adds to the woes of the corrugated box manufacturers. Kirit Modi, President, Indian Corrugated Case Manufactures Association, said, “We have appealed to the government to remove the 10 per cent import duty on kraft paper, as the cumulative impact of these increases is 20 per cent.” India is one of the fastest growing paper markets, with the government thrust and budgetary allocation to education. The domestic paper industry is estimated to be around 10 million tonne. Of this, the writing paper segment accounts for 3.8 million tonne, packaging grade paper around 4.5 million tonne, while the newsprint industry is about 1.7 million tonne.

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Sweden-based Convertec has installed its first Braillemaker One digital printing and inspection machine in the Asian subcontinent. The European-headquartered converter installed the region’s first Braillemaker One at its label printing plant outside New Delhi. Convertec’s local agent Creed Engineers assisted in the installation. The new machine aims to meet the demand for Braille printing of pharmaceutical products exported from India, one of the leading exporters of pharmaceutical products to Europe. The Braillemaker One, equipped with 100 per cent inspection, is designed to print on plain labels, leaflets for cartons, booklets and multi-ply pharmaceutical labels.

Nutech installs second NovaCut diecutter for further expansion Noida-based Nutech Packaging has installed a Bobst NovaCut, the second die-cutter from the Switzerland-based finishing equipment manufacuturer. Besides the two NovaCut machines, Nutech Packaging’s plant is equipped with a third Bobst machine, which is a folder-gluer. The 20-year old packaging manufacturer prints paper boards and provides final products for the liquor and cosmetics industry. The company also manufactures corrugated boxes but only for quality concern customers and in house consumption. Jatinder Shroff, Director, Nutech, said, “Our business is growing at the rate of 35 per cent annually, and

we expect further growth in the future. The machinery expansion will enable us to meet the growing demand for packaging products.” With the addition of machinery and the need to deliver customer orders in a timely manner, the company is also planning further expansion of the facility. The Nutech plant is equipped with multicolour presses from Planeta and Akiyama and a mono unit from Heidelberg, plates for which are fired by the inhouse REE. The plant is also equipped with a Germanmade rotogravure press. The in-house design team works on sample products, which are produced on the Kongsberg machine. Nutech converts 450 tonne of paper board and kraft paper into producing packaging products and employs 150 persons at its plant.

Modern Packaging & Design May-June 2011


NATIONAL NEWS

Bhargav Mistry among five Global Screen Masters

(L–R): Scott Fresener, Ad Verteeg, Bhargav Mistry, Michel Caza, Charlie Taublieb

Bhargav Mistry, Managing Director, Grafica Flextronica and DMI was among the five Global Screen Masters who conducted live workshops on various facets of advanced screen printing at the recently concluded FESPA AMERICAS at Orlando, USA. The workshops were held from February

Rasna introduces convenience packs for the powdered drink market

Recognising the needs of a fastmoving metropolitan lifestyle, Rasna has come up with a novel stick pack of its existing product ‘Fruitplus’. Saina Nehwal, India’s number one shuttler unveiled the new packaging in New Delhi. Also accompanying Saina was Rasna’s Chairman and Managing Director, Piruz Khambatta. He said,

Ban to impact packaging sales of India’s film extruders

The recent ban on plastics packaging is likely to impact the Indian plastics processors, especially the recently adopted ban on the sale of gutka and other tobacco products. Sunil Jain, President, Rajoo Engineers

10

24-26, 2011. All the way from India, Grafica despatched its Nano Premier League (NPL) package to the US for the purpose of conducting live workshop on graphics screen printing jointly with Michel Caza. A set of creative samples produced at DMI were also distributed to all participants and visitors to generate interest in print finishing for value addition in the US. FESPA AMERICAS was an exhibition cum conference organised by FESPA. This was one of the first of its kind creative live workshop on advanced screen printing organised by FESPA. It was a unique combination of exhibition with live workshop initiated by FESPA on experimental basis. Bhargav Mistry, said, “It was a memorable experience to jointly work with other four global screen masters at FESPA AMERICAS.” “Rasna is proud to be consistently present in the market, and we have been committed to our consumers with the quality and nutritious value of our products. The benefit of these consumers only has yet again formed the basis of our growth. Rasna Fruitplus Singles intends to offer a convenient and hassle-free experience. Children and adults can carry the sticks to their schools, playgrounds and workplaces, respectively.” Rasna Fruitplus Singles has also combined ‘choice’ with ‘convenience’. This product would be available in a mono-carton comprising variedly flavoured stick packs – orange, lemon, mango, pineapple and mixed fruit. Unlike some other concentrates, which take time to dissolve in water, Fruitplus Singles gets dissolved within five seconds and offers greater nutritional value of fruits. Ltd, said, “The move would have far reaching repercussions for the plastics packaging industry in India as, by conservative estimates, about 35-40 per cent of the plastics packaging industry serves the gutka industry. It will be interesting to note how the big stakeholders would react this year as they built huge capacities

DCGI makes barcoding mandatory for pharmaceutical packaging The Drug Controller General of India (DCGI) has proposed to make it mandatory for medicines intended for domestic supply to also bear barcodes. This was disclosed by Dr Surinder Singh, Drug Controller General of India (DCGI), Ministry of Health & Family Welfare, Government of India. The Commerce Ministry unveiled an ambitious scheme to add serial numbers to all exported medicines via the printing of S1-compliant 2D barcodes on primary packaging and 1D or 2D codes on secondary packaging this year. DCGI added that there have been more sweeping proposals for the addition of serial numbers to the unit-pack level on all medicines destined for use in the domestic market. The Unique Identifier (UID) number will also be printed on the pack in a user-readable format so that it can be sent via text message to a centralised phone number for authentication. He said that the pharmaceutical industry has reservations about the costeffectiveness of this scheme. NR Munjal, President, Indian Drug Manufactures’ Association, who was also present at the press conference, said that total cost of the printing of 2D barcodes will add another burden on the industry and the cost of drug will escalate by about 40 per cent, which will certainly be a burden on the consumer. to cater the gutka industry. Over the years, many processors have added equipment solely to serve the gutka industry.” According to industry experts, the chewing tobacco/pan masala industry is awaiting clarity from the government on the substitute raw material to be used as packaging material.

Modern Packaging & Design May-June 2011


NATIONAL NEWS

Flex eyes `1,000-crore revenue from non-plastic packaging

HNGIL to invest `5,000 crore in five years to hike production capacity Hindusthan National Glass Industries Ltd plans to invest up to Rs 5,000 crore in the next five years to set up new facilities and expand existing capacity. The firm, which had a total production capacity of 9.40 lakh tonne in the last fiscal expects it to go up to 12 lakh tonne in 201112. HNGIL currently has plants at Bahadurgarh in Haryana, Nashik in Maharashtra and Neemrana in Rajasthan. It is also setting up a new one at Naidupeta in Andhra Pradesh. R L Khandelia, President, HNGIL, said, “We are looking to invest nearly `5,000 crore to set up a greenfield facility and also to augment capacity in the existing plants. We plan to invest Rs 2,500 crore to set up a new facility, for which it its scouting for a location in Rajasthan, Haryana and

Modern Packaging & Design May-June 2011

Madhya Pradesh. We are looking for about 500 acre of land and are in talks with the governments in these three states and wherever we find the land we will set up the new facility.” He said the new plant will have three manufacturing container glass units and two for float glass. The capacities at the existing facilities are also being enhanced. The company has already spent `160 crore at Bahadurgarh for equipment and machines in the last fiscal. At present, the Bahadurgarh plant produces 2 lakh tonne per annum, which will go up to 3.1 lakh tonne by 2012.

Packaging major Uflex, which started manufacturing non-plastic-based alternative innovative packaging solutions to plastic pouches, is eyeing a `1,000-crore revenue from this new product by end-this fiscal. The company has already started manufacturing the eco-friendly product and plans to manufacture around 36,000 tonne per annum to cater to the market demand. R K Jain, President (Finance and Accounts), Uflex Group, said, “We expect around `1,000-crore revenue from this new product by FY 12 and expect it to increase over the years. We plan to manufacture around 36,000 tonne per annum to garner an around `1,000-crore revenue by end of this fiscal.” The Supreme Court’s landmark decision to ban the use of plastic in sachets for storing or selling tobacco, gutka and pan masala came into effect pan-India from March 1, 2011.

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WORLD NEWS

Robert Willett becomes CEO at Cognex Corporation

Robert Willett

Cognex Corporation has announced today that Robert Willett, the company’s President and Chief Operating Officer, has been promoted to Chief Executive Officer. Willett will continue to report to Dr Robert J Shillman, Chairman of the Board, who will take on the newly created role of Cognex’s Chief Culture Officer. “Since joining Cognex just three years ago, Rob has done excellent job of both managing our business during the 2009 downturn and in laying the groundwork for our company’s record-breaking financial performance in 2010,” commented Dr Shillman. He continued, “His leadership was instrumental in every key area, including choosing strategic markets to pursue growth, thus establishing our product development priorities and, finally, guiding and motivating the talented team of Cognoids around the world to achieve these. Robert is an immensely capable business leader and a true Cognoid who takes his work seriously. He embodies our motto of ‘Work Hard, Play Hard and Move Fast.’”

IPACK-IMA and Expo 2015 plan a global showcase IPACK-IMA 2015 is scheduled to take place in conjunction with the Expo 2015. The change in schedule from the traditional March dates to May 19-23, 2015, is bound to create a perfect synergy between the mainstays of the exhibition, the leader

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A&R Carton buys a stake in SP Containers Swedish cartons group A&R Carton has bought another 34 per cent of food and retail packaging supplier SP Containers, thus becoming the majority shareholder of the company. A&R, which has 14 factories across 8 countries in Europe, now owns 67 per cent of SP Containers. The deal comes two and a half years after A&R first invested in the company. SP Containers specialises in paperboardbased containers and cups for products such as ice cream, dairy, confectionery and pet food. Besides supplying to the UK, the company has export markets in continental Europe, Scandinavia and the Baltic countries. Paul Nixon, Managing Director, SP

Conair aligns products and personnel to assist sheet & film extruders, thermoformers

As part of a continuing effort to support the unique needs of customers in specific market segments, Conair is positioning an expanded range of equipment and services to address the needs of companies producing plastic film & sheet used in thermoformed containers and packaging. Materials involved may be styrene, polyolefins and, increasingly often, Polyethylene Terephthalate (PET) and biopolymers. “During the recent economic downturn, we learned that our customers are most concerned about finding specific solutions that can help them stay competitive and profitable. Listening to their concerns, we have come to understand that in packaging, processing & food safety industries, and the Expo. In the process, it will draw worldwide interest towards Milan with ‘Feeding the Planet, Energy for Life’. IPACK-IMA 2015 will extend over the entire South and East areas of the Fiera Milano exhibition centre, adjacent to the entrance of the Expo area and conveniently connected

Containers, commented, “With the assistance of A&R Carton’s resources, SP Containers will be able to develop at a much faster rate than previously. We look forward to further cooperation with A&R Carton.” To this, Per Lundeen, Chief Executive, A&R Carton, added, “We are pleased to increase our share of SP Containers. SP Containers’ products complement A&R Carton’s product portfolio well.” they are interested in equipment and technology, but only insofar as it brings them direct, tangible benefits. We believe that Conair is well positioned to deliver those benefits and help companies in this important market,” noted Gene Flockerzi, Vice President, Sales - Packaging, Conair.

To achieve their objectives of increasing productivity, reducing scrap, ensuring quality and cutting costs, film & sheet extruders and thermoformers can draw upon the expertise and service of key Conair people. to the city through the underground network. Topping off the ensemble into a single, one-of-a-kind global event, Tuttofood – the global professional exhibition dedicated to the agro-food industry organised by Fieramilano – will also be staged in conjunction with IPACK-IMA. Tuttofood will take up the west area of the exhibition complex.

Modern Packaging & Design May-June 2011


WORLD NEWS

Leading packaging machine builders join Rockwell Automation PartnerNetwork programme Douglas Machine Inc., KliklokWoodman and Nercon Engineering & Manufacturing have joined the Rockwell Automation Machine Builder programme. The programme gives end-users access to skilled machine builders that have proven their ability to deliver high-quality, innovative machinery. As part of the Rockwell Automation PartnerNetwork framework, the machine builder programme consists of industry-leading Original Equipment Manufacturers (OEMs) who

share Rockwell Automation’s business values and are committed to delivering solutions to help lower manufacturers’ total cost of ownership. To become a part of the PartnerNetwork programme, which includes thousands of specialists in industries, applications, geographies, technologies and services around the world, machine builders must demonstrate both innovation and market leadership in machine design and development that incorporate Rockwell Automation solutions. Members of the programme will benefit from the opportunity to increase market awareness with customers, expand into new market sectors and improve technical & functional excellence.

McDonald’s commits to sustainable packaging

SIG Combibloc produces new carton format for Sunraysia

will not only differentiate the brand on supermarket shelves, but will also provide clear benefits including efficient and long-life storage and easy pouring. Gavin Cox, Commercial Director, Sunraysia, said, “Our aim has always been to provide premium quality and natural healthy juices to our discerning consumer. The new combifitMidi carton pack will ensure that our juices are protected from light & air, and the quality and nutrition are conserved at all times.” Sunraysia’s tomato, prune, beetroot, carrot, mango and pear juices packaged in the 750-ml combifitMidi carton will be available from UK supermarket giants including Tesco, Sainsburys, ASDA, Waitrose and Ocado.

Fast food restaurant giant McDonald’s has set out a vision to eventually source all its packaging from sustainable sources. The company said that over time its suppliers would provide agricultural raw materials for its food and packaging from land that has been certified as sustainable by an external third-party evaluation process. McDonald’s Sustainable Land Management Commitment (SLMC) will first focus on the five areas that it believes will make the highest impact – packaging, beef, poultry, coffee and palm oil. Jim Skinner, Chief Executive Officer, McDonald’s, said, “We will continue to focus on developing sustainable sourcing practices and broadening our menu choices. Each year, we set goals that challenge us to put our resources towards strengthening communities and helping maintain a world that can carry all of us well into the future.” To this, Francesca DeBiase, Vice President, Strategic Sourcing, McDonald’s, added, “We know that our customers care about where their food comes from.”

Nano-bricks to improve food packaging

for longer and may replace some foil packaging currently in use. Scientists have said that ordinary plastic soda bottles tend to lose their fizz after just a few months of storage on grocery store shelves. Manufacturers can apply the new coating to these bottles, to slow down the loss of CO2 gas and help sodas stay bubbly for several more months, or even years. The coating could also extend the shelf-life of portable food packages

known as ‘Meal, Ready to Eat’ (MREs) that sustain soldiers in the field, with the added benefit of being microwavable.

SIG Combibloc has claimed that Sunraysia will be the first in the UK to use the combifitMidi carton format, 750 ml. Sunraysia has previously packaged its long-life juices in Polyethylene Terephthalate (PET), glass and competitor carton formats. But, the firm claimed that the new carton pack

Scientists have recently announced that a new material containing an ingredient used to make bricks shows promise as a transparent coating for improving the strength and performance of plastic food packaging. Termed as ‘nano-bricks’, this film appears as bricks and mortar when observed under a microscope. This coating could help food products and beverages stay fresh and flavourful

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Modern Packaging & Design May-June 2011


WORLD NEWS

Inert packaging material keeps food safe and taste intact

Recall of a product that has been tainted by its packaging can result in considerable monetory losses and harm the reputation of a company. Although the instance of a chemical migrating from the packaging to the food is less common, the retail supply chain needs to have the knowledge of the chemicals present in the

Danone Canada adopts green packaging technology

Danone Canada has announced two major innovations in packaging: a new ecological manufacturing process for its individual serving products, called ‘expansion’, and the use of an ecological high-density polyethylene for its drinkable yoghurt packaging. These innovations have come in direct response to Danone’s corporate objective of reducing

Modern Packaging & Design May-June 2011

packaging to ensure that there is no health risk and the food reaches the consumer in good condition. The main legislative driver, the European directive, ensures that food does not get tainted by its packaging. It outlines that chemicals from packaging should not endanger human health or change the composition, or cause decomposition of the packed food. It also stipulates a maximum migration limit of no more than 60 mg of the chemical for every kilogram of food substance. “It is a measure of inertness of the packaging rather than safety considerations,” said Chris Howick, Manager, Product Stewardship, Ineos ChlorVinyls. He added, “If a manufacturer uses a material at the maximum migration limit, then it must show that the limit is obeyed.”

Cardia and Wesco announce exclusive distributorship

the company’s carbon footprint by 30 per cent by 2012. “These bold environmental initiatives, which are in line with our mission and objectives for reducing our carbon footprint, have made us completely rethink our product packaging in the interest of the environment and wellbeing of our consumers,” said Anne-Julie Maltais, Manager - External Communications, Danone, Canada. The expansion process involves adding an inert agent to the polystyrene plastic. This agent forms a thin layer of foam in the polystyrene, thereby reducing the overall density of the plastic from approximately 18 per cent. Thus, the weight of individual serving packages of Activia, Stonyfield, Silhouette and Creamy brands is reduced by the same percentage.

Pa c k a g i n g specialist Johnsen & Jorgensen has introduced a new range of bottle filling, capping and cleaning machinery, thus strengthening its reputation as a one-stop shop for packaging solutions. The new filling equipment includes a singlehead, low-vacuum operated machine that can fill approximately 350 bottles per hour and, for larger plants, a four-head in-line version with a capacity to fill over 600 bottles per hour. “We believe that this new range of equipment will not only benefit our existing customers but strengthen our one-stop-shop appeal to new prospective packaging clients,” said Mike Bogod, Specialist Sales Manager, Johnsen & Jorgensen. Bottles and dispensers make up the main segment in the cosmetics industry, while jars are offered in a variety of materials. According to the company, it is responding to growing customer demand for advice and recommendations on filling equipment as well as its core products of containers and caps, and hence offering a dedicated range of nine machines.

Cardia Bioplastics Limited (Cardia) has recently announced appointment of China’s leading plastics distribution company Wesco China (Wesco) as exclusive distributor for China. Wesco is a joint venture with Sasol Limited, a leading South African petrochemical company. Wesco will distribute Cardia’s portfolio of Biohybrid™ resins derived from sustainable resources throughout China. The exclusive distribution agreement enables Wesco to offer customers the comprehensive range of Cardia Bioplastics sustainable resins to Chinese packaging and plastic products industries. China has recently emerged as the world leader in sustainable energy production through investments in various areas such as hydropower, solar, geothermal and biofuels. Following this success, China is establishing its environmental credentials further in an important area of sustainable plastics. China’s demand for environment-friendly bioplastics, which are plastics that are biodegradable or derived from renewable resources, is rapidly developing.

New packaging range by Johnsen & Jorgensen

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WORLD NEWS

New glow-in-the-dark bottle from Heineken

Heineken has developed a news aluminium can that combines the icecold feel of a metal can with the classic shape of a glass bottle. It is designed to entertain party goers. According to Heineken, the glow-in-the dark bottle was launched

Suppliers get bioplastics deal for London 2012 Olympics

In a landmark agreement between organisers and bioplastics producers, it has been agreed that the packaging destined for the London 2012 Olympic Park will have to be made from compostable bioplastics if it cannot be recycled in existing waste streams.

China becomes export destination for Hindustan Tin Works Hindustan Tin Works Ltd (HTW) continues its success story in exports, with a fresh order from China, potentially making India another export hub for metal can industry in Asia. Exports from HTW – the leading can manufacturer of India – have grown by 341 per cent in the last five years. It now exports to 22 countries across the world including the US, Australia, Europe, Africa, the Middle East and South East Asia, with its latest customer, China.

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in Milan at the design trade show Salone del Mobile. On the heels of the bottle redesign, Heineken announced plans for another new design initiative called ‘Open Design Explorations’. The project aims to create new concepts for bars, clubs and social spaces, one of which will be a pop-up club at the city’s 2012 furniture fair. The design brief for this concept club asks designers to become part of a multidisciplinary team that will study social interaction in clubs around the world. This exploration will provide authentic insights that will help create the pop-up club. LOCOG, the Games’ organising committee, has signed an agreement with the National Non-Food Crops Centre (NNFCC), the trade body that represents biopolymers producers, for NNFCC to oversee suppliers of nonrecyclable packaging to the Games. Under the agreement, all non-reusable and non-recyclable packaging – eg, crisp packets, fast-food trays or liquid cartons – must be independently certified under the EN 13432 standard for compostability. The compostable packaging should be made from starch or cellulosebased plastics. Plastic Polyethylene Terephthalate (PET) bottles made from standard oil-based polymers will not be included in the agreement, as these can be recycled in existing waste streams. HTW attributes its export growth to India’s low-cost manufacturing base, consistent and strict quality regimes which it has strictly enforced. HTW has been certified by Transpacific Certifications Limited (TCL) for ISO 9001:2008 and Hazard Analysis and Critical Control Points (HACCP) and is an approved supplier to the major multinationals. So, China may be exporting millions of cans to entire world, but there is one Indian company – HTW – that exports metal can components to China.

Crown, Clemson partner for packaging education programme

Crown Holdings Inc., the world leader in metal packaging technology, has become the first corporate ‘Partner in Packaging’, a new initiative of the packaging science programme at Clemson University. As part of the partnership, Crown will donate a gift of cash for use as unrestricted programme funds, and gifts-in-kind of metal packaging fabrication equipment, faculty travel and regular participation of company personnel in the educational mission of this programme. The value of Crown’s gift is estimated at $400,000 over the five years. A commitment to help students learn about metal packaging is at the heart of the partnership. The laboratory equipment provided by Crown will give students hands-on experience in can manufacturing, testing and production of physical prototypes for research purposes. To further support knowledge transfer, Crown will send key personnel to Clemson every semester to lecture and mentor students on metal packaging innovations. Crown will also support faculty to attend Interpack, the leading international packaging trade show, to be held in Germany in May 2011 and 2014.

Modern Packaging & Design May-June 2011


TECH UPDATES

Mushroom-based packaging from Dell Computers

Ecovative Design has created mushroom-based packaging. Dell is the first technology company to start pilot shipments of this packaging, and will be testing these on its PowerEdge R710 servers. This new packaging reduces solid waste and fossil fuel consumption. This is achieved as the packaging is made of compostable material, and requires one-tenth of the energy to produce in comparison to Styrofoam. Packaging is a large contributor to waste and fossil fuel usage, and hence a huge concern for companies in addressing sustainability issues. Thus, this new mushroom packaging is a noteworthy innovation, as it is a sustainable form of packaging using agricultural waste that can then be composted. Most companies today are seeking ways to improve the sustainability of their operations across their entire value chain, from energy usage, water usage and waste, to name a few. Companies choosing to purchase Dell servers or other Dell products using this sustainable mushroom-based packaging are improving their operational effects on the environment, and thus their image. Not only will they be contributing less to landfill waste, but also they will be indirectly supporting the reduction of fossil fuel usage.

Quadpack to unveil innovations in make-up and foam pump

Quadpack will launch innovations in foam pumps as well as new airless and make-up packaging development at the next MakeUp in Paris show, to be held from June 23-24, 2011. The company will launch a new foamer manufactured by Apollo, designed for make-up removal. According to Quadpack, Apollo foam pumps use patented technology to achieve outstanding foam quality. The new foamers avoid metal parts in the product path, thereby greatly reducing product compatibility issues. Quadpack will also showcase at MakeUp in Paris the latest in airless make-up containers that protect products from external contamination and preserve their integrity. These containers will include Dual 2-in-1 packs that blend foundation and concealer in a single tube or bottle, the glass-effect crystal range and an airless spot pen with brush applicator, offering clog-free precision dosage and targeted application of foundation. Quadpack is a leading provider of packaging solutions for prestige, masstige and mass market beauty and skincare brands. It sources and develops customised packs through a strategic network of manufacturing partners.

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World’s thinnest phone by Sony Ericsson Current smartphone manufacturers are in the race to make the ‘world’s thinnest phone’, but XPERIA Arc has managed to achieve this feat – a slender, tactile device. Measuring 125 x 63 x 8.7 mm and weighing 117 g, the chassis is plastic rather than metal – and not soft-touch plastic – but it bows nicely in the middle, making the device that feels thinner than what the spec sheet might suggest. Sony Ericsson’s use of shiny chrome-effect plastic is an acquired taste, but it is limited to buttons and edges at the left edge, a microUSB socket on the right edge – above a small volume rocker, with a camera shortcut further down the side – and a power/lock button on the top adjacent to a micro HDMI port covered with a small dust-flap. The plastic battery cover – finished with a two-tone paint job – opens to reveal both microSD and SIM slots that are blocked by the battery. Arc’s crowning glory is a 4.2-inch 854 x 480 capacitive touchscreen from Sony Ericsson. It is 0.2-inch bigger than XPERIA X10. A ‘regular’ LCD TFT presents excellent visuals, although viewing angles are on the narrow side.

Aged to perfection The iPhone is now being retired after three years because its touchscreen no longer functions efficiently. In contrast, the pointand-shoot camera works like new even after seven years of use, but is being retired because it is not digital. After more than three years of use, abrasion of the hard-anodised surface of the iPhone reveals the raw aluminium underneath. In contrast, the camera’s shell wears in a similar way but its emulated metallic finish is only surface deep and its wear shows awkward artifacts of the injection moulding process used to create it. Consumer products today stay new for only a brief period after being removed from their package, and then they function as ‘used’ products. Most people welcome and find this wear and ageing of products as aesthetically pleasing. A Japanese term for this is ‘wabi-sabi’, which describes the aesthetically pleasing wear of an object as it decays over time. It celebrates the purity of the imperfect. Thus, ageing with dignity is a criteria that designers should recognise in their efforts.

Modern Packaging & Design May-June 2011


TECH UPDATES

Wines now supplied in plastic containers Major distributor of alcomalts, beers and fine wines, Societe de Vin Internationale LTEE has used plastic packaging for the first time to supply wines to its airline customer, Air Transat charter airline. The 1 L PET barrier bottle was delivered by Amcor Rigid Plastics. The Polyethylene Terephthalate (PET) stock container weighs only 54 g, while its glass predecessor weighs 430 g. The bottle is made with KHS Plasmax’s special barrier coating technology. It also has an aluminium screw cap. The KHS Plasmax Silicon Oxide barrier coating safeguards the contents from oxidation by sealing the container from the inside. Plasmax is a Food and Drug Administration (FDA)approved passive barrier for products that are sensitive to oxygen. This transparent material, with a thickness of less than 100 nm, is resistant to delamination, abrasion and cracking. During recycling, the barrier coating can be removed easily and does not pollute the recycling stream. Some of its advantages include reducing fuel consumption in the airline industry, cutting down logistics expenditure and allowing producers to decrease their impact on the environment by decreasing the quantity of packaging and, in turn, reducing the waste sent to landfill.

Monobloc configuration to run labelling processess The DecoBloc labeller from Krones AG will make it possible to create a monobloc configuration synchronising a modularised labeller. This will feature a Sleevematic carousel, a Shrinkmat tunnel and a Linadry unit for predrying the containers. Users can then use this monobloc to run all common labelling processes, with enhanced flexibility. Whether it is coldglue, pressure-sensitive, hotmelt or shrink and stretch sleeves. The docking stations feature motorised height adjustment, so that irrespective of the floor level involved, the labelling stations can be swiftly prepared for a product change-over at the touch of a button. Different machine sizes offer outputs of up to 72,000 containers an hour. Servomotors are used to ensure maximally accurate dress positioning. For sleeving applications, there is a choice between shrink-sleeve labels with a downstream Shrinkmat tunnel or stretch-sleeve labelling. There is also an option for camera-based alignment of the containers on an embossed marking.

A ‘clever little bag’ from Puma

Knowing that shoe boxes contribute millions of tonnes of waste each year, an essential step in Puma’s longterm sustainability programme was to create a packaging system that would reduce the brand’s footprint, from its energy and water use to its waste and CO2 emissions. For this, Puma turned to Yves Béhar and his team at fuseproject. “My thoughts were immediately about reinventing the way shoes are shipped and how they are experienced by the consumers,” said Béhar, Founder, fuseproject. He added, “But the logistics and material research was really challenging.” Béhar and his team spent 21 months conducting extensive research and development. After nearly 40 prototypes and 2,000 sketches, Béhar developed the ‘clever little bag’. This unique packaging system eliminates the shoebox entirely. Instead, it consists of a die-cut sheet of ink-free, thin-gauge recycled paperboard that tapers to form four walls, which are held in place by a 20 per cent, non-woven polypropylene bag.

Modern Packaging & Design May-June 2011

Gold-plated window electrodes for organic solar cells Researchers at the University of Warwick have developed a gold-plated window as the transparent electrode for organic solar cells. These electrodes have the potential to be relatively inexpensive since the thickness of gold used is only 8 billionth of a metre. This ultra-low thickness means that even at the current high gold price, the cost of the gold needed to fabricate one square metre of this electrode is only around £4.5. It can be readily recouped from the organic solar cell at the end of its life. This method can be scaled up for large area applications like solar cells. Organic solar cells have long relied on Indium Tin Oxide (ITO)-coated glass as the transparent electrode, although this is largely due to the absence of a suitable alternative. An ultra-thin film of air-stable metal like gold would offer a viable alternative to ITO; however, it has not yet proved possible to deposit a film thin enough to be transparent without being too fragile and electrically resistive to be useful.

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TECH UPDATES

A movie-inspired design show by Disney and DuPont Corian Light Tape company contributes to the ‘TRON designs CORIAN’ exhibition, providing their unique, high-tech and proprietary electroluminescent film technology, which will be used to create fascinating lighting effects inspired by the film ‘TRON: Legacy’. Light Tape by Electro-LuminX Lighting Corporation (USA) is an advanced technology, thin-film light bulb. It has no glass, gas or mercury, stays cool to touch, creates zero light pollution and is highly flexible. Being extremely robust, Light Tape has a long lifespan and ultra-low carbon footprint. With a wide choice of colours, widths and custom shapes, Light Tape can be used both indoors and outdoors with stunning effects. Using less than 100 watt of power for every 100 m length, Light Tape is contributing to CO2 emission reduction on a global scale.

Champagne house can pack 8,500 bottles of famous fizz an hour with new Cermex line Cermex has created a line that, at full pelt, can pack nearly 8,500 bottles of Veuve Clicquot every hour. Three elements of the line were major advances from its predecessor – the heavy integration of robotics; automation of format changeovers, which has cut the time taken from more than two hours to less than 20 minutes; and an improvement in the protection of bottles and their secondary packaging. The line can handle 16 different formats of packing to accommodate producing corrugated cases of 6 or 12 bottles in a top-to-toe arrangement. These may or may not be packed in Design Boxes; and may be in different bottles, including standard 75cl yellow-label, lightweight and special options or the premium ‘Grande Dame’ shape. Equipment in the installation includes an AN110 gantry packer, two Fanuc M710 50-kg robots that have automatic gripping head changeover, an F272.40 tray erector, a WB45.80 wrap around case packer and a P4 palletiser.

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Toothbrush recycling to reduce carbon footprint Preserve is no stranger to sustainability – the company has been turning recycled plastic, including post-consumer polypropylene food packaging, into toothbrushes since 1997. It has also added tableware and kitchen products made from 100 per cent recycled plastic to its lineup. To help keep its used toothbrushes out of landfills, the company created a mail-back pack, which functions as a postage-paid return mailer for consumers wishing to recycle their toothbrushes. Preserve grinds the toothbrushes and uses the polypropylene to make products such as plastic lumber. Made from a Biaxially Oriented Polypropylene/Polyethylene (BOPP/ PE) laminate, the pouch is 80 per cent lighter than the previously used package. The lighter materials reduce the package’s carbon footprint and decrease packaging material costs.

Proco Machinery upgrades its Multipak Palletizer Packaging System The Multipak Palletizer Packaging System from Proco Machinery Inc., a leading supplier of automation systems for the plastics container industry, has introduced several enhancements for greater performance and flexibility for bottle manufacturers. The new features include an automatic pallet feed magazine, which stores and feeds the pallets onto a pallet conveyor that efficiently moves pallets in and out of the system. Other enhancements are an automatic slip sheet magazine, which stores slips sheets and places them between each pallet layer and an automatic top frame magazine that stores top frames and places them on top of the pallet. The Multipak Palletizer boasts a modular construction and operates as a semi-automatic system or in fully automatic mode at line speeds up to 150 bottles/min. It is fitted with heavy-duty castor wheels that allow the unit to be easily moved from one line to another. Its rectangular shape enables it to fit in most blow moulding lines without occupying much machine space. The unit can handle half-cube or full-cube pallet sizes up to 105 inches. It can also be configured for tray and box packaging.

Modern Packaging & Design May-June 2011


DESIGN INNOVATION

In a sea of look-alikes, the challenge is to bring to the market new and improved product concepts where the packaging does more than simply contain and protect the contents. Packaging innovation is crucial to the future of packaged goods, with user convenience being a key driver. As smart packaging concepts are predicted to be commonplace features in the future, this column is a tribute to the latest innovations in packaging designs.

Re-sealable snack-pack for crispy nachos

Doritos tortilla chips have been in the market since 1964. However, adding a fresh appeal to its brand is Peter Parlov’s geometric packaging with surface triangulations. The principle advantage of this design is that its folds and dimensions allow easy opening & closing of the pack, without a clip. This is suitable as a quick snack option for consumers constantly on the move, without compromising on the quality of the chips, even after opening it. The package is made of cardboard, which serves the dual functions of environmental sustainability, while at the same time imitating the shape and natural texture of the triangular chips, also called nachos. The inspiration for this design comes from ancient Mexican history. The final form of the packaging resembles the classic totem poles of Aztec architecture. The design is also a visual standout on supermarket shelves, since its flat and angular surfaces offer ergonomic value, and create a perfect canvas for expressive & attractive illustrations. Manufacturer: Doritos

Home compostable packaging

Marijuana just got greener. OrganiCann’s sustainably grown organic, medical cannabis is now available in environmentally friendly packaging. OrganiCann’s new packaging is made from certified-compostable film printed with water-based inks. The compostable film is made from sustainably produced wood. OrganiCann’s packaging safely biodegrades in home or commercial compost. It will even biodegrade in a wastewater environment. Unlike many compostable packages that require the high heat and pressure of commercial compost facilities, OrganiCann’s packaging will safely biodegrade in home compost. Patients can place the packages in home compost piles where they typically biodegrade in just a few weeks. OrganiCann offers home compostable packaging for a range of products from dry cannabis and joints to concentrates and even cannabis-infused teas.

Manufacturer: OrganiCann

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Modern Packaging & Design May-June 2011


DESIGN INNOVATION

Sneaker Model No.1

The team at Depot WPF design house took up the challenge to differentiate the MLK© packaging on the store shelf and to distinguish it from the products by the big dairy producers, and emerged successful. The milk cartons from MLK © may not look any different at first sight, but a closer look reveals its distinctive characteristics. The graphics on the package utilise natural farming patterns – a family farm, where the products are manufactured in a traditional way. Illustrations are hand-made (with a pencil), which enables to stress the hand-made production process. In addition, a pencil technique makes the image ‘soft’. The brand visual identity consists of black and white graphic patterns, which were taken from the real environment of the small milk farm. The patterns of the real farm were used in order to reflect the naturalness of the dairy production and the products. Interestingly, MLK © won the Epica Awards 2010.

Manufacturer: Society27

Instant innovation through instant food

Nestle’s highly popular culinary unit, Maggi, has recently launched a new range of microwaveable ready-to-meals under its ‘Topfinito’ brand. The range comprises four exciting flavours. The high-barrier plastic containers for this packaging has been developed by design-firm Rexam through its unique Rotary ThermoForming (RTF) technology. These containers have superior retort and barrier performance and zero in-built stress as they are moulded in the melt-phase. They are filled on a modified high-speed can-filling machine at Nestlé factory in Conow, Hamburg. The cups are then sealed with a double-seamed easy-open aluminium foil and an injection-moulded lid . It is decorated with insulating-shrink labels to preserve Maggi’s brand identity on super-market shelves. This modern and convenient single-portion pack is designed for a delicious and nutritious meal catering to people ‘on the go’. The 380 gm meals can be heated in a 600 W microwave oven for only three minutes and can be readily consumed. The packs have a minimum shelflife of a year without the need for refrigeration or freezing, so the meals can be stored and used anywhere.

A multi-purpose bottle to clean home

One can now ‘Flip, Mix, Clean’, with the innovative household cleaner from Replenish. It features a PET spray bottle with a built-in measuring cup, along with a four-ounce pod of concentrate that is attached to the bottom. So, to use, flip the product upside down, squeeze the pod until the measurement cup is full, and add water. Each pod has enough fluid for four full bottles. As the product is designed for reuse, and the system is based on a concentrate, Replenish uses 90 per cent less plastic, oil and CO2 emissions than pre-mixed household cleaners. Manufacturer: Replenish

Manufacturer: Nestle

Modern Packaging & Design May-June 2011

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LEADERS SPEAK

“We want to participate in the growth of the injectables market” …asserts Mohan Joshi, Country President, Schott Glass India. Having been associated with Schott and its pharmaceutical glass packaging operations for over a decade, he underlines the traditional importance of glass and recent innovations making a headway in the industry, in an exclusive interview with Annabel Dsouza… Current market potential of pharmaceuticals India is on its way to become one of the largest pharmaceutical markets worldwide. As shown by a new study published by the auditing and consulting company Pricewaterhouse Coopers (PwC), sales of pharma products in India may rise from $19 billion in 2009 to around $50 billion in 2020. This growth will be driven and supported by domestic demand in India’s prosperous middle class as well as the booming exports of high-quality generics and biosimilars. Packaging is an integral operation of high-end pharmaceuticals and a double-digit growth is expected from the packaging division as well. Growth drivers of India’s pharmaceutical packaging market The increase in lifestyle diseases such as diabetes and hypertension has contributed to an increased demand for injectables – a trend that is expected to continue further. In addition, patients admitted in hospitals expect quick recovery and return to home as soon as possible. Here, injectables play a vital role to fulfil the expectations of patients admitted in hospitals. Further, increasing numbers of insurance companies are

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entering the health sector. From our point of view, this will result in not only an increasing demand for pharmaceutical products, but also a rising need for high-quality pharmaceutical packaging. A reliable supply of glass tubing is, therefore, important for both packaging manufacturers and pharmaceutical companies. The pharmaceutical industry has grown from reverse engineering technology to a highly technical and innovative business. India has taken giant strides in making world-class drugs and also in the field of biotechnology, and Schott is proud to be associated with this value chain. Penetration of global innovations in Indian market Indian pharmaceutical companies are investing heavily in their injectables business in order to create world-class facilities. Compared to other countries in the world, India has the highest number of US Food and Drug Administration (USFDA) approvals. The expertise gained over the years has given an edge to companies here for producing quality products. Multinational companies, therefore, often look towards India and plan to make it their manufacturing hub.

Modern Packaging & Design May-June 2011


LEADERS SPEAK

Important innovations here are medicines manufactured through biotechnological methods or those based on proteins. These biopharmaceuticals treat or protect against increasingly frequent severe illnesses such as cancer and rheumatic diseases. Among other things, these medicines are characterised by extremely high specificity, selectivity and completely new mechanisms of action. These drugs affect disease-causing molecules in a targeted manner. Because two people having the same illness do not necessarily require the same medication, a customised treatment in the form of biopharmaceuticals is assuming a greater importance today. The product group biopharmaceuticals also place special demands on packaging and raise the question as to how sensitive active substances can be packaged and stored properly. The use of high-quality vials, syringes, cartridges and ampoules is essential for achieving the industry’s goal of high productivity with modern production and filling systems. For this, the demand is constantly growing for highquality pharmaceutical packaging that can be processed easily. Also, a worldwide trend being observed is the shift from vials to prefilled syringes for special drug applications based on the demand for a precise dosage and the need for increased user-friendliness. This trend will also be seen in India in the near future. Unique role of glass in the pharma packaging space There is a consistently high demand for glass packaging and we are confident that this will continue based on the advantages that glass offers for the protection of drugs. Our Fiolax® glass tubing, first introduced to the market 100 years ago in 1911, is a borosilicate glass that has been optimised for use in pharmaceutical packaging and is known for its high resistance to chemicals. It can be easily sterilised and features excellent barrier characteristics for medications. Because of its low alkali content and optional Ultraviolet (UV) protection, it offers long-term stability as required for ensuring effectiveness of medicines. The precisely shaped glass tubing with low geometric

Modern Packaging & Design May-June 2011

tolerances also resists breakage and scratches, an important feature for machine processing during mass production of such containers. Delivering quality solutions to Indian market Schott recognised early the underlying potential of the pharmaceutical packaging market, and therefore started manufacturing pharmaceutical tubing in India in Jambusar, near Baroda, in 1998. Today, Schott Glass India manufactures and supplies Type 1 pharmaceutical glass tubing to our customers. They then use it for manufacturing vials, ampoules, cartridges and other types of primary pharmaceutical packaging as per requirements of the pharma industry. With the growth of pharma market in India, Schott Glass India has increased its production capacity by almost three times. Besides local products such as Neutral Glass Clear (NGC) and Neutral Glass Amber (NGA), it will produce Fiolax, which is a popular premium glass tubing for manufacturing pharmaceutical containers. International quality is the key for pharmaceutical companies and Schott Glass India has, therefore, taken several initiatives for improving the quality of its products as per international standards, following its vision of always being a step ahead in terms of performance and quality. For example, we were the first glass manufacturer in India to publish our Technical Terms of Supply (TLB SGI) for NGC and NGA and also to receive ISO 9002 certification by Rhineland/BerlinBrandenburg Inspectorate (TÜV). We have also developed an information and tracking system for Fiolax glass tubing that offers customers precise information and important manufacturing, material and quality parameters for a given match. Thus, it is possible to track all details of a production process for a period of 10 years from the date of manufacturing all the way to the final glass tubing. This can be done by what is called ‘Traceability’ as per requirements of the pharmaceutical industry. At the same time, we have ensured

maintaining cost-competitiveness to meet the omnipresent price pressures that will continue to increase in the future. Preparing for overcoming challenges ahead The ‘Made in India’ label is probably the biggest challenge for the industry. Companies in the developed world have a rigid and longstanding system of documentation and system procedure. Therefore, it is never enough just to create and run a world-class facility. One always has to keep in mind the fields of pre- and post-manufacturing, logistics, compliance issues, documentation requirements as well as consistency in the quality of products and services. Thanks to our uniform worldwide quality standards in manufacturing, Schott is always in a position to provide its customers with products of the same high quality from various sites. The company simultaneously maintains a close presence with customers, which has been possible with various manufacturing sites for pharmaceutical tubing in India, Germany, Spain and Brazil. Together, these facilities produce approximately one million kilometres of pharmaceutical tubing each year. Future beckons As a pharmaceutical glass tubing provider, we want to participate in the growth taking place in the injectables market. We have invested heavily on capacity expansion and are fully capable to cater to international quality for our domestic market. Moreover, we have implemented a consistent quality and tighter dimensional control of Outside Diameter (OD) and Inside Diameter (ID) for ensuring that pharmaceutical companies gain optimum yield on their high-speed machines. We have also been able to further eliminate cosmetic defects thanks to the latest manufacturing technology. Schott has invested in its human resources, technology and processes to support the ambitious growth plan of its associated Indian pharmaceutical companies and will be able to serve the challenges for sustainable quality and services in the coming years.

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LEADERS SPEAK

“Globalisation has increased awareness about the high quality of Indian productsâ€? ....believes Debdeep Kole, Director, Koley Converting Machinery (P) Ltd. He believes that with the entry of multinational players in the Indian packaging industry, the country is witnessing a gradual shift towards flexible forms, as is the global norm. Kole highlights the need for maintaining high quality and spreading awareness for the same, in conversation with Anwesh Koley‌ Current trends in the Indian packaging industry The packaging industry in India has witnessed immense growth in the past few years and is continuing its upward trend due to the buoyancy in the sector. Although recently, there have been changes in the use of some packaging processes and materials, the sector has hardly experienced any overall setback. Factors driving growth in the packaging sector Today, a growing proportion of consumers are looking for good quality and high-level packaged products. We are witnessing an increase in consumer expectations regarding high-quality packaging not only to sustain the contents of the products inside, but also to enhance their aesthetic appeal. Also, quality packaging boosts the value of products, which is beneficial for manufacturers of Fast Moving Consumer Goods (FMCG) and other related goods.

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Challenges faced by the industry A few products, such as gutkha and khaini, have made some massive changes in their packaging following court orders that caused stoppage in the production of these products and, in turn, the processing machinery. This production halt resulted in the industry being stagnant for a few months. After the court order was relaxed, the market gradually has returned to progress. Also, through the years, government norms have increasingly been tightening on packaging, as the display of important information is now mandatory for companies. Expansion plans for the future A number of innovations are emerging today; hence, it becomes essential that we adapt and innovate in order to stand against the growing competition in the market. In order to do so, we have decided to bring latest technology machinery from overseas to process our items for ensuring higher accuracy and Modern Packaging & Design May-June 2011


LEADERS SPEAK productivity. These machines will function along with our existing equipment that are domestically sourced, and hence give us an edge in manufacturing that couples the best of both worlds. Latest innovations in technology In the current scenario, where pollution has become a major factor in our country’s welfare, we have witnessed a huge increase in foil and paper packaging. This prompted us to design specialty machinery for paper and aluminium foil, which are currently growing in demand. Adopting green manufacturing techniques is another area gaining strength, and we would like to contribute to this for ensuring that our products cause minimal damage to the environment. Sustainable production will attract a lot more attention in the near future as global norms will become more stringent with regard to environmental concerns. Future of flexible packaging in India The growth in flexible packaging has shown great variety and depth. The best gains are expected in the world’s emerging markets, including Eastern Asia, Eastern Europe, Africa and the Middle East. India, specifically, will witness enormous growth due to various reasons. The most important of these is growth of the middle class with a population of more than 400 million, and a large disposable income. Also, the change in production techniques from the more traditional rigid packaging to flexible forms of today will have a positive impact on the industry. With globalisation bringing more and more multinational companies to India, awareness regarding quality has increased and will continue to do so until there is no information gap among industry players. It will also ensure the availability of modern plants and equipment for the flexible packaging industry. Threats from Chinese machinery entering India The current buyers of machinery in the Indian market are more educated in comparison with the scenario a few years ago. Also, they now understand that reliability and service support of inexpensive Chinese machinery do not match those from India and overseas, which are comparatively expensive. The global customer is fast understanding the importance of quality and is showing tremendous enthusiasm towards Indian products, which score much higher on this aspect over Chinese products.

Modern Packaging & Design May-June 2011

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FACILITY VISIT

Hindustan National Glass & Industries Ltd

Driving the sustainability index With a pan-India manufacturing presence, Hindustan National Glass Industries Ltd (HNGIL) has emerged as the undisputed leader in the container glass industry and forayed into float glass segment also. The packaging industry is witnessing a resurgence in demand for glass bottles, especially in the Southern & Western regions. Annabel Dsouza explores the company’s efforts to meet this surging market while also mapping its future strategies.

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s India’s demographic structure changes to suit a surging economy and rapid urbanisation, the country’s packaging industry is witnessing growing demands in terms of volume as well as innovations. This holds true especially for the container glass segment, which scores significantly high on the sustainability index. Glass packaging accounts for almost 7-8 per cent of India’s total packaging consumption and the industry is currently worth over $ 16 billion. As container glass manufacturing in India soars to greater heights, it is both intriguing and important to understand the meticulous functioning of the market leader in this sector – Hindustan National Glass Industries Ltd (HNGIL). Started in the early 1950s, with a focus on the container glass, HNGIL holds more than 55 per cent of this marketshare in India and has today emerged as a household brand in the glass bottles domain.

Building the foundation Along with an established presence in the float glass segment, packaging remains HNGIL’s key strength and the company invests great efforts to maintain this leadership status. With its headquaters in Kolkata, HNGIL

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has a pan-Indian presence. This is another advantage of HNGIL, with seven manufacturing plants across the nation, from Rishikesh (Uttaranchal) to Puducherry (Tamil Nadu) and from Halol (Gujarat) to Rishra (West Bengal). The company also has a strategic manufacturing presence at Bahadurgarh (Delhi) and Neemrana (Haryana). The Sinnar container glass facility, located 30 km away from Nashik city, was acquired by HNGIL in 2005 from Larsen & Toubro Ltd (L&T), and there has been no looking back ever since. A noteworthy achievement of this HGNIL facility has been its drastic capacity enhancement. This is a typical advantage of HNGIL, as it seeks to convert loss-making ventures into profitable enterprises. Elaborating on the sturdy and steady growth curve of this facility, CSK Mehta, Vice President, HNGIL, says, “Glass is the most eco-friendly solution available to the global packaging industry, and we try to make the entire manufacturing process as sustainable and efficient as possible. After our take over, we have increased the capacity of this plant from 320 tonne per day to 400 tonne, with energy savings of about 15 crore per year.”

Photo: Joshua Navalkar

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FACILITY VISIT

This operational efficiency coupled with state-of-the-art technology enables HNGIL not only to seize domestic demand but also cater to an evolving exports market in over 20 countries all over the world.

Impressive infrastructure Spread over an expansive area of 70.27 acres, this facility currently runs four individual section lines, with a daily output of about 15 lakh bottles per day. The plant caters to the glass bottling demands of all major brands of liquor, Fast Moving Consumer Goods (FMCG) and pharmaceutical products in the region. The facility is wellequipped with a convertible furnace having a melting capacity of 390 tonne per day and four Independent Section (IS) manufacturing lines. Mould is a critical aspect of glass bottle design and manufacture; hence, the in-house mould workshop enables HNGIL to exercise better control over precision and delivery of the final product. Considering the high-speed IS machines at the plant, the moulds are specifically designed for increased accuracy along with efficient cooling mechanisms. As glass is a 100 per cent recyclable resource, cullet or broken glass constitutes about 30-40 per cent of the batch mixture that is fed into the furnace. However, the glass industry is facing a challenge in recovering used containers from the market. The other raw materials for glass manufacture include natural minerals such as silica sand, quartz

Narrow-neck moulds for beverage bottles

sand, soda ash, dolomite, feldspar and coke. These materials are stored in large silos having a capacity of nearly 400 metric tonne. Here, the contents are automatically weighed, homogenised and conveyed to the furnace. At 1,500°C, the furnace from HORN Glass Industries AG is among the latest in glass melting technology.

Efficiency meets quality In keeping with HNGIL’s commitment towards efficiency, Mehta states, “As compared to its past power consumption of 300 kW per day, we have upgraded the plant in order to reduce its consumption to about 175 kW per day. Even furnace oil consumption has been reduced from 115 litre per tonne of glass to 95 litre per tonne. Also, in terms of Liquefied Petroleum Gas (LPG) usage, we have brought down the consumption from 27 kg of gas per tonne glass to less than 9 kg per tonne. We are currently planning to switch all operations from LPG to Liquefied Natural Gas (LNG), so as to reduce costs and enhance sustainability.” Even at the glass conditioning front, the forehearth from SORG GmbH is maintained at 1,200°C, from where the viscous glass is transferred to the IS machines. Here, the glass is moulded into the required shape and size using the blow & blow process for narrow-neck bottles, press & blow process for wide-mouth bottles and the Narrow Neck Press & Blow (NNPB) process for higher output of lightweight

Improvisation in quality and quantity

Glass is the most eco-friendly solution available to the global packaging industry, and we try to make the entire manufacturing process as sustainable and efficient as possible. CSK Mehta

Vice President, HNGIL & tough bottles. The IS machines from Emhart are optimised from double to triple gobs to enhance production cycles and reduce downtime. At the annealing lehr, the glass forms are gradually cooled to release stress and ensure longevity of the bottles. The bottles then proceed towards quality assurance stages, where each bottle is assessed by auto inspection machines from SGCC as well as visual checks by experienced professionals. The automatic quality inspection lines ensure immediate feedback and zero error into the system. This is followed by random sampling of hourly batches, where the respective sample is subjected to polariscope analysis

High-speed production Photo: Joshua Navalkar

Modern Packaging & Design May-June 2011

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FACILITY VISIT

for adequate stress control and other customer specifications. Besides, this plant is equipped with an on-site ceramic printing facility with three decorating lines. After moving through all manufacturing and processing stages, the glass bottles are stored in a 12,000 sq ft warehouse, having a capacity of 10,000 metric tonne. With intelligent planning and management, the total breakage loss at this storage facility has been reduced from 10 per cent to nearly 1 per cent. This warehouse infrastructure is being improved further to store up to 35,000 metric tonne of containers.

On an expansion drive

Complete automation in packaging

Precision moulds designed for high speed Photo: Joshua Navalkar

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With a strength of more than 600 employees, HNGIL emphasises considerably on employee health and welfare. Being a loud noise zone, all workers are provided with the appropriate gear that includes ear plugs, aprons, shoes, helmets, etc, as prescribed by industry regulations. Also, the company ensures that all workers at hazardous locations of the plant undergo regular heath checkups and other medical facilites. After optimising its resources to achieve a capacity of 400 metric tonne, the company has ambitious plans to further expand this facility by adding the world’s largest end fire furnace and six additional IS lines. This will be a 150 per cent capacity enhancement, which aims to deliver an output of about 650 metric tonne. Being a market leader, HNGIL is expected to meet the demands of the region’s ever-growing alco-bev segment as well. Mehta avers, “Today, glass has a sustainable Compounded Annual Growth Rate (CAGR) of about 10-11 per cent. This translates into production of 300-400 metric tonne of glass or the need for one more furnace every year. HNGIL has been striving to meet this demand by putting up greenfield facilities and building

on its key strengths to emerge with dependable solutions. Similarly, we have upgraded another furnace at our facility in Neemrana, Haryana.” He further explains, “Another key strength of HNGIL is its ability to integrate world-class technologies from various suppliers. We have leveraged our presence as the market leader to complement the machinery obtained from some of the leading brands in the business like Sorg, Horn, Emhart, SGCC, etc. Through this significant expansion, we hope to target the export potential as well.”

Creating milestones In 2009, HNGIL was rated as the best Indian company in the glass & ceramic category by Dun & Bradstreet – a leading credit rating agency. Apart from this, the Sinnar facility has received several accreditations for its best-in-class manufacturing practices. As the company gears itself to further establish its presence in the container glass segment of Western India, this facility will play a pivotal role in achieving this goal. Today, the Sinnar facility prides itself on having some of the most honoured names in the industry as customers. These include Nestle, Unilever, Dabur, Cipla, Pfizer, among others. With enhanced production capacity, the solutions provided by HNGIL will not only improve in volumes but also facilitate world-class innovations in India. On this note, Mehta concludes, “Apart from current plans, this plant will also witness addition of two more lines to its capacity in the near future. With significant investments, we are looking forward to a total of 12 production lines to fully utilise this plant’s capacity. However, the challenge before us is to maintain cleanroom specifications similar to those in developed countries. Achieving these standards will bring us on par with global standards of manufacturing, thereby giving HNGIL a complete edge in the industry.”

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SECTOR WATCH

Quality standards in packaging

Raising food safety and hygiene value We live in a rapidly changing world where yesterday’s status quo is no longer good enough. Requirements to improve food product quality & safety, enhance and stabilise food composition & nutrition, extend shelf-life & product stability, build customer confidence, provide information, etc on food packages are fast becoming market demands. Beverley Lewis tracks the increasing demand for high-quality packaging in the food and beverages sector.

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uality food packaging plays a vital role in ensuring the purity, safety, preservation and protection of food products. Right packaging of fresh and processed foods is also important during bulk transportation, unit packaging for distribution and prevention of wastage. With proper and quality packaging, food products can be protected against severe and varied climatic conditions. “Quality standards can be divided into process standards and product standards. Most of the product standards in India are governed by the Bureau of Indian Standards (BIS) and process standards are as per the International Organization for Standardization (ISO) guidelines, while also managing the Standard Operating Procedure (SOP),� says V K Baheti - Director, Operations, Manjushree Technopack Ltd.

Quality control Akin to many other manufacturing industries, the food packaging industry is adopting more improved technology each year, with an eye on increasing productivity. But while productivity is the final goal for any company in the private sector, the food packaging industry faces unique challenges to its margins. Commercially sterile foods are processed and packaged such that they remain free of microorganisms that are of public health significance, and also prevent the growth of any microorganism under normal non-refrigerated storage condition

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SECTOR WATCH

& distribution. This may be accomplished by aseptic processing and packaging. Aseptic processing and packaging refers to a technique in which food is commercially sterilised outside the package, cooled and aseptically filled in a previously sterilised package. This is followed by hermetic sealing with a sterilised closure in a microorganism-free atmosphere. The end-product is a hermetically sealed container holding sterile food, which can be stored for prolonged periods under ambient conditions. On the basis of the acidity level, foods may be divided into low-acid foods and acid foods. Low-acid food means any food, other than alcoholic beverages, where any component has a pH value greater than 4.6 after heat processing. These foods are considered perishable, as pH above 4.6 may support the growth of microorganisms, such as Clostridium botulinum, which cause food spoilage or poisoning. A good manufacturing practice is essential to ensure the safety and quality of these food products. Aseptic processing and packaging of low-acid foods is a complex food manufacturing operation. It requires careful control at all stages of production to produce and maintain the asepsis of the food processing, filling and packaging systems. The control system embraces a large number of inter-related operations. The objective of this system is to provide general guidelines for the operations of aseptically processed and packaged low-acid foods and to advise on the necessary measures for production of safe and wholesome low-acid foods. “The quality of our purchased products and raw materials is ensured through rigorous supplier assessments, coupled with regular supplier audits and 100 per cent inspection of all incoming parts, the critical dimensions of which are measured through an in-house co-ordinate measuring machine. The suppliers are provided with monthly feedback on the quality of parts

Modern Packaging & Design May-June 2011

received as well as their on-time delivery performance,” asserts Ashok Gourish, Business Head, Bosch Packaging India.

Maintaining the hygiene The hygiene requirements in the food packaging industry have significantly increased over the past decades. A good example of this is hygiene requirements in the production of ready-to-eat meals, which do not have to undergo any antiseptic treatment such as boiling or grilling, but are to be simply heated by the end-consumer. Several factors are essential for protecting the hygiene and quality of goods produced by the food industry. Only by continuously following all necessary requirements can the industry offer a quality product to customers. The materials used for packaging of food products must meet high hygiene standards in order not to cause deterioration in the quality of the packed good. Adds Baheti, “The guidelines for packaging, specifically food packaging, are very stringent, as the product in the packs is consumable.” Food hygiene standards are complied with those mentioned in the ‘Codex Alimentarius’ of the World Health Organization (WHO). This codex was the source of the European Standard E 93/43/EWG, which was used for enactment of national laws in different member states. Biological food safety hazards are not as commonly linked to packaging materials as they are to food manufacturing processes. However, these should still be included in a hazard analysis. Quality issues, on the other hand, are just as significant and include mould, product leakage, transferable ink, etc. For example, shelf-stable food products can be severely compromised with mould growth due to faulty cans or packaging containers that do not meet the food manufacturer’s specifications. To prevent similar issues from occurring, packaging facilities should test their containers, cartons and other packages with the ingredients and food products to be packed in them for ensuring that

We expect that with more and more multinationals looking towards India as a growth story, it is only a matter of time before India adopts world-class packaging standards. V K Baheti

Director, Operations Manjushree Technopack Ltd

Quality awareness is on an upswing, with the entry of multinational food companies in India, who demand same quality standards as those prevalent in developed countries. Ashok Gourish

Business Head, Bosch Packaging India

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SECTOR WATCH

no reactions occur. Every new type of packaging material should be tested before it is introduced.

Why do these issues occur?

As the Indian economy continues to grow at a robust rate, companies will have to invest in R&D to meet the demand for innovative and high-quality packaging. Didier Lacroix

Senior Vice President, Worldwide Sales & Marketing, Cognex Inc

Food safety issues in the food manufacturing and packaging industries occur due to human errors, which are unpredictable and difficult to control. Although most of manufacturing processes used today are fully automated, it is impossible to remove the human element from the process. Even with the most automated functions, there will always be a need for maintenance technicians, equipment operators, packagers, drivers, etc to ensure smooth running of the entire operation. “The assembly of our machines is as per the Bosch Production System, which ensures lean manufacturing practices through the availability of the right part at the right time. The assembly of machines is carried out by trained technicians as per documented Work Instructions, which is linked to an Internal Check Document. The Internal Check Document forms the basis for clearing the machine for final trials and factory acceptance test,” informs Gourish. He claims, “During the assembly of the machine, regular process audits are conducted by an independent team, which ensures that quality is built into our products. Internal trials are

conducted with customer-supplied films & product and the machines are cleared only after these meet the customer’s specifications in all respects.”

Automated equipment Automated equipment greatly increases production rates, cuts down the number of necessary production employees and eliminates the possibility of human error. But, even with these processes, the potential for failure remains. Several packaging facilities today use automated printing equipment to produce nested containers. A product label is printed on containers, which are then automatically stacked before they come off the production line. Beyond this, workers are responsible for placing the nested stacks in appropriate cases before shipping them to the customer. As workers cannot see all containers, it is possible that mixed containers may be packaged in one case. In such cases, it would be a timeconsuming and unnecessary task for workers handling the nested stacks to visually check individual cups before packing them. Moreover, there are plant procedures that can greatly reduce the occurrence of mixed products at this level. During changeover, the plant can have a procedure that requires signatures from the operator, supervisor and a representative from the quality department, to verify that all previous printed materials and packages have been removed from the line before starting the new run.

The solution

Courtesy: Manjushree Technopack Ltd

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The motto for today’s consumer-driven economy seems to be ‘more is better’. This is obvious in case of manufacturing plants that operate 24 hours a day and 7 days a week, including holidays. Today’s manufacturers work at a fast speed trying to fill orders and keep up with automated equipment, and hence often do not notice label errors or mixed materials. Thus, it is important for food manufacturers and packagers to cooperate and implement hazard-based

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SECTOR WATCH

analysis programmes, such as Hazard Analysis Critical Control Point (HACCP) Programmes, for recognising potential food safety issues before they reach consumers. Until recently, such risk-based programmes have been most widely used in the food industry by ingredient suppliers and food manufacturers. However, some manufacturers are now asking their packaging suppliers to implement formalised HACCP programmes and food safety practices to identify potential hazards. This valueadded approach to plant operations takes food safety out of the hands of the operator and into HACCP systems.

Quality management system Quality control, quality assurance and quality improvement are three main components of quality management. This system focusses on product quality, as well as the means to achieve it. Hence, the thrust is on both quality assurance and control of processes & products. This enables consistency in product quality. The cornerstone of a quality-oriented organisation is the concept of the customer and supplier working together for mutual benefit. For this to become effective, the customer– supplier interface must extend into, and outside of, the organisation, beyond the immediate customers and suppliers. Industry players note that India’s highly fragmented packaging industry estimated at `8,000 crore with a growth rate of 22-25 per cent per annum can become the outsourcing hub for packaging if global standards are adopted. “To realise this potential, the Government has planned to initiate some concrete steps in the area of food safety standards such as, the phased implementation of the food Safety & Standards Act 2006, which would bring in better standards and make the sector more competitive as well as usher in better packaging standards and norms. This will ultimately pass on the valuable benefits to the end consumer. With better legislation in place, India will be able to

Modern Packaging & Design May-June 2011

make its presence felt in developed countries through better and higher export potential,” states Didier Lacroix, Senior Vice President, Worldwide Sales & Marketing, Cognex Inc.

This is helping Indian companies to raise the quality bar and achieve stringent requirements,” claims Gourish.

High-quality packaging standards in India

Food packaging, as distinct from mere ‘packing’, plays a visible and catalytic role in a modern economy with widespread adoption of product branding and development of consumer preferences. This happens to the extent that any consumer product is packaged such that it meets the criteria of safety, convenience and attractiveness, and also gains marketshare. In aggregate, packaging as a sectoral activity boosts consumption and economic growth. Heightened competition in all product sectors within the country as also the increasing need to look for export markets have contributed to the rising demand for appropriate, cost-effective packaging material and technologies. “In the last few years, India has witnessed great improvements in the quality of packaging in the high-end product category, though significant packaging improvisation is still required for products in the low-end category, especially those marketed in rural areas. As the Indian economy continues to grow at a robust rate, companies will have to invest in R&D to meet the demand for innovative and high-quality packaging. Indian packaging industry today accounts for over $ 14 billion and is expected to grow at a rate of 15 per cent per annum,” says Lacroix. The growth in the packaging industry has resulted in greater specialisation and sophistication in terms of health (for packaged foods & medicines) and environment-friendliness of packaging materials. The demands on the packaging industry are challenging, given the increasing environmental awareness among populations. The slogan by World Packaging Organisation (WPO), ‘Better Quality of Life Through Better Packaging’, sums up the significant position that packaging occupies in the modern economy.

India is an evolving market as far as packaging expertise is concerned; hence, packaging standards here are not on par with their western counterparts. “But we expect that with more and more multinationals looking towards India as a growth story, it is only a matter of time before India adopts world-class packaging standards. In the next few years, we expect huge investments in

Benefits of quality management assurance Improvement in product quality Improved image through reduced damages/ avoidance of recall actions Reduced development costs Adherence to defined specifications or legal requirements Reduction in transport damages and higher degree of service Optimisation of logistics costs through tailored packaging solutions Optimisation of handling and packaging material costs state-of-the-art packaging machinery, processes and trained manpower,” reveals Baheti. This will ensure that India is not left behind other developed countries in terms of packaging quality standards. The field of packaging has taken giant strides all over the world. With new materials, new production technologies and emerging packaging trends, the challenge lies in keeping pace with the developments and ability to provide economic solutions that meet quality requirements. “Quality awareness is on an upswing, with the entry of multinational food companies in India, who demand same quality standards as those prevalent in developed countries.

Better life through superior packaging

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MARKET TRENDS

As the consumer goods industry in India realises the role of packaging as the most powerful tool of brand identity, the packaging printing segment is gaining momentum in terms of aesthetics as well as innovations. Annabel Dsouza discovers the world of colours and graphics in a wide range of laminate and labelling applications. 36

Modern Packaging & Design May-June 2011


MARKET TRENDS

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ackaging has served the Indian economy by preserving quality and lengthening the shelflife of food products while also enabling their mass distribution. However, today, packaging is essential for all commodities on the market, including domestic appliances and industrial equipment. Over the years, packaging has evolved from the simple act of ‘packing’ to a distinct art as well as a science that plays a catalytic role in determining the image of a brand while also influencing consumer preferences. The huge value addition and employment involved in packagingrelated activities ensure that modern-day packaging meets the criteria of safety, convenience and attractiveness in order to gain marketshare.

Connecting with the brand It is said that an object without adequate packaging remains only as a commodity and not a brand. Thus, the market appeal of a company is closely linked to the industry presence of its brand, which in turn is represented by the attractiveness of its packaging. Thus, packaging has emerged as the strongest tool that reinforces brand identity and loyalty. Consumers have to not only connect with a specific product on a supermarket shelf, but also choose it over other brands and that too repeatedly. This customer psychology is compelling manufacturers to direct considerable resources into differentiating their products through efficient packaging techniques. Packaging printing is one of the most crucial operations in the journey of a product to market. Digital packagingprinting market is expected to reach $4 billion by 2014. Today, as the Indian packaging industry is keeping pace with global standards in efficiency and sustainability, the market is witnessing new materials and substrates for packaging. As a result, the printing segment has to constantly innovate in terms of contemporary designing along with increased delivery. Anuj

Modern Packaging & Design May-June 2011

Desai, Director, Image Care Pvt Ltd, says, “The role of graphic designers is to understand the printing technology and deliver creative solutions to the packaging industry. A team of product & graphic designers and print specialists can create spectacular results. India still has a scope for improvisation in this field. Our designers are respected all over the world and our print companies are creating new standards, but what is needed here is teamwork in order to create new benchmarks.”

Optimising the method Offset is the predominant technology used in India, although gravure is still growing in India with increasing numbers of new presses and electronic engravers being imported each year. In India, gravure is majorly used for flexible packaging, which is also growing at double-digit rates. The turnover of flexo printing in India is at 20-25 per cent of flexible packaging turnover, although it is showing fast growth with narrow web presses and also with import of wide web flexo, mainly for the food processing industry. With the advent of flexible packaging and increased demand for large-volume printing solutions, there has always been a debate between flexographic and gravure processes. Both these have their own share of strengths and drawbacks. Flexography has drastically outnumbered gravure in the Americas and Europe, whereas in India, gravure is almost unrivalled in its marketshare and standing. However, that has been sponsored in the past as a result of less stringent environmental legislation, which resulted in the use of less expensive, but more hazardous plate-making techniques (etching). Conventionally, the gravure process is known to be a high-quality and highefficiency process for package-printing applications. Perfect register accuracy and easy & fast register setup are the key to success. Excellent colour and image reproduction as well as consistent performance over the entire print run

Our designers are respected all over the world and our print companies are creating new standards, but we need teamwork to create new benchmarks. Anuj Desai

Director, Image Care Pvt Ltd

Although there is not much competition in high-volume or high-end packaging, getting and retaining skilled manpower is difficult. K Selvakumar

Director, Lovely Offset Printers

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MARKET TRENDS

Courtesy: Promopack

have been the classic benefits of the gravure process. In Asia, rotogravure printers have close to 50 per cent marketshare in the packaging industry. Flexography has been the choice of packaging printers due to its advantages in terms of producing good quality impressions on many different substrates. It is the least expensive and simplest printing process used for decorative printing in packaging. Flexography has been used to print corrugated containers, folding cartons, multiwall sacks, paper sacks, plastic bags, labels, adhesive tapes, wrappers, etc. This process has been a conventional favourite due to two primary reasons; first, it is a relatively simple operation and, second, it easily adapts to the use of water-based inks. The widespread use of waterbased inks in flexographic printing means a large reduction in Volatile Organic Compound (VOC) emission as compared to the heat-set web or gravure printing processes. Flexography is a combination of letterpress and rotogravure printing. It uses relief plates comprising flexible photopolymer plates and quick-drying, low-viscosity solvent, water-based or Ultraviolet (UV) curable inks fed into a two-roller inking system. These rubber plates are mounted onto the printing

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cylinder with double-faced adhesive. Often, the high costs associated with customising the flexographic printing process have been a major deterrent in its widespread application. The photopolymer plates need support from thin metal sheets and are attached to the printing cylinder with fastening straps for close register or ink alignment. This adds to the cost of the plate and requires higher timelines. But when quality printing is critical, this type of plate can make all the difference. As India’s packaging industry is surging to greater heights, the labeling and converting applications are witnessing new and improved innovations in terms of wet glue, pressure-sensitive, flexible and wrap around labels. The industry is currently estimated to be `20 billion and expected to cross the $ 2 billion mark by 2014. Wet glue labels segment is expected to continue growing at 15 per cent, while pressuresensitive labels will grow at about 30 per cent. These high-end labels are produced using gravure and flexography techniques.

Customising processes The product lifecycle of consumer goods has significantly reduced in

recent years. Today, products are developed and launched on the market at a rapidly increasing pace. As a result, there is extreme pressure of time in packaging production. At the start of a production process, it is usually not certain where and how a job will be printed. Consequently, the data often still needs to be adapted to individual printing conditions in offset, gravure or flexo printing. Third-party data also has to be checked in relation to the subsequent printing process. This is not only a labour-intensive procedure, but also calls for extreme flexibility in image reproduction. Dealing with different colour standards and specifications defined by customers – who are often prominent manufacturers of branded goods – is a major challenge, since it is important to maintain a consistent brand design in different production processes. The ultimate colour result is intended to be as consistent as possible, even when repeat jobs are involved or packagings are produced by different printing processes and on different materials. Extensive expertise, process control and flexibility are necessary in order to reliably comply with these demands in the usually stressful environment of day-to-day production operations.

Time and cost savings In new-age digital printing, the market is welcoming established printers like Canon, Epson, Hewlitt Packard and Roland into the packaging domain. The solutions offered by these new inkjet printers permit maximum colour quality in packaging proofs on a great diversity of materials, such as paper and film. At the same time, this method is significantly faster and inexpensive as compared to an analog proofing system or a press proof. Processes such as plate making, cylinder preparation or photoengraving are cost-effective and time-saving. Automation of packaging printing operations is another key determining

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MARKET TRENDS

factor. Information Technology (IT)controlled printing processes guarantee high colour accuracy, repeatability and detail definition when producing complete tone and halftone proofs. The flexibility of packaging prepress operations is greatly increased, since automation allows particularly simple proof production and even directly on the customer’s premises by means of remote proofing laminates. K Selvakumar, Director, Lovely Offset Printers, says, “The pre-press software used in UV printing and narrow web presses allows for tremendous control over operations. The high levels of automation and high-speed presses equipped with several quality control devices ensure high productivity, low wastage and zero error in production.”

Countering challenges As the Indian packaging industry gears up to leverage growth opportunities in the years to come, awareness and attention to high-end printing

Modern Packaging & Design May-June 2011

and graphics technology will be an important deciding factor. A plethora of export opportunities are awaiting Indian converters, which highlight the need for the printing standards in India to meet global benchmarks. Selvakumar states, “On the technology front, we are on par with international players. The difference may be in the number of high-end machines available in our country when compared to those in developed markets. But, today, technology is open and Indian companies can afford to make huge investments and still make ample profits.” Elaborating on the way to approach this, he says, “The first is generating the capital to acquire latest technology, which never comes cheap. Second, there is always the problem of finding high-volume jobs to justify the investment. Although there is not much competition in high-volume or high-end packaging, getting and retaining skilled manpower is difficult. Many printers are already servicing

the overseas market their capacities.”

to

optimise

On a promising note Apart from brand building, the Indian packaging printing industry is yet to realise a very unique benefit offered by cutting-edge printing solutions. Signing off, Desai adds, “The packaging industry is currently facing problems of brand imitation and poor quality. This gives the print design sector an opportunity to introduce anti-counterfeiting features such as holograms and barcodes, which will help preserve the safety of consumers. Legislation alone cannot prevent brand damage. Hence, there has to be an emphasis on awareness in terms of better quality inks and raw materials as well as cost-efficient, state-of-theart printing presses. Printers as well as packaging consumers must realise the potential of technology and innovations if they are to meet world standards.”

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PACKAGING PERSPECTIVES

Food packaging

Convenience, creativity and consistency Being highly perishable in nature, packing and delivery of milk and milk products require the use of specialised packaging materials, to protect these from contamination and spoilage. Besides, quality of these products must be maintained at all times. A wide variety of packaging materials like glass bottles, foils, metal containers as well as plastic tubs, jars, pouches, etc, are available today, all of which successfully accomplish these requirements. P V Narayanan

F

ood and food products form one of the largest consumption categories in India. Spending on food accounts for nearly 21 per cent of the Gross Domestic Product (GDP). A dramatic evolution in this segment is envisaged due to growing income, changing lifestyle and rising demands for healthy foods. Specifically, domestic spending on food and food products is worked out to be 31 per cent of the income. Indian domestic food market is expected to grow by about 40 per cent in the near future. Currently, the overall food consumption market is estimated at $ 258 billion and is likely to touch $ 344 billion by 2025. This figure

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was $ 155 billion in 2005, and grown at a Compound Annual Growth Rate (CAGR) of 4.1 per cent.

Dairy segment: An overview Among fresh and processed foods, milk & milk products form a significant group, which uses a variety of packaging materials, packages processing and techniques. In India, milk & milk products are still marketed and distributed using traditional methods, as the industry has not yet deployed modern techniques and new systems for packaging. Milk production in India has risen from 112 million tonne in 2009 to 1,215 million tonne in 2011 (a 4.1 per cent increase). Of the total milk produced, about 46 per cent

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PACKAGING PERSPECTIVES

is consumed in the liquid form, while 47 per cent is processed to other traditional products including cottage butter, ghee, paneer, khoa, curd, malai, etc. The remaining 7 per cent is used to produce milk powder, processed butter, processed cheese, etc. Some of the prominent milk products include ghee, butter, cheese, ice cream, milk powder, malted foods, condensed milk and infant foods. Milk and milk products are highly perishable items; hence, appropriate packaging becomes mandatory to ensure their safe delivery and proper storage. These products are spoiled rapidly at temperatures above refrigeration as well as in the presence of oxygen and other external atmospheric contaminants. The factors governing the package selection broadly include the macro and ambient environments, effect of moisture, gases (particularly oxygen), heat & light, handling, storage and transport system. Consumer convenience and cost aspects are the other driving forces that influence selection of packaging materials. Further, legislative aspects should be conformed to for proper packaging of these products. With regard to the `4,300-crore ice cream market, the organised sector accounts for `1,700 crore. Eight cities contribute to 60 per cent

Modern Packaging & Design May-June 2011

of the organised sector, of which 50 per cent is the take-home segment. The per capita consumption of icecream in India is 750 ml as against 30 litre in the US and 1.2 litre in China. The region-wise consumption pattern of this product in India is as follows: West (35 per cent), North (30 per cent), South (20 per cent), East & Central India (15 per cent). Specifically, North (Delhi) and Gujarat put together account for 30 per cent of the country’s marketshare in this segment. The chocolate product mix is yet another segment showing considerable growth promise, with a growth rate of 27-28 per cent as against 30 per cent in Europe and Australia.

Packaging systems: A review Packaging has assumed a greater role in the marketing and distribution of dairy products. Continuous introduction of new product varieties and increasing consumer demographics have provided excellent opportunities for new package development and creative packaging with shelf retail packaging. Milk: Since long, milk was supplied to households by vendors at the doorstep in aluminium containers with measures. This

method of distribution put milk open to contamination and adulteration. Subsequently, glass entered the market through organised processing and supply. The salient features of glass include transparency, rigidity, hygiene, non-toxicity, neutral, compatibility and high-reuse value and recyclability. However, it also has some shortcomings such as high tare and fragility. The late 70s witnessed a shift towards pouch packaging, with the Low-Density Polyethylene (LDPE) film, which, subsequently, over the years, moved towards co-extruded two-layer/threelayer film with combinations of LDPE and Linear LDPE (LLDPE). Technology has played a big role in reducing the thickness of film(s) from around 102 Âľm to 55 Âľm. Domestic availability of quality Form-Fill-Seal (FFS) machines has helped in the exponential growth of the use of plastics-based films across the country. Introduction of aseptic cartons, generally termed as tetrapack, is indeed a breakthrough that offers higher shelf-life (3-6 month) and, more importantly, even without refrigeration. Flavoured milk: The commonly used packages for flavoured milk include glass bottles with crown cork or aluminium tagger lid or snapon plastic top, sachets and aseptic tetrapacks. The latest packaging

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PACKAGING PERSPECTIVES

material to enter the market is translucent High-Density Polyethylene (HDPE) bottle with aluminium foil cap. Ensuring package–product compatibility requires the packaging material to be odour-free & taintfree, have good wet strength/light resistance and good seal/bond strength and also be leak-proof & tamper-evident. Condensed & evaporated milk: Sweetened condensed milk is more popular in India and the doubleseamed Over-The-Counter (OTC) cans is the package material generally used. From fully top seamed lid, easyopen lids have now become very common. Traditional Indian dairy products: These fall under five major categories, viz. concentrated products (kheer, gulab jamun, burfi, etc), fat-rich products (ghee, butter, etc), fermented products (curd, lassi, shrikhand, etc), coagulated products (eg, paneer) and heat-desiccated products (eg, khoa, rabri). Except a few, most of these products are made and sold on a short shelf-life basis by the unorganised sector, with little or no knowledge of packaging. If processed, packed and distributed in an organised manner, these products will find excellent global presence. Conventional packaging media such as leaves, paper and specialty papers as well as mud/ceramic pots/cartons are still in vogue. These are generally used as short-term and short shelf-life packages. With the exponential growth of these product groups as well as the entry of few organised dairies into these product mix categories, the packaging systems have witnessed a sea change. Moreover, new technologies have come into play, both in processing and packaging, with updated and scientifically proved strong materials. Lacquered tinplate containers with easy-open ends, thermoforms from different plastics-based sheets – including High Impact Polystyrene

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Classification of milk & dairy products Liquid milk: Pasteurised, flavoured, condensed and evaporated milk Dairy products: Milk powder, butter, ghee, ice cream, malted milk foods, cheese and yoghurt Traditional products: Paneer, khoa, shrikhand and Indian sweets (HIPS), Polyvinyl Chloride (PVC), Polypropylene (PP), Polyethylene Terephthalate (PET) or co-extruded sheets – are some of the commercially used packaging materials used today. These could be a manually operated single-dose packaging, semiautomatic or completely automatic systems. Attempts have been made to adopt vacuum and gas flush packaging; however, these have not been commercially successful. Products such as milk powder, butter, ghee, ice cream, malted milk food cheese and yoghurt are, however, marketed in new packages using better conversion and packaging technologies with novel materials. Butter is packaged in different forms based on quantity. Portion packs are made in tissue/aluminium foil wraps, or thermoformed PP/ HIPS tubs with foiled lids (peel off). Institutional packs are packed in G&G wrap printed folding board cartons. For long shelf-life, printed and

Continuous introduction of new product varieties and increasing consumer demographics have provided excellent opportunities for new package development and creative packaging with shelf retail packaging.

hermetically sealed tinplate containers and thin-wall lightweight aluminium containers are used. Metal containers usually have printed foil tagger. Ghee essentially needs to be protected from chemical spoilage and rancidity caused by oxygen, heat, moisture and metal ions. Earlier, bulk distribution was done in 4 gallon containers, but currently it is packaged in 15-kg tinplate containers. Other quantities of ghee packed are 250 gm, 500 gm and 1,000 gm (1 kg) in three-layer and five-layer co-extruded films, which are generally surface printed. The fivelayer structure is usually nylon-based, which provides longer shelf-life. It has an HDPE component on the inside, which provides better oil resistance and adds to moisture barrier. Nylon, serving as a high oxygen barrier, prevents rancidity in the product. PET and lined carton are also used for this purpose. Milk powder: Whole and skim milk powder are the major varieties sold in packs. Whole milk powder is obtained by removing moisture through heat, steam or drum drying. Skim milk powder is obtained by removal of both moisture and fat. As these products are highly sensitive to moisture and oxygen, a high-barrier package is desired with vacuum/gas flush packaging. Tinplate containers with vacuum and gas flush packaging have been used for a long time. Subsequently, with the development of multi-ply high-barrier structures made of PET/MET PET/foil/polyamide with heat seal media have found acceptance in this domain. For bulk distribution in 25-kg weight, multiwall paper bags with Polyethylene (PE) loose liners and/or kraft/ PE-laminated layers are used. Ice cream: Ice cream is a frozen dessert with a blend of milk cream, sugar, flavour and stabilisers. This product demands low-temperature storage and protection from contamination, moisture loss and

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temperature fluctuations, along with amenability to excellent printing. Common package types are polycoated printed folding board cartons, PP/HIPS/HDPE/co-extruded sheets thermoformed or injection moulded tubs/cups with snap-on LDPE lids or polycoated printed paperboard die-cut sheets. Flexible laminates with multicolour prints are used as tubs and sachets/pouches. Biaxially Oriented Polypropylene (BOPP) or PET laminates are used for packing candies. Reuse, promotional packs are also used, particularly to attract the children consumer segment. Instead of heat-seal substrate, the latest trend is of cold seal coating. Malted foods: Generally marketed in retail consumer packs in quantities of 200-1,000 gm. These products are highly sensitive to moisture and oxygen, resulting in product lumping and rancidity. These factors essentially govern the package selection. A variety

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of package types are used today to pack these products. Conventional packages used earlier include tinplate and glass containers. Recently, there has been a shift towards the use of flexible laminated pouches and lined carton. Laminated pouches may include pillow or stand-up or bag-in-box and pet jars; of these, the latter is also being replaced by PP jars. Higher capacity plastic jars up to 2.5 kg have also been introduced. These are either blow moulded or stretch blow moulded. The lids of these jars are injection-moulded screw caps. The flexible pouches based on PET/MET PET/PE or PET/MET BOPP/ PE and lined cartons are usually refill packs and more economical. These pouches could be pillow-type, standup and side or bottom gusseted.

Packing quality with safety The dairy products industry in India continues to be distributed among

small, medium and large sectors. Traditional Indian milk-based sweets will serve local/domestic markets within a given distribution radius in the years to come. However, high-end products will be best produced and marketed by the organised sector with higher growth rate. Both the market leaders and close competitors will have the opportunity to add to their product mix and the StockKeeping Units (SKUs) in their respective areas. Packaging with excellence in print & appeal as well as shelf-ready packages will become the niche in the coming years, with demands for more innovative and creative ideas. P V Narayanan is Chairman of Cognizance Packaging. He is also the Secretary General - IPMMI, and Chief Executive - PFFCA. He is a recognised UNIDO, ITC, and CFTC (UK) expert consultant in the field of packaging. Email: peeveen@gmail.com

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PACKAGING PRINTING

Colour calibration

Synchronising the shades Imagine a graphic that appears, say ‘red’ onscreen and ‘orange’ in print, that is, the colour of image onscreen differs from that in print. This mismatch can be avoided by calibrating the printer using a colour management system, which includes tools for calibrating monitors, printers, etc. These tools have various generic profiles and the means to customise profiles for any device, to ensure that the colour in print is consistent with that of onscreen image. Bhargav Mistry

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ow many printers (printing professionals) and print buyers really know the concept and essence of ‘What You See Is What You Get’ (WYSIWYG) in letter and spirit? This term is used in computing to describe a system in which the content displayed onscreen appears very similar to the final output, ie, in print. Back in 2004-05, the colour management system was quite immature and very few printers had the knowledge of this system. Even today, only few printers are aware of this system, which is the secret to become a great printer. The colour profiles must be standardised. Actually, this is one of the most important areas of focus for every printer. Simply laying the dots is not important, but achieving the right target colour is more important in today’s demanding and competitive world. In the understanding of a colour management system (ICC profiles, Calibrations, etc), one name stands out in this field in India – Kiran Prayagi – an expert in the field of colour science and theory with enormous practical

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knowledge. At a conference on colour management system held some time around 2004-05, Kiran Prayagi had highlighted on the need for increasing the understanding of Red-Blue-Green (RBG) & Cyan-Magenta-Yellow-Key (black) (CMYK), monitor calibration, etc. However, simply attending seminars and workshops is of no use unless the knowledge gained at such events is practically applied. An important aspect here is to match the prints with what is seen on screens. Therefore, as an attempt to shed some light on the mystery of colour calibration, following are some of the most common terms associated with this.

Colour values It is known that computers are basically functionless until programmed. They require instructions for every action, including how to interpret and display colour. Due to the presence of several different manufacturers of monitors, scanners, printers, cameras, etc, it is unlikely that they all receive exactly the same set of instructions. This is where the problem lies. When same colour values are sent to two different monitors, the results usually vary. Similarly, when

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same colour values are sent to different printers, they yield different results. The solution lies in a process that is somewhat analogous (albeit more involved) to the way one can tell a camera what colour is white (also called setting the white balance). With a little knowledge, people can learn to communicate with their devices regarding colour, and improve communication between each other. This will help avoid the print shock syndrome, where the colour of the print appears nothing like what is seen onscreen.

Colour calibration It is the process of updating or recreating the colour profile of a device (scanner, printer or monitor). It means attempting to set the hardware and software to achieve optimum (predictable) colour results. After a device is calibrated, it can be integrated into a colour management system.

Colour workspace This refers to the working colourspace in which a current job is kept. This can be explained in another way: one pulls a file out of a filing cabinet and places it on the desk in order to work on it. And after finishing the work, one puts it back in the filing cabinet, away from the desk. Likewise, each time one opens an electronic document, the computer retrieves it from the hard drive and places into the Random Access Memory (RAM) for perusal and editing. After the changes are made to it, saved and closed, it is moved back from RAM and to the hard drive, along with the changes made. The same theory is applicable to colourspace. When a document is opened in an image manipulation application such as Photoshop, it is tossed into the current colour workspace for editing. But an important requirement here is that it needs to be seen. The screen or monitor then tries to interpret the colour values that it receives from Photoshop in order to properly display and update it as one

Modern Packaging & Design May-June 2011

is editing. To do this, the colour values of the workspace need to be converted to the colour values of the screen. This is called ‘conversion’ and is done constantly as the image is being edited and updated.

Colour profiles Every device reproduces colour differently because of the instructions it had received when it was made. When colour-producing devices start communicating with each other, they have their own method of colour interpretation. A computer’s operating system supplies the screen (monitor or display) profile, which makes sense if one remembers that it is the computer that sends instructions and signals to the screen. The working colourspace of the current job is determined by the colourspace chosen in Photoshop, under Color Preferences. Photoshop promptly notifies while opening a document that the colourspace is different and wants to know whether one would like to convert it. This means that the colours in one’s source document are in a colourspace, which differs from the working colourspace selected in Photoshop. Photoshop understands this because the source document has a colourspace profile associated with it, which defines its colour values. Each time a new document is created in Photoshop, the profile of the current workspace is attached with it. Not only can each device and document have their own profiles, there are even profiles for specific combinations of printer, ink and paper. Colour profiles can be created manually or purchased.

Creating a colour profile Creating a colour profile is one method to improve print quality, and a valuable talent as well. It has following pros and cons. Pros: Once one learns to make profiles, it becomes easier to work with different types of printers, inks and papers. It is completely a custom creation of an individual. Third-party software is available for help, such as traditional profile maker Monaco EZcolor (www.monacosys.com) and ColorVision PrintFIX (www.colorvision.com). Cons: To do it right, one needs to invest in a light source having the same

Playing with profiles Every device interprets colour differently, the process of calibrating one’s equipment and what a colour profile actually is. Here is described how colour profiles can be created manually or purchased, along with the merits and demerits of each.

Colour management system (CMYK)

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right in Photoshop CS3’s or CS4’s Print dialog box, and follow the below-mentioned steps: Go to Print: Document– Color Handling: Photoshop Manage Colors Printer Profile: Choose the specific profile for the paper on which to print Rendering Intent: Relative Colorimetric Black Point Compensation: Select Before clicking the Print button, one should make sure that the correct paper is selected and the printer’s own colour management is disabled. If the prints do not match with that on the screen, it is recommended to calibrate and profile the monitor. colour temperature as that of the monitor. Test prints are held under it to judge the colour matching. Good variety of paper must be used to print on to ensure consistent results. It is a time-consuming process. It involves creating (or finding) a test chart, which includes a colourful image plus a set of standard colours (for a particular operating system), and shades of gray in approximately 10 per cent increments. The goal of creating a colour profile is to enable the printer to duplicate, as closely as possible, the way the test chart appears onscreen. This is done by tweaking the printer adjustments in Photoshop. And then Media type is set to select the type of paper being used. Further, quality and other colour adjustments are made in the printer’s Advanced Options dialog. The test image can then be printed and compared under the special light. In essence, the settings can be tweaked in the Advanced Options dialog and printing proofs until the colours to match are achieved, and then the Profile must be saved.

Purchasing (or downloading) colour profiles This is another method to ensure the

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right colour profile. However, it has its own share of pros and cons. Pros: 1. It is faster than creating one’s own colour profile. 2. There is no learning curve. 3. Some companies give these for free (eg, paper and ink companies, user group sites, etc). Cons: 1. These profiles are created by other people; thus, the result may not be 100 per cent according to the buyer. 2. These can be expensive, as a different profile is needed for each combination of printer, ink and paper used (Profiles can cost around `1,250 each). 3. Some profiles are only available in sets, which may include some that are not needed.

Maintaining colour quality on print So, the WYSIWYG is not really a myth. Actually, the procedure is easy to perform but it is important to understand the correct workflow and, for this, one must have in-depth knowledge of the Photoshop, ICC Profiles, Color Sync and other similar software & applications. Some extra effort on this subject can drastically change the printing quality. Therefore, printers must take more interest to participate in informative knowledge sharing workshops on colour management and related areas of prepress activities.

How to matching actual prints with screen display

Disclaimer: Screen printing process is a vast subject and its techniques vary from job to job and application to application. This article attempts to shed light on screen printing process in a nutshell and the information shared here is not a complete knowledge in itself.

In Photoshop’s Color Settings dialog box, select Adobe RGB as the working space. Set the RGB colour management policy to Convert to Working RGB. Uncheck the mismatch warning dialog boxes. For printing, make these selections in the Color Management area to the

Bhargav Mistry is Director of DMI, and MD of Grafica Flectronica, manufacturer of fully automatic and semi-automatic screen printing machines. Email: bhargav@graficaindia.com

Modern Packaging & Design May-June 2011


INDUSTRY UPDATE

Checkweighing

Profit boost with innovative feedback control An important parameter, feedback, helps in fine-tuning processes or products and eliminating errors in the systems of enterprises. Checkweighing is a method that offers standard feedback functions to improve production performance and efficiency while reducing costs through a flexible and adjustable system. Here is an overview of some checkweighing solutions that can help companies maximise production and stay ahead of the curve. Gunter Schilpp

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ackaging of goods is a meticulous process, as even the smallest of errors in filling or checkweighing can prove to be extremely costly for established brands. The origins of such errors are often unpredictable, and sometimes unavoidable. These usually arise from subtle changes in the manufacturing environment, inherent product characteristics or filler deficiencies. In case these adverse factors are known, an action plan must be figured out to reduce their effects when these do occur. One way to do this is by using a checkweigher that communicates

Mettler Toledo’s feedback control integrates data collection for checkweighing Courtesy: Mettler Toledo

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with the product filler. Checkweighers are machines for weighing packaged commodities. These usually function at the end of a production run and ensure that the weight of a packaged product is within specified limits. Any packs outside the tolerance limit are removed automatically from the production line. Moreover, checkweighers with a feedback control function can greatly improve the filling process to increase profits, while also ensuring compliance with Weights and Measures regulations. Additionally, these can help with one of the largest issues that brands usually have to face – product loss. Overfilled containers mean giving

Advanced feedback control with a combination statistics feature uses combination of feedback and statistics to its full potential Courtesy: Mettler Toledo

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INDUSTRY UPDATE

away a product basically for free. This is where innovative feedback control functions pay the largest dividends for manufacturers.

Greater control within reach Modern checkweighing solutions offer standard feedback functions for improving packaging line performance to a certain extent. Some even work automatically to keep filler heads properly adjusted. However, the latest technology allows far greater leaps forward in manufacturing efficiency. These advanced systems have been developed with the knowledge that every gram of wasted product in the short term contributes to tonnes of wasted products in the longer term. This knowledge give manufacturers a powerful command over packaging lines – reducing product giveaway, improving product quality, boosting productivity, refining product data analysis and meeting or exceeding all legal requirements. Extended feedback control can help achieve these benefits by focussing on distinct areas of major concern, where maximum savings are possible. When evaluating feedback control options, the following four features are critical to maximising line performance: Integrating data from the checkweigher in feedback calculations: Using combination statistics allows for incorporation of statistical output of the checkweigher in feedback calculations. This automatically adjusts fill levels to ensure that at the end of production run, manufacturers can avoid a statistic mean value that is too low, which could lead to regulatory sanctions. Automatic overfill elimination: Optimal overfill functions monitor the production and automatically adjust the target weight to bring it closer to the labelled weight. This function also takes full advantage of regulatory tolerance values.

Modern Packaging & Design May-June 2011

Control factor choice: A technology with two control factors allows manufacturers to influence fill level correction behaviour depending on the product being produced. Manufacturers can decide which error – underfill or overfill – should be corrected more quickly to suit their requirements. Differential control: This feature gives even greater control over fill-level correction behaviour and is used in cases where extreme weight fluctuations are experienced. It defines how fast a correction is made according to the size and speed of a negative fill trend and uses an amplification factor for additional tweaking.

Saving product wastage New extended feedback control improves the existing, standard feedback control by increasing the level of precision and adjustability. It is only through such machinery that brands can bring the unnecessary product loss fully under control. Standard feedback control manages this loss to some degree, but there is considerable scope for improvement. It is absolutely imperative for the target weight to be as close as possible to the nominal or labelled weight, and thus prevent unnecessary loss of profit through giveaway. The best way to achieve optimum performance is

by combining the standard feedback programme with a statistics function in the checkweigher. Advanced feedback control with a combination statistics feature uses a combination of feedback and statistics to its full potential. This function controls the filler to ensure regulatory compliance and ascertain that the mean value of the complete production run is greater than the labelled weight of the product. Constant mean weight value control also avoids manual adjustments of fill levels towards the end of a production run to fulfil net content laws. According to feedback received, the filler is instructed to fill more or fill less. The target weight, in combination with the optimal overfill function, is automatically moved closer to the labelled weight. Both these functions can be used separately or in combination depending on product characteristics and production line requirements. These will significantly reduce product giveaway resulting from product overfill and scrapped products due to underfill while also improving efficiency. For example, in the processing of raw material, such as margarine, cooking fats and oils, the checkweigher feedback control automatically corrects the filling behaviour of upstream fillers to optimise the margarine portions. To further reduce waste, the feedback function must be adaptable

The checkweigher communicates with product filler Courtesy: Mettler Toledo

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INDUSTRY UPDATE

to suit particular products and environments. A differential control, with an amplification factor, is crucial for cases of extreme overfilling or underfilling. In such a circumstance, the operator must be able to decide the level to which the filler is controlled, based on a particular measurement series, to bring large deviations under control more quickly, thereby saving unnecessary product loss. Extended feedback control allows the operator to do this with ease, cutting costs and increasing profit in previously unreachable areas of the production line. For example, in the packaging process, manufacturers need to prevent both overfilling and underfilling of dry bulk products such as tea, flour, sugar or spices. Directly connecting a checkweigher to the packaging machine will proactively control the filling process of the bags. Similarly, the two control factors feature allows greater flexibility than standard feedback control functions. With this feature, the correction of either overfill or underfill can be prioritised by setting different manipulated variables and catering to production lines where underfilled products are recycled into the process, as well as those where these are scrapped. Saving product waste is the key to advanced feedback control: reducing costs through a truly flexible, adjustable system.

Time is money Saving on product loss is good for a company, but it must not come at the expense of line speed. If brands are to increase profit in a competitive market, decreasing downtime and boosting throughput of packaging lines is an excellent place to start. Innovative feedback control functions must therefore be developed to increase productivity and should be easily integrated. One of the essential features of feedback control is that it carries out tasks automatically and constantly

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An essential feature of feedback control is that it carries out tasks automatically and constantly throughout the filling & weighing processes, with all functions making quick corrections during and throughout product runs. throughout the filling & weighing processes, with all functions making quick corrections during and throughout product runs. Likewise, the ability to modify correction speeds and preferences means that companies can fine-tune their parameters in a shorter period of time compared to that with a standard feedback control. By refining these processes for the highest possible line speeds, this advanced feedback control can make a real difference on a firm’s balance sheet. Speed is of equal importance when integrating a new checkweigher or add-on into an existing setup. Highquality customer service is an absolute must to ensure that no time is lost as a result of preventable complications. For example, companies making the switch to advanced feedback control must be advised and aided in the arrangement and layout of their packaging line, typically placing the checkweigher as close as possible to the filler.

Protecting the brand It is absolutely crucial that any feedback control function allows brands to comply with industry Weights and Measures guidelines, and avoid the fines and loss of consumers’ trust that might result from breaking regulations or shipping underweight products.

Switching to an innovative feedback control function is a guaranteed way of avoiding the unwanted attention of regulators, and upholding consistently high quality. After production commences, the target weight is automatically adjusted (a proactive function not possible with standard feedback) to make full use of the permissible range. This function ensures that customer rights are observed at all time, and brands are able to avoid the eventuality of costly legal actions. Extended feedback systems can also help meet legal requirements without the cost of losing optimum efficiency. A proactive optimal overfill feature can take into account the fact that a certain production percentage (2 per cent) is allowed to fall below the set limit for that product, and adjusts the filler accordingly. It is this attention to detail that can help manufacturers get a welcome head-start on their rivals.

A sure winner The success of a modern checkweighing system is, to a large extent, inherent to the finer details. Innovative feedback control has the capability to take checkweighing to new heights. Through such a system, the checkweigher and filler work in sync to achieve the best possible results and extremely smooth filling process, irrespective of the specificity and evolution of these requirements. Gunter Schilpp, Head of Product Management, Mettler Toledo Garvens, is into global marketing activities in the field of checkweighing applications and solutions at the company. With over 14 years of experience in the packaging industry, he is responsible for transforming complex technical issues into clear customer value messaging, global solution launches, market strategy development, research & checkweighing development collaboration as well as brand strengthening & marketing strategy creation. Email: gunter.schilpp@mt.com

Modern Packaging & Design May-June 2011


POLICY MAT TERS

Design dynamics in MSMEs

Gaining competitive edge through innovation An important aspect of development is continuous change, and this is applicable to proper growth of industries as well. It is essential that companies continuously focus on design and innovation, as ignoring this can result in stagnation, and thus the fear of being left behind. A majority of micro, small and medium enterprises in India have remained isolated from the sphere of innovation; thus, the government has now taken an initiative with a unique intervention scheme to encourage design expertise in the sector. Jitendra Rajput

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onotony is one of the most uncomfortable and unacceptable state for human mind. Therefore, we keep changing our environment and tools around us, which help make our lives more comfortable. Change is an ongoing process from the evolution of sapience, and this is evident in all ages throughout the practices of day-to-day life and business of mankind. In the present era as well, change drives us to continuously upgrade our systems and threatens with consequences of being left behind if this is ignored. At the same time, there are few who bring changes in the dynamics and lead the market with new offerings. These change agents outshine the competition and force others to adopt new practices by imitation or creation of better offerings.

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There are two ways of approaching a solution. The most common one is to take a route that has been tested and proven. This approach is quite common and used by most people, and hence does not produce solutions that are competitive and distinctive. Therefore, one must try not to attract value at a premium and one that is less risky and equally less tempting to sell in the market. There is a design approach to the same situation. Creating improved and distinctive solutions that are innovative, as per customers’ need, better then the existing ones and attractive (functionally as well as visually), catering to real needs of a situation like cost-effectiveness, efficiency, simple and more appealing to customers. These innovative solutions need additional effort to produce more value. There is a need to involve vision, backed by right insights and iterations. Design plays

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POLICY MAT TERS

an important role in changing the value of products and also defining new paradigm of the present business scenario.

Micro, small and medium enterprises sector The Micro, Small and Medium Enterprises (MSME) sector could be considered as the bottom of pyramid of the industrial infrastructure of national economy. It has been recognised as one of the key sectors for employment generation and overall economic development of our country. This sector provides employment to nearly 60 million people and accounts for nearly 45 per cent of India’s manufacturing output. Approximately 26 million MSME units exist in the present industrial map, contributing to 45-50 per cent of total exports in the country.

Design challenges in MSME sector Early 40 years as a closed economy and the last 20 years as a liberalised economy have posed several challenges to MSME sectors. Quality as an early-stage advantage in the 90s has lessened the growth options in the current scenario. New products, improved quality and processes, variety in the market & demand as well as fierce competition has left fewer options for distinction and growth. Due to the changing scenario, varied market demand, available choices and international products, domestic enterprises are facing great difficulty in selling products in most segments. Dependency on borrowed or imitated products has left lesser options for customers having access to products that meet their specialised needs at a competitive price. Also, the imitation model, lack of research and refinements of products, etc have created issues with selection of the right process, material and outlook, thereby leading to a loss of competitive advantage.

Modern Packaging & Design May-June 2011

Where we lacked in last 50 years For the last few decades, design has been perceived as a specialised activity and a specialist job in the manufacturing scenario. Design has a direct association with appeal and ease to connect with its user/observer; therefore, it was often associated with giving an ornamental/aesthetic face lift to products. Design was also misunderstood as a domain expertise for products and visuals, leading to non-adaptation and exploration in other fields of manufacturing processes. Financial glitches to invest in design activities have been a major hindrance in the development of capability and learning in the current year. Fear of failure and protection of intellectual property was one of the issues to take initiative for new product development by MSMEs. Lack of access to design resource is also a major disability in connecting practical issues with design thought process in the MSME sector. Approaching a design expert, identifying right opportunity and a vision to graduate from a producer to an innovator enterprise has been absent in this sector. In recent years, very few design experts have established a connection with this sector to create innovative solutions and bridge the gap between the two. A majority of design professionals have found it more lucrative and convenient to associate with large industries, whereas the MSME sector has been deprived of such interventions in most areas. Government initiatives in early days for design awareness has not been the way they have promoted technology and management practices in industrial sectors. Due to the lack of such initiatives, the gap between design practitioners and manufacturers has also been wide in the last few decades. Except introduction of design education through National Institute of Design and the Indian Institutes of Technology (IITs) in the 60s and 70s, there has been a

lack of initiative to promote design for industrial or social issues. Also, there has been an absolute draught in terms of support to the MSME sector. In a nutshell, the reasons behind the slow initiatives for design in the MSME sector in the last 50 years include lack of awareness about design, financial inability to invest and availability of resource with aligned thought process and courage to deal with MSME issues. Looking at existing SME models of design economies across the world (Italy, Japan, S Korea, etc), Indian MSME sector needs to graduate to the next level of the industrial platform, which includes capabilities of innovation at grassroots levels. The products must be improved according to the customers’ preferences and existing best practices while also identifying new opportunities. Apart from the basic offering, there is a need to look into the process of manufacturing, packaging, logistics and communication, for which a creative approach must be adopted as per companies’ requirements and context. Design approach is most important and critical in identifying such opportunities and generating breakthrough, efficient and cost-

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POLICY MAT TERS

effective solutions. Design approach to tackle present demand, future options and sustainable growth will be the key to success.

Government initiative to promote design in MSMEs In order to encourage design expertise in MSMEs, a unique and ambitious design intervention scheme for the country’s MSMEs – Design Clinic Scheme – has been launched as an initiative of Ministry of MSME, Government of India, under National Manufacturing Competitiveness programme. The objective of this scheme is to bring the MSME sector and design expertise at a common platform and provide expert advice and solutions on real-time design problems, resulting in continuous improvement and value addition for existing products. This model brings design exposure to the doorstep of industry clusters for design awareness, improvement, evaluation, analysis and design-related intervention. This scheme will assist industrial clusters to open a channel for design information inflow for creative, innovative and futuristic approach towards the product, process, operations, manufacturing and business design. The scheme will

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help generate insights for opportunity identification and design intervention for competitive and breakthrough solutions for MSMEs. For design awareness and intervention, the National Institute of Design (NID), Ahmedabad, will assist the Ministry of MSME, Government of India, as a nodal agency for implementing the scheme. The institute’s background of design education and industry projects will help in reaching to a majority of MSME clusters, with the help of designers and design institutions across the country. Representative of MSMEs, apex commerce bodies and government organisations (MSME institutions, district industry centres, state government bodies, etc) are also providing assistance in connecting with MSMEs in different parts of the country. The objective of design clinic scheme is to enhance industry competitiveness and productivity with the help of design intervention at various functional levels. The awareness about design among MSMEs is the key to adaptation of design methodology in the sector. This scheme is structured to provide designrelated assistance through design awareness seminars, a detailed design research to understand the cluster and remedial solutions through clinic workshops. Design projects would help MSMEs in various stages to develop competitiveness by involving design experts from the industry and working closely on products/processes/ communication in the business domain of the MSME unit.

Financial assistance The scheme provides financial assistance at different stages to reduce the risk of return on investment and eliminate hesitation of MSMEs to take up design for better product positioning. The scheme activities are divided into three stages for better understanding and implementation of design, keeping in mind the industrial context related to design initiatives of MSME units.

Design awareness seminar: The fund allotted for design awareness seminar will be up to `60,000 for one seminar, which is on reimbursement basis. Design awareness programme: The fund allotted to each design awareness programme is up to `4,00,000, of which 25 per cent (up to `1,00,000) will be contributed by the organising association through collection or member’s fund.

Design project: The design clinic programme shall support initial design work by reimbursing 60 per cent of the designer fee up to a maximum limit of `9,00,000 in case of a group with up to three MSME applicants. The design clinic programme shall support initial design work by reimbursing 60 per cent of the designer fee up to a maximum limit of `15,00,000 in case of a group of four or more MSME applicants. Funding assistance up to `2,00,000 (`150,000 from Government of India) shall be available for finalyear student projects done for the MSMEs. Therefore, the design clinic scheme is considered as one of the biggest design initiatives for the MSME sector in the country. The objective of Government of India to make manufacturing sector competitive through design initiative is visionary and foresightful and expected to change the industrial scenario in the coming years with the help of MSMEs and design expertise in the country. Jitendra Rajput, Co-ordinator, Design Clinic Scheme, National Institute of Design. He is a Mechanical Engineer and specialises in automotive industrial design. He is currently in-charge of implementation, scheme promotion, communication and coordination between Government, MSME representatives, apex commerce bodies and designers. Email: jitendra_s@nid.edu

Modern Packaging & Design May-June 2011


CURTAIN RAISER

Interpack 2011 Interpack will once again bring together the world’s best packaging experts and their innovations at Dusseldorf, Germany, from May 12-18, 2011. This is among the world’s most distinguished trade shows dedicated to the global packaging and converting industry. This edition of Interpack will seek to address the key concerns of the global packaging fraternity while also highlighting the surging potential within emerging economies.

Modern Packaging & Design May-June 2011

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CURTAIN RAISER

Leveraging today’s solutions for tomorrow’s needs With the packaging industry’s numero uno trade fair on the horizon, the global fraternity is keen on sharing this platform to address new challenges faced by the industry and reveal cutting-edge solutions for the same. In its 53rd edition, Interpack 2011 highlights the potential emerging economies and the role of packaging technology in these regions.

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n recent times, the fundamental role of a package has moved on to incorporate myriad functions, encompassing numerous applications and industries. This has not only made the global packaging market highly competitive and technology-driven but also entrusted the humble package with a great responsibility of poverty alleviation and mass distribution. Therefore, Interpack 2011 aims at a larger purpose of creating awareness in terms of anti-counterfeiting and recyclable features offered by packaging. To be hosted at Dusseldorf, from May 12-18, 2011, Interpack is one of the most distinguished trade shows for the global packaging business. Interpack has come to be recognised as the world’s leading business enabler for the packaging domain. However, considering the changing market dynamics and increased demands from In a nutshell

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What

Interpack 2011

When

May 12-18, 2011

Where

Dusseldorf, Germany

Organisers

Messe Dusseldorf

Net exhibition space

174,00 sq m

Exhibitors

2,700

Visitors

175,000

Countries

60

Official website

www.interpack.com

Contact source

interpack@messeduesseldorf.de

the packaging technology, it seems only apt that the theme at Interpack 2011 is safety, convenience and sustainability. This takes into account a steadily growing participation from developing countries, where packaging is considered to be impacting the social and economic landscape. Christian Traumann, President, Interpack 2011, states, “Demographic changes today determine the market potential of tomorrow. The global food & beverage industry is a growing market, as the worldwide expenditure on food products and beverages continues to expand. A major reason for this expansion is the demographic growth; by 2050, more than 9 billion people will be living on this planet, which is 30 per cent more than the number that lives today.” He points out, “Since the middle of the 20th century, population has grown almost exclusively in the developing and emerging countries. In the future, a majority of the population will be living in Asia. However, the highest growth in population will take place in Africa. In these regions, the young population will be significantly high in the years to come.” He continues, “At present, however, the per capita consumption of packaged food products in these regions is quite low due to lack of retail infrastructure. This is likely to change as demographic developments will increase the demand for new and packaged products in these regions. Today, the markets with the largest

Modern Packaging & Design May-June 2011


CURTAIN RAISER

Christian Traumann, President, Interpack 2011 On evolution of Interpack to become the most sought-after exhibition for the packaging industry… With packaging being an extremely dynamic sector, Interpack is the world’s leading platform where the latest innovations in packaging and associated process technologies can be experienced first hand. Our mission statement is ‘Anyone who wants to know what drives the market and what solutions are on offer around the world will attend Interpack’. Interpack was launched in Düsseldorf in March 1958, with 255 exhibiting companies from nine different nations. The show was spread across an exhibition area of 30,000 sq m. It was visited by 32,544 trade visitors from 42 countries. Ever since, Interpack has continuously built upon the needs and solutions of the packaging market. Whether it was mechanisation of the packaging process, introduction of automation or innovative packaging technologies, these developments were first presented to the market at Interpack. In 2008, Interpack celebrated its 50th anniversary, with 2,700 exhibitors and 171,000 visitors from 121 countries. Interpack 2011 will witness even more developments, with a large share of exhibition space being booked by companies that supply processing and packaging machinery as well as raw materials. The number of exhibitors from emerging countries has increased this year, and thus we expect a large number of visitors from these countries. On key highlights of Interpack 2011… Visitors at this edition of Interpack can expect a unique range of solutions, technologies and processes from exhibitors across the world. One of the highlights will be the ‘SAVE FOOD summit’, which will emphasise the role of individual elements of the value chain in terms of packaging, logistics and transport and how they can contribute to reducing global food wastage. It will reveal different reasons for global food loss, taking into consideration industrialised as well as emerging and developing countries. As a basis, the results of three in-depth studies done by the Food and Agriculture Organization will be presented for the first time. The summit will also present solutions and concepts on how the packaging industry can effectively reduce food wastage and contribute to a sustainable development. Also, the Metal Packaging Plaza will serve as a new meeting point for the international metals packaging fraternity and its supplier industries. Another major element of Interapck 2011 will be the Innovationparc, which has been an interactive concurrent programme since 2005. This programme is an established forum to encourage creative exchange between exhibitors and visitors. growth rates for packaged food are in Asia, Latin America and in the Middle East & Africa.”

Special themes With regard to safety functions, advent of smart packaging in the pharmaceutical, skincare and cosmetics industries have increased the importance of anti-counterfeiting measures & prevention of brand imitation. Interpack 2011 will witness the latest in Radio Frequency Identification (RFID) tagging and tamper-evident caps & closures technology. The second theme being convenience packaging, it is a major factor determining commercial viability of a package. Traumann

Modern Packaging & Design May-June 2011

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Dear Reader, ‘Modern Packaging & Design’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the packaging industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Modern Packaging & Design’. Authors whose articles are published will receive a complimentary copy of that particular issue and an honorarium cheque. Published by Infomedia 18 Ltd, ‘Modern Packaging & Design’ is the leading bi-monthly magazine exclusively for manufacturer and user fraternities of the packaging industry. Well supported by a pan-India readership of over 80,000 and our strong network of 26 branch offices across the subcontinent, this magazine reaches out to key decision makers among the manufacturers of products, machinery and allied segments. Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost. So get going and rush your articles, write-ups, etc… Look forward to hearing from you, soon! Yours sincerely,

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CURTAIN RAISER

consumption of resources. Considering this, Interpack 2011 will display the latest developments in energy-efficient production and packaging processes & equipment.”

A perfect blend Some of the leading names in the packaging business will be sharing their

knowledge and insights on breakthrough innovations at the event. Among the foremost exhibitors at this edition of Interpack are Dupont, Heidelberg, Huber, Schott, Krones, Stratmore, Seyfert, etc. Thus, Interpack 2011 is set to showcase a perfect blend of products and ideas, with an aim to ensure a flourishing packaging industry in the years to come.

avers, “There is a strong demand for ‘ready-to-go’ food and beverages, as time spent for food preparation and consumption is becoming a depleting resource. Small and single portion packages are very popular. In Europe, more than 100,000 new food products are being introduced to the market every year. This indicates a high diversity of products and package formats. Packaging machinery must not only keep up with this increasing variety, but also minimise downtimes for the change in the production lot.” Sustainability is a crucial index whereby industries and technologies measure their current success and draw future strategies. With the surging growth of flexible packaging, especially in the food packaging segment, Interpack 2011 will showcase lines processing energy-efficient from leading brands in the business. Traumann confirms, “Climate change, energy requirements and limited resources are the focal challenges at present. Packaging must thus be a sustainable operation, which optimally utilises all available resources. Today, manufacturers of consumer goods, packaging materials & machinery are developing innovative processes in order to continuously reduce

Modern Packaging & Design May-June 2011

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IN THE NEWS

GEPPIA to present innovations by French equipment manufacturers

GEPPIA, the French partnership for food and non-food processing and packaging machinery will participate at Interpack 2011. Its objective is to present innovative technologies and latest industrial and commercial products from leading French equipment manufacturers exhibiting at the tradeshow, and to provide comprehensive solutions to the global packaging industry. After five years of existence, GEPPIA has assembled nearly a hundred members and partners. It includes just about all equipment manufacturers specialised in the design and manufacture of packing machines and automated packaging lines, as well as part of the manufacturers making process machines and materials. GEPPIA will showcase high-tech innovations of about 30 of its members, who are all French equipment manufacturers specialising in the field of packaging. Some of the latest products to be displayed at the event include VersaFilm®, a new range of shrink-wrappers without sealing bar by CERMEX (SIDEL group). Another is Roll’n blow thermoforming machine, for production of bottles from a basic plastic sheet by the SERAC Group.

Beckhoff launches automated handling module Beckhoff will present its control technology for packaging machines at Interpack 2011. This is a highly dynamic handling solution for products and packaging in the food industry. The H 130 handling module combines high-tech mechanical engineering from MULTIVAC with state-of-the-art control technology from Beckhoff. The pick-and-place robot is based on TwinCAT automation software and EtherCAT as the fast communication system. The TwinCAT Kinematic software controls the highly dynamic pick-and-place robot for handling of packaging. The Food and Drug Administration (FDA)-compliant Beckhoff stainless steel operating panel and servomotors are specially designed for stringent hygiene requirements in the food industry. The H 130 handling module functions either as an autonomous pick-and-place robot, or it can be fully integrated into MULTIVAC’s automated packaging lines. It automates a wide range of handling tasks in packaging processes and is characterised by high speed and precision, fast convertibility and a consistent hygienic design.

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Oystar presents packaging machinery innovations Oystar will present one of its innovations at Interpack 2011, namely, an ergonomically designed HMI panel with future-oriented technology with which every Oystar machine will be equipped from now on. The panel standardises operations of all machines of the company through uniform hardware and software so that customers – no matter which Oystar machines they use for manufacturing – now only have to adhere to a single navigation concept. Handling of the panel is intuitive and is performed using a modern multi-touch system on widescreen displays (10-21 inches). Machine workflows and current messages are systematically displayed and recognised at one glance. The standard HMI can also be configured with optional widgets in order to satisfy individual customer requirements. Another exhibit that will be shown at Interpack 2011 is a universal rotary filling and sealing machine from OYSTAR Hassia India. The Ecocup 785 fills cups with a volume of up to 500 ml and can be used for a wide variety of products. This also enables quicker product changes.

Bottelpack® aseptic machines from Rommelag Rommelag will exhibit in a demonstration every hour a Bottelpack® 4010M aseptic machine for making unit dose eye drops. It will also display new high-voltage leak detector HVLD 926 for non-destructive leak testing of large-volume containers. Rommelag is the inventor of the Blow-Fill-Seal (BFS) Bottelpack® technology and can look back at its successful company history stretching over almost five decades. With this success, it has become a global market leader in over 80 countries. The company offers its customers a complete range of packaging solutions and services for filling liquids, gels and pastes. These are tailored to individual needs of the customers in terms of container design, production capacity, unit volumes and product development. These also include a first-class worldwide customer and spare part service along with the facility to carry out stability tests and contract filling. The flagship of the Rommelag company are the BFS Bottelpack® aseptic machines. The centrepiece is the sterile pyrogen-free container manufacture, aseptic filling of sterile products and hermetic sealing in one operation. Hourly outputs can reach 30,000 ampoules for container sizes from 0.1 ml to over 2,000 ml. An integrated US class 100 (ISO 3) clean room in the filling area is also offered with the machine.

Modern Packaging & Design May-June 2011


IN THE NEWS

New transparent and flexible biopolymer for blown film extrusion from FKuR FKuR has launched a new transparent, flexible biopolymer called Bio-Flex® F 2201 CL. This material has a high content of renewable resources and, in line with other resins in the BioFlex® family, can be processed easily on standard Low-Density Polyethylene (LDPE) blown film lines and converting equipment. With a renewable resource content of approximately 60 per cent, this grade is a consistent advancement of the Bio-Flex® family. Its mechanical properties exhibit high elongation and flexibility along with good puncture resistance. Bio-Flex® F 2201 CL can ideally be used to adjust the properties of all available Bio-Flex® family resins. Also, due to its good interplay strength, Bio-Flex® F 2201 CL is recommended to be used as a mid-layer in a co-extruded structure. Its mechanical properties make it the perfect partner for Bio-Flex® A 4100 CL in a transparent three-layer combination. The combination of these two transparent grades offers superb and unmatched clarity for a biodegradable blown film available today while maintaining a very high content of renewable resource material. This is about 60-80 per cent depending on the variation in polymers of the final structure.

Bericap to focus on weight savings at Interpack 2011 International closure manufacturer, Bericap will be displaying its range of proven products and new developments aimed at a variety of markets such as the beverage, food, automotive, chemical and agrochemical industries. This year’s spotlight falls on the subject of ‘Lightweight Design’. In the past, lighter closures were developed more for carbonated drinks and still water, but today greater attention is being given to the ongoing development of lighter packaging for aseptic filling and hot-filling processes. New developments have been launched for the food market, specifically for edible oil and squeezable products. Besides benefitting from cost-savings generated by using lighter closures, manufacturers are concerned for conserving non-renewable resources and reducing the greenhouse gas effect. The demand in technical applications is for closures that protect contents from counterfeiting. This is all the more important, as global players in the chemical industry need to protect their products against product piracy, particularly where these are manufactured in developing countries. With years of experience in one-piece closures for hot filling in Polyethylene Terephthalate (PET), Bericap has been a driving force in the development of lightweight closures, particularly in conjunction with weight-reduced bottlenecks.

Modern Packaging & Design May-June 2011

Canvironment Week set to raise sustainability awareness

Atit Bhatia

Canvironment Week 2011, the second in the series of the global event promoting sustainable and environmentfriendly cans, will be introduced at Interpack 2011. The launch is all set to receive a grand flag off by ringing the ‘Sustainability Bell’ by can makers, industry leaders and government bodies representing different countries present at both shows. This global initiative will be unveiled at the Metal Packaging Forum hosted by Empac, following a presentation by Atit Bhatia, Senior Vice President, Hindustan Tin Works Ltd (HTW), and President, Canvironment Week, where he will share his experiences and learnings filled with entertainment, art, film, fashion, etc from Canvironment Week 2010, as well as the vision for the initiative. Bhatia said, “We officially plan to flag off the proceedings for Canvironment Week 2011 by ringing the Sustainability Bell during Metpack and Interpack, which we believe would be the best platform to launch the second year for this global movement.” Canvironment Week was launched last year where a number of activities were executed for promoting sustainability through a global campaign. It is an initiative by HTW, and the first of its kind in the can making world to promote sustainability, where can makers from various countries conduct parallel activities, which are linked together under a global umbrella.

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EVENTS CALENDAR

National Rudrapur

Ahmedabad

Uttarakhand Sep 23-26, 2011 Gandhi Park

Gujarat Oct 14-17, 2011 Gujarat University Exhibition Hall

Pune

Maharashtra Nov 18-21, 2011 Auto Cluster Exhibition Centre, Pimpri-Chinchwad

Chennai Tamil Nadu Dec 16-19, 2011 Chennai Trade Centre, Nandambakkam

Indore

Madhya Pradesh Jan 6-9, 2012 Poddar Plaza, Nr Gandhi Hall

Aurangabad Maharashtra Feb 17-20, 2012 Garware Stadium, Chikkalthana

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details contact: Infomedia 18 Ltd, Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: engexpo@infomedia18.in

PackPlus South 2011

The total packaging, processing and supply chain event with display of packaging machines and equipment like coding and on-line printing machines, foiling, capsuling, feeding & labelling machines, packaging containers, packaging materials, software, etc; July 1-4, 2011; HITEX Exhibition Centre, Hyderabad For details contact: Neetu Arora Print-Packaging.com Pvt Ltd F 101, Tower No 7 1st Floor, International Infotech Park, Vashi Navi Mumbai 400 705 Tel: 022-27812093, 022-27812619 Fax: 022-27812578 Website: www.packplussouth.in

Food & Technology Expo 2011

An international exhibition focussing on food processing & packaging machines & technologies; July 29-31, 2011; at Pragati Maidan, New Delhi For details contact: Anil Rana NNS Events & Exhibitions Pvt Ltd Meri Delhi House 25/10, East Punjabi Bagh New Delhi 110 026 Mob: 098102 13597 Email: anilrana_ars@yahoo.co.in

Compack Expo 2011

The Comprehensive Packaging Expo (COMPACK) is recognized as a trusted base for various manufacturers of packaging machines, materials, logistics providers and end users. This three day event will prove to be a major hub

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for expanding business network; August 5-7, 2011; at Chennai Trade & Convention Centre, Chennai For details contact: Smart Expos T-6, Agarwal Court - K G Plaza, 41-44 General Patters Road Chennai - 600 002 Tel: 044-2860 4087/2860 3086 Fax: 044-28604261 Email: info@smartexpos.in Website: www.smartexpos.in

IPEX South Asia 2011

Printing is among the most crucial aspects of the packaging industry. This is among the leading printing industry trade shows that will showcase a wide rage of digital presses and printing-converting solutions of today’s packaging demands; September 16-19, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Guru Prasath IIR Exhibitions India 751/ 5th Floor Solitaire Corporate Park Andheri Kurla Road Chakala, Andheri (E) Mumbai - 400 093 Tel: +91 22 4020 3329 Fax: +91 22 4026 3000 Email: guru.prasath@informa.in Website: www.ipexsouthasia.com

India Converting Show 2011

This will be a platform to showcase the latest converting solutions in through advanced machinery and best-in-class practices. The

concurrent India Flexo Show and India Corrugated Show will offer a further insight into the strategic moves required by the Indian industry in order to keep pace with the global market trends; November 23-26, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Neetu Arora Print-Packaging.com F 101, Tower No 7, First Floor International Infotech Park Vashi - 400 705 Tel: 022-27812093/27812619 Fax: 022-27812578 Email: info@packplus.in Website: www.indiaconvertingshow.com

India Packaging Show 2011

Among India’s most exhaustive packaging events, this brings together seven established niche shows dedicated to distinct segments. The show aims to bring together the worldwide manufacturers and providers of machinery, materials and services for food, pharmaceuticals and packaging industry from India and neighbouring countries; December 7 - 10, 2011; at NSIC Exhibition Centre, Okhla Industrial Estate, New Delhi For details contact: Prateek Kaushik Print-Packaging.com Advant Navis Unit No A1101B Noida-201301, Uttar Pradesh Tel: 0120-3075400 – 04 Fax: 91-22-27812578, Mob: 09899981610 Email: info@packplus.in Website: www.indiapackagingshow.com

Modern Packaging & Design May-June 2011


EVENTS CALENDAR

International PrintEx11

This is Australia’s premier print and design exhibition dedicated to the graphic arts and communications industries. Staged every four years in Sydney since 1999, this trade-only event provides an unparalleled opportunity for networking in a dynamic and interactive business environment for a competitive edge; May 4 – 6, 2011; Sydney Convention & Exhibition Centre, Darling Harbour, Sydney, Australia For details contact: Guy Freebody Reed Exhibitions - Australia Locked Bag 7888 Chatswood DC NSW 2067, Australia Tel: 02 9422 2568, Fax: 02 9993 8342 Email: guy.freebody@ reedexhibitions.com.au Website: www.printex.net.au

ecoPack systems 2011

For details contact: Messe Düsseldorf GmbH Postbox 10 10 06 D-40001 Düsseldorf Germany Tel: +49 (0)211 4560-01 Email: interpack@messe-duesseldorf.de Website: www.interpack.com

Propac Arabia

This is the ideal place to get acquainted with Saudi Arabia’s packaging sector where potential buyers can source and select the best packaging solutions that meet their particular needs. It will also provide a perfect gateway for international and domestic suppliers to capitalise on excellent growth and business opportunities and an exhaustive range of cutting-edge technology; May 29 - June 01, 2011; at Jeddah Centre for Forums & Events, Saudi Arabia

This conference is a new and exclusive platform for sustainable innovations from the plastic packaging and machinery industry. This event will see more than 200 practitioners from beverage, food, cosmetic and pharmaceutical market in Europe engage actively in discussions on current topics, on May 10-11, 2011; at Maritim Hotel Düsseldorf, Germany

For details contact: Al-Harithy Company PO Box 40740 Jeddah 21511 Saudi Arabia Tel: +966 (0)2 654 6384 Fax: +966 (0)2 654 6853 E-mail: ace@acexpos.com Website: www.acexpos.com

For details contact: PETnology/tecPET GmbH PO Box 120 429 D-93026 Regensburg, Germany Tel: +49 941 870 2374 Email: ecoPack-systems2011@ petnology.com Website: www.ecopack-conference.com

Korea Pack 2011

Interpack 2011

This is among Europe’s leading convention zones for the latest technology and concepts in packaging. With sustainability and safety as its key features, this exhibition-cum-conference will highlight cutting-edge machinery and processing lines for all major enduser industries like food 7 beverage, cosmetics, pharmaceuticals; May 12-18, 2011; at Dusseldorf Exhibition Centre, Dusseldorf, Germany

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This is an important exhibition for processors and convertors seeking to explore the innovations and technologies of the Far East. The key strength of this show has always been high-speed packaging lines aimed at zero-error and lower consumption; June 14 - 17, 2011; at Korea International Exhibition Centre, Gyeonggi-do, South Korea For details contact: Kyungyon Exhibiton Corporation Rm. 501, Kumsan Building 17-1, Yoido-dong Youngdeungpo-gu, Seoul, South Korea Tel: +82 (02) 785-4771 Fax: +82 (02) 785-6117/8 Email: sara@kyungyon.co.kr Website: eng.koreapack.org

ProPak Asia 2011

This is among Asia’s largest event for international manufacturers and suppliers of machinery, technology and materials in the sectors of packaging, filling, processing, quality assurance, test and measurement and the related fields of automation, transportation, storage, refrigeration, ingredients, labelling and pollution control; June 15-18, 2011; at Bangkok International Trade & Exhibition Centre, Thailand For details contact: Piyaporn Lertpongsopon Bangkok Exhibition Services Ltd (BES) SPE Tower 9th Floor 252 Phaholyothin Road Samsennai, Phyathai Bangkok 10400 Tel: (+66) 02 615 1255 Fax: (+66) 02 615 2991 Email: Piyaporn@besallworld.com Website: www.propakasia.com

Taipei Pack

This exhibition will draw together professionals from the packaging industry to bring unparalleled information and innovation to the regions’ surging converting machinery market. The show will focus on end-applications industries to promote and facilitate wider networking among leaders and decision-makers in the global packaging fraternity; June 22 - 25, 2011; at Taipei World Trade Centre, Taipei, Taiwan For details contact: Barbara Kao TAITRA (Taiwan External Trade Development Council) 333 Keelung Road Section 1, 5-7 Floor, Taipei 11003, Taiwan Tel: +886 (2) 2725-5200 Fax: +886 (2) 2757-6245 Email: tppack@taitra.org.tw Website: www.taipeipack.com.tw The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of ���������������������������������������������

Modern Packaging & Design May-June 2011


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: Sandeep Nema and John D Ludwig : ` 11,250

Adhesion and Adhesives Technology: An introduction 2nd Edition Editor : Alphonsus V Pocius Price : ` 6,000

This volume presents a historical perspective of injectable drug therapy, common routes of administration, and biopharmaceutics of NCEs & NBEs; an in-depth discussion on the preformulation & formulation of small & large molecules, including ophthalmic dosage forms; a presentation of parenteral primary packaging options – glass & plastic containers, as well as elastomeric closures; a definitive chapter on container-closure integrity; and new chapters on solubility & solubilisation, formulation of depot delivery systems and biophysical/biochemical characterisation of proteins. First published in 1984 (as two volumes), and last revised in 1993 (when it grew to three volumes), this latest revision addresses the plethora of changes in science, and the considerable advances in the technology associated with these products & routes of administration. The third edition of this book maintains the features that made the last edition popular, but comprises several brand new chapters, revisions to all other chapters, as well as high-quality illustrations. The three-volume set of Pharmaceutical Dosage Forms: Parenteral Medications, is an authoritative, comprehensive reference work on the formulation and manufacturing of parenteral dosage forms, effectively balancing theoretical considerations with the practical aspects of their development. As such, it is recommended for scientists and engineers in the pharmaceutical industry & academia, and will also serve as an excellent reference & training tool for regulatory scientists and quality assurance professionals.

The revised edition of this popular introductory text on adhesion science and adhesives technology focusses on the underlying fundamentals of three major disciplines of this field – adhesive bond mechanics, adhesives chemistry and surface science. The book includes several helpful practical suggestions about how measurements can be made, how surfaces can be modified and how adhesives can be formulated to lead to a useful result. The second edition adds a set of practical problems to most of the chapters. The book is intended to be a ‘first text’ on adhesion science and adhesives technology. The aim of this book is to provide the reader with the fundamentals of each of the three disciplines, as these are important for those who practice this joining technology. The text also includes a number of helpful tips on how to test adhesives, prepare surfaces for bonding as well as general guidelines on the formulation of adhesives. This book is targeted at an audience with some knowledge of college level chemistry and physics. It will be particularly useful for scientists who are studying beginninglevel adhesion science. The breadth of information provided will be indispensable to practicing adhesiologists as well.

Available at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 Tel: 022-2207 4484/6631 8958 • Telefax: 022-2203 4058 • Email: thadam@vsnl.com

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Modern Packaging & Design May-June 2011


PRODUCT UPDATE

This section provides information about the national and international products available in the market

Powder filling machine

Vacuum packaging machine Ace Technologies offers semiautomatic powder filling machine. This is suitable for all powders and granules. The machine has high filling accuracy due to unique design feature. Wide table design helps accommodate more containers. It requires minimum change parts. All contact parts are of SS 316. Microprocessor-based control, zero dripping, and accurate slippage control are other important features.

Ace Technologies Mumbai - Maharashtra Tel: 022-2854 0743/0645 Fax: 022-2870 0281 Email: acetechnologies@vsnl.com

Plate making machine Innovative Flexotech offers photopolymer plate making machine for pharmaceutical batch printing. It performs exposure, washout, drying and treatment in complete functions. The exposure unit comes with instant light-up Philips high-intensity lamps, unique digital timers for back/main exposure, good quality lamps cooling/ exhausting system and quick vacuum draw-down pump with an indicator. The features of washout unit include: easy access design, special bristle good for all kinds of plates washout, suitable for Perc+NBA & green chemicals and good result for 175 LPI one per cent reproduction. Drying unit comes with features such as drying drawer with uniform heat distribution, temperature adjustable by a precise controller, unique air circulation and exhaustion design and over-heat sensor for safety and protection. Features of treatment unit are: chemical-free operation, digital timer for light finishing control and Philips UVC high-intensity lamps equipped with powerful air exhausting for large size models. Innovative Flexotech Pvt Ltd Ahmedabad - Gujarat Tel: 079-2685 2439 Email: info@flexo.co.in

68

Monarch Appliances offers vacuum packaging machine, which is used to pack food products. Vacuum packaging increases the shelf-life of products. The machine vacuums the product along with the shape of the product that comes out with the pack. The advantage of this chamber machine is that even the space surrounding the product outside the package is vacuumed. These chamber machines can also be used to pack products with a modified atmosphere. Very low residual oxygen figures can be obtained by first pulling a vacuum before the injection of gas. Vacuum packaging machine is useful for packing cheese, meat, fish, dairy products, peanuts, dry fruits, sea foods, coffee beans, pillows, PCBs, spices, instant food, bakery products, chemicals, electric components and pharma products. Monarch Appliances Rajkot - Gujarat Tel: 0281-246 1826, Fax: 0281-301 9788 Mob: 098252 15733, 093767 77277 Email: monarchrajkot@gmail.com

Horizontal flow wrapping machine Bosch Packaging Technology India offers for the horizontal flow wrapping machine Pack 201. This mid-range speed machine is easy to maintain and is designed for delicate product handling. It is ideal for wrapping bakery goods, trays, candy bars, wafers and non-food products. Easy format changes for packaging various sized products are made possible through the adjustable folding box, allowing for maximum machine efficiency and improved package quality. The simple and smart design incorporates minimal parts to increase reliability, streamline maintenance and allow for greater adaptability. All data is stored on a flash card. The on-board UPS protects data in case of power loss. The logical structure and the use of graphics simplify the use of the operator screen. The screen displays parameter entry, errors and production statistics. The Pack 201 is available in full stainless steel, it ensures a long lifecycle while safeguarding against leakage, spoilage, cleaning and humid environment. Bosch Ltd (Packaging Technology Division) Verna - Goa Tel: 0832-669 2042, Fax: 0832-669 2028 Mob: 091588 81011 Email: boschpackaging@in.bosch.com

Modern Packaging & Design May-June 2011


PRODUCT UPDATE

On-line digital printing technology M&M Technologies offers on-line digital printing technology. It provides the printers with high-resolution Piezo ink-jet technology, thereby offering the packaging industry the most efficient and state-of-the-art technology in terms of hardware, software, accessories and consumables. In terms of application, it is the most cost-effective modern technology used for marking, printing and also helps in traceability. This is very user-friendly, robust and compact. The simplified operation at each level of production process is versatility in application software to design, logos, text, barcodes (1-D and 2-D barcodes, QR codes), variable and fixed data field, option for multi-colour printing, standalone or network printing. Low maintenance and easy operability makes the system more user-friendly. Printing can be done on coated or uncoated corrugated boxes, aluminium foil, glass, metal for address printing, pharmaceutical primary, secondary package printing and even on pallets. This system can also be linked into multi-plant and multilocation with wi-fi and Internet connection. M&M Technologies Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-2778 1580 Email: mp@mmtechnologiesindia.com

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PRODUCT UPDATE

Photoelectric gap sensor Lubi Electronics offers ‘Sunx’ RT-610 series photoelectric gap sensor. It is ideal for gap sensing, mark sensing and address reading. In this sensor, the beam axis alignment is not required, as the emitter and receiver are integrated in a single body. It has a sensing range of 10 mm, 20 mm and 50 mm. The models with a sensing range of 10 mm and 20 mm are available in red LED type and green LED type for mark sensing. This sensor provides high reliability, as the housing material is made of die-cast aluminium. It can be used effectively in typical applications such as packaging, pharma and machine tools industry. Lubi Electronics Ahmedabad - Gujarat Tel: 079-2220 5471 Fax: 079-2220 0660 Mob: 093274 97006 Email: info@lubielectronics.com

Plastic brightner/shiner Plast Fine Polymers offers plastic brightners/shiners/ whitener for natural transparent, colours and milky white endproducts. This is used for adding clarity and gloss finish to natural transparent polymers. It gives shining and bright finish colours to end products. This brightner/whitener removes yellowness and dullness from the end-products and makes them super milky white. This product is used in virgin, second, dull natural or milky white sutli, ropes, twine, reprocess granules, HDPE-LDPE-PVC pipes & profiles, box strap, PET jars, spoon, container, carry bags, liners, sheet, yarns and other end-products. A main advantage of this product is that it saves excess use of white pigments and titanium dioxide for opaque end-products. Plast Fine Polymers Ahmedabad - Gujarat Tel: 079-6524 2332 Mob: 098255 87152 Email: plastfine@indiatimes.com

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Modern Packaging & Design May-June 2011


PRODUCT UPDATE

Digital colour mark sensor Lubi Electronics offers ‘Sunx’ LX-100 series digital colour mark sensor. This can detect any marking because the sensor is equipped with red, green and blue LED element. In order to expand the functionality, the sensor comes with dual mode, ie, mark mode (ultra high-speed response) & colour mode (high-precision mark colour discrimination) to suit any application. This sensor comes with Mode Navi technology for enhancing features and is easy to use. It is provided with a four-digit digital display, 12-bit A/D converter, D-code, key lock, timer, NPN or PNP outputs, IP67 protection, etc. It is used in many applications/industries, especially in packaging, food, pharmaceuticals, textile, plastic & many more. Lubi Electronics Ahmedabad - Gujarat Tel: 079-2220 547 Fax: 079-2220 0660 Mob: 093274 97006 Email: info@lubielectronics.com

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PRODUCT UPDATE

Auger filler Saurabh Flexipack Systems offers Smart-EX auger filler. This vertical form-fill-seal machine is cost-effective and designed for entrepreneur, mid-scale and large-scale manufacturers. It requires very little floor space. The machine is intelligent, PLC-controlled, with pneumatic operations. It is suitable for packaging pouches of size in the range of 0.5-500 g, with good speed and weight precision. The machine is good for free-flowing fine powders like turmeric, mehandi, besan, atta, talcum powder, ground spices, herbal powder and all kinds of fine powders. Specifications of the machine include: filling capacity 0.5-500 g, filling speed 1,000-4,000 pouches/hr, PLC control, pneumatic mode of operation, weighing accuracy 0.5 per cent of set volume, weight of the machine 50 kg (approximate), dimension can be 1,000 x 950 x 2,450 (approximate), power requirement 220 V singlephase or 420 V three-phase, and compressed air requirement 6 CFM with pressure 6 bar. The machine is available in a variety of models: 0.5-10 g, 5-50 g, 10-100 g, 50-250 g and 100-500 g. Packaging material used are laminated films. Saurabh Flexipack Systems Pvt Ltd Pune - Maharashtra Tel: 020-2749 2722, Fax: 020-2749 1347 Email: saurabhpackaging@hotmail.com

Vertical form-fill-seal machine Wraptech Machines offers high-speed vertical form-fill-seal machine for producing centre-sealed pouches handling all types of free-flowing/nonfree-flowing powders/granules/solids. The machine handles a single-reel film stock of maximum reel diameter 530 mm on 76 mm core. The machine has the facility to be provided with a variety of filling heads. Draw down of the film is through vacuum pressed draw-down belts, controlled through a servo-motor drive. The length of the bag is controlled by print registration system, which is PLC-based. For unprinted film, the bag length can be adjusted from a single-touch keypad provided on the front panel. Filling range of the machine is 25-2,000 g depending on bulk density of products & fill weight that the maximum pouch size can accommodate. Output can be up to 120-140 packs/min depending on product flow properties, pack size, type, quality and thickness of laminate being used. Wraptech Machines Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-2787 1743, Fax: 022-2761 2807 Email: marketing@wrapmachines.com

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Modern Packaging & Design May-June 2011


PRODUCT UPDATE

Digital paper moisture meter Cole-Parmer India offers the ‘Delmhorst P-2000’ digital paper moisture meter. This electrical resistance-type moisture meter comes with three separate scales: paper, baled scrap paper and reference. The moisture scale range for paper is 4.3-18 per cent, for baled paper the range is 5-40 per cent, and for the reference scale it is 0-100 per cent. The meter measures through built-in pins and optional pin electrodes. The contact pins mounted on top of the meter provide 0.8 cm (5/16’’) penetration for testing paper tubes or corrugated stock. The meter also features an audible out-of-range alarm, internal calibration check, 100 data point memory, and average/ maximum readings. This meter is provided with a 9V battery and hard plastic carry case. Optional and replacement electrodes & accessories are also available. The paper moisture meter is ideal for testing paper materials such as paperboard, corrugated stock and paper tubes. Hence, it finds applications in the print & paper, packaging, food & beverage and manufacturing industries. Cole-Parmer India Mumbai - Maharashtra Tel: 022-6716 2222, Fax: 022-6716 2211 Email: response@coleparmer.in

Modern Packaging & Design May-June 2011

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PRODUCT UPDATE

Vibratory bowl feeder Elscint Automation offers a special vibratory bowl feeder for large caps having diameter of more than 100 mm. Plastic caps require feeding for automatic capping machines as well as other special pharmaceutical and consumer goods feeding machines. These caps have to be oriented in one direction, which can either be open side facing sky, open side facing ground or even the open side facing centre of the bowl or away from it. The feed rate achievable in case of such large caps is about 60-80 caps/min depending on the size of the plastic cap. As most of the caps come out in ‘open side facing sky’ orientation, they need to be twisted to change the orientation to ‘open side facing ground’. A versatile tooling along with feeder can twist caps of any diameter in 180o or as required. Elscint Automation Pune - Maharashtra Tel: 020-2712 2059 Fax: 020-2712 2994 Email: sales@elscintautomation.com

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Modern Packaging & Design May-June 2011


PRODUCT UPDATE

Rotary coder Bhavmark Systems offers RM-2 , a compact rotary coder with instant dry thermo fusible ink. This coder can print date, batch number, price and other information. It is applicable to most soft and flexible packaging materials, eg, cellophane, PP, PE, aluminium, cardboard, etc. Maximum speed can be up to 35 m/min and maximum printing area 30 x 35 mm. It is easy to install on all types of continuous motion packaging machines such as flow pack units and form-fill-seal machines. Important features include: driven by high-speed stepping motor, self-test, quick configuration, automatic temperature control, LED display, and quick replacement of modules. Bhavmark Systems Thane - Maharashtra Tel: 022-2819 8722, Fax: 022-2818 0455 Email: sales@bhavmark.com The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of ���������������������������������������������

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PRODUCT INDEX

To know more about the products in this magazine, refer to our ‘Product Index’ or write to us at spedit@infomedia18.in or call us at +91-22-3003 4684 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better. Sl No Product

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

Pg No

Acrylic bending machine ................ 47 Air cooled sealer................................ 43 Ammonia liquid chiller ......................... 2 Auger filler......................................... 72 Batteries ........................................... 5 Battery charger .................................. 63 Bearing ............................................. 65 Beer filling line................................... 57 Belt scale........................................... 67 Beverage filling line............................ 57 Blade bending machine...................... 47 Bottle unscrambler ......................... FIC-A Brake pad ........................................... 5 Brewing technology ........................... 59 Bulk milk cooler................................... 2 Butterfly valve ...................................... 2 Cable carrier .................................. 65 Cable connector ................................ 65 Capping machine .......................... FIC-A Cartoning machine ........................ FIC-A Case erector.................................. FIC-A Case packer ............................FIC-A, 67 Case sealer ................................... FIC-A Chain................................................ 65 Check weigher................................... 67 Checkrod less loadcell ....................... 67 Clutch plates & cover assemblies .......... 5 Coating laminating machine............... 71 Cold-aseptic filling technology ............ 59 Connector ......................................... 65 Contrast/colour scanner ....................... 9 Conveyer belt .................................... 71 Conveyor....................................... FIC-A Conveyor system ................................ 77 Conveyor technology.......................... 59 Counters & power supplies ................ FIC Cutting machine ................................ 47 Cylindrical sensor................................. 9 Dairy machine.................................. 2 Digital colour mark sensor.................. 71 Digital indicator ................................. 67 Digital paper moisture meter .............. 77 Digital platform scale ......................... 67 Digital temperature controller.............. 39 Digital universal scale......................... 67 Double sheet monitoring system............ 9 Drive ..........................................39, BIC Drives & automation .......................... 63 Dual channel with modbus ................. 39 Dynamic controller ............................. 39 Embedded system .......................... 63 Encoder............................................ FIC Exhibition- Complete Packaging Expo.. 82 Exhibition- Packplus South 2011 ......... 80 Expanded polyethylene capseal....... FIC-B Extrusion laminating machine.............. 71 Fastback revolution seasoning system ........................... 77 Fibreoptic amplifier .............................. 9 Filling and closing technology............. 59

Sl No Product

60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117

Pg No

Filling machine .............................. FIC-A Filter.................................................... 5 Flow wrapping machine ................. FIC-A Forked photoelectric sensor .................. 9 Gasket .......................................FIC-B Gasoline system................................... 5 Gear pump ......................................... 5 Gripper ............................................. 51 Heater controller ............................ 63 High capacity bag palletiser ............... 27 Horizontal flow wrapping machine ...... 68 Horizontal form-fill-seal machine..... FIC-A Horizontal form-fill-sealpackaging machine............................ 17 Horn ................................................... 5 Hot melt coating machine .................... 1 Hot melt laminating machine................ 1 Induction sealing............................ 43 Inductive switches................................. 9 Industrial automation..................... 31,69 Industrial control & sensing device ..... FIC Inspection & monitoring technology..... 59 Inspection & testing device.................. 67 Inspection machine ............................ 71 Intralogistic ........................................ 59 Inverter.............................................. 63 Invertor/variable frequency drive ........ FIC Labeling technology .......................BC Labelling & dressing technology .......... 59 Labelling machine .......................... FIC-A Laminating machine ................... 1,13,71 Level controller.................................. FIC Lighting ............................................... 5 Liner.............................................. FIC-B Loadcell & indicator ........................... 67 Lubricant ............................................. 5 Measuring & monitoring relay ...... FIC Measuring sensor................................. 9 Metal detector ................................... 67 Mini sensor.......................................... 9 Motion control system ....................... FIC Multihead scale ................................. 67 Non-woven laminating machine....... 1 Online B2B marketplace.............. 7,83 On-line digital printing technology ...... 69 Overwrapping machine .................. FIC-A Packaging and palletising technology..................... 59 Palletising robots ................................ 27 Photoelectric gap sensor..................... 70 Photoelectric sensor........................... FIC Plastic brightner/shiner ....................... 70 Plate heat exchanger............................ 2 Plate making machine ........................ 68 Platen hot melt machine....................... 1 PLC................................................... 39 Plug valve............................................ 2 Pneumatic valve ................................... 2 Pneumatics & hydraulics cylinder ......... 51 Pressure regulator .............................. 51

Sl No Product

118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176

Pg No

Process tank......................................... 2 Process technology ............................. 59 Product handling equipment ............... 77 Profile controller................................. 39 Programmable logic controller ........... FIC Programmable terminal ..................... FIC Proximity sensor ................................ FIC Powder filling machine ....................... 68 Rail tanker........................................ 2 Railway product ................................. 63 Refrigerant pump ................................. 2 Refrigeration ........................................ 2 Relay ................................................... 5 RFID................................................. FIC Rinser and pasteuriser ........................ 59 Robotic palletiser............................ FIC-A Rotary coder ...................................... 81 Rotogravure coating machine ............. 71 Rotogravure printing machine ............. 71 Safety light curtain ........................ FIC Screw compressor ................................ 2 Sealer................................................ 43 Self-adhesive tapes............................. 69 Shrin wrapping machine ................. FIC-A Shrink bundler ............................... FIC-A Shrink film ................................BC,FIC-A Shrink film packaging machine ........... 27 Shrink sleeve applicator.................. FIC-A Skin wrapping machine ...................... BC Slitting machine ................................. 71 SME loan .......................................... 21 Solar power ....................................... 63 Solenoid valve ................................... 51 Solventless laminating machine ............. 1 Spark plug........................................... 5 Starter motor ....................................... 5 Stretch blow-moulding technology....... 59 Stretch film packaging machine .......... 27 Stretch wrapping machine................... 27 Switching relay.................................. FIC System weigher .................................. 67 Systems engineering ........................... 59 Tanks & silos .................................... 2 Temperature controller.................. FIC,39 Thermoforming machine................. FIC-A Timer................................................ FIC Tire balancer ..................................... 67 Tray sealing machine...................... FIC-A Ultrasonic sensor.............................. 9 Universal controller ............................ 39 UPS................................................... 63 Utility support equipment .................... 63 Vacuum packaging machine........... 68 Ventilator ........................................... 69 Vertical form-fill-seal machine ...FIC-A, 72 Vibratory bowl feeder ......................... 78 Vision sensor .................................... FIC Washer........................................... 59 Wiper blade......................................... 5

FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

Modern Packaging & Design May-June 2011

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ADVERTISERS’ LIST Advertiser’s Name & Contact Details Beumer Group Gmbh & Co. Kg

Pg No 27

31

BIC

13

T: +86-579-8205-0435 E: bori@bori.cc W: www.bori.cc

T: +91-80-22999269

51

E: info@camozzi-india.com

Krones AG

11

FIC A

59

21

T: +91-22-26541803

Smart Expos

Sreelakshmi Traders 9

T: +91-44-24343343 E: sreelakshmitraders@gmail.com

E: manish.sahay@leuze.in

W: www.sreelakshmitraders.com

W: www.cgtmse.in

T: +91-79-26870825

Ultraplast Chainbelts Pvt Ltd 39

E: info@ultraplast.in

E: info@mifasystems.com

W: www.ultraplastindia.com

W: www.mifasystems.com

Vora Packaging Pvt Ltd

Nanjing Lehui Light Industry Equipment Co., Ltd

W: www.enerconaciapacific.com

T: +86-25-5273-3625

E: pankaj@vorapack.com

Heat And Control

E: haze.strategy@lehui.com

W: www.vorapack.com

77

Network 18 Ltd

T: +91-79-23827180

Nichrome Ltd T: +91-20-66011001

T: +886-4-2359-9850

17

W: www.welead.com Yamato Scale Co Ltd

E: contact@hirel,net

E: marketing@nichrome.com

T: +81-78-9185567

W: www.hirel.net

W: www.nichrome.com

W: www.yamato-scale.co.jp

Our consistent advertisers

67

FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

������������������������������������� 84

71

E: welead@ms17.hinet.net

W: www.ita.moneycontrol.com

63

FIC B

T: +91-22-24012330

Worldly Industrial Co., Ltd. 79

T: +1800-103-5311

W: www.heatandcontrol.com

Hi-Rel Electronics Pvt Ltd

57

W: www.lehui.com

E: info@heatandcontrol.com

71

T: +91-129-4113187

E: skumar@enerconmail.com

T: +91-44-42103950

69

T: +91-80-40854444

Mifa Systems

T: +09600344430

E: compack@smartexpos.in

W: www.smartexpos.in

W: www.leuze.in

43

82

T: +91-44-28603086

69

T: +91-22-27781580

E: cvkdprabhu@cgtmse.in

1

E: huadi@huadi.us W: www.shhuadi.com

M+V Marketing - Leuze Electronic

W: www.clearpack.com

W: www.dasesing.com

E: info@krones.com

W: www.mmtechnologiesindia.com

E: anthony@in.clearpack.com

T: +86-21-3365-8333

T: +49-9401-700

M & M Technologies Pvt Ltd

BC

T: +86-21-5779-4228

E: mkp@mmtechnlogiesindia.com

T: +91-22-42532222

Shanghai Dase-Sing Packaging Technology Co., Ltd

Shanghai Huadi Machinery Co., Ltd

W: www.krones.com

W: www.camozzi.com

E: info@packplus.in

E: leo@dasesing.com

W: www.khs.com/india

T: +91-120-4055252

Enercon Asia Pacific Iss Pvt Ltd

47

E: partho.ghose@khsindia.com

W: www.boschindia.com

Credit Guarantee Fund Trust For Mic

W: www.indiamart.com

E: keith@del3.vsnl.net.in KHS Machinery Pvt. Ltd

80

W: www.packplussouth.in

T: +91-79-2644-0331

E: sanjay.chakravarty@in.bosch.com

Clearpack India Pvt Ltd

7, 83

T: +91-11-46157777

5

W: www.omron-ap.com

T: +91-22-27812093

E: pr@indiamart.com

Keith Electronics Pvt Ltd

FIC

Print Packaging.Com Pvt Ltd

T: +1800-200-4444

W: www.bonfiglioliindia.com

Camozzi India Pvt Ltd

65

E: info@igus.in

W: www.igus.in IndiaMART InterMESH Limited

Omron Automation Pvt Ltd

Pg No

E: in_enquiry@ap.omron.com

T: +91-80-39127800

T: +91-44-24781035 E: sales@bonfiglioliin.com

Bosch Limited

Igus India Pvt Ltd

Advertiser’s Name & Contact Details

T: +91-80-40726400

W: www.idmc.coop

W: www.bharatbijlee.com

Bori Machinery Imp.& Exp.Corp

2

E: idmc@idmc.coop

E: vishwajyoti.vengurlekar@bharatbijlee.com

Bonfiglioli Transmissions (Pvt) Ltd

IDMC Limited

Pg No

T: +91-2692-225399

T: +49-2521-240 E: vt@beumer.com W: www.beumer.com

Bharat Bijlee Ltd

Advertiser’s Name & Contact Details

www.engg-expo.com

Modern Packaging & Design May-June 2011



Modern Packaging & Design - May-June 2011