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Modern Packaging & Design

July-August 2013


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EDITORIAL

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Redefining the packaging paradigm

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he footprint of packaging is clearly visible across an array of applications. Packaging not only serves the basic purpose of protecting its content but also adds value in multiple ways from the factory floor to the end user. As the dual impact of technology and innovation propels packaging on a continued basis, the coming days are likely to witness its greater penetration in consumer and industrial spheres alike.

Anniversary

As per recently published information, the $ 24.6 billion Indian packaging industry comprises 22,000 companies with value offerings ranging from raw materials to machinery and ancillaries. Significantly, almost 85 per cent of the above units belong to the Micro, Small and Medium Enterprises (MSMEs) category.

While India is the sixth largest packaging market worldwide, the per capita consumption of packaging in the country still figures at the bottom of the list with only 4.3 kg per person per annum, as compared with Germany’s 42 kg and Taiwan’s 20 kg. That said, the Indian packaging sector today stands at the cusp of a gigantic growth wave, owing to the increased demand for flexible packaging mainly from the food and pharma industries as well as the increase in breadth and depth of consumer goods. Added to this, various measures by the government to allow FDI in multi-brand retail will be a harbinger of many emerging opportunities for the packaging industry in India. At the same time, the current challenges facing this highly fragmented industry include the need for regulatory clarity in packaging, raising consumer awareness towards sustainable packaging and emphasis on green packaging materials.

Amid such rapidly evolving industry trends, welcome to the 8th Anniversary Edition of Modern Packaging & Design! This special edition not only reflects on the fast-evolving Indian packaging sector but also envisions a path forward and takes this discussion to the next level of engagement among various stakeholders.

Editorial Advisory Board P V Narayanan Member of Board APEDA (Ministry of Commerce)

M K Banerjee Director-Creativity & Innovations (Global) Essel Propack Ltd

R Krishnamurthy

Themed ‘Breaking packaging stereotypes’, this Anniversary Special brings forth eight important areas that promise strategic impact in enabling the sector to leap into the next orbit. Here’s a quick glance of the spectrum – raw material, machinery, processes, quality & security, supply chain, design innovation, printing & graphics and types of packaging. All of these eight sections provide focussed information on emerging challenges and opportunities that we believe will empower you to successfully make the impending transition and add miles to your success journey. Have a good read and share with us your valuable feedback.

Raising a toast to this special edition, I would like to thank all our internal as well as external stakeholders who continue to inspire us along this fascinating journey. Cheers!

Director-Marketing & Operations Orient Press Ltd

S Das Managing Director Nordson India Pvt Ltd

Manas R Bastia manas@network18publishing.com

Modern Packaging & Design July-August 2013

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8

CONTENT S

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Anniversary

Anniversary Special 20 Raw Material 32 Machinery 42 Processes 48 Quality & Security 60 Supply Chain 66 Design Innovation 72 Printing & Graphics 78 Types of Packaging

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84 86

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Insight & Outlook Packaging consumption: Seeing the big picture P V Narayanan, Member of Board, APEDA (Ministry of Commerce) Holistic brand building: Looking beyond logos Alpana Parida, President, DY Works and Aakriti Goel, Senior Marketing Manager, DY Works

Highlights of Next Edition Special Focus: Plastic Packaging

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In Conversation With

Ashok Gourish, Business Head, Bosch Packaging Technology India

Insight & Outlook: Caps & Closures

REGU L AR SEC T ION S Editorial ................................. 3

Tenders ................................. 89

News, Views & Analysis ........ 8

Event List............................. 90

Technology & Innovation .... 12

Products................................ 92

Technology Transfer ............. 14

List of Products.................. 100

Projects ................................. 88

List of Advertisers .............. 101

Details on page no. 90

Cover illustration and design: Chaitanya Surpur and Sharad Bharekar

Note: ` stands for Indian rupee, $ stands for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise

Modern Packaging & Design July-August 2013

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Business Insights •Technologies•Opportunities

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Views and opinions expressed in this magazine are not necessarily those of Network18 Media & Investments Ltd (Network18)*, its publisher and/or editors. We at Network18 do our best to verify the information published but do not take any responsibility for the absolute accuracy of the information. Network18 does not accept the responsibility for any investment or other decision taken by readers on the basis of information provided herein. Network18 does not take responsibility for returning unsolicited material sent without due postal stamps for return postage. No part of this magazine can be reproduced without the prior written permission of the publisher. Network18 reserves the right to use the information published herein in any manner whatsoever. Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Network18. Senior Editor: Manas R Bastia Printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Network18, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. Modern Packaging & Design is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 27106. Network18 does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition. *Ownership of this magazine stands transferred from Infomedia18 Ltd (Infomedia18) to Network18 Media & Investments Ltd (Network18) in pursuance of the scheme of arrangement between Network18 and Infomedia18 and their respective shareholders and creditors, as approved by the Hon’ble High Court of Delhi and the necessary approval of Ministry of Information and Broadcasting is being obtained.

Modern Packaging & Design July-August 2013

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NEWS, VIEWS & ANALYSIS

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Anniversary

Tetra Pak inaugurates stateof-the-art factory in India

Tetra Pak® has inaugurated its latest world-class factory at Chakan, near Pune, in India. The plant is designed to meet the growing demand for Tetra Pak processing and packaging solutions across India, South and Southeast Asia and the Middle East. The € 120 million (` 700 crore) facility

marks a significant milestone in Tetra Pak’s increasing presence in the Indian subcontinent. Dennis Jönsson, President & CEO, Tetra Pak, said,

A Schulman inaugurates masterbatch manufacturing facility in Vadodara

A Schulman Inc inaugurated its plastics masterbatch manufacturing facility in Vadodara, Gujarat, India, will manufacture masterbatch products for India’s growing flexible packaging, appliance and consumer products markets. Initially, its annual capacity is projected to be approximately 10,000 metric tonne. The area of this plant

“We appreciate the trust and belief that the Indian dairy & beverage industry has in Tetra Pak. Today, India ranks among our fastest growing markets. Investing in this factory demonstrates our strong commitment to supporting our customers to meet growing consumer demand in the region.” Spread over 45 acres, the new Tetra Pak plant employs the most advanced packaging material production technologies and equipment in the world. Among various other facilities, the new plant will have a straw production unit, a processing systems workshop, a filling machine renovation and a technical training academy. The localisation of these processes will greatly increase responsiveness to market demands. It will also house a Product Development and Innovation Centre, which will have a laboratory, a pilot processing plant and a pilot packaging plant to meet the product formulations and development needs of customers. The new plant doubles production capacity of Tetra Pak packaging material to 8.5 billion packages per year, with the potential of scaling it up to 16 billion packages. is 45,000 sq m, and it is strategically located near A Schulman’s customers’ manufacturing facilities in western India. “This plant will be dedicated to providing innovative masterbatch solutions to meet the needs of flexible packaging, white goods and cosmetics manufacturers in India,” said Derek Bristow, Vice President & General Manager – Asia-Pacific region, A Schulman. Avani Jain

Cermex opens new plant in India

Cermex has expanded its industrial network in Asia with the opening of a plant in Pune, India. The company will assemble three models of machines from each major family of its product line, including one designed in India. The team, which was put in place in late 2011, is supported by a high-tech design office, which uses the PLM tool and

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Modern Packaging & Design July-August 2013

Parker Hannifin India expands in Chennai

(L-R) Viren Patel and Arijit Sen, Country Managing Director, Parker Hannifin India Pvt Ltd

Parker Hannifin, one of the leaders in motion and control technologies, has expanded its network in India with the opening of a new ParkerStore by FEC India Pvt Ltd. Based in Chennai, the new ParkerStore will offer a wide range of pneumatic, hydraulic, seals and filtration products and components. Viren Patel, President, FEC India Pvt Ltd, explained, “Representing Parker as an exciting new venture will enable us to expand our existing services for low & high pressure hoses and couplings with a complementary business unit. This, we believe, will open up many new opportunities in the future.” Sankar Vishwanath, Business Development Manager, ParkerStore in India, added, “The ParkerStore programme offers all our distribution partners a proven business model that they can develop for use in their local areas. It offers real value both to the store operators and to their customers, bringing Parker technology and expertise within easy reach of everybody involved in the field of motion and control.” With annual sales exceeding $ 12 billion, Parker Hannifin is one of the leading diversified manufacturers of motion and control technologies and systems, providing precision-engineered solutions.

the latest in Cloud computing technologies. This gives Cermex the ability to create end-

of-line packaging machines in Pune that are specially adapted to the local market. This is the case for the Vertical Pick & Place Case Packer, which is one of the three machines assembled in India. The two other machines are an automatic shrink-wrapper with sealing bar and a palletiser (P9 – 4 axis Gripping/Transfer), chosen as a function of local industry needs.


NEWS, VIEWS & ANALYSIS

Manjushree Technopack on an expansion drive

Manjushree Technopack, a leading PET bottle & preform manufacturer, is looking at consolidating its global operations by setting up its first office in the Middle East. The company is already exporting to the Gulf region, Thailand and Africa. Another development at Manjushree is the commissioning of its single largest PET preform manufacturing plant in south Asia, boosting the company’s total capacity from 50,000 MTPA to 80,000 MTPA. Further, the company had committed investments of ` 150 crore to two new greenfield facilities in Harohalli and Bidadi. “The Bidadi facility has been commissioned during the year 2012–13. The commissioning of the state-of-the-art production facility has greatly enhanced our capabilities, particularly in the rapidly growing PET preform segment. In addition to the significant increase in capacity, the level of automation that we have adopted in the new facility is also expected to improve efficiencies and reduce manpower costs,” said Vimal Kedia, Managing Director, Manjushree Technopack. Avani Jain

Smart announces blow moulding facility in India

Smart Machineries and Moulds Pvt Ltd has inaugurated its new plastics extrusion blow moulding manufacturing facility in Western India. The facility will focus exclusively on serving the growing demand for blow moulding products applications in their respective markets. The new facility near Mumbai will manufacture all sizes of extrusion blow moulding machines, which include single and double station machines. The annual capacity is projected to be approximately 24 to 36 machines. The new

ELPIE Engineers bags ‘Certificate of Commendation’ for PP non-woven fabric making machine

1.6 to 3.2 m fabric width with 12–150 GSM. India’s first indigenous, hightech and high output PP In the 3rd National Awards non-woven spunbond line with for Technology Innovation in 3.2 m fabric width and 450 kg/ Petrochemicals & Downstream hr capacity was commissioned Plastics Processing Industry successfully in India in 2012. (2012–2013), a ‘Certificate of This machine produces zero Commendation’ was awarded wastage as wastage is fed to the to ELPIE Engineers Pvt recycle extruder to make new Ltd for its PP non-woven fabric with allowable variation Certificate of commendation fabric making machine of ±5 per cent only. Further, the in the category of ‘Innovation of Polymer PP non-woven fabric making machine has Processing Machinery & Equipments’. This energy efficiency of 0.65–0.7 unit/kg, no noise award ceremony was organised by Ministry pollution, is environment friendly and easy of Chemical & Fertilizers, Department of to operate with the help of a single-touch Chemical & Petrochemicals, Government of console. ELPIE dedicates this award to J P India, to promote innovation in the industry. Aghera, Technical Director, who is the brain ELPIE’s PP non-woven spunbond lines behind the machine and the real achiever. offer various customised sizes ranging from Avani Jain

Ipack-Ima organises first conference on sustainable packaging in East Afripack

Ipack-Ima SpA, a leading event organiser specialising in B2B shows for processing, packaging, material handling and converting organised its first international conference titled, ‘Sustainable Packaging for Competitiveness and Development on SME’s in EAC Region’ in Rwanda on June 3–4, 2013. The event received support from the Italian Trade Promotion Agency and the Italian Ministry of Economic Development and was held in partnership with East African Community, UNIDO and Kenya’s Ministry of Industrialization and Enterprise Development.

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facility is strategically located near Smart customer’s manufacturing facilities in Western India, and near the coastline of the Arabian Sea, which will facilitate the shipment of machines for faster delivery. Shreeram Rane, Managing Director, Smart Machineries and Moulds Pvt Ltd, said, “This plant will be dedicated to providing innovative solutions to meet the needs of blow moulding processors in India. By opening this new facility near Mumbai, we are strengthening our position to serve our growing customer base in this attractive market.”

Modern Packaging & Design July-August 2013

The event was presided over by Professor Claudio Peri, Professor Emeritus, University of Milan, who presented an agenda that raised the interest of a large, attentive public. Both organisers and partners had a double objective which was to emphasise the importance of packaging as a strategic leverage for technological upgrade and increased competitiveness of local SMEs. In this connection, a dedicated paper was presented at the CAMI conference, which was held on June 10-14, 2013, that gathered the Ministers of Industrialization from across the continent in Nairobi to promote East Afripack 2014, the first exhibition

showcasing the global state of the art of processing, packaging and converting technology scheduled for September 9–12, Nairobi. The Kigali conference is one more step in the path leading up to East Afripack 2014, which also includes roadshows and presentations across the region to build awareness among the local business community on the issues of processing & packaging technology and promote the 2014 event. According to research and estimates by UNIDO, in the last decade, 6 of 10 emerging economies enjoying the highest growth rates have been located in Africa. Both data and forecasts bode well for East Afripack 2014.


NEWS, VIEWS & ANALYSIS

Monachem develops nano-based solutions for the packaging industry

Monachem Additives Pvt Ltd has developed Nanoadd® nano-based solutions for the packaging industry. This would be launched during the 9th Plastivision India 2013 exhibition that will be held in Mumbai. Shamik Shah, Vice President – Sales & Marketing,

Brückner Group predicts future of plastics at Chinaplas 2013

More than 14,000 visitors, 1/3rd from overseas, visited Chinaplas 2013 in Guangzhou – a clear sign for the ever-increasing importance of one of the world’s biggest fairs in the plastics sector. This year’s slogan ‘The Future is in Plastics and Rubber’ perfectly matched the market-oriented technologies for enhanced productivity, quality and energy efficiency presented by the Brückner Group. At the all-time crowded booth, numerous interesting discussions focussed on Brückner Maschinenbau’s latest solutions for value-added film production on most advanced equipment such as battery separator film, capacitor films or shrink films; Brückner Servtec’s comprehensive services for film stretching lines of any brand; Kiefel’s high-performance technologies for the automotive, packaging and medical industries and PackSys Global’s advanced packaging equipment, especially their new lines for cosmetic tubes. Also in the focus was the new image with picture motifs of the companies of the Brückner Group that was launched at Chinaplas.

Monachem Additives Pvt Ltd, said, “The key features of this product are highly platy morphology, leading to higher aspect ratio; unique combination of polar and apolar functionalities, leading to affinity with wide range of macromolecules; mean particle size of 0.095–0.130 µm for different grades; specific surface area of 80–120 m2/gm and customised surface treatment for different applications. When

it comes to usage, then in the automotive sector, this product could be helpful for downgauging, improving tensile, flexural impact strength and lowering the weight of the component. In packaging, its usage can lead to improvement of barrier properties, clarity and mechanical properties. In the wire & cable industry, it can help in the improvement of fire-retardant properties.” Avani Jain


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TECHNOLOGY & INNOVATION

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Anniversary

BASF launches new solution for paper production

Under the brand name XELOREXTM, BASF has launched a unique solution for the production of paper and board. The new BASF brand of multifunctional 4-in-1 wet-end chemistry responds to the diverse challenges the paper industry is facing these days. Whether it comes to reduction in complexity of production, a higher stability of operations, a boost for productivity or improved costefficiency, a broad range of needs are addressed by using XELOREX. By applying XELOREX, customers can gain clear improvements

Sirane launches versatile retail cooking bag solution

The new versatile cooking bag from Sirane is simple to use, simple to open, cooks food to perfection and can be used in almost any cooking environment, from ovens to barbecues, griddles to hot plates. It is a foil bag capable of withstanding significant

Optimised filling technology with BEUMER Fillpac R

BEUMER has expanded its product portfolio with the rotating filling machine BEUMER Fillpac R. This machine, designed for capacities of 300–6,000 bags per hour, can fill all types of valve bags. The complementary bag placing technology for all common bag types rounds out the product portfolio. The weight accuracy of the bags is guaranteed by a calibratable weighing unit. Together with a special bag placer, the BEUMER Fillpac R can fill even woven polypropylene bags. The three-position cylinder that regulates the coarse and fine

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Modern Packaging & Design July-August 2013

in stability of operations. The outstanding improvement of the Initial Wet Web Strength (IWWS) reduces the number of breaks and this way improves productivity. XELOREX also provides enhancements of dry strength parameters, which is particularly important in the production of packaging paper and board. Manufacturers of both, packaging and graphical papers, benefit from the additional productivity increases that XELOREX yields. The improved IWWS, less stickies and clean water circuits lead to a higher efficiency because of less downtime.

direct heat, allowing for its use on a barbecue and in an oven. The food will be tender, retain all the juices, flavours and goodness, and can be sold over the counter in the pack. The bag is available in different sizes and in a standard and non-stick version. It comes with a clear top panel (so users can see food being cooked) and can be heat-sealed. It also has a great opening mechanism – when the bag is hot, the top surface can be peeled away, leaving the food on a foil base. It can then be stirred, turned if required, allowed to cook for longer and browned, or served directly. It is perfect for meat, fish, poultry and vegetables – anything that can be cooked in an oven or on a barbecue. flow is protected from dust, because it is positioned vertically and outside of the dirt area. The cylinder for bag discharging is also located in the dust-free zone above the filling spout. This solution minimises wear and tear on both cylinders, ensuring longer service life. BEUMER has also equipped the optimised filling machine with an automatic bag weight correcting device. This device automatically adjusts the weight of subsequent bags. Almost all built-in components of the BEUMER Fillpac R are freely available commercially. This reduces delivery times for spare parts and lowers capital costs for the user.

Pregis introduces black bubble air cushioning

Pregis Corp has commercialised another protective packaging first – black bubble air cushioning with high-recycled content. Astro-Bubble® Renew™ has been reformulated to give brand owners a new, more elegant way to cushion their products throughout the distribution chain, while also providing environmental benefits via recycled content. Target applications include consumer electronics, cosmetics, jewellery, fulfilment/mail order, furniture, glass/ china, industrial equipment/supplies, medical, militar y/government, pharmaceuticals, retail and other products, which can benefit from improved positioning. Additionally, the opaque black bubble is ideal for applications that desire concealment/ theft deterrent properties. Astro-Bubble Renew is available in coex (low-density polyethylene/ nylon) and monolayer (linear-low density polyethylene) options with bubble sizes ranging from very small, small, medium and large, while bubble diameters range from 1/8- to ½-inch. Recycled content is 40 per cent for the coex version and 25 per cent for the monolayer version. The product is durable and offers high air retention properties, making it ideal for performance-oriented applications. It can be used for cushioning, surface protection and void-fill. Its lightweight characteristics help minimise transport weight, which helps lower fuel consumption and carbon emissions throughout the supply chain.


TECHNOLOGY & INNOVATION

Anchor Cheddar to use Aplix seal technology

Sealed using Aplix seal technology, the Anchor Cheddar packaging will be the first branded block cheese in the world to use the new easy ‘pinch’ close seal. Aplix seal packaging removes the need to line up the packaging channels to reclose the pack, making it much easier to close and ensuring that Anchor Cheddar stays fresher for longer.

Latest high-tech packing solution from Cortec®

As part of Cortec®’s green concept, Cortec laboratories has formulated an environmentally improved version of VpCI® 126 films, manufactured using a state-of-the-art reprocessing line. VpCI 126 Blue combines the latest film technology with the most effective corrosion protection for metal products. Sealing the product in this film protects metal parts from rust, tarnish, stains, white rust and oxidation for up to five years. It replaces hazardous conventional rust preventatives such as oils and desiccants. By using VpCI 126 Blue, customers get a safe and economical solution because it eliminates degreasing or coating removal. It can be used immediately, does not contain free amines, phosphates or halogen-based materials and is non-toxic.

Avery Dennison expands Prime Film Portfolio

Avery Dennison Corporation has added four new facestocks with a Bleached Glassine (BG) liner to its Prime Film Portfolio of Biaxially Oriented Polypropylene (BOPP) films. The Prime Film Portfolio is an engineered family of films purpose-built for the specific marketing and container needs of the home & personal care and food &

beverage market segments. All of the film constructions in the portfolio are anchored with the company’s proprietary S7000 adhesive, which delivers excellent clarity, conformability and productivity for highspeed converting. The S7000 adhesive delivers 50 per cent less ooze, reducing adhesive contamination and clean-up. Available in white, clear and metallised options, the new BOPP film constructions are ideal for rigid containers.


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TECHNOLOGY TRANSFER

th As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration.

Anniversary

Air bubble packaging film

A Korean company is offering its existing plant manufacturing air bubble film. This plant (model: YS1200, YS1000, YS1400) is equipped with modern facilities in accordance with excellent quality production. The consumption of air bubble sheet is a profitable business due to increasing demand in India.

Areas of application

Packaging industry: It can also be used for agricultural applications instead of LDPE where additional thermal insulation is required.

Forms of transfer

Equipment supply, turnkey

Bar code generating and printing

A Thailand-based firm seeks to offer their services in bar code generation and printing. They use highly professional methods and their expertise will be useful depending on clients’ requirements. Other than consultancy, they provide training for barcode generation, which would help the manufacturer improve its prospects in the long term.

Areas of application

Printing industry, bar code auto ID section

Forms of transfer

Consultancy, turnkey

Biodegradable substitute of wooden logs

An Indian firm is offering a green innovative technology – Coir Atlas. It is an eco-friendly and biodegradable substitute of wooden logs used by steel industry for shipment of flat products, viz sheets/plates and coils.

Areas of application

Packaging and transportation Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, Asian and Pacific Centre for Transfer of Technology (APCTT) of United Nations Economic and Social Commission for Asia and the Pacific (UNESCAP), APCTT Building, C-2, Qutab Institutional Area, New Delhi 110 016, Tel: 011-3097 3758 (Direct), 011-3097 3710 (Board), Fax: 011 - 2685 6274, Email: srinivasaraghavan@un.org, Website: www.apctt.org For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer/seeker through this website, before contacting APCTT for further assistance.

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Technology Requested

Technology Offered

Modern Packaging & Design July-August 2013

Adhesives, specialty additives and their intermediates

A leading UK-based company is seeking innovative investment opportunities in organic chemistry, chemical formulations or processes including manufacturing, technology licensing, acquisition, joint venture and distribution. The company has a reputation for technical innovation in high-quality performance products. The company seeks to acquire rights to novel chemistry products, innovative technologies, formulations, compounds and applications that are in synergy with its current range of activities, and that will increase the diversity of its manufacturing base. Patents or know-how would be desirable.

Areas of application

Plastics rigid and flexible packaging, laminate printing and processing, etc

Forms of transfer

Manufacturing, technology licensing, acquisition, joint venture and distribution

Recycled PET bottle machinery

A Poland-based company specialising in recycled PET polyester polyols manufacturing is looking for an alternative proposal of design and engineering of bigger (about 25 KTPA) production plant. It plans to start with good quality recycled PET flakes, which will be delivered in big bags. Hence, the company requires a complete package offer for this service.

Areas of application

Beverage packaging industry

Forms of transfer Others

Share and Solicit Technology

The mission of Modern Packaging & Design is to spread the technology culture. Here is an opportunity to be a part of this endeavour by sending your technology on offer or technology requirements. If you belong to any of these two categories, you are invited to furnish the techno-commercial details for publication. The write-up needs to be as per the format of this section with information about the particular technology offered or requested, its areas of application and forms of transfer.

Contact: Modern Packaging & Design Network18 Media & Investments Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028. Tel: 022-3003 4671 • Fax: 022-3003 4499 • Email: spedit@network18publishing.com


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IN CONVERSATION WITH: Ashok Gourish

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Anniversary

“THE

PACKAGING INDUSTRY IS GROWING

IN SPITE OF THE ECONOMIC SLOWDOWN” …opines Ashok Gourish, Business Head, Bosch Packaging Technology India. In an exclusive interview about with Sweta M Nair, he discusses the packaging machinery sector and the current trends in the industry, offers insights on the entire gamut of packaging and reveals what keeps him motivated.

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Modern Packaging & Design July-August 2013


Ashok Gourish

Could you tell us about your journey in the packaging machinery sector and how Bosch is faring in the industry?

My journey in the packaging machinery sector has been very pleasant. I joined Bosch in 2009, and since then it has been an interesting and exciting journey. Bosch Packaging Technology India is an ISO 9001:2008 certified company involved in manufacturing and marketing machines, modules and systems for food, confectionery and pharmaceutical industries. With high-quality packaging machines and systems, we deliver a complete concept to suit requirements based on modern technology – from ergonomic design right up to user friendliness. The modularly structured machine concepts of Bosch allow it to react quickly and flexibly to satisfy customer’s individual requirements. In addition, Bosch offers comprehensive after sales services that are regarded as best in class. The Packaging Technology Division of Bosch in India started in 1995, and the Goa operations commenced in 2007. In India, the Packaging Technology Division has the following business units: Confectionery and Food with vertical and horizontal packaging machines including chocolate and confectionery wrappers Pharma with washing, filling and sealing/capping machines Last year, we had a significant milestone as we inaugurated the state-of-the-art manufacturing plant at Verna in Goa with an investment of ` 340 million. We have a good market footprint, and the installed base is significantly increasing year on year. We have sold a number of machines to leading names across industry segments in India and abroad.

What are the advanced trends in packaging equipment for the food processing sector in India?

The food segment has high prospects as it has started looking for innovations in packaging. With increasing urbanisation, there is a noticeable increase in the consumption of packed food. Also, with

an increase in the population of working women, there is an increase in consumption of ready-to-eat and fast-food items. Wellsealed, attractive packages that ensure better shelf-life is the trend. To add to it, we all know that the retail sector, through its supermarkets and hypermarkets, is undergoing a massive change. Therefore, the ease in displaying these products at the end of the retail chain is also an important trend. Filling trends are also changing as we notice reusable pouches and smaller pouches becoming more popular among consumers. Also, consumer demand will increase for easy peel, re-closable and easy packaging. Traceable packaging with radio-frequency identification and intelligent packaging is also becoming popular. We see a lot of technical advancements in packaging such as tamper-proof seals, one-time use packages and holograms that help to eliminate the risk of products being duplicated. Microwaveable packaging is also much in demand now. Research and development for new machines will be fully based on the market requirements in addition to overall equipment efficiency, automation and user friendliness. Leaner operating cost is also considered important for development from the packaging equipment perspective.

In terms of packaging equipment, what challenges are still being faced in the pharma sector in the country?

Challenges are present in every sector and industry. In addition to meeting customer demands in terms of cost and quality, companies have to be looking at ways of running leaner and more efficient packaging operations. Severe margin pressures from rising raw material costs and price sensitivity pose quite a challenge to the packaging industry. Thus, cost has always been the main challenge in this segment. The pharmaceutical industry has huge potential for growth but will remain price sensitive from the packaging equipment point of view to ensure the availability of pharmaceutical products to end customers.

In all these years, what has become the focus of Bosch’s packaging business in India?

Bosch will strive to fulfil growing market needs with best-in-the-industry solutions and to strengthen its existing leadership position. Our focus is to provide new products and best packaging solutions with good technology and services to our customers. This particular segment is fast growing, and our focus is to fulfil the growing market demands. We have seen a double digit growth year on year, and our focus is to continue this growth journey. We have invested in state-of-theart technology at our new plant in Goa. This plant aims at producing worldclass German technology machines that are affordable and available to the Indian market.

One of the most challenging phases you have faced professionally...

In India, the packaging industry is quite fragmented and competitive. It is a challenge to stay ahead and maintain the leadership position in this industry. However, the market is looking for valuefor-money products of high quality and technology, which is an advantage for Bosch. Whenever there is an economic slowdown, the capital investors are the first ones to relook that which will pose a challenge for growth, but I love such challenges.

What motivates you in life?

I believe that motivation is both the desire and willingness to do something. It is what gets you started and keeps you going. The best way to motivate oneself is to set inspiring, worthy goals. I am very proud of Bosch, and the value system here is a great encouragement. My young and enthusiastic team at the Verna plant also motivate me to achieve greater results. The packaging industry is growing in spite of the economic slowdown, and this is quite a motivating factor to make sure that Bosch India achieves constant and consistent growth. Email: sweta.nair@network18publishing.com

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8

ANNIVERSARY SPECIAL

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Anniversary

Raw Material Plastic packaging: Ensuring flexibility with hygiene...............................................................20 Flexible packaging: Offering convenience and ease of use ......................................................22 Interface - Rajeev Bhatia, Chief Executive Officer, Premier Pigments & Chemicals ...........26 Roundtable - Is India ready for the bioplastic packaging revolution?.....................................30

Machinery Robotic palletiser: Enhancing precision and safety .................................................................32 Conveyor technology: Conveying outstanding performance ...................................................34 Interface - Yatindra R Sharma, Managing Director, KHS Machinery Pvt Ltd ...................38 Roundtable - Do Indian packaging companies have the know-how to meet growing market demands? ........................................................................40

Processes Maintaining the cost–quality ratio: Developing new processing techniques ..........................42 Processing packaging materials: Ensuring substantial weight reduction .................................44 Interface - Vimal Kedia, Managing Director, Manjushree Technopack Ltd ........................47

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Modern Packaging & Design July-August 2013


ANNIVERSARY SPECIAL

Quality & Security Package labelling: Raising the bar on quality ..................................................................................48 Quality control initiatives: Improvisation through innovation ..........................................................50 Food safety in the global village: Product inspection challenges for multinational organisations Neil Giles, Marketing Communications Manager, Mettler-Toledo Product Inspection, Safeline, UK ...... 54 Interface - Satyadeep Ray, Director, Holostik India Ltd .................................................................56 Roundtable - How important is RFID for packaging and has it evolved in India?........................58

Supply Chain Logistics: Reducing costs and increasing efficiency .........................................................................60 Cold chain solutions: Effective food storage and transport ...............................................................62 Interface - A V P S Chakravarthi, Managing Director, Ecobliss India Pvt Ltd ............................64

Design Innovation In-mould decoration: Increasing product appeal ..............................................................................66 CAD/CAM technology: Detailed design for optimum output ........................................................68 Interface - Rajeev Bajaj, Head Manufacturing, Autodesk India & SAARC ..................................70

Printing & Graphics Printing technologies: When packaging gets inked! ........................................................................72 Aesthetic innovations: Gravure goes hi-tech! ....................................................................................74 Interface - Ravi Jain, Founder and Chief Executive Officer, Grover Zampa Vineyards.................76

Types of Packaging R&D initiatives: Creating more value with less resources ................................................................78 New packaging materials: On the eco-friendly path .........................................................................80 Interface - Lakshmi Ramakrishnan, Chief Executive Officer, Essen Speciality Films Pvt Ltd ....82

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8

RAW MATERIAL: Plastic packaging

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Anniversary

Ensuring flexibility with hygiene

Significant changes in food packaging technologies have included the use of new packaging materials, new combinations of standard materials and new methods of manufacturing containers. While none of the basic materials used to package Food and Beverages (F&B) has escaped change, more changes have occurred in the area of plastics than any other material. Anwesh Koley delves into the world of F&B packaging and the role of food grade plastics. Latest innovations

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he Indian packaging industry is a thriving industry, and it has been the focal point for tremendous opportunities for manufacturers of late. Its exponential growth record in India varied between 22 and 25 per cent annually as compared to 4–5 per cent globally in 2011. The dynamics of the industry are a bit fragmented and unstructured, but with terms such as ‘global village’ turning into reality, it has forced industry players to adapt to modern and advance technology providing world-class standards. Currently, the packaging industry is going through a transition period due to increasing awareness among customers. Quality, hygiene and

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face value are making imprints in the minds of people. Packaging is a proven asset to offer better shelf-life for products to customers and to help keep the flavour intact for a longer time. This is lending a hand in the normal busy life of consumers. India, being the 2nd and 3rd largest producer of vegetables and fruits, respectively, in the world, is concentrating on packaging to meet stringent international standards. The growth parameter for the packaging industry is directly linked to the growth trends of the fast moving consumer goods segment, which is highly influenced by choices of consumers. A high disposable income has enhanced the lifestyle of consumers who have wider choices available in the market.

Modern Packaging & Design July-August 2013

An increasing population and growing consumer demand for packaged foods have forced the F&B industry to look at new technologies that provide flexibility, ease of operation and constant tracking of the production process. Suresh Singhal, Managing Director, Himalayan Group of Industries, says, “Manufacturers are working on guidelines for keeping transparency in the production process for assuring consumers’ health and hygiene. This demands continuous monitoring and efficient traceability of the entire production process in the food manufacturing plant. Innovation is an ongoing process, and we cannot rule out any possibility in developing new materials for new packaging.” Every day, several trials are being performed to make new materials suitable for better packaging, which is economical and environment friendly. Working on innovative ideas by keeping various factors in mind such as cost-effective solutions, environmentfriendly alternatives and appealing appearance vis-à-vis competing with international standards is the target of manufacturers. Disposable packaging materials used to ship and protect purchased items as well as disposable containers used for F&B are of special interest these days. New product avenues using the thermoforming process for fruits, vegetables and ice cream will change the perception of packaged food. Packaging companies across the country are keeping a tab on these innovations and aggressively moving towards adding value to the packaging industry.


Plastic packaging

Rigid packaging technology for the F&B industry

Glass packaging had a monopoly over F&B packaging for a very long period of time across the globe. Recent advanced developments in plastic products such as polyethylene terephthalate, polypropylene, polycarbonate, highdensity polyethylene and low-density polyethylene are giving strong competition to the traditional concepts of packaging. Universal standards and compliances worked for establishing non-toxic plastic products have not only brought down the overall cost of packaging but also given viability on the grounds of safe transportation. Another factor keeping rigid packaging ahead is its tamper-proof characteristics. This comes out to be a boon for companies who bank on their superior quality as it disallows any tampering of products. Consumers still do not trust packaged food items manufactured in India, which is in complete contrast with globally manufactured packaged food. However, with steady awareness, the demand is slowly increasing. Emphasis on non-toxic, bisphenol A-free products are ensuring healthy and hygienic

products. “Availability of good quality raw material, complete automated machines and hygienic manufacturing process are making plastic packaging a more suitable option for the F&B industry. All these factors are trying to change the psychology of Indian consumers to wipe out apprehensions about can food. Today, it can be said that the Indian packaging industry adheres to international standards as many companies are original equipment manufacturer suppliers to world class companies,” adds Singhal.

Ensuring F&B hygiene standards

Much attention is been given to accounting health, safety and hygiene of the product. A major challenge for the packaging industry has been to retain the essence of the food products packed in. As packaged food is trying to carve a niche in the Indian market, innovative ideas have been implemented to keep the flavour intact. Production companies are taking numerous steps for producing goods in a controlled environment causing least chances for contamination. Provision of clean rooms is an evident example of the importance given to hygiene. Tetra packs, polypropylene jars and containers etc have replaced the kitchen shelf as they are much easier to maintain and have better shelf-life. “Till date, emphasis on hygiene was laid in the pharma sector only, but as of today, we notice similar compliances are being adopted for F&B packaging products. We strive towards abiding to Class 10000 Clean Room designs providing 99 per cent hygiene to all products,” mentions Singhal.

Competition for plastic packaging

Plastic packaging is fiercely facing tough competition from the conventional style of packaging such as glass and metal. Metal packaging has dominated the major agro products segment, and glass has been traditionally used for beverages. Singhal laments, “The stigma attached to plastics due to its chemical composition

Availability of good quality raw material, complete automated machines and hygienic manufacturing process are making plastic packaging a more suitable option for the F&B industry. All these factors are trying to change the psychology of Indian consumers to wipe out apprehensions about can food. Suresh Singhal

Managing Director, Himalayan Group of Industries

and supposedly toxic ingredients is taking its course of time to change. However, when it comes to plastic packaging, the pros outweigh the cons and consumers are fast waking up to these.” Other packaging manufacturers are vehemently pressurising the government to ban plastic products for environmental reasons and trying to malign the plastics industry. However, with modern technologies and stringent regulation on manufacturers, every care is being taken to use environmentfriendly recycled raw material and to produce low carbon emissions from manufacturing units. Plastic packaging is now accepted globally in every sector. F&B has been the most competitive sector with the use of various packaging materials. Plastic packaging, however, has time and again proved to be the best solution with regard to cost effectiveness, hygiene and decrease in transit breakage. Email: sweta.nair@network18publishing.com

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RAW MATERIAL: Flexible packaging

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Anniversary

Offering convenience and ease of use With an expanding middle class and rising income levels, the patterns of consumption are changing substantially and the demand for quality and convenience-based products is increasing. This is expected to stimulate greater consumption of branded products and increase the use of rigid and flexible packaging. Anwesh Koley gauges the growing market for flexible packaging and the reasons why it is gaining fast acceptance.

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lexible packaging finds varied use because of its ability to provide strength, moisture resistance, aroma retention, gloss, grease resistance, heat retention, sealability and printability. This type of packaging has gained vast acceptability because it protects the product against environmental threats such as moisture, heat and chemical reactions. The added advantages of flexible packaging are convenience in handling the product and its cost benefits.

Current market condition

Nonetheless, plastic, the most commonly used substrate in flexible packaging, is facing pressure because of issues of environmental protection and safe disposal. These issues act as a major impediment in flexible packaging becoming an all-pervasive medium. On the other hand, paper and paperboard are environment-friendly and also enjoy the advantages of easy handling and efficient process implementation. Moreover, flexible packaging mandates additional capital requirements and technical know-how for efficient manufacturing operations.

major section of the Indian society, have the choice of purchasing just the required amount of products. The flexible packaging market has got a leg up from the growth in the processed food, personal care and hygiene industries as well as the boom in the retail sector. Courtesy: Borealis “The demand for smaller packaging and increasing consumerism due to higher Packaging Pvt Ltd, says, “As flexible purchasing power also bode well for the packaging’s advantages of ease of market. However, there is a certain lack handling and lesser storage space become of quality consciousness among end users, increasingly appreciated, traditional and they tend to gravitate towards lowrigid packaging will take a backseat. In grade products, hampering the sales of addition, flexible packaging scores over flexible packaging. Processors can dig

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With a compounded annual growth rate of 17 per cent, the Indian flexible packaging market is one of the most dynamic and fastest growing in the country. Kalpesh Sharma, AGM (Marketing), Parikh

Modern Packaging & Design July-August 2013

traditional packaging for reasons such as keeping the product from adulteration and moisture, convenience of disposal and cost savings on transportation.” For a company to be successful in the Indian flexible packaging market, it needs to understand end-user requirements and provide packaging materials that offer better barrier properties. Flexible packaging offers the advantage of packing smaller quantities compared to traditional packaging, and hence, middle class consumers, comprising a


Flexible packaging

Flexible packaging scores over traditional packaging for reasons such as keeping the product from adulteration and moisture, convenience of disposal and cost savings on transportation. Kalpesh Sharma

AGM (Marketing), Parikh Packaging Pvt Ltd

deep into this fragmented market by making consumers more aware of the advantages of flexible packaging, offering superior quality product lines and pricing their products more attractively,” adds Sharma. Additionally, the existence of more than 800 processors in the Indian market creates a fiercely competitive marketplace, fostering price wars. The use of new polymers, which enhance packaging requirements as well as facilitate innovative techniques for faster packaging, will help companies grow in the Indian flexible packaging market. With the advent of metallised films and other novel materials, the industry will be looking at increasing the quality of products, and thereby, the per unit sales. In fact, the market is expected to treble its output in the next seven years, from 1,000 kilotonne in 2007 to 3,100 kilotonne in 2014, owing to the greater demand from the processed food, pan masala and retail segments.

Benefits of paper packaging

Although substrates, such as plastic, have gained vast acceptability, the attractiveness of paper and paperboard consumption

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remains. Currently, India is ranked 15th in the world for its paper and paperboard consumption and is expected to improve its rank in the future. Paper is the fastest growing substrate segment, with a growth rate of 6–7 per cent. The total demand for paper is currently estimated to be about 6 million tonne, of which about 40 per cent is consumed by the packaging industry. If the demand for paper continues to grow at the same rate, the total paper consumption is expected to double by 2014.

Indian and global markets for paper packaging

Laminated products including form-fillseal pouches, laminated tubes and tetra packs are growing at about 30 per cent per annum. There are about 600–700 packaging machinery manufacturers, 95 per cent of which belong to the small and medium sector located all over India. Germany and Italy are the latest suppliers of packaging machinery to India, but the focus is now shifting to Taiwan, Korea and China. The Indian packaging machinery imports are about $ 125 million. The Indian packaging machinery exports are rapidly growing, and India has emerged as a key importer. India’s per capita packaging consumption is less than $ 15 against the worldwide average of nearly $ 100. “The large growing middle class, liberalisation and organised retail sector are the catalysts of growth in packaging, and the food and pharma packaging sectors are the key driving segments,” adds Sharma.

Market for corrugated box packaging

Multinational companies are demanding corrugated boxes of international standards, and the pattern of buying packaging is changing. Prices of corrugated sheet and converted boxes have remained low due to over-capacity, manual operations and low productivity. Besides, transport constraints and high freight costs have meant that small to medium-sized corrugated box plants are located near customers.

Modern Packaging & Design July-August 2013

The over 4,000 corrugated board and sheet plants in India are highly labour-intensive, employing over half a million people, both directly and indirectly. The industry is converting about 2 million tonne of Kraft paper into corrugated boxes. Factories are spread out in all parts of India, even in the remote and industrially backward areas. “This present scenario is already being challenged by the sweeping changes that are beginning to take shape. More inline automatic plants are being set up as corrugated box makers gear up to meet the new demands for high-precision boxes with attractive graphics and large integrated production capacities,” adds Sharma. Inline automatic board and boxmaking plants will ease the present semi-automatic production processes. Deployment of folder gluers and rotary die cutters will be on an increase as corrugated board and sheet are used for display/promotional packs, packageon-package and dispensers. Advances in multi-colour, flexo printing will facilitate in-house flexo-printing and do away with screen printing and contract printing on offset presses.

The way forward

The large and growing Indian middle class and the growth of organised retail in the country drive the demand in the flexible packaging industry. Another factor, providing substantial stimulus to the packaging industry, is the rapid growth of exports, which requires superior packaging standards for the international market. In terms of the ease of usage, flexible packaging also offers greater ‘flexibility’ to consumers and this has gone down well in the market. “A package must protect what it sells and sell what it protects. Modern methods of consumer marketing would fail were it not for the messages communicated on the package. The information provided on packaging allows consumers to make informed decisions on the product’s purchase and use,” opines Sharma. Email: sweta.nair@network18publishing.com


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RAW MATERIAL: Inter face - Rajeev Bhatia

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Anniversary

“Development of bioplastics combined with efficient recycling has revolutionised the plastic packaging industry” …believes Rajeev Bhatia, Chief Executive Officer, Premier Pigments & Chemicals. In an interaction with Anwesh Koley, he explains why the plastics raw material industry has been criticised for causing environmental damage and industrial pollution and the causes for the rapid growth of the plastics industry which is being complemented with healthier and energy-efficient manufacturing methods.

How do you perceive plastics as a packaging material and does plastic packaging contribute to plastic waste?

Since the last two years, the demand of eco-friendly plastic products has increased to about 85–90 per cent. Research and development in the field of plastics is constantly going on, and manufacturers are looking for biodegradable and ecofriendly plastics. The effect of conventional plastics on the soil is far more severe as compared to bioplastics. Biodegradable plastics have negligible impact on the soil and thus on the environment. Plastic waste is a significant portion of the total municipal solid waste. According to industry estimates, approximately 10,000 tonne per day of plastic waste is generated in the country, of which packaging products have a substantial share. Development of bioplastics combined with efficient recycling has revolutionised the plastic packaging industry. Further, people are now aware of hazardous chemicals. The plastic packaging industry is hence using products that are free of lead and benzene. Although there are not many manufacturers who produce such products, people are willing to spend more for such products.

Why is it essential to have efficient plastic waste management?

Various international reports have shown that more than the harmful impact of conventional plastics to soil and water, it is the blocking of drainage systems due to littering that adds to pollution. Also, such blockages prevent rain water from percolating to the

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and is also having a competitive edge in production and cost, he does not get any incentive from the government or any other institution to pursue any such measures.

Have bioplastics been instrumental in revolutionising the packaging industry?

ground, thereby reducing the ground water levels. Recycling of plastics should be carried out in a manner such as to minimise the pollution during the process and as a result to enhance the efficiency of the process and conserve energy. Plastics recycling technologies have been strategically divided into three general types – primary, secondary and tertiary. This helps in ensuring the right technique for the right material.

What are the various problems plaguing the plastic packaging industry?

In terms of energy conservation in plastics production, the availability of power is a major problem for plastics producers. The steps taken towards green manufacturing and renewal of energy are not seriously taken in the industry till now. A major reason for this is the fact that its implementation is a costly affair and if a manufacturer finds that his competitor is not following the norms

Modern Packaging & Design July-August 2013

Several companies are exploring the development of bioplastics using carbon dioxide as a raw material. The potential for a process that converts waste carbon dioxide into a useful product is increasing, but whether the material produced using this technique will prove commercially viable will ultimately depend on whether these new polymers are cost effective to produce. A new sugar-based bioplastic that can be sourced from non-food crops and produced via a low energy process is also expected to reach the market within the next five years. Rigid packaging has a projected share of 52 per cent of the bioplastic packaging market in 2013. From the price point of view, bioplastics are definitely more expensive, but the environmental benefits warrant its usage. Even the machines that produce biodegradable plastics are about 20 per cent more expensive as compared to standard machines. The largest exporter of such machinery is Germany and, for cheaper machines, it is China. Even Taiwan has come up in a big way in making machines that are fast being accepted globally. This is due to the rapid growth of the Indian plastics industry, which is witnessing a 40 per cent growth. Email: sweta.nair@network18publishing.com


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RAW MATERIAL: Roundtable

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INDIA ready BIOPLASTIC PACKAGING revolution? Is for the

Anniversary

Bioplastic packaging is gaining ground globally as both manufacturers and consumers are waking up to its environmental and application benefits. Anwesh Koley examines the current state of bioplastic packaging technology in India. Dipak Vyas

Director, Neo Pack Enterprises

Bioplastic development efforts have focussed predominantly on starch, which is a renewable and widely available raw material. As a packaging material, however, starchbased bioplastics are extremely brittle. Starch alone cannot form films with satisfactory mechanical properties (high percentage elongation and tensile & flexural strength) unless it is plasticised, blended with other materials, chemically modified or modified with a combination of these treatments. Common plasticisers used include glycerol and other low-molecular-weight poly-hydroxycompounds, polyethers and urea. Starch-based thermoplastic materials have been commercialised and dominate the market of bio-based, compostable materials. Food-related applications include films for food wrapping and thermoplastics for food packaging and other food containers such as bowls, plates, cups and egg trays. Starch is economically competitive with petroleum and has been used in several methods for preparing compostable plastics.

Editorial take:

Ravi Kumar

Director, Shiv Pooja Plastics

Although the use of biodegradable materials in the flexible packaging industry is limited, the need to move in the direction of more eco-friendly packaging is strongly acknowledged by both consumers and the industry. Producers of films, inks, adhesives and resins are actively involved in research on new materials from renewable sources that are compostable and whose disposal can limit environmental impact. However, the physical properties of raw materials derived from various vegetable resources are different from those of conventional films. This has a bearing on their machinability, which is of primary importance to a converter’s operations. This has prompted global players in the packaging domain to test and show the capability of their printing and laminating machines to print and convert profitably such new materials, while also continuing to improve equipment efficiency in eco-friendly sustainable operations. Minimum levels of waste are essential to ensure sustainable operations while at the same time cost saving for profitability.

Govind Bhandari

Director, Shrink Packaging Systems Pvt Ltd

From 2010 onwards, bioplastics technology is changing with the commercialisation of bioplastics produced directly by natural/ genetically modified organisms and the introduction of non-biodegradable, bio-derived Polyethylene (PE). These materials are expected to account for a quarter of the total bioplastic packaging market demand by 2020 around the world. Polyhydroxyalkanoates are forecasted to achieve a CAGR of 41 per cent and bio-derived PE a staggering 83 per cent over the period. Traditional bioplastic packaging technologies based on starch, cellulose and polyester are each expected to show a decline in market share by 2020. In 2011, rigid packaging had a share of about 52 per cent of the bioplastic packaging market, while flexible packaging accounted for the remaining 48 per cent. Retail and food service trays and containers are the largest single pack type for bioplastic packaging, followed by flexible film. Flexible packaging is expected to have a growing share of the bioplastic packaging market in India over the next 5 to 10 years. Email: sweta.nair@network18publishing.com

Bioplastics technology in India is experiencing heightened activity because of its numerous benefits. While manufacturers might find it more expensive to opt for biodegradable packaging, what cannot be ignored is that the future of packaging will see a lot of bioplastics usage.

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Modern Packaging & Design July-August 2013


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MACHINERY: Robotic palletiser

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Anniversary

Enhancing precision and safety

In the age of extreme competition, reducing overall costs and enhancing the quality of products have increased the need for automation in manufacturing processes. Avani Jain highlights the advantages of robotic palletisers, which have found increased use by packaging companies.

Courtesy: OYSTAR Holding GmbH

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ver the past few years, packaging technology for food, pharmaceuticals and cosmetics has undergone a remarkable change due to the rising awareness of Indian consumers. The growing trend in the packaging industry is automation and the usage of robotics, which ensure better productivity and efficiency through a combination of speed and accuracy. A K Dhagat, General

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Manager, Mother Dairy (a unit of GCMMF Ltd), notes, “If we talk about the food packaging sector, then the use of automation equipment makes the process more hygienic as everything is system controlled and no human intervention is needed. Further, it ensures ease in operations. When companies go in for large production, they need automation equipment to handle this mass production. Thus, it assumes much importance in all the packaging sectors, including food packaging.” Today, the modern Indian consumer looks to buy quality products that are attractively packed and yet hygienic and safe. This can be ensured through the use of robotic systems in packaging. With the introduction of new robot system technologies, the face of manufacturing will undergo major changes. One area, in particular, where measurable savings are seen is in the automated palletising of products of all shapes, sizes and weights.

Modern Packaging & Design July-August 2013

Khalil Nathani, General Manager – OEM, Rockwell Automation India Pvt Ltd, says, “In order to differentiate their products, manufacturers need to continuously innovate, which is impacting their product life cycles. Globalisation has thrown in some never-before competitiveness challenges. Also, a surging middle class is driving demands, and manufacturers have to continuously scale up to seize this opportunity. Manufacturing assets that are highly productive and versatile to adopt changing products are the order of the day, and the packaging industry is no exception. Speed, accuracy/consistency and flexibility to manage a variety of products are common requirements for packaging machinery. Thus, automation and robotics play a pivotal role in meeting all these requirements of modern manufacturing industries to enhance their business performance.”

Evolution of robotic palletisers

Robotic palletisers have evolved rapidly over the last few years. Nathani avers, “Earlier, robots were used only to perform high-speed repetitive tasks to increase productivity. However, the evolution of vision systems and precision actuation systems and the convergence of these technologies with kinematics have impacted the intelligence and usage of robots across a wide spectrum of applications. In addition, flexibility in selection of pay load, reach and


Robotic palletiser

duty of the robotic arm combined with integration of a vision system and selection of choice of end effector has opened up tremendous application avenues in packaging, as they handle infinite possibilities of product types and the need for orientation of products in the packaging process. Further, reduced cost of acquiring robotics technology is opening commercial feasibility for numerous applications.”

The automation advantage

Robotic palletisers alleviate the need for manual stacking of bags, cartons or drums onto a pallet; these are also used for increasing end-of-line productivity and improving the presentation of stacked pallets. These palletisers are suited for applications involving production from one, two or more lines where flexibility is required and space is at a premium. In most cases, a robotic palletiser provides a better alternative to manual palletising technology due to many factors including increased output, continuous & automated monitoring of operations, safer working environment, less damage due to smoother bag handling, flexibility to handle a large range of products, adaptability to new products, reliability and measurable return on investment within two years. Nathani notes, “Robotic palletisers offer capabilities to meet the versatility, productivity and consistency demands of modern manufacturing requirements. These offer flexibility to change form and matrix of product to be palletised with least effort, thus ensuring the flexibility to pack a variety of products with the lowest downtime to set the machine for product change. Further, higher throughput can be achieved as a result of optimum path control algorithms and higher speeds of operation. Robotic palletisers also ensure consistent delivery with high precision and ensure best-quality packing and reduced product rejections.”

Increasing productivity

In the last few years, the flexibility, speed, payload and reach of robots have increased

and have greatly resulted in increasing productivity. Nathani says, “Advanced optimum path control algorithms enable robots to travel optimally from point A to B with coordinated movements of multiple axes with the shortest path, which reduces the stroke length and, in turn, the cycle time for every pick and place. Moreover, the use of high-speed AC synchronous motors ensures faster traversing speeds, further reducing cycle time. In all, these reduced cycle times help manufacturers to produce more in the same time, thereby impacting the efficiency of their manufacturing assets.”

Benefits of robots

Of all the benefits offered by robotic palletisers, precision and safety assume much importance. Nathani notes, “Robots use multiple closed loop AC synchronous motors working in coordination to achieve a motion. A closed loop motor offers capability to control the position precisely, ensuring that the product is placed on the pallets accurately in a programmed matrix consistently. Further, advancement in actuation technologies has generated capability in end effectors, which grip the product to apply precise pressure consistently to avoid any damages to the product. Also, a vision system adds visualisation capability to orient the product and place it in a desired order on a consistent basis. Thus, all these technologies help to considerably enhance the quality and consistency of packaging.” He adds, “Manufacturers strive for a risk-free work environment by ensuring safety to humans, assets and products. Modern control systems used for controlling robots integrate safety control features such as safe off, safe speed and safe networks to ensure safety requirements for a safe and productive manufacturing environment.” With advancements in robotics in the 21st century, it is no surprise that many packaging companies are turning towards using robotic palletisers. The obvious benefit is improved efficiency, and therefore, greater profit. Email: avani.jain@network18publishing.

If we talk about the food packaging sector, then the use of automation equipment makes the process more hygienic as everything is system controlled and no human intervention is needed. A K Dhagat

General Manager, Mother Dairy (a unit of GCMMF Ltd)

The evolution of vision systems and precision actuation systems and the convergence of these technologies with kinematics have impacted the intelligence and usage of robots across a wide spectrum of applications. Khalil Nathani

General Manager – OEM, Rockwell Automation India Pvt Ltd

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MACHINERY: Conveyor technology

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Anniversary

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Conveying outstanding performance With line control and automation assuming importance in the packaging industry, especially beverage packaging, adoption of integrated conveyor technology has assumed much importance in the present scenario. Avani Jain looks at the importance of efficient conveyor technology and lists its advantages in improving line efficiency, speed and flexibility.

obility s i m p l i fi e s and improves our everyday life. Conveyor applications also keep the industry moving right along. Whether used in a production process or production area, for further processing or storage and delivery or for other different requirements, the focus is always the same, ie conveyors need to span the distance efficiently and transport items as quickly as possible from point A to B. Reliable conveyor technology is the backbone of efficient packaging. So critical is its role that it can be compared with the circulatory system of the human body, where conveyors act as the arteries and veins of the production line and the filler is the heart of the system. Conveyor technology assumes much importance in packaging, especially in the beverage packaging industry, and if utilised correctly, it can be exploited to raise one’s line efficiency to a whole new level. Over the years, many developments

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Courtesy: FlexLink AB

have been made in conveying systems so as to ensure flexibility and speed. Eike-Sebastian Hagen, Executive Vice President – Operations, KHS Machinery Pvt Ltd, says, “The choice of the right conveyor system is essential to achieve the required line performance. Only the correct conveyor layout with proper buffers allows running the line at its highest efficiency. Hence, the correct conveyor system is not a question of advantage or disadvantage, but it is essential to ensure that the required line performance can be achieved.” He adds, “In the beverage industry, we use container conveyors [with belt or air conveyors for empty Polyethylene Terephthalate (PET) bottles], pack conveyors and pallet conveyors. All these conveyors connect with the individual machines of a beverage line. Furthermore, conveyors work as a buffer to ensure that the line still runs in full speed when one of the integrated machines runs with a lower speed for a certain period.”

Modern Packaging & Design July-August 2013

Courtesy: KHS GmbH

Evolution of technology

Over the years, various changes have been observed in conveying systems. Hagen notes, “At present, conveyors run with low energy consumption, thanks to variable centralised or decentralised drive concepts with high-efficiency drives (premium efficiency). At KHS, we also design low-noise conveyors. Advancements have also been made in developing conveyor systems for conserving resources with intelligent, energy-saving belt lubrication systems. Further, several changes are made to ensure that the operation of conveyor systems can be consistent and practically maintenance-free. Also, extremely longlasting conveyor systems have appeared in the market, thanks to a stable design and high-quality materials used in their manufacturing.”

One solution for multiple issues

The use of integrated conveyor technologies offers numerous benefits and is equally important to address many of the general production issues


Conveyor technology

Ergonomic design enhances worker safety and reduces repetitive motion injuries and other hazards.

Enhancing speed and flexibility

Integrated conveyor technology can help arrange the production to avoid inefficient stopand-go operation in the filling or packing line and enable maximum system performance while at the same time minimising machine stoppages. Eike-Sebastian Hagen

Executive Vice President – Operations, KHS Machinery Pvt Ltd

and trends pertaining to packaging line changeovers. The large-scale obstacles that can be addressed with conveyor add-on solutions include new packaging technology, new packaging materials and just-in-time inventory management. With regard to changeover efficiencies, the conveyor plays a crucial role of transferring products from one location to another effectively, without causing harm to the product or workforce in the process. In the converting operation, there are many ways by which conveyors can aid processors in reducing changeover times. From an economic point of view, automation of conveying operations enables packaging solution providers to achieve the required throughput volume and competitive consistency. Advanced monitoring and control capabilities enable them to maintain higher up-time for their packaging lines and reduce packaging waste, energy consumption and rejected packages.

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Conveying means transporting goods or products horizontally or vertically from one place to another. When spanning the distance, the goal is to move the objects as quickly and reliably as possible since transport time is actually unproductive time. Increasing personal safety is another important issue. If the conveying process is integrated into a uniform operator control and automation system, it is possible to achieve a markedly higher throughput at the end of the line. Hagen details, “All processes and components in a turnkey system must mesh perfectly to enable the machine to run to the best of its ability. Integrated conveyor technology can help arrange the production to avoid inefficient stop-and-go operation in the filling or packing line and enable maximum system performance while at the same time minimising machine stoppages.” He adds, “KHS provides conveyor systems in a modular design. This allows us to provide the perfect layout for any customer and to react flexibly to individual demands of each customer. The correct design of the line layout allows customers to run the line with maximum flexibility and highest efficiency.”

Improving line efficiency

There are two essential considerations for achieving good line efficiency. First, through the design of the conveyor layout, as a people-friendly design essentially manages man and material movement and reduces stress for operators. Machine-friendly design layout also helps in supplementing machine performance. Second, conveyor technology is important for line control and modulation. Line control and programming take into account different scenarios based on inputs from performance of the machine and sensors placed at key points throughout the line.

Modern Packaging & Design July-August 2013

Hagen details, “Only components that are perfectly aligned with each other can turn the sum of individual machines into a reliable, highperformance and energy-efficient system. Acting as a reliable link between individual production machines, conveyors provide continuous and flexible supply of the required containers. Combined with a specialised system control that helps to configure production in order to avoid an inefficient stop-and-go operation, conveyor systems developed by our company help in achieving maximum performance with minimal machine downtime.”

Reaching total excellence

A correct conveyor system design allows bottlers to reduce downtime, rejections, maintenance cost in spares and high wear & tear of parts. It gives bottlers the opportunity to truly automate their line, thus minimising the number of operations. Further, good conveyor systems help in achieving greater productivity and increased profitability with an integrated product portfolio and comprehensive solutions. These help in lowering operating costs through targeted minimisation of energy requirements. All these finally equate to a sizeable savings for the business. Thus, conveyors as a total system can be as complex and equally rewarding as any other packer machine on any other line. Hence, bottlers must ensure that conveyors always work smoothly. This can be done seamlessly using the correct design, materials and smart programming.

Future trends

In the future, trends would include decentralised control systems to ensure that customers can arrange each individual transport segment separately and that customers have flexible control. In addition, conveyor systems designed for optimum cleaning, with different hygiene designs that can adapt to all requirements, would be another trend that will surface in the time to come. Email: avani.jain@network18publishing.com


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MACHINERY: Inter face - Yatindra R Sharma

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Anniversary Anniversary

“The demand for quality total solutions is a challenge for packaging machinery providers” …opines Yatindra R Sharma, Managing Director, KHS Machinery Pvt Ltd. In a conversation with Avani Jain, he highlights various growth opportunities for the beverage packaging machinery industry in India. He also underlines the need for highly innovative packaging solutions in the beverages segment in the present scenario.

How is the demand for packaging machinery in the beverage segment in India?

innovative solutions that are durable and long lasting.

What are the challenges facing packaging solutions providers?

The Indian market is growing at a rapid pace when it comes to the beverage sector. Every segment in the beverage sector, ie water, juices, soft drinks and beer, has seen double-digit growth at a compounded annual growth rate in the last 4–5 years. Thus, there is volume growth, which means that the business for beverage packaging machinery is definitely promising. Further, the food industry is growing at a fast rate, and this is boosting the growth of the allied packaging industry.

What are the key growth drivers for the industry?

The main driver for the growth of the packaging machinery industry is the demand for cost-efficient technology with strong project management. At present, all players in the food and beverage sector are looking for single-window solutions where they can give a complete project to one provider along with full responsibility for execution. This phenomenon will become more prominent in the years to come. Hence, people who are into single machine manufacturing will have to graduate to the level of providing total solutions in terms of technology, operational capability, installation/ commissioning project management, troubleshooting etc. Thus, packaging machinery manufacturers are looking for indigenous innovations and international partners to provide such solutions and execution capabilities at lower costs.

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The demand for quality total solutions is a challenge for packaging machinery providers who have to pay much attention to the quality and workmanship of machines. They will even have to compete with international players such as China, Italy and Spain in terms of degree of automation and reliability of machines.

What are the leading innovations making headway in the segment?

Companies are increasingly talking about lightweighting, high-productivity machinery and so forth. Aseptic packaging of juices is now done in paper cartons, ie tetra packs. Soon, we will see ultra-high temperature and flavoured milk in plastic bottles. The beer industry has already undergone a different kind of revolution in terms of using lightweight glass bottles, thus increasing the brew house production capabilities for increasing the capacity of their packaging lines, ie from 18,000 bottle/hr to 36,000 bottle/hr. Many changes are happening in the spirits industry, with decoration of bottles gaining importance. These changes in the beverage segment are driving innovations in the allied packaging machinery industry. Therefore, the packaging machinery industry has to look into all these aspects and provide

Modern Packaging & Design July-August 2013

What are the recent research and development initiatives of your company?

We are constantly involved in providing technologies that are demanded by the Indian market. At present, we are working to develop aseptic packaging technology for milk. We are also looking at high-capacity packaging solutions for various segments in the beverages sector. Besides, we are working on developing foam, fill and seal technology for powders and liquids.

What is the future of the packaging machinery industry?

The packaging machinery segment has a bright future and will continue growing for the next 50 years at least. The Indian market is growing at a healthy pace. Many industries are in foreign collaborations and are constantly innovating new technology solutions. The Indian market is also providing opportunities to foreign multinationals to come to India and set up their plants. Email: avani.jain@network18publishing.com


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MACHINERY: Roundtable

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Do INDIAN PACKAGING companies have the KNOW-HOW to meet growing

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MARKET DEMANDS?

With the increased competition facing the Indian packaging industry in the global as well as domestic arena, packaging machinery manufacturers need to adopt new trends as soon as possible. Avani Jain speaks to industry experts to find out the technological capability of Indian packaging companies to meet the demand of the rapidly growing market. Mahendra N Patel

Chairman, Mamata Group

Indian packaging companies are performing well in the country. Almost all companies are offering technologies that can face competition from foreign companies. Due to the high energy cost, all technical advancements are oriented towards reducing energy consumption in the plastics processing sector. Thus, changes are made in machinery for improving energy efficiency and speed. Companies are making constant efforts to make machines energy efficient through allelectric drives, servo drives, AC variable drives, improved temperature controls, insulation etc. Further, new processing techniques that can reduce energy consumption and moulding time are being developed. Thus, exports have improved to a great extent. China is ahead of India in terms of quantity of machines but is behind us in terms of quality of machines. The quality of our machines is close to European standards, while the pricing is similar to what is prevalent in the Far East. Thus, Indian packaging companies surely have the know-how to meet growing market demands.

Editorial take:

Niket Mankad

General Manager, Pace Packaging Machines Pvt Ltd

Thanks to the ever-growing FMCG and retail sectors, the packaging industry across India is experiencing an exponential growth. The global packaging industry is expected to grow to $ 820 billion by 2016, and the Indian packaging industry is growing at a rate of about 18 per cent annually. It is projected to become the fourth-largest packaging market in the world, with revenues of $ 43.7 billion in 2016. The Indian packaging industry will also face major challenges such as urbanisation, increasing health consciousness, low purchasing power resulting in purchase of small packets, changing food habits and rural marketing, pushing demand for sachets. Apart from these, few key parameters such as primary & secondary packaging protection, convenience, environmental aspects, increasing emphasis on the look, sales appeal and quality of retail packaging will be the focus of developments. Thus, the Indian packaging industry needs to be ready to work on these points to meet global and domestic competition.

Avra Mitra

Senior Manager – Key Accounts, Business Unit-Web Fed, Bobst India Pvt Ltd

The demand for flexible packaging machines is growing constantly. This is because the demand for flexible packaging is increasing. Further, the growth of the processed food industry has propelled the growth of the packaging market in India. This increase in domestic demand for flexible packaging is driving the growth of the flexible packaging machinery segment in India. Not only the big companies but also mediumscale enterprises in the segment are investing in new technologies and machines and moving up the value chain so as to meet the competition in domestic and global markets. When we talk about flexible converting/ packaging machines, companies are increasingly talking about shifting from conventional technologies to digital printing machines. Another trend is that all leading technology providers are working towards developing new technologies for energy optimisation of primary machines. Companies are also trying to move towards building energy-efficient systems for their machines. Email: avani.jain@network18publishing.com

With growing FMCG and retail sectors, the demand for packaging is increasing by the day. Indian packaging companies need to adopt the latest technologies to meet the growing competition in domestic and global markets. Keeping in mind the willingness and abilities of domestic companies, Indian packaging and allied machinery manufacturers do have the know-how to meet growing market demands.

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Modern Packaging & Design July-August 2013


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PROCESSES: Maintaining the cost–quality ratio

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Developing new processing techniques Packaging innovation makes recognising and understanding brand identities relatively simple. A brand’s packaging needs might range from updating current packaging to creating new and innovative packaging for a new product on the horizon. However, innovation can come at an exorbitant price. Sweta M Nair finds out how one walks this tight rope of maintaining a lucrative cost–quality ratio.

Courtesy: Tetra Pak

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oday’s packaging needs are co-mingled with numerous distribution and retail environments. The science of creating the right package that addresses both consumer and retail environments should not be underestimated. A retail package involves not only the product package structure and specifications but also the secondary and tertiary packaging. Where new packaging technology involves new equipment, package development ensures manufacturability and certification. In the light of such developments, manufacturers are trying to maintain the cost–quality ratio in developing new package processing techniques.

Getting it right

The chain involves all entities who drive packaging development; hence, it is not the onus of manufacturers alone. It usually involves basic packaging material manufacturers, convertors and

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brand owners working together towards a well-defined innovation objective. In the packaging business, this has to be an ongoing initiative to get a competitive edge for all concerned. Quite obviously, the objective has to be to get better overall cost-effectiveness without sacrificing or compromising on the primary packaging requirements. In the event of striking the right balance, it is very important that one has to understand that the objective has to be not the development of a ‘cheaper’ product, but the need to target the development of technologically superior products that deliver overall cost benefits to the whole packaging system through lightweighting (or source reduction, as it is technically known), faster packaging speeds that lead to higher throughput, reduction in the number of conversion operations or lower conversion costs, lower wastages across the supply chain, lower transport costs, better cube utilisation leading to lower number of

Modern Packaging & Design July-August 2013

truckloads for transportation of both packaging materials and packaged products, recyclability/reuse, less postconsumer waste, replacing inputs based on scarce non-renewable resources by those made from renewable sources like plants or, alternatively, better functional properties, aesthetics, more convenience or a longer shelf-life. “Even though the new innovation may be more expensive on a per kg basis, it has to deliver overall cost benefits as compared to an existing or alternative packaging system. Quite often, the innovation enables a new and more cost-effective and sustainable system to replace a traditional system, thus opening up new application areas or end uses. This is where flexible packaging scores, and a lot of this has been happening when we have developed new flexible packaging systems that have replaced rigid or semi-rigid packaging systems,” says Pradeep Tyle, Chief Executive Officer, Global Films Business, UFLEX Ltd.

On being cost effective

The use of flexible packaging materials in markets around the world is growing steadily. Additional applications of these materials could increase although challenges do exist. Flexible packaging is replacing rigid and semi-rigid packaging because of their overall costeffectiveness, source reduction and superior sustainability credentials. On the continuation of this philosophy, Tyle elaborates, “Flexible packaging makes more inroads into areas that are traditionally the stronghold of rigid and semi-rigid packaging systems. At a


Maintaining the cost–quality ratio

more basic technology level, the trend is towards wider and faster equipment for production of basic packaging materials like packaging substrates and for their conversion. This delivers higher productivity and more throughput that leads to lower production costs and lower energy consumption per unit of product. This also applies to end-user packaging machinery.” Process improvements also contribute; for example, plasmaenhanced vacuum metallisation of films

The Mantra How to strike the right balance? I would once again warn against the ‘cost–quality’ mindset as this implies a trade-off or compromise on quality to get a cost benefit. It is important that basic packaging requirements are not sacrificed as the very preservation and shelf-life of the product is at stake. What needs to be done is to generate cost benefits with new and technologically superior products or systems. Source reduction is an essential part of our development strategy. This could apply either to development of lighter weight flexible packaging materials that replace heavier components of a rigid or semi-rigid packaging system (eg replacing a glass or rigid plastic bottle with a flexible pouch) or to downgauging of film thickness for existing flexible packaging applications (eg replacing an existing film ply with a lower thickness ply or converting a complex four or five ply laminate structure into a functionally equivalent three-layer structure). At UFLEX, we have been successful in developing 8-micron-thick biaxially oriented polypropylene film and 6.5-micron-thick biaxially oriented polyethylene terephthalate film that have been drop-in replacements for films ranging from 12 to 20 micron in thickness in existing applications without sacrificing on functional properties and webhandling capabilities. These downgauged films are not ‘cheaper’ products but are technologically better films that deliver source reduction between 33–50 per cent. - Pradeep Tyle

for better film/metal bond strength and higher barrier properties or the development of transparent aluminium oxide coatings that deliver the highest moisture & gas barriers in transparent films and enable transparent see-through packages that can be optically scanned, subjected to metal detection and heated/ cooked in a microwave oven. In terms of packaging system trends, the highgrowth systems have been stand-up pouches & bags, contoured & on-the-go plastic containers, shrink-sleeves/labels, high-barrier plastic bottles and more flexible packaging in general.

Walking the tight rope

Another way of achieving this ratio is to standardise – this is where real cost savings can be achieved. Material standardisation is truly the way to create tremendous savings. By buying larger quantities, one can create economies of scale and it becomes easier for converters. Also, with the goal of minimising waste or excess packaging, delivering a pristine product should not take a back seat. “When a product has certain minimum basic packaging requirements for maintaining it in pristine condition up to the point of sale and/or consumption, there can be no question of diluting these or compromising on them unless, of course, the brand owner is prepared to make a sacrifice on shelflife requirements or aesthetics, both of which could turn off consumers. The objective has to be to develop a new packaging system or materials that deliver these basic requirements more cost-effectively or more sustainably. Of course, it is important to see that a product is not overpackaged. To achieve this, the packaging system or material usage has to be optimised. Such customisation is usually possible only with flexible packaging, which is our primary business,” adds Tyle. Although lightweighting of packages automatically leads to source reduction and cost benefits, there is an overwhelming emphasis on this now not only for commercial reasons (eg material

Quite often, the innovation enables a new and more cost-effective and sustainable system to replace a traditional system, thus opening up new application areas or end uses. This is where flexible packaging scores, and a lot of this has been happening when we have developed new flexible packaging systems that have replaced rigid or semi-rigid packaging systems. Pradeep Tyle

Chief Executive Officer, Global Films Business, UFLEX Ltd

savings, transport costs etc) but also because this leads to more sustainable packaging solutions (eg better cube utilisation, lower number of truckloads, lower emissions during in-bound material transport and during distribution/sale, lower energy consumption, reduced carbon footprint etc). With no downside to lightweighting, one must ensure that in the process, there is no loss of strength or load-carrying capacity of the package, no compromise on minimum functional property specifications, no additional incidence of damage during transit and distribution and, of course, no adverse consumer reaction. The consumer should preferably be clearly advised about the improvement in sustainability of the lighter package so that there is no bad after taste. Email: sweta.nair@network18publishing.com

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PROCESSES: Processing packaging materials

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Ensuring substantial weight reduction Although packaging plays a key role in protecting products, it can also end up as waste in landfill, dumping grounds or as litter. By reducing packaging, we can gain cost benefits in materials, energy and transport. Progress has also been made in lightweight packaging. This often involves selecting new materials that enable less material use. Sweta M Nair presents the latest techniques that are being adopted by companies when it comes to substantial weight reduction.

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eduction in packaging is being met with a good success rate across various packaging segments. Companies are traditionally focussed on reducing packaging material simply as a route to cutting costs. However, the true focus lies in developing innovation in light, stronger and better materials that also have a lower environmental impact. To achieve these goals, new technologies are critical to ensure a continuous programme for packaging reductions.

At the onset

Companies can reduce the weight of packaging by using lightweight materials, optimising structural & material design, developing concentrated versions of products and eliminating unnecessary packaging. Mark Bunker, Communications Director – Europe & AMEA, Rexam Beverage Can, says, “Material reduction is not only an efficiency gain but also reduces transport demands and brings fuel and logistics cost savings across the supply chain. As one of the leading global beverage can makers, Rexam has a strong track record of improving its raw material efficiency. In 2010, Rexam cut the raw material per tonne of production by 7.3 per cent by continued sharing of best practices and the on-going application of six sigma and lean enterprise, including increasing the number of discs cut per square metre of aluminium, thereby getting more out of each roll of aluminium and reducing the amount of scrap needing to be recycled.”

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Courtesy: Rexam

Less packaging is not necessarily more environment-friendly. Correspondingly, the weight and volume of waste are not always indicators of environmental impact. An integrated approach is necessary, using flexible mechanisms that cover the entire processing chain of product and packaging. Talking about the weight reduction trend prevailing in the plastic packaging segment, Karlheinz Weinmann, Head – Corporate Communications, Brückner Maschinenbau GmbH & Co KG, says, “An upcoming trend in international film markets will lead to more demand for innovative, thinner Biaxially Oriented Polypropylene (BOPP) films, requiring less raw material. To date, packaging films are made of products based on crude oil. In times of limited resources and ever-increasing oil prices, the clear objective of film manufacturers is to

Modern Packaging & Design July-August 2013

produce thinner films – with unchanged or even improved properties – in order to reduce raw material consumption. Previously used BOPP film of 20 µm thickness is nowadays moving towards 17.5 micron in thickness. With film manufacturers looking to reduce material costs and lower their carbon footprint, downgauging is very important.”

Taking a step further

Versatility in plastic film for packaging allows for downgauging; however, when older lines are involved, it could prove detrimental in terms of production stability and efficiency. On account of the implementation of ‘High-End System Components’ and improved process technologies, Weinmann sheds light on how Brückner Maschinenbau is able to offer film manufacturers optimum line efficiency for the production of thin


Processing packaging materials

Material reduction is not only an efficiency gain but also reduces transport demands and brings fuel and logistics cost savings across the supply chain. Mark Bunker

Communications Director – Europe & AMEA, Rexam Beverage Can

Packaging films are made of products based on crude oil. In times of limited resources and ever-increasing oil prices, the clear objective of film manufacturers is to produce thinner films in order to reduce raw material consumption. Karlheinz Weinmann

Head – Corporate Communications, Brückner Maschinenbau GmbH & Co KG

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films. “Smooth guiding and stretching of ultra-thin films; controlled drives on all feeding film rolls over the entire line ensure a gentle handling of the film without damage to surface; highly flexible machine direction orienter multi-gap technology; transverse direction orienter with excellent air distribution over the entire film width; web tension control in pull roll & winder and highly accurate thickness control with fast-acting profile control at die lip are some of its offerings. In addition, the simultaneous orientation process offers a well-defined advantage in terms of thickness reduction. Brückner has taken a pioneer position with its unique LISIM® Technology,” says Weinmann. Just a gram or two saved in the weight of a package can have a tremendous impact on the environment and energy efficiency when considering the millions of individual packages produced each year. For instance, as per a global lightweighting programme in 2011, Rexam was able to touch metal saving close to 10,000 tonne across its can making business. “One of the intrinsic benefits of beverage cans is that they are lightweight and are therefore a very efficient form of packaging that is welcomed by retailers as they are easy to stack and are space efficient. We are continually advancing our technology enabling Rexam to produce packaging that remains suited to changing consumer needs and evolving customer requirements. Compared with thirty years ago, the aluminium can is 40 per cent lighter with can midwalls that are about as thin as a human hair while the quality, strength and efficiency of the packaging is not compromised. Lightweighting cans is a technical process in which our engineers and quality teams work closely with our customers to ensure that the filling process of cans remains efficient and quick,” adds Bunker.

Laying the right tracks

Products need adequate packaging throughout the supply chain, as

Modern Packaging & Design July-August 2013

provided by the combined properties of primary, secondary and transport packaging. By presenting some of the techniques followed by companies could give one an insight on how important it is to ensure substantial weight reduction. Brückner has identified that the reduction in certain process steps (eg lamination and coating) up to end packaging is also a distinguishable trend. This is exactly where multi-layer films are applied. By means of so-called function layers, whether ethylene vinyl alcohol, polyamide or others, special film properties can be attained – for barrier requirements in particular – in either 7-layer clear or 5-layer metallised films. Such properties normally can only be attained by means of a subsequently manufactured composite film. At their own technology centre, Brückner has developed several new promising multi-layer film types and has implemented this known-how in their film stretching line technology, viz adjustment of the extrusion and filter system in order to attain thinner function layers (1–4 µm), special die for the corresponding exact layer arrangement (rearrangement of the layers must not occur) and process control to ensure the smooth implementation of the required stretching tension without damage to the thin layers. On the other hand, the can must be designed to give the anticipated shelflife specified for a particular product. It must also withstand mechanical handling on the filling lines, internal pressures during processing and possible careless handling during transport and storage, yet still present an attractive package to customers. With Rexam’s offerings that include the lightweight CDL ends that were launched in 2011, the company has retained the existing benefit of being 100 per cent recyclable along with 10 per cent savings in metal due to CDL ends. These metal savings are achieved through a combination of a reduction in the blank diameter of the end and the gauge of the metal. Email: sweta.nair@network18publishing.com


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PROCESSES: Inter face - Vimal Kedia

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“Sustainability comes at a price”

…states Vimal Kedia, Managing Director, Manjushree Technopack Ltd, when talking with Sweta M Nair regarding the process changes that are taking place in the Indian packaging industry. From weight reduction plans to sustainability issues, he discusses the dynamics of plastics in the packaging industry. Has the growth in the packaging industry maintained its pace with that of the changing times?

Currently, the plastic packaging industry is growing at the rate of 15 per cent. Overall, plastics consumption will be 13 million metric tonne by 2015, and it is slated to go up to 20 million metric tonne by 2020. This is a phenomenal growth rate. The per capita consumption in India is about 5 kg as against 60–80 kg in developed countries. This shows that we have a very long way to go. The best part about plastics is that the easy availability of different grades is suitable for various applications, mouldability and convertability. That is why manufacturers are switching over to plastics.

What are the hassles related to packaging when we talk about reducing weight and wastage?

As polymer prices continue to increase year over year, manufacturers have a tough time maintaining pre-determined price levels. To offset that price hike, we are trying to implement innovative ways to achieve reduction in packaging in its weight and waste while processing. The wastage is very high in developing countries because we do not have the sophisticated technology that developed countries have at their disposal. Moreover, we cannot afford such machines because our volume is not large. Instead, we resort to ways of weight reduction by using enhanced mould technology. There are some good mould makers in India, and competitive moulds from China, Korea and Taiwan are also making their way into India. Better moulds mean less weightage. However, weight reduction in any product is a long exercise in R&D that every manufacturer has to go through. Redesigning is being done and extra material is taken off from

Anniversary

I say this because if you purchase five 1 litre bottles of a particular product, then the total weight of the packaging will be about 135 g. If the same quantity is bought in one bulksized bottle, then the weight equals to only about 90 g – almost a forty per cent reduction in weight. We must use plastics more wisely, improve recycling technology and use recycled content with virgin resins.

How does one maintain the cost–quality ratio in packaging? the profile where it is not required. In the last two years, we reduced over 7 per cent of weight in Coca Cola and Pepsi bottles of different sizes. We were able to do this because of new advancement in design technology. Earlier, the neck of the bottle was heavy, which was not required, so the size of the neck was reduced. Similarly, if you look at the bottom of a plastic bottle, it is usually very thick. This technology was again improved, and we took out the extra material from this part. This continuous process of weight reduction must be done to reduce cost in view of the increasing cost of raw materials. Two years ago, a 500 ml polyethylene terephthalate water bottle used to weigh 15 g, now that same bottle weighs only 10.5 g. This forty per cent reduction in weight that has been achieved is very big.

What are your thoughts on the sustainability of packaging?

We need to make a conscious effort to reduce the weight of the package. Working on new technologies is one way to achieve this. At the consumer level, more encouragement should be given to consume and purchase in bulk.

Maintaining the cost–quality ratio is a big challenge because when you reduce cost, you also ought to reduce material. When this happens, the quality of the product might decrease. To avoid this and maintain a good cost–quality ratio, we keep on upgrading our machinery and moulds. We procure moulds only from original equipment manufacturers. Certain standards need to be followed in packaging, so we cannot compromise on that. Simultaneously, R&D is being conducted to create raw materials that have higher barrier properties; this will further enhance the shelf-life and stability attributes of the packaging. In order to make sure the business is profitable in the light of such developments, we could look at new markets because sustainability comes at a price.

Which are the untapped product segments when referring to blow-moulded bottles?

Fresh milk being sold in blow-moulded bottles could be the next big thing in India, and switching edible oil from flexible pouches to blow-moulded bottles could be a boon for Indian consumers. Email: sweta.nair@network18publishing.com

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QUALIT Y & SECURIT Y: Package labelling

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Raising the bar on quality The increasing need for enhancement of packaging security measures is warranted by the ever-growing demand of higher and stricter norms and also due to government regulations that remain dynamic. With the increase in the number of global transactions for goods, packaging security assumes wider dimensions as requirements vary according to consumers. Anwesh Koley delves into the reasons why security has gained importance for packaging and the way forward for this essential quality requirement.

he Indian labelling industry is complex, dynamic and is growing fast. Karl Vandenbussche, Director, Reynders Label Printing India Pvt Ltd, says, “Although the per capita consumption of labels in India is the lowest in any analysed region, it also has the highest growth rate in the world, at 19 per cent. In India, wet glue labels, although still growing in double digits, are fast making way for pressure-sensitive and flexible film labels. The bar-coded labels market is growing by 30–35 per cent in India, and it is already making way for smart Radio Frequency Identification (RFID) labels across the globe. Narrow web flexo and combination presses are

growing in India as compared with the growth of digital label presses in advanced countries.” Wet glue has been dominant in India because of its obvious ease of production and simplicity in application. Nevertheless, wet glue labels although huge in quantity and with continued double-digit growth were overtaken in value but not in quantity, by pressuresensitive labels in 2003–04. In contrast, the flexible shrink and wraparound labels form the highest growth segment of the label industry (more than 24–25 per cent), but this growth is on a small base. The Indian pharmaceutical packaging business is evolving into a specialised industry. This is

supported by a rising confidence of developed countries in domestic pharmaceutical companies. Moving away from mainly focussing on products, pharmaceutical companies now put much greater emphasis on the quality and consistency of the primary packaging material as well as its branding. “Being faced with malpractices and counterfeit issues in the Indian market, there is also a very strong direction towards the traceability of the product. Multinational packaging companies have discovered the existing growth potential in India. These companies have set up a base here to reap the benefit from growth, which in turn has raised the bar on quality and technology of the packaging material.

Courtesy: Packaging World

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Modern Packaging & Design July-August 2013


Package labelling

Advancements in pharmaceutical packaging

Courtesy: Packaging World

This has resulted in ease of getting an entry into the regulated market,” adds Vandenbussche.

Efficient labelling solutions

It all depends on the in-house pre-press where the latest systems must be installed that will give a head start when it comes to producing printing plates of unusual sharpness of detail and overall consistency. The print offices should be equipped with state-of-the-art presses capable of combining several printing techniques (eg flexography, screen print and hot & cold foil stamping) to obtain the highest achievable result. If a labelling company has efficient suppliers, it can obtain the largest range of printable materials and adhesives to tackle the most difficult applications in the most awkward conditions. Modern consumer product marketing experts believe that the product packaging and the label have to be attractive enough to help a product sell on its own. This requires the high value addition that is associated with the pressure-sensitive segment especiall y its new varieties suc h as c lear see-through and, in some cases, with shrink-wrap labels. It is estimated that flexible, pressure-sensitive, wraparound and shrink-wrap labels will rapidly take away market share from paper-based labels. India has already shown huge potential in terms of labelling solutions and is a market that is ready to be exploited at present.

While the Indian pharmaceutical industry is highly advanced with the highest number of US FDA approved plants outside the US, it yet has to embrace the pressure-sensitive technology similar to most countries across the globe. More than 60 per cent of the labelling in India is still wet glue, the traditional form of labelling. Innovations are happening more rapidly in the self-adhesive or pressure-sensitive label technology that most other industries have adopted, eg health & personal care, durables, automotives etc. The pharmaceutical industry is not far behind now. “The requirements for advanced labelling with respect to regulations, applications and functionality are increasing by the day, and companies are able to address these requirements with products such as low migration labels, hanging labels, booklet labels, blood bag labels, syringe labels etc,” says Vandenbussche. Driven by an increasing demand for quality, innovations in the field of pharmaceutical packaging have also been pushed in the same direction. “Manufacturers of pharmaceutical packaging have started to invest in more modern machinery equipment in order to maximise outputs and reach a higher quality level. This trend is also supported by pharmaceutical companies that export their products to other countries and regions as well as up-coming biotech companies. For them, stable supply and a high product quality are key success factors as far as packaging is concerned,” avers Vandenbussche. This also has an impact on the producers of raw materials, eg the glass tubing used by converter companies in order to produce pharmaceutical containers. It is important to have a high level of quality control, which is built on standardised procedures to ensure complete detection of non-conformities at every stage of production. A final inspection with a camera control will further eliminate defaults not visible to the human eye.

The requirements for advanced labelling with respect to regulations, applications and functionality are increasing by the day, and companies are able to address these requirements with products such as low migration labels, hanging labels, booklet labels, blood bag labels, syringe labels etc. Karl Vandenbussche

Director, Reynders Label Printing India Pvt Ltd

Packaging is done with utmost care to guarantee the integrity of products both in transport and when stored in the warehouse.

Challenges facing the package labelling industry

The label industry is facing many small hurdles hindering its growth. The first is that the printing industry as a whole has been disorganised and fragmented, lacking investment in specialised components and tools. “There is a dearth of technology developments, research and development, standardisation, testing and certifying as well as training facilities. Although foreign direct investment and organised retail growth are seen as drivers for the package labelling industry, environment, health, safety and best practices are some of the issues that must be tackled for the industry to address its customers’ needs,” opines Vandenbussche. Email: sweta.nair@network18publishing.com

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QUALIT Y & SECURIT Y: Quality control initiatives

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Improvisation through innovation The Indian pharmaceutical industry has been witnessing a steady growth over the past decade thanks to Indian pharma companies making diligent efforts to make India the preferred destination for pharma investments. This has resulted in a flurry of technological innovations being undertaken by pharma companies in India in order to bring the best to end consumers. Anwesh Koley analyses the various innovations in the pharmaceutical packaging security market and the way forward.

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he Indian pharmaceutical packaging business is evolving into a specialised industry. This is supported by a rising confidence of developed countries in domestic pharmaceutical companies. Moving away from mainly focussing on generic products, pharmaceutical companies do not put much emphasis on the quality and consistency of the primary packaging material as well as its branding. This has lead to the pharma packaging industry evolving into a specialised sector that has assumed equal importance as the content inside the package. With the growth of modern technologies, the type and form of pharmaceutical packaging are changing rapidly. Drug packagers are trying to reduce the cost of packaging and consequently the industry is also rising. A V P S Chakravarthi, Managing Director, Ecobliss India Pvt Ltd, says, “The segmentation can be individual or a combination of two or more in segments such as blister packs, vials, tubes, caps & closures, flow fill seals, bottles for suspensions, tubes, blowmoulded containers, thermoforming blisters, bulk drug containers in addition to the regular printed boxes, labels, flexible laminates and so on.” Although many of the above segments cater to non-pharma industries such as fast moving consumer goods, electrical/ electronics etc, the packaging industries supplying to the pharma industries maintain their uniqueness because of the high standards they need to adhere to.

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Line of separation

There is no separate line drawn among the general packaging industries that they belong to pharma packaging exclusively or otherwise. However, there are many packaging industries that maintain their exclusivity by contributing to the pharmaceutical sector. Even logistics companies in India and around the world have specialised chambers and temperature-controlled divisions for carrying pharmaceutical cargo because of its high quality and time importance. Dr A K Sinha, Vice President – Formulation, Morepen Laboratories Ltd, says, “A step in this direction is through the bar coding industry. The bar coding industry had a fillip with the

Modern Packaging & Design July-August 2013

onset of the retail revolution in India and is gaining ground across all formats of sale and across all industry sections. As traceability becomes the need of the hour, the new track & trace/2D coding will bring the next level of security for tertiary, secondary and primary packages giving companies and the government traceability for products, which will ensure ‘patient safety’. Government regulations on track & trace have given the bar coding industry a great growth opportunity.”

Witnessing improvement

While there has been a tremendous improvement in developing new drugs and new molecules, the packaging industry in India is still to catch up


Digital v/s Quality control of fset initiatives printing

Polypropylene collapsible bags with corrugated board lining have been extensively used outside India for carrying bulk drugs or intermediates. This trend is slowly being adopted in India as well now. A V P S Chakravarthi

Managing Director, Ecobliss India Pvt Ltd

The bar coding industry had a fillip with the onset of the retail revolution in India and is gaining ground across all formats of sale and across all industry sections. Dr A K Sinha

Vice President – Formulation, Morepen Laboratories Ltd

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with the pace of innovations that have occurred in the very products that they need to contain. However, of late, significant initiatives have occurred in packaging too. “The use of heavy drums which contribute to massive transport costs when they are shipped empty to the manufacturing industry is minimised abroad. Polypropylene collapsible bags with corrugated board lining have been extensively used outside India for carrying bulk drugs or intermediates. This trend is slowly being adopted in India as well now,” adds Chakravarthi. Similarly, packaging supplied to formulation industries has seen a dramatic development in the recent past to catch up with the global requirements. Smart packaging using radio-frequency identification technologies is set to grow in the coming years with demand from the user industry. With continuous improvement in global technology, the Indian consumer is also well aware of the requirements in terms of pharmaceutical packaging. “India has also witnessed a radical change in the past one decade that is nothing but a dramatic improvement in consumer awareness and the quest to know more about the product. This paved a new era in the primary packaging industry for pharmaceuticals to produce a better patient-interactive packaging, unlike in the past,” says Dr Sinha. Driven by an increasing demand for quality, innovations in the field of pharmaceutical packaging have also

Modern Packaging & Design July-August 2013

been pushed in the same direction. Manufacturers of pharmaceutical packaging have started to invest in more modern machinery equipment in order to maximise outputs and reach a higher quality level. This trend is also supported by pharmaceutical companies that export their products to other countries and regions as well as up-coming biotech companies. For these companies, stable supply and a high product quality are key success factors as far as the packaging side is concerned. This also has an impact on the producers of raw materials and glass tubing that are used by converter companies in order to produce pharmaceutical containers.

Importance of pharma packaging

Pharma packaging products represent the starting point of the value chain. The quality of the packaging product has an impact on all further steps within the process, and its steady supply is the precondition to make medical products available when and where they are needed. At a time when countries across the globe are investing heavily in the pharmaceutical industry and ensuring consumer satisfaction, India has also shown improvement in terms of quality. However, there remain areas where India needs to gear up and adopt more advanced labelling and bar-coding methods in order to counter the manufacturing of spurious drugs and to ensure stringent quality as practised worldwide. Email: sweta.nair@network18publishing.com


inspection challenges 8 Product for multinational organisations QUALIT Y & SECURIT Y: Food safety in the global village

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Considering the range of global & local food safety standards with which manufacturers must comply to retain access to markets is a principal industry concern, as are the growing importance of carbon footprint reduction and price pressures on raw ingredients. Product inspection technology is therefore of critical importance to maintain manufacturers’ competitiveness in the global village. Neil Giles

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he scrutiny that Multinational Organisations (MNOs) manufacturing food & pharmaceuticals are under to produce safe & high-quality products is intense and growing. Brand owners face expensive product recalls at the behest of state organisations [Food Standards Agency (FSA) in the UK and Food and Drug Administration (FDA) in the US] if their products are found to be contaminated with foreign bodies such as glass or metal fragments. The FDA lists some two dozen recalls on its website in December 2012 alone, while in the UK, in the same period, the FSA issued a product withdrawal notice for certain batches of cheese from three major supermarket chains due to the risk of metal fragments. Globalisation of food supply chains is also increasing

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food safety awareness. Safeguarding public wellbeing and peace of mind presents a great challenge for food & pharmaceutical manufacturers.

Navigating the supply chain Food & pharmaceutical manufacturing supply chains are becoming more complex, with raw ingredients being increasingly sourced from one part of the world, processed into a final product in a second region, before being exported to a third. This globalisation means that MNOs must comply with more regional regulations by using inspection technology. MNOs must also adhere to international supply chain standards and guidelines set down by individual retailers such as WalMart, Tesco and Marks & Spencer. Thus, the balancing act for MNOs is to have a global presence while retaining the ability to act locally to meet regional safety requirements.

Modern Packaging & Design July-August 2013

This situation is not expected to become any easier in the near future. More countries are expected to introduce regulations governing food manufacturing, requiring the use of precision metal detection and X-ray inspection systems capable of identifying foreign bodies in food & pharmaceutical products and removing rejected packs from the processing line. There is also a trend towards applying stricter guidelines inspired by those in effect in the pharmaceutical industry to food production lines. This is particularly true for nutraceuticals – foods enriched with nutrients and vitamins – where product traceability from the raw ingredient to the store shelf is a concern area for standards developers. Standards regarding ingredient declaration and labelling on packaging have become rigorous, leading manufacturers to invest in vision inspection systems to automate the label inspection process. The 2011 US Food Safety Modernisation Act includes several clauses that previously only applied to standards for the pharmaceutical industry, such as the requirement for food manufacturers to adopt ‘track and trace’ technology. In Europe, the General Food Law contains provisions for traceability, covering all food products and animal feed. China’s State Food and Drug Administration (SFDA) has introduced legislation making serialisation compulsory for food & pharmaceutical products. The Global Food Safety Initiative (GFSI) has had an important role to play in harmonising regional standards for food safety, helping to increase


Food safety in the global village

the transparency and efficiency of the global food manufacturing supply chain, reducing costs and providing assurance of safe food for consumers. Many retailers and governments have looked to the GFSI quality standards when developing their own guidelines, and it will become increasingly important for manufacturers to be certified to GFSIapproved standards if they want to work with multinational food brand owners and supply major retail chains.

Streamlining production Strict control over production to minimise the risks of physical contamination is important. Additionally, the rising costs of raw ingredients used in food production and increasing labour costs make cost efficiency important for global manufacturers. In response, they are searching for solutions (checkweighers or X-ray inspection systems) to monitor quality parameters (fill-level, shape and size) to reduce wasteful product underfill and overfill. Pressing economic needs drive manufacturing efficiency. Production line uptime is critical in meeting customer demands, and equipment needs to be fast, reliable and easy to set up and changeover between jobs. Under the glare of scrutiny from agencies, food & pharmaceutical manufacturers also need data at their fingertips, providing an audit trail that proves due diligence throughout. A further dimension to the waste factor is the pressure for MNOs to operate in an environmentally sustainable fashion. This is causing them to consider a raft of issues such as the energy consumption of their processing lines, including their product inspection systems, helping to reduce their overall carbon footprint.

Meeting the challenges Advances in product inspection technology break new ground in intelligence and sophistication. Many feature automated data collection that enables manufacturers to demonstrate compliance with food regulations to protect themselves against contamination claims that may occur in

the future. Product inspection systems (eg X-ray inspection machines) are being developed to further reduce energy consumption, allowing manufacturers to shrink their carbon footprint and support sustainability efforts. Food & pharmaceutical manufacturing lines have unique requirements; hence, the most suitable product inspection solutions for each individual line must be selected. The process to find the right technology really begins with a Hazard Analysis and Critical Control Points (HACCP) audit on the food production line. This is a legal requirement in the European Union and the US, and is becoming increasingly important in Asia. It will establish the most likely contamination points on a production line. Where a risk is identified, a Critical Control Point (CCP) should be established immediately after the point where contamination could occur. The HACCP audit also identifies the most likely forms of contamination (eg metal or glass shards, stone or bone fragments) at each CCP through the investigation of the origin of raw ingredients, the manufacturing process and the packaging format. Product inspection systems can then be located at the point where they will be most effective, limiting the risk of foreign body contamination. The choice of technology then depends on the nature of the contaminant threat,

and the specific location of the equipment is ‘validated and justified’ by following the simple steps of the HACCP audit. MNOs’ commitment to safety and quality for consumers must be total. The harsh consequences are fines, product recalls, site shutdowns and huge damage to their own and their customers’ brands. By working in partnership with product inspection equipment suppliers that have global experience and local account handling expertise, MNOs can be confident they can avoid such damage. These close relationships with suppliers can help food & pharmaceutical manufacturers safeguard consumer wellbeing, protect their brand and grow their business. Neil Giles is Marketing Communications Manager at the Mettler-Toledo Product Inspection Division of MettlerToledo, based in the UK. He currently specialises across all four main product inspection technologies, which are x-ray, metal detection, vision inspection and checkweighing. He is a member of the Chartered Institute of Marketing, with over 20 years of experience in the food & pharmaceutical industries and has extensive knowledge of equipment for the packaging, process weighing and inspection sectors. Email: neil.giles@mt.com

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8

QUALIT Y & SECURIT Y: Satyadeep Ray

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“Holographic packaging also improves the aesthetic appeal of the product” …opines Satyadeep Ray, Director, Holostik India Ltd. In an exclusive conversation with Anwesh Koley, he highlights the importance of holographic packaging in India where spurious products pose a constant threat to quality and life.

Tell us about the holographic packaging industry in India.

Previously, in India, packaging was primarily through the use of polyester, coupled with simple printings on the external packaging. These could be customised or non-customised. However, with the advent of holography, manufacturers who faced the problem of duplication resorted to this technique. Holography is essentially a sophisticated technology of laser optics. It can never be duplicated, thus providing vital security to packaged products. With the arrival of holographic packaging in India, companies were assured that their brand image would remain secure and the authenticity of their product is retained. The various types of holographic materials used in packaging are holographic packaging films, hologram hot stamping foils, holographic aluminium foils, hologram labels, hologram tape/security tape and hologram stickers. Nowadays, package designers are familiar with holographic treatments such as laminated films or transfer films. Apart from providing security, holographic packaging also improves the aesthetic appeal of the product. It provides a higher visual treat to the potential consumer at first glance compared to ordinary printing which is staid in its appeal.

How does holography provide security to packaging?

Earlier, companies used to resort to conventional printing on laminates and pouches made of polyester. Now, on the same material, holography is used. With holography, it becomes difficult to duplicate the product as it ensures a unique identity

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holography is used through the same technique as used in plastic packaging. Customers perceive higher value addition because holography provides differentiation and shelf appeal, bringing products to the front of the shelf. In this era, where customers face the psychology of choice, holography helps in getting the attention of customers and eventually a purchase. This is because holographic images can ‘move’ and ‘speak’ to consumers through optical motion, and packages with holograms provide enough eye candy to attract attention and gravitation towards the package. for each product. By being able to avoid replication of products, manufacturers have seen a boost in their sales as holography strengthens brand identity and thus ensures higher revenues. This is particularly important for pharmaceutical products where it is essential to ensure that quality standards are maintained. The cost involved in holographic packaging is not substantial as the procedure involves embossing holographics on polyester or other materials used. Embossing involves a technique of applying heat and pressure that transfers the hologram from the metal plate to the polyester. It is marginally more expensive than ink printing but offers far more advantages.

What are the advantages of adopting this technology?

Due to certain government policies, manufacturers are resorting to paper packaging instead of plastic packaging in certain sectors. Even in paper packaging,

Modern Packaging & Design July-August 2013

Is the packaging industry enthusiastic in adopting holography?

The large population of India ensures that the demand for packaging products is always on the rise. This has a direct impact on the spurious product market where counterfeiting is a major concern. The duplication problem is higher in India, and holography provides vital solutions to prevent this. Holography can be used on aluminium surfaces, paper and polyester, which is the most common. This technology has already entered the country, and with the high levels of research and development taking place in every industry, we can expect more enthusiasm from packaging companies towards anti-counterfeiting. However, the government must be lenient and flexible towards holography. If this technology is made mandatory for the relevant sectors, it will go a long way in providing quality to consumers and preventing spurious products from entering the market. Email: sweta.nair@network18publishing.com


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QUALIT Y & SECURIT Y: Roundtable

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How important is for and has it evolved in

RFID

Anniversary

PACKAGING INDIA?

Brand custodians operating in key segments are actively looking to increase their growth momentum. Counterfeiting becomes a major challenge for these custodians in markets where brand awareness is trivial and customers tend to purchase products relying on visual appeal. Anwesh Koley interacts with industry experts to gauge the importance of Radio Frequency Identification (RFID) technology.

Sailesh Kapur

Sales and Marketing Director – Materials, South Asia, Avery Dennison

Businesses can effectively track their products, manage inventory and forecast demand from customers by using RFID technology. RFID standards (EPC Global Gen2), improvement in hardware performance and low-cost passive labels/tags are now leading to wide-scale deployment and usage across various industry sectors that include leading manufacturing, DC and retail companies. RFID can help gain greater item-level authentication beyond techniques of optical security. More sophisticated than barcodes, RFID solutions can be encoded with large amounts of variable information, giving greater control in identifying and tracking products. It also offers increased memory capacity, costeffectiveness and reduced risk for error. RFID solutions for track and trace, rapidly accepted in Western markets at carton and unit levels, are at a nascent stage in emerging markets such as India; however, emerging markets are catching up. RFID technology can create ‘smarter’ supply chains that are more efficient, responsive and secure.

Editorial take:

Jay Singh

Research Analyst, Society of Manufacturing Engineers

In spite of growing applications of RFID technology in the industry, the technology is not fully mature and suffers from issues of attenuation and interference. Typically, the tracking of goods and assets starts with information exchange between the reader and the RFID tag, and within such a system, the ‘readability’ of tags plays a critical role on performance of the tracking system. In other words, the usefulness of the RFID system depends on the integrity of the data and in ensuring that there is no single point of failure. With the growing multitude of hardware (readers and tags), with very little to no standardisation, it becomes extremely important to test the same for readability. Various security mandates by global giants (100 per cent readability of pallet tags through dock doors and 100 per cent readability of case tags on distribution centre conveyor belts) have prompted many experts to declare this first phase a failure due to harsh distribution environments.

Julian Sperring

Regional Director & General Manager, Intermec Technologies

RFID is an emerging technology that is gaining wide acceptance in many industries, particularly in pharmaceutical, healthcare and retail. Mandated use of RFID on goods at pallet, case and item level continues to churn the consumer product goods, logistics and retail industries. RFID is evolving as a major technology enabler for tracking goods and assets around the world. It can help hospitals locate expensive equipment more quickly to improve patient care, pharmaceutical companies to reduce counterfeiting and logistics providers to improve the management of moveable assets. While the technology has received more than its fair share of media coverage over the last 12 to 18 months, many are still unfamiliar with RFID and the benefits it can offer. With this minimal exposure of the technology in the retail and manufacturing industries along with the non-conductive environments for radio frequency such as metal and liquids, there exists a great need for research to be conducted in hardware as well as software. Email: sweta.nair@network18publishing.com

In the context of the Indian market, as the organised retail sector rapidly evolves, the need for brand owners to differentiate and ensure security of their brands and products becomes a key focus. As a consequence, anti-counterfeiting and tamper-evident solutions such as RFID are going to evolve faster.

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SUPPLY CHAIN: Logistics

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Reducing costs and increasing efficiency

With rising interest in saving costs, the packaging industry in India has begun using lightweight packaging materials, which not only help in reducing the logistics cost but also help companies in achieving sustainability. Avani Jain looks at the current trends and lightweight packaging solutions adopted by companies in this segment.

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ogistics is a critical component relevant across all sectors, and it has to be optimally managed for smooth functioning of production and distribution. With rising competition, it has become even more important to enhance the efficiency of the system in increasing manufacturers’ competitiveness. Given India’s fledgling status in infrastructure development, packaging innovations are a crucial value addition to the progress and prosperity of the logistics industry.

Lightweight packaging Environmental regulations in the last few years have increased the importance of

efficient packaging and logistics systems. Issues such as the energy and cost required for producing and transporting packaging as well as the pollution created during package manufacturing and use is worrying every company in the segment. This has led companies to rethink their strategies, the result of which is lightweight packaging solutions. These solutions offer more than one benefit including reduction in logistics costs. Sunil Jain, President, Rajoo Engineers Ltd, notes, “Reducing film and wall thickness has become the new trend in the packaging segment. Today, packaging companies are rigorously working towards source reduction in basic raw materials

Courtesy: Ecolean AB

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Modern Packaging & Design July-August 2013

through developing technology and machines that support it. This in turn is helping in reducing the logistics costs to a very large extent.” Lightweight packaging means consumption of lesser amount of raw material to make the product, which reduces the cost of materials and transportation and also lessens the waste & energy demand. Lightweight packaging materials help in reducing logistics cost, as their usage in packaging directly means lighter loads or fewer lorries needed to ship the same amount of products, helping to reduce transportation energy, fossil fuel consumption, decrease emissions and lower shipping costs. Flexible packaging offers large energy savings per year in manufacturing and transportation. The potential for reducing petroleum use by reducing package weight in transport is impressive. Lighter packages can reduce carbon dioxide emission during transportation by as much as 12 per cent. If the same packaging were re-usable rather than single use, another 16 per cent reduction in carbon dioxide emission can be expected. Thus, lightweight packaging helps in saving the environment and reducing the logistics cost to a large extent. This calls for designing optimised pack styles that suit industry-specific requirements. While the focus should be on reducing packing gram/unit, safety margins should be incorporated by taking into account the transportation difficulty, road conditions, weather and handling capabilities. In emerging countries such as India, infrastructure for smooth logistics operations is still developing. Unitisation not only reduces the consumption of


Logistics

packing material but also eases handling and prevents pilferage.

Lightweighting Lightweighting can be achieved by using low-density materials, by developing novel multi-layer thin film or foamed sandwich structures. Ketan Bhatt, Owner, Drashti Packaging, says, “Various lightweight packaging materials are available in the market today. Some major products that enable manufacturers to create sustainable packaging include low-thickness polyester films, low-thickness metallised polyester films, biaxially oriented polypropylene films and multi-layer polyethylene films. Further, new specialty films offer an opportunity for reducing packaging weight and transportation & logistics costs.” Earlier, companies used to over-engineer the films because the product should remain safe during transportation. However, today, with new technologies available, companies are shifting to lightweight packaging solutions. Flexible pouches, such as sachets, are replacing Polyethylene Terephthalate (PET) bottles, which use lesser amount of fuel and lead to reduced greenhouse gas emission during transportation. Further, these sachets are easy to handle and prove cost-effective to customers as well. Thus, by carefully testing different packaging materials, manufacturers and distributors of goods can determine the exact amount of packaging needed to protect an item or items without creating unnecessary waste, thereby reducing logistics costs. Metallised films are used in some applications instead of aluminium foil. These metallised films are light in weight, and the cost of raw materials used to manufacture them is also very low. These films are exported to foreign markets as well. “With growing awareness about reducing packaging costs, lightweight flexible packaging is outperforming conventional methods of packaging, as it weighs less than many other types of rigid packaging, eg PET and glass containers, and incurs lower transportation & logistics costs,” notes Bhatt.

Further, successful exploitation of bio-based lightweight packaging materials can help reduce transportation costs and contribute to a reduction in landfill requirements & carbon dioxide emissions. Analysis of the properties of the novel bio-based polymers indicates that these can be stiffer or with higher elongation than conventional plastics used in packaging. This suggests that reduction in the weight of food packaging is possible by developing ultra-thin materials reinforced with fibres/microfibrils or by using foamed sandwich materials. Thus, in an integrated packaging model, the number of products per trade unit or logistics unit can be optimised to reduce the overall packaging materials used. The packaging logistics approach involves reviewing packaging as an integral part of the logistics costs. Reduction in yield losses, optimisation at design stages etc are some of the initiatives that companies are taking these days.

Reducing film and wall thickness has become the new trend in the packaging segment. Today, packaging companies are rigorously working towards source reduction in basic raw materials through developing technology and machines that support it. Sunil Jain

President, Rajoo Engineers Ltd

Future trends Effective logistics management can overcome the disadvantages in the short term, while providing cutting-edge competitiveness in the long term. This can be compensated by innovations in packaging technology to adapt to the transient changes in Indian infrastructure. Thus, packaging forms a crucial necessity for every sector. Packaging has a significant impact on the efficiency of logistics systems and activities such as manufacturing, distribution, storage and handling throughout the supply chain. In an era of rising energy & overall costs and scarce resources, companies need to work towards packaging that adds value to end-products, conserves the environment and reduces logistics costs. Thus, to achieve the goal of reducing logistics costs and the amount of materials used for packaging, companies can adopt lightweighting, which means that less fuel is needed to ship the packaging to companies and, in turn, to stores or retail consumers. Email: avani.jain@network18publishing.

With growing awareness about reducing packaging costs, lightweight flexible packaging is outperforming conventional methods of packaging, as it weighs less than many other types of rigid packaging, eg PET and glass containers, and incurs lower transportation & logistics costs. Ketan Bhatt

Owner, Drashti Packaging

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8

SUPPLY CHAIN: Cold chain solutions

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Effective food storage and transport India’s logistics infrastructure, particularly its cold chain part, has caught the attention of the packaging sector owing to a surging food industry. As Indians demand better quality fresh foods and ready-to-eat meals on the retail shelf, Avani Jain probes packaging solutions complementing conventional cold chain systems in India.

ackaging has a significant impact on the efficiency and effectiveness of retail supply chains, where efficiency can be achieved through adaptation and development of packaging solutions that are compatible with logistics systems. Packaging also affects supply chain effectiveness because it represents an interface between the supply chain and its main customers. This is especially evident in complex supply chains, which are fast putting fresh foods and perishables on the retail shelf. Fresh and ready-to-eat convenience food products are emerging trends in the urban Indian lifestyle. Products such as pre-cut fruits & vegetables and ready-to-cook meals require an intricate cooling chain, exclusive distribution within a limited regional area or the use of modified atmospheric pressure technology. Although processed

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Courtesy: AVANTE International Technology Inc

and packaged food is very popular in the Indian retail space, the industry has to ensure futuristic processing and packaging solutions for quality & safety of the end-user. To ensure that products are not damaged or compromised throughout the retail supply chain, food industries are increasingly adopting cold chain technology. With increasing purchasing power among India’s surging middle class, individuals with higher socio-economic status and more economic means are likely to consume fresh vegetables and fruits not only in higher quantities but also in greater variety. Hence, the cold chain serves the function of keeping food fresh for extended periods and eliminating doubts over the quality of food products. In all the supply chains it is concerned with, cold chain logistics favour higher levels of integration

Modern Packaging & Design July-August 2013

because maintaining temperature integrity requires a higher level of control of all the processes involved. It may even incite third-party logistics providers to acquire elements of the supply chain where time and other performance factors are the most important, even farming. Cold chain logistics systems may be defined as a series of inter-related facilities for maintaining ideal storage conditions for perishables from the point of origin to the point of consumption in the food supply chain. The chain starts at the farm level (harvest methods, postharvest and pre-cooling) and continues till the consumer or retail level. A well-organised cold chain reduces spoilage, retains the quality of harvested products and guarantees cost-efficient delivery to the consumer. Packaging forms an integral component of the cold chain industry.


Cold chain solutions

Cold chain technology

Temperature control in the shipment of foodstuffs is a component of the industry that has continued to rise in sync with international trade. As India focusses its export economy on food production, the need to keep these products fresh for extended periods has gained importance. A core component for the success of an ideal cold chain is the type of container used and the refrigeration method. Duration of transit, size of shipment and ambient or outside temperatures are important in deciding the type of packaging required. These can range from small insulated boxes that require dry ice and rolling containers to large plastic trays with a self-sustaining powered refrigeration unit. Some major cold chain packaging technologies include Dry ice: Solid carbon dioxide is about –80°C and keeps a shipment frozen for an extended period. Dry ice does not melt but sublimates on contact with air. Quilts: These are insulated pieces placed over or around freight to act as buffer during temperature variations and to keep the temperature relatively constant. Thus, frozen freight will remain frozen for a longer period, often long enough not to justify the usage of more expensive refrigeration devices. Quilts can also be used to keep temperature-sensitive freight at room temperature, while outside conditions substantially vary. Reefers: These are temperaturecontrolled containers, which can be a van, small truck or a semi or a standard ISO container. These containers, which are insulated, are specially designed to allow temperature-controlled air circulation maintained by an attached and independent refrigeration plant. However, the way reefers operate in the country is often debated. Devanshu Gandhi, Managing Director, Vadilal Industries Ltd, notes, “Since ice creams are highly perishable products, they require a proper cold chain. Indian refrigeration vehicles ply

hardly 200 km per day as against the foreign countries, where they travel almost 600 km per day. So the logistics involve huge costs.”

Challenges faced

Despite the benefits offered by cold chain infrastructure, it is yet not properly developed in the country. Vikas Mittal, Managing Director, McCain Foods India Pvt Ltd, says, “Food products like frozen foods in any country is fully dependent on the support from cold supply chain facilities. An efficient cold chain transports frozen products in a stipulated timeframe while maintaining the required temperature. In India, the cold chain segment is largely dominated by fly-by-night suppliers and small businesses with poor networks. As the services are not integrated, it leads to wastage and damage to food due to frequent handling and transfer. Hence, we had to work closely with third party cold chain operators to implement the latest technology in infrastructure and cold chain refrigerated transport.”

Since ice creams are highly perishable products, they require a proper cold chain. Indian refrigeration vehicles ply hardly 200 km per day as against the foreign countries, where they travel almost 600 km per day. So the logistics involve huge costs. Devanshu Gandhi

Managing Director, Vadilal Industries Ltd

The road ahead for India

The proportion of products packaged for cold chain systems at Indian ports has constantly increased due to various trade liberalisation policies, machinery, auto components and increased food products consumption. Value-added food products are expected to increase, which will enhance the need for more secure containerised transport. The cold chain industry is expected to grow at double-digits owing to organised retail and growth in the processed food sector. Ever since its advent in India, packaging logistics has been dominated by small players with small capacities and poor deployment of handling, stacking and monitoring technologies. While it has received a lukewarm response from almost all sectors, the food segment has welcomed innovations in packaging logistics and has bolstered investment in cold chains and allied machinery. Email: avani.jain@network18publishing.com

Food products like frozen foods in any country is fully dependent on the support from cold supply chain facilities. An efficient cold chain transports frozen products in a stipulated timeframe while maintaining the required temperature. Vikas Mittal

Managing Director, McCain Foods India Pvt Ltd

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SUPPLY CHAIN: Inter face - A V P S Chakravar thi

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Anniversary

“Packaging has a significant impact on the efficiency and effectiveness of retail supply chains” …opines A V P S Chakravarthi, Chairman, Indian Institute of Packaging – Hyderabad and CEO & Managing Director, Ecobliss India Pvt Ltd. In a conversation with Avani Jain, he highlights the intense synergy between packaging and logistics systems in order to deliver value throughout the supply chain.

How does packaging contribute towards an efficient supply chain network?

Packaging plays a major role across the gamut of the supply chain by providing various features such as protection, safety and compatibility. While these are basic benefits provided by packaging, the value-added features of greater utility in a rapidly changing retail environment such as providing tamper evidence, anticounterfeiting and track & trace are also provided by packaging. In addition, packaging has a significant impact on the efficiency and effectiveness of retail supply chains, where improvements can be achieved by development in packaging logistics. The core supply chain management issues involve choosing the right product, case and pallet sizes in a manner that will help increase product sales while lowering inventory, transportation and packaging costs.

What logistics challenges are faced by Indian packaging companies?

The logistics challenges include rising fuel prices, pressure of shipping fewer volumes and the demand to adopt environmentally responsible ways at various processes such as storage, handling and transport, which account for higher costs.

What are the recent packaging innovations in the logistics sphere?

Although the flexible intermediate bulk containers have been in use for few decades now, they are still considered one of the best space-saving transport-worthy packaging solutions when compared to rigid containers. With the technology advancing, they now come in different

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constructions – U-panel, circular/tubular, baffle, four side panel and round. Further, a European bottle manufacturer has recently come out with an innovative design that enables a bottle neck tuck in the bottom of another bottle. This design has helped to save space while packing bottles on a pallet and has also eliminated the use of secondary shippers. Thus, while ideas are unlimited, designs need to be operation-friendly as well.

How can packaging be designed for sustainable logistics?

Few attributes of sustainable packaging are reduced packaging and maximised use of renewable or reusable materials; usage of lighter weight materials; reduced CO2 emissions through reduced shipping loads; complying with regulations regarding hazardous chemicals and packaging & waste legislation; optimised usage of materials from certified, responsible sources and reducing the flow of solid waste to landfill. Because disposal by

Modern Packaging & Design July-August 2013

consumers has become a great problem, there is opportunity for supply chain optimisation. It can be achieved by using less packaging of direct-to-consumer shipments. Even lighter packaging can help in this regard. For example, the bending stiffness of paperboard affects consumer experience and the rigidity of packages. Hence, lightweight paperboards can provide the requisite thickness and stiffness at lower basis weights, thereby enabling significant savings through a yield advantage. These lightweight paperboards with optimised primary fibre raw materials and high bending stiffness help keep the product without blemish and the packaging in its original shape through the entire chain. Thus, sustainable packaging always serves as a win–win situation for manufacturers and users in the long run.

How do you perceive the progress of the Indian packaging industry?

Thanks to the ever-growing FMCG & retail sectors, the Indian packaging industry is experiencing an exponential growth. The total turnover is $ 27.6 billion and is expected to grow to about $ 43.7 billion by 2016, whereas the global turnover is about $ 550 billion. Further, India’s per capita consumption of packaging is only 4.3 kg per person per annum, as against Germany’s 42 kg and China’s 20 kg, which is very low compared to global standards. Thus, initiatives are needed to convert the large unpacked commodities into processed, packed and well-presented commodities. There is scope for innovation, entrepreneurship and logistical advancements. Email: avani.jain@network18publishing.com


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DESIGN INNOVATION: In-mould decoration

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Anniversary

Increasing product appeal

In-Mould Decoration (IMD) enhances the visual appeal of products and is a sure-shot way of branding these days. Sweta M Nair delves deep to find the kind of market penetration that IMD enjoys in the country.

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n-mould finishing technologies that include in-mould painting, coating, cutting, assembly, multimaterial and more are being investigated, and in some cases, highly touted as a solution to rising costs and competitive pressures. This technology to a certain extent saves labour, time and costs. In-mould technology may not be the solution for every application, but in-mould finishing can be the most astute choice. “IMD reduces secondary work with perfect quality. It gives a rich look to the packaging. The printing quality is very high, which makes the packaging last for a longer period of time,” says Nanda Kumar T, President, Wittmann Battenfeld India Pvt Ltd.

in the marketplace. Prashant Mandewal, General Manager, YUPO Corporation, Japan, says, “No post-labelling operation is required for IML decoration as the bottle gets immediately ready to dispatch with decoration. This again saves energy, glue, labour and working/ stocking space. This enables to score on cost advantages. Switching to IML technology can overcome the issues of inflation, increasing electricity cost and difficulty to attract human talent. Because IML bottles are ready to be dispatched immediately after production, they enable faster supply and the moulder can save on labour and overall production cost.

Adding value

Going a step ahead, In-Mould Labelling (IML) is an advanced pre-decorating technique used for injection moulded containers and lids. It was pioneered in Europe during the early 1970s. The technique has become a very popular method of product enhancement and has replaced self-adhesive and heat transfer decoration. The IML process entails the label being placed into an open mould and held in the desired position by electrostatic attraction. The mould closes and molten plastic resin is injected into the mould where it conforms to the shape of the object. The hot plastic envelopes the label, making it part of the moulded object. This new style of packaging is increasingly appearing on supermarket shelves. The high resolution graphics that are the signature of IML are improving the looks of a growing number of products

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Modern Packaging & Design July-August 2013

The trending topic

For IMD, durable goods have increasing applications, with the automotive market being the largest. In Asia, IMD’s largest applications are in consumer electronics. Its applications in packaging are growing by leaps and bounds. IMD offers design flexibility and productivity advantages versus other decoration methods after moulding. These benefits include design flexibility; multiple colours, effects and textures with a single operation; long-lasting graphics manufacturing productivity and systems cost reductions. This allows brands to express their personalities, while manufacturers easily


In-mould decoration

manufacture products with radically different looks. Through the use of IMD technology, one can achieve different colours, effects and textures that are complete when the part comes out of the mould. When any of these factors need to change, there is no need to re-tool or change resin colour. Just simply change the film to change the appearance or texture dramatically. Life-lasting graphics are encapsulated between film and resin with IMD. Unlike traditional first surface graphics that can wear off, second surface IMD graphics cannot be removed without destroying the part. Using IMD technology results in manufacturing gains such as reduced secondary operations and labour, production that moulds and decorates in one operation, elimination of adhesive (cost & process), lower system costs in many applications and reduced inventory with capability to stock only one colour of resin. “In India, IML decoration is now the buzz word, almost all top companies are aspiring to start IML for their own products. Companies such as HPCL, Valvoline, Pidilite, Dabur, Unilever, Harsheys, Godrej, Amul, Castrol, Vadilal, Diversy, Nerolac and others have started using IML. It is for such applications that YUPO became an industry leader in the production of 100 per cent recyclable, tear and chemical-resistant synthetic which has applications in the print, design and packaging worlds that were virtually limitless. Ongoing research and development allows YUPO to innovate products for new applications. Our research and development teams are constantly working to create new grades that further expand the many opportunities to use YUPO,” shares Mandewal.

The real deal

Some of the brands have their own labelling facility for their product. With IML, these brands can bypass one complete process of decoration, resulting in saving for the company. It is a hygienic technology because there

is no handling of products by human hands; thus, it is apt for oil and food packaging. Other contamination issues can also be avoided. Further, by reducing the overall cost of the container, the revenue can significantly increase for the company. Selling more quantity is possible due to IML, and to a certain extent, the issue of counterfeiting can also be dealt with. As a step towards social responsibilities, IML also helps to reduce the carbon footprint. By giving the product a premium look to stand out in the category, IML enhances decoration and reduces the rejection rate of packaging. “IML reduces the chances of duplicating the product as the YUPO IML substrate is a special product and not available easily in India. Mitsubishi Chemical India Pvt Ltd handles direct sales to printers by coordinating with respective brands,” says Mandewal. Because multiple tools and automation are involved in the IML process, it is critical to understand the time taken and to communicate with brand owners the time involved for IML projects. Educating them on the benefits, costs and complexity of using IML can be challenging. Some of the issues surrounding IML include choosing the right IML, and optimum substrate materials are the beginning. It is advisable to choose a supplier with expertise in IML and who can deliver the product on time. This is critical to the success of the project. The label is just as important as the plastic substrate material, so making sure that the label supplier has the type of equipment necessary to provide the labels is also important. IMD offers unique opportunities for plastic product designers, particularly for highly contoured parts requiring complex, multi-coloured decoration. However, most applications are not this demanding. Therefore, processes such as heat transfers, hot stamping and pad printing should be examined for their suitability to a given product before turning to IMD, as these processes are usually less costly for most applications. Email: sweta.nair@networkpublishing.com

IMD reduces secondary work with perfect quality. It gives a rich look to the packaging. The printing quality is very high, which makes the packaging last for a longer period of time. Nanda Kumar T

President, Wittmann Battenfeld India Pvt Ltd

No post-labelling operation is required for IML decoration as the bottle gets immediately ready to dispatch with decoration. This again saves energy, glue, labour and working/stocking space. This enables to score on cost advantages. Prashant Mandewal General Manager, YUPO Corporation, Japan

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8

DESIGN INNOVATION: CAD/CAM technology

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Anniversary

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Detailed design for optimum output The development of new packaging products has undergone tremendous change owing to technological advancements. Companies involved in product design for packaging are now able to produce complex designs faster and with a higher degree of quality. Sweta M Nair sheds light on the latest computer-aided technologies that ensure high-grade designing.

he apparent change in designing packaging products has been fuelled by the development in Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM). These entities have rapidly changed the way products are conceived, designed, manufactured, tested, evaluated and promoted. On looking at the past, the change in aesthetics and design becomes all too obvious. CAD/CAM technology can bring about a change in materials, details and intricacies in design, manufacturing methods and the factors of time and cost in the development of packaging products. This task is made easy by the growth in computer hardware specifications that enable CAD/CAM software to handle large amounts of data quickly and efficiently. Talking about the change that has been brought out by these software programs, Vineet Seth, Managing Director – India & Middle East, Delcam Plc, says, “Until about 20 years ago, bottles were predominantly made of glass. Soon after, they were replaced by plastics. This happened because advanced CAD/CAM systems were able to help designers create more accurate profiles, sharper features and complex contours, which were otherwise ‘designable’ but the manufacturing of which was tedious or inefficient. In short, CAD/CAM made the usage of plastics popular and economical. CAD provides designers the power of working with virtual models in 3D, and therefore, apart from visualising the

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form and shape, it also allows accurate dimensional details to be output for manufacturing – be it 2D or 3D.”

Right tools Increased productivity in design and manufacturing is also attributable to rendering tools of the current generation. These tools, present in CAD/CAM software programs, allow designers to produce realistic images and animations of the designed product. For instance, highly accurate contactless scanners are used to collect point data from a prototype or an existing part. CAD software such as PowerSHAPE are able to automatically recognise holes, fillets, bosses, ribs, chamfers etc from such scans or ‘dumb’ 3D models that can then be fine-tuned to better dimensional or functional accuracy. “The translation of these 3D models or their quickly extracted core-cavity or electrodes into NC programs is now possible with only a few clicks of the mouse due to the tight integration of CAD and CAM within the same environment. All of these factors have contributed to the efficient design and manufacturing of complex shapes in packaging design,” affirms Seth.

Modern Packaging & Design July-August 2013

The right tools in these programs if leveraged appropriately can incredibly benefit the packaging industry. At the onset, rapid designing of the most demanding shapes, even those which traditional modelling systems find difficult or impossible, can be carried out with the help of these programs. Texture wrapping to add extra value to designs by incorporating complex features such as embossed logos, grip surfaces and other patterns is another notable feature. Morphing to carry out complex ‘what-if ’ modifications to existing designs is one of the functional aspects of CAD/CAM software. Automatic electrode extraction, machining and inspection as well as fully integrated 2D and 3D machining (up to 5 axes) to create moulds, tools and models to exactly replicate the CAD

Courtesy: Delcam


CAD/CAM technology

model is another area which is crucial to the packaging industry. Because re-engineering has become mainstream in packaging, designers are able to convert existing physical models or parts into CAD data and further improvise on the design. Artistic CAD/CAM can be used to create complex 3D relief models directly from 2D artwork or photographs. Ultimately, the program’s fast and high-quality rendering for better product visualisation before design finalisation increases efficiency.

Approach road When referring to innovative packaging design, CAD/CAM is one of the most sought after and efficient methods. “Let us consider a bottle used to package wine. Using attractive labels is one way of presenting the brand; however, innovation is when you actually have a 3D shape of grapes and vines on the bottle itself. Such innovative designs are also possible by manual methods such as artistic carvings, but the time taken and the repetition of the same design across hundreds of mould cavities are not economical. Hence, it is not efficient in the current sense. Further, the quality of work varies across the many mould cavities that are needed for production. With CAD/CAM, this is not only easier than manual methods but also highly accurate and cost-efficient. Furthermore, ‘Tribrid Modelers’ such as PowerSHAPE provide designers the ability to take any 2D image or a 3D relief or a polygon mesh model to be mounted directly onto a given surface or a solid,” reveals Seth. The time savings in such a method is substantial. The use of CAD/CAM in innovative designs also means quick changes in terms of any product improvements, without the necessity to start from scratch. Taking efficiency to a whole new level, CAD/CAM technology has automated some of its routine operations. For novice users, wizardbased interfaces are the best for this purpose. For instance, splitting a component into the respective core and

cavity along with any addition slide cores or pins, selecting a mould base for a given set of core-cavity, extracting an electrode from a defined burn region, creating a cooling channel, making subtle changes to a design by morphing, wrapping a label or a triangle model onto a surface etc are examples of how these routine operations are automated. Mundane tasks (eg adding components to a mould base, ejector pins, runners, guide pins etc) are often a variabledefined feature that helps designers to quickly align these based on the ratio or pre-defined variables. Advanced users and designers with programming knowledge can use the ‘Macro’ functionality or the ‘Application Programming Interface (API)’ functionality to gain greater control over customised automation. In CAM, templates can be created for routine parts, thereby reducing setup times, as well as utilising features such as background processing and multi-threading. Speed and feed parameters can also be set up in the library as a function of tool type, size, material and the machine on which it will be cut. “Often, most advanced packaging companies use the automation features in the CAM software for ‘lightsout’ machining, thus increasing their productivity without increasing costs,” states Seth.

Acceptance rate Despite its evident benefits, CAD/CAM software is not as widely used as it should be although it helps to streamline manufacturing production operations across segments. Small players in the packaging industry are apprehensive about CAD/CAM as they perceive it as an expense. “I would like to believe that CAD/CAM is being increasingly used in the packaging industry than before. However, the tools or processes being used are often not very productive. One of the things that we have to bear in mind is that the packaging industry demands a CAD software program that excels in complex surface modelling. It also needs

I would like to believe that CAD/CAM is being increasingly used in the packaging industry than before. However, the tools or processes being used are often not very productive. One of the things that we have to bear in mind is that the packaging industry demands a CAD software program that excels in complex surface modelling. Vineet Seth

Managing Director – India & Middle East, Delcam Plc

functionality in the software that allows the use of surfaces, solids and triangle data in the same window; quick and interactive splitting of core and cavity, as well as the rapid design of mould tools. Further, in order to make the overall process meaningful, the CAM software should complement CAD by quickly and efficiently generating toolpaths for complex shapes while considering the safety aspects of gouges and collisions,” shares Seth. Perhaps a change in perspective will help the industry to look at this technology as an investment which helps achieve better designs, higher accuracies and cost-effective solutions. Moreover, owing to market trends, CAD/CAM specialists are becoming increasingly affordable and the learning curve for novice users are not as steep as they used to be. Email: sweta.nair@network18publishing.com

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DESIGN INNOVATION: Inter face - Rajeev Bajaj

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Anniversary

“CAD/CAM technology can help in the entire process of packaging” …affirms Rajeev Bajaj, Head Manufacturing, Autodesk India & SAARC. In an exclusive conversation with Sweta M Nair, he points out how CAD/CAM technology can prove beneficial to the packaging industry, which is rapidly expanding to meet the increasing needs of the food, beverage, consumer products and pharmaceuticals industries.

How useful is CAD/CAM technology when creating innovative packaging designs?

Competition and continual demand for new ways to package products are driving more innovative designs. Market pressures demand that manufacturers constantly search for new ways to make products more flexible, faster and cheaper. Electronic and robotic innovations are increasing. Autodesk’s products enable new ideas to be tried and tested in a virtual environment that combines mechanical, electrical and hydraulic/pneumatic systems. In addition, 3D modelling, rendering and visualisation capabilities of tools considerably enhance the ability to achieve desired results. Autodesk 3ds Max can be extensively used towards this end.

In terms of automating routine operations, what are the features incorporated in CAD/CAM technology?

3D technology from Autodesk provides productivity tools for engineers that enable design reuse and automation of repetitive tasks through rules based engineering. It provides a platform to create corporatewide applications for automating bid and order processes. These automated routines can then be deployed on desktops, as a web deployment or as a mobile application, for use by sales and/or engineering teams. Integrated sales & design engineering capabilities is something that is unique to Autodesk CAD/CAM solutions.

Can the use of CAD/CAM technology help to produce complex designs more quickly and to a higher quality?

CAD/CAM technology can help in the entire process of packaging, including

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the construction & design of packaging machinery & plants. The following are key challenges that CAD/CAM technology can solve: Reliability: Profitability for food processing, beverage and pharmaceutical suppliers relies heavily on the operation of their manufacturing plants. At the end of the manufacturing process, packaging is the last stage before delivering products to market. Machine downtime means dissatisfied customers and loss of earnings. Packaging machinery must be reliable. Autodesk’s sophisticated design tools include virtual prototyping and simulation to test products without the need for costly physical builds. Ease of use: Industries are demanding packaging machines that are easy to use, to reduce the need for skilled labour and the costs associated with training staff. Ease of use improves operational efficiencies. Ergonomic factors can be investigated using Inventor’s simulation, kinematics and visualisation capabilities to ensure that the operator–machine interface is intuitive and safe. Operator training can utilise

Modern Packaging & Design July-August 2013

instructional videos created using Inventor’s animation capabilities. Integrated solutions: The packaging process involves many different operations including forming, filling, sealing, wrapping, labelling, sorting, accumulating, counting and palletising. All these stages involve different packaging machines. There is also a need to integrate their operation. Autodesk provides the industry a standard data format to exchange information between Autodesk and third party products enabling conceptual, mechanical and electrical engineers to collaborate in designing integrated systems. Simpler maintenance: The industry cannot afford to spend long periods of time maintaining packaging machinery, as downtime negatively impacts deliveries and revenues. Packaging machinery manufacturers have to design products that are simple to maintain. Simpler maintenance means service engineers can work faster, reducing downtime and maximising operational effectiveness. Inventor enables modular designs to be created during product development. Autodesk’s Streamline Web project and document publishing environment provides secure access to maintenance documentation across the world. Modular design: Companies designing packaging machines look for commonality and standardisation across their product ranges to reduce costs and improve timeto-market and maintainability of their products. Autodesk Inventor offers a range of design features such as content manager to catalogue standard parts and Productstream providing fast and easy access to reusable designs. Email: sweta.nair@network18publishing.com


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PRINTING & GRAPHICS: Printing technologies

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Anniversary

When packaging gets inked! Traditional ways of ensuring shelf safety, such as balancing the lipid and aqueous phases with stable fats and sufficient sugar, adding salt and food acids or antimycotics, are not enough for most new products anymore. Sweta M Nair discovers how innovations in packaging and printing are now helping achieve these functional goals and more.

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ith intense competition to stand out on the retailer’s s h e l f, packaging in the X factor when it comes to buying a particular product, dozens of product choices in every category, the buying decision is usually made in less than two seconds. To cater to this need, a huge variety of substrates are available which is driven by functional requirements such as product protection and high-speed forming, filling and sealing. With an extremely demanding supply chain, packaging is the longest leadtime ingredient for most consumer packaged goods. Since forecasting consumer demand is a constant problem and losing sales due to product unavailability is a cardinal sin for product managers, a solution of using the most high-tech printing technologies could ease the pain. Processed food has changed. People now prefer foods that are minimally processed, that contain less fat, salt, sugar and other carbohydrates and more fresh ingredients. Shelf-life is not just a measure of months on a grocery shelf; it can mean added usability at home. Manufacturers use packaging to protect their products during storage and shipment and to satisfy their customers. One aspect of packaging that provides significant benefit is extending the shelflife of the product within the package. A growing trend is to use flexible packaging materials that offer convenience to consumers.

Modern technologies For flexible films, most plastics such

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Courtesy: Micro Inks

as polyethylene, polypropylene and polyester have chemically inert and nonporous surfaces with low surface tensions causing them to be non-receptive to bonding with printing inks, coatings and adhesives. Surface treatment systems increase surface energy to promote adhesion for printing, coating, lamination and other converting processes. Flexible packaging, by definition, is made from a pliable material that can be filled, sealed and retains an element of flexibility. There are many different types of flexible packaging, from flexible drink pouches to grocery bags. Elaborating on this subject, R Y Kamat, Director – Marketing & Sales, Micro Inks India, says, “Printing technology not only makes packaging more attractive but also improves the shelf-life of the product. Undoubtedly, in flexible packaging, lamination printing offers improved protection and shelf-life. The use of different types of

Modern Packaging & Design July-August 2013

laminate structures with excellent barrier properties enhances the shelf-life of the packaged product. Some of the low-odour and low-migration consumables protect and keep the product in its original form and taste. Packaging required with high aberration resistance, high heat resistance and high scuff is made possible with modern printing technologies that obviously increase better life of products on the shelf.”

Advanced innovations Greater competition, need for labelling of quality, quantity and price of goods according to government-prescribed norms and preference for packaged goods have resulted in innovation and introduction of technology in the packaging market. Kamat says, “MicroHuber, being one of the leaders in flexible packaging, offers a complete range of products for gravure and flexo


Printing technologies

printing and also for folded cartons and offset food packaging. Our Estralam & Microlam ink systems cover the gravure lamination printing requirements. Our Hiflon & Microfresh ink systems cover the Flexo CI press printing needs. We also offer the high gloss coating for CI press printing. Micro Inks always believes in service and executes value addition to printer as well as print buyers in the circle. Keeping environmental responsibility in mind, the introduction of rotational bigger packing adds value to service, and thus reduces the disposal of waste in the environment. As a part of our service, the Micro introduced ATM (Any Time Matching) is a computerised colour matching concept that adds value to the packaging fraternity. Nevertheless, it is our responsibility and utmost focus to impart best services and products as per today’s need.” The growing middle-class, opening of shopping malls, customer-friendly and growing retail markets, increasing industrial output and strong exports have

helped the development of the packaging industry. The flexible packaging industry uses key materials such as plastics, paper and metals that are made from foil or paper sheet or laminated paper and plastics layers. Packaging of food has come a long way in India, and it has constantly been experiencing dynamic introductions of new technology. Micro Inks offers a solution to this industry segment. Kamat says, “Our new toluene-free ink system is most suitable for food packaging. This newly developed ink system is free from the aromatic resins and is fully based on an aliphatic resin system. It does not contain solvents such as toluene and ketones and is considered safer for use in food packaging. The new toluene-free lamination ink system and low migration offset inks for folded cartons will be our thrust area for food packaging. Our new range of Flexo UV inks will also support the rising demands from narrow web flexo printing.” Email: sweta.nair@network18publishing.com

The use of different types of laminate structures with excellent barrier properties enhances the shelf-life of the packaged product. Some of the low-odour and low-migration consumables protect and keep the product in its original form and taste. R Y Kamat

Director – Marketing & Sales, Micro Inks India

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PRINTING & GRAPHICS: Aesthetic innovations

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Anniversary

Gravure goes hi-tech!

Printing is a process for reproducing text and images typically with ink on paper using a printing press. It is often carried out as a large-scale industrial process and is an essential part of the packaging business. Sweta M Nair presents the latest developments that are brewing in the printing technology segment.

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ravure is a printing method in which an image is applied to a printing substrate by use of a metal plate mounted on a cylinder. Unlike other processes, gravure printing uses a depressed or sunken surface for the desired image. The image to be reproduced is etched into the metal plate, sometimes by using laser. The metal plate is bathed in ink during the process and then wiped clean before application to the substrate. While gravure printing can produce high-quality results rapidly, the costs are significantly higher than other printing methods, including flexography or various forms of digital printing.

ongoing renaissance in packaging. Despite gravure’s undoubted printing quality, the process until only a few years ago was regarded as conservative and not very innovative, as well as less cost efficient in comparison with its competitor flexography. This somewhat antiquated image of gravure printing has changed now due to numerous technological innovations in the process. Improved automation in pre-press, which can be operated fully automatically, as well as faster engraving and shorter make ready times at the presses, have significantly increased the productivity and cost efficiency of the process. In fact, flexography has practically no cost advantage anymore over gravure. Because flexography has improved its quality over recent years, it has become more expensive and therefore lost the cost advantage that it had in the past. This also indicates that there is always a price to be paid for quality.

Current scenario A glance at the share of the different print processes in the production of flexible packaging material used in huge quantities by large brand owners to pack food products and confectionery shows gravure printing to be excellently positioned. Gravure printing clearly is the leading process in dynamically developing packaging markets in the emerging countries in Asia. This is particularly the case in China and India with their rapidly growing markets and more than one billion consumers each. The unique selling points of gravure, such as excellent quality and high consistency even at high print runs, naturally favour gravure’s position in these markets. The high number of packaging gravure printers in these countries also shows the enormous potential for the gravure printing industry. In India alone, there are some 500 packaging gravure printing plants, a significantly higher number than the 350 plants in total operating in Europe. In fact, many of the packaging gravure

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Market share

printers in India are not equipped with the latest gravure printing technology. However, these printers are now investing in modern gravure printing technology to meet the increasing demands of the growing Indian market. This is currently changing traditional structures of retail trade, as particularly in the big cities, all kinds of consumer goods as well as everyday essentials are now distributed by large super and hyper markets. However, it is not only the high quality of gravure printing that explains its

Modern Packaging & Design July-August 2013

To maintain its competitiveness and good market position, the gravure printing industry is continuously working to further develop the process towards even higher productivity and efficiency. Speaking about the latest innovations taking place in printing technology, R Y Kamat, Director – Marketing & Sales, Micro Inks, India, says, “The packaging market is the most dominating market in printing. Among the packaging, flexible is dominating in growth. In flexible packaging, there is a transformation from conventional gravure printing to hi-tech gravure printing, where the printing equipment is computerised and fast. The printing speed has gone up to 400 to 450 mt/m. Most often, printing


Aesthetic innovations

cylinders are mechanically engraved and make printing more sharp and attractive. In flexo printing, very high speed CI presses are installed. Flexo printing brings an option to print short run jobs to make it more viable and economical. All such innovations brought a lot of improvement in the aesthetic look of the package. The latest innovation with respect to rigid packaging is ultraviolet printing on coated board and metallised board, which is eye catching for consumers unlike conventional printing.” With the ongoing dynamic economic development in emerging markets in Asia such as China and India, as well as the remarkable economic ‘renaissance’ in Latin America with its rapidly growing market for consumer goods and the changing of the retail structures towards the North American and European models, gravure printing offers the best opportunities for further positive development. The gravure printing industry has good reasons to look forward with confidence, provided that it

can maintain its high technical standard and continuously improve the process. Printing technology for packaging not only adds aesthetic value to the product but also catches the consumers’ attention as the technology plays a vital role in making the product more attractive and also enhances the quality of the product by using ecofriendly substances. “Branding is really important and most essential to maintain long-term sustainability. New versions and eco-friendly products are really making strong brands in different consumer product divisions. In food packaging, people are moving towards non-toxic and eco-friendly inks that obviously make the packaged food product a strong brand. Manufacturers are moving towards using biodegradable products in printing which also help to improve branding with time. In a nut shell, technological advancements in printing technologies with today’s need are constantly improving the brand image,” affirms Kamat. Email: sweta.nair@network18publishing.

Among the packaging, flexible is dominating in growth. In flexible packaging, there is a transformation from conventional gravure printing to hi-tech gravure printing, where the printing equipment is computerised and fast. R Y Kamat

Director – Marketing & Sales, Micro Inks, India

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PRINTING & GRAPHICS: Inter face - Ravi Jain

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Anniversary

“Designing graphics is not a mindless exercise” …states Ravi Jain, Founder and Chief Executive Officer, Grover Zampa Vineyards. In an exclusive conversation with Sweta M Nair, he discusses the major role that designing and graphics plays in creating and positioning a brand in India’s nascent yet growing wine market.

What are the thought processes put into designing the graphics on a wine bottle?

Let me begin with a brief introduction. Grover Zampa Vineyards was formed as a result of a merger between Grover Vineyards Ltd and Vallee De Vin Pvt Ltd. The combined entity owns widely recognised brands in the Indian wine market. Each of our brands has a distinct feel to it. This has been achieved by establishing a good connect with the respective target audience through effective graphics. For instance, La Réserve, as the name suggests, is a reserved collection. It is French oriented and so a little bit traditional. The graphics on the label denote the brand’s age, maturity, style and finesse. On the other hand, One Tree Hill is a young brand; it is a no-frill wine. The name has been derived from the only mango tree that stands tall in our estate at Nashik. The graphics had to appropriately position the brand in the market. This brand is targeted towards the younger lot where we aspire to demystify the complexities associated with drinking wine. With this wine, consumers need not worry about pairing it with the right glass or food. Our other brand, Santé is known for its colourful graphics and is definitely hard to miss. The graphics on the label was created by Mario Miranda, the well-known cartoonist. This valuefor-money wine comprises graphics that capture the vignettes of the Goan lifestyle. In Art Collection, we refreshed the graphics where special paintings have been featured on the labels. This activity took us close to six months. We have connected the whole experience of drinking wine with art. Hence, designing graphics is not

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more importantly, its identity. Given the challenges in the kind of industry we are in, we are working towards this and will hopefully have a solution soon.

Are small bottles of wine consumed more in India?

a mindless exercise. It is not just a two or ten day exercise either. There is a fullfledged brief that is involved, and it takes a substantial amount of time to concoct effective graphics.

What are your thoughts on creating custom-made bottles for wine?

For the One Tree Hill brand, the bottle is still the same, but we are in the midst of trying to create a proprietary bottle. It is very difficult to create custom-made bottles in India because the volume required is very small – it is 1 million cases of wine a year compared to 250 million cases of liquor and more than 250 million cases of beer. For liquor, every decent-sized brand creates a proprietary bottle. This, in fact, becomes part of the total package, and brands can convey their attributes very distinctively. For instance, a square bottle is easy to store and a rectangular label sits perfectly on such a shape. Basically, every bottle shaped in a certain way has a good reason to be; it communicates the brand’s message, styling, pricing and,

The market share of small packs in India and around the world is very less; it is also diminishing. In case a consumer wants to try a new product, small packs in such scenarios are very handy. However, at a large social gathering, it is always the full bottles that are preferred and consumed. Moreover, in restaurants where a considerable amount of consumption occurs, wine is sold by the glass, so the share of small packs further diminishes.

Will wine make the switch from glass to plastic bottles?

It is highly unlikely that premium wine will be made available in plastic bottles. Even premium liquor will not be available in plastic bottles. Moreover, there is a whole ritual associated when uncorking a wine bottle – it is customarily and culturally oriented. You cannot make a change overnight to a plastic bottle. If there is a problem of logistics, then it could be considered. Plastic will not match up to the premiumness of glass. I do not expect wines priced higher than ` 600 to be sold in plastic bottles. Glass is premium and fresh. Pouring out wine from a plastic bottle – not many would like to make this switch. Given a choice between glass and plastic, consumers will prefer the former when it comes to wine. Wine has character, and it is only glass that can match up to its total worth. Email: sweta.nair@network18publishing.com


8

T YPES OF PACKAGING: R&D initiatives

Anniversary

Creating more value with less resources In an era of rising energy costs and scarce resources, companies need to constantly adopt R&D initiatives to develop new solutions or packaging materials without increasing cost. Avani Jain analyses the R&D initiatives undertaken by companies to create quality solutions and materials with less utilisation of resources.

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ackaging forms a crucial necessity for every sector. It helps manufacturers to transport products to consumers, increase shelf-life, minimise breakage, reduce handling costs, safeguard public health, provide product information and create consumer convenience. Plastic packaging accounts for more than 50 per cent of the total packaging in India. From toiletries to food products, plastics are present everywhere. The global outcry towards reducing environmental impact and reducing costs by creating new materials at affordable prices has prompted companies to undertake R&D initiatives rigorously. This has lead to development of new packaging materials such as bioplastics, degradable plastics etc. Also, this trend has prompted companies to adopt downgauging solutions for creating more value with less resources.

Cost scenario for bioplastics Oil price fluctuations have put pressure on the prices of conventional plastics, resulting in fluctuating prices of finished products as well. Although bioplastics producers do not expect a dramatic

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decrease in the price of their products, conventional plastics are becoming more expensive due to increasing oil prices, and this is highly affecting the plastic packaging industry. An analysis

bioplastic resins cost at least twice as much as petroplastic resins. Currently, the cost of bioplastics is 4–5 times higher than commodity plastics; besides, there is lack of awareness about it among processors in the industry. Unless these alternatives offer comparable performance in processing and use, processors will be sceptical of its use. Thus, the biggest challenge currently is appropriate R&D initiatives in developing bioplastic materials for packaging and cost effectiveness of basic raw materials. Clearly, economies of scale will help improve the price differential if more bioplastic resin manufacturing capacity comes on-line in the future. Further, bioplastics are mainly aimed at the plastic packaging market, which has stringent material specifications (eg moisture and gas permeabilit y). Thus, in order to gain foothold in the market, Courtesy: DOMCA SA bioplastics must provide from Frost & Sullivan reported that the similar or better properties than bioplastics market in India had grown petroleum-derived plastics. by 30 per cent in 2008 and will grow On the commercial viability front, at a Compounded Annual Growth the usage of bioplastics in packaging Rate (CAGR) of 7–9 per cent between applications is still a new concept in 2009 and 2015. However, at present, India. The raw materials required to

Modern Packaging & Design July-August 2013


R&D initiatives

Courtesy: Odwalla Inc

produce bioplastics are not available in India and have to be majorly imported from countries such as France. Because the sourcing of bioplastic resin is a very costly affair, it makes these plastics very expensive. Hence, not many companies take to manufacturing of bioplastics due to low awareness and high price of bioplastic resin. This has a direct impact on the packaging industry. Also, at present, the technology is not costcompetitive with petroleum-derived plastics. Moreover, the awareness about such plastics is very less and the government support to companies in the segment is also not up to the mark. However, keeping in mind the need for new packaging materials, the situation will change in the future because of R&D initiatives for reducing cost undertaken by companies in the segment.

Efforts to create more with less Apart from involving in constant R&D initiatives for bringing down the cost

of bioplastics, companies have also taken to downgauging solutions for creating more value with less. The rising raw material prices have led plastic packaging companies to move towards R&D efforts for exploring the possibility of downgauging the packaging material for cost and resource reduction. Downgauging means reducing the amount of material in a product while still maintaining or even improving the properties of that material. For example, just a gram or two saved in the weight of a package can have a tremendous impact on the environment and lead to cost and resource reduction when you factor in the net gain of millions of individual packages. With the demand for environment-friend ly packaging, companies are increasingly adopting strategies to reduce the weight and cost of product packaging and downgauging packaging materials. In recent years, the weight of the polyethylene terephthalate mineral water bottle has also reduced drastically from 78–90 per cent to 28–32 per cent. When it comes to flexible packaging, the film thickness has been reduced by nearly 30 per cent than it was used until a few years back. Further, a decade ago, the thickness of the film used for packaging milk was 60–75 micron; however, now the thickness is reduced to 55 micron only. All this has led to cost and resource reduction. With the sole aim of ensuring environment-friendly packaging and reducing costs, plastic packaging companies have adopted rigorous R&D efforts and the result is employing various steps for downgauging of packaging materials. Pramthesh Pandya, Head – Unit & Business Development, Parikh Packaging Pvt Ltd, notes, “We have taken to optimisation of film & laminate structures after proper stability study. We are also making use of new-generation polymers and films to provide higher strengths at lower thickness. By undertaking these steps, we are able to reduce per pack weight,

We have taken to optimisation of film & laminate structures after proper stability study. We are also making use of new-generation polymers and films to provide higher strengths at lower thickness. By undertaking these steps, we are able to reduce per pack weight, thereby leading to less material usage, less energy consumption and less cost incurred without compromising on the basic properties. Pramthesh Pandya

Head – Unit & Business Development, Parikh Packaging Pvt Ltd

thereby leading to less material usage, less energy consumption and less cost incurred without compromising on the basic properties.”

Future outlook The packaging industry in India is poised to take a huge leap in the coming years. At present, downgauging and bioplastics are the two main results of the extensive R&D efforts undertaken by the packaging industry in India for developing new materials at affordable costs, and there is still a long way to go. Thus, the future of new packaging materials and solutions is bright because of the high growth prospects of the Indian market. Email: avani.jain@network18publishing.com

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8

T YPES OF PACKAGING: New packaging materials

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Anniversary

On the eco-friendly path With awareness about sustainability and increasing environmental consciousness, the packaging industry in India has begun to adopt various innovative solutions for ensuring environment-friendly packaging. Avani Jain looks at the innovations in packaging that ensure sustainability.

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urrent industry statistics indicate that about 100 million tonne of plastics is produced worldwide each year. However, in India, the nature of plastics usage in various applications is merely on-tenth of the amount consumed in the US; hence, the demand for plastics in packaging will definitely increase. So the plastics packaging industry must look at the alternatives to avoid the problems of waste management and culminating effects on the environment. At present, a large sense of awareness is witnessed among industrial circles for use of technologies with an inclination towards sustainabilit y and environment safety. This has spurred industries to promote more environment-friendly technologies and materials, and hence several innovations are happening to ensure environment-friendly packaging. Apurva Kane, Senior Vice President, Mamata Machinery Pvt Ltd, notes, “Environment-friendly packaging means two things, ie the use of minimum possible material and materials that are recyclable. If a company achieves these two objectives, then it is said to be moving towards sustainability.” He adds further, “Keeping in mind environment-friendly packaging, some of the leading innovations are usage of bio-degradable/compostable films as well as recyclable environmentally

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Modern Packaging & Design July-August 2013

sustainable films. So, we have focussed our development efforts to design machines which are versatile and are able to process not only laminates but also more sustainable non-laminated co-extruded films. Further, we aim to develop a technology that allows customers to process biodegradable and recyclable films. At present, the technology that we are offering to the market helps in making thinner films. We have developed a new product, ie foam-fill-seal machine – a patented technology that uses recyclable film and not laminate.”

Degradable plastics

When it comes to environmentfriendly packaging materials, new degradable plastics top the list. The American Society for Testing of Materials and the International Organization for Standardization define degradable plastics as “Plastics which undergo a significant change in chemical structure under specific environmental conditions. These changes result in a loss of physical and mechanical properties, as measured by standard methods.” Degradable plastics undergo degradation from the action of naturally occurring microorganisms such as bacteria, fungi and algae. Plastics may also be designated as photodegradable, oxidatively degradable, hydrolytically degradable or those which may be composted. There are a number of biodegradable synthetic resins available. These


New packaging materials

include polyalkylene ester, polylactic acid polyamide ester, polyvinyl ester, polyvinyl acetate, polyvinyl alcohol, polyanhydride etc. These materials exhibit degradation promoted by micro-organisms. This has often been coupled to a chemical or mechanical degradation step. There are five different kinds of degradable plastics, ie biodegradable, compostable, hydrobiodegradable, oxo-biodegradable and photo-degradable. These can be either organically based from renewable resources or synthetic with a petroleum base. These materials can be used for trash bags, mulch films, trash can liners, shrink films, netting, healthcare industries, food service products, bubble wrap, bread bags, polyethylene paper cups, polystyrene trays and soak pads, stretch wraps films, food packaging applications etc.

Courtesy: Moore Recycling Associates Inc

Bioplastics

Another type of new packaging material that is gaining prominence these days is bioplastics. With only few players, the bioplastics industry in India is in a nascent stage. While bioplastics find use in some limited applications such as food service items, bags and packaging, this trend is set to change with innovations and improvement in quality, making it more accessible to the masses. Often referred to by their chemical component Polylactic Acid (PLA), bioplastics are derived from renewable biomass sources such as vegetable oil,

corn starch, pea starch or microbiota, in contrast to fossil-fuel plastics, which are derived from petroleum. Bioplastics are made from 100 per cent natural materials, and the manufacturing of bioplastics consumes 65 per cent less energy than conventional plastics. PLA is more popular and used to manufacture bags and water bottles. As per estimates, plastics derived from plant materials currently make up 0.2 per cent of the roughly 350 million metric tonne of plastics consumed each year. However, this volume could jump substantially over the next decade or so due to growing demand for eco-friendly packaging and other products that use biomass as feedstock. Further, until recently, many bioplastics found limited range of applications due to their poor mechanical properties. However, recently introduced materials and additives are leading to the development of a new generation of bioplastics that find applications in more demanding end-use environments. Thus, at present, the efforts in polymer development are majorly directed towards processing renewable bioplastics by utilising natural precursors. However, there is a long way to go before bioplastics are completely accepted by the market as there remains a big gap when it comes to costs. Umesh Sharma, Managing Director, Julison Packaging India Pvt Ltd, says, “The demand for new packaging materials, such as bioplastics, is increasing continuously. They will define the future of the plastics industry, keeping in mind the huge costs of petroplastics. However, there should be adequate steps taken to reduce the cost of new plastics as otherwise their market would remain restricted as not every company would be able to afford to use bioplastics to pack products.� Thus, although the eco-friendly alternatives to plastics such as bioplastics are gaining foothold in the consumer products category, they are yet to prove their durability, pliability and cost effectiveness as the good old plastics in

Environment-friendly packaging means two things, ie the use of minimum possible material and materials that are recyclable. If a company achieves these two objectives, then it is said to be moving towards sustainability. Apurva Kane

Senior Vice President, Mamata Machinery Pvt Ltd

packaging. However, the future of new packaging materials, such as bioplastics and degradable plastics, appears encouraging mainly because of the growth prospects of the Indian market.

Environment-friendly future

W hen considering environmentfriendly packaging, multiple factors must be taken into account, including the actual and energy costs of production & transportation, the quantity of raw materials used for manufacturing, toxicity & carbon emissions in production & decomposition and the overall biodegradability of the finished product. Packaging companies are working efficiently towards fulfilling all these parameters. The packaging industry has begun to carry out extensive research in this regard so as to develop new packaging materials to ensure sustainability and environmentfriendly packaging. Thus, the future of plastics packaging looks environmentfriendly at the moment. Email: avani.jain@network18publishing.com

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8

T YPES OF PACKAGING: Inter face - Lakshmi Ramakrishnan

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Anniversary

“Attractive plastic packaging adds value to the product and lures customers” …opines Lakshmi Ramakrishnan, Chief Executive Officer, Essen Speciality Films Pvt Ltd. In a conversation with Avani Jain, she talks about the growing demand for innovative and quality plastic packaging in the country. She also underlines the future trends in the segment.

How is the demand for plastic packaging in India? What types of plastics are being used in packaging?

The demand for plastic packaging has increased drastically over the years. Now, people are increasingly demanding quality product packaging. Thus, quality plastic packages along with improved look and feel are desired by everyone. In addition, people preferred plastic packages earlier only to reduce their cost, but slowly and gradually the situation is now changing and people are buying plastic packages because these are flexible. Moreover, it is seen that attractive plastic packaging adds value to the product and lures customers. Further, if we talk about food packaging in particular, then these days, polypropylene and polystyrene containers are increasingly being used for food packaging. This demand is bound to increase in the future.

What are the research and development initiatives of your company?

We majorly concentrate on downgauging the weight of products, thereby saving raw materials and reducing costs. In the past, we have done so for many products and these products have been very successful in the market. We are also continuously involved in improving the quality of products. Moreover, we adopt measures for reducing the cost of products through efficient utilisation of resources. This keeps us ahead in the competition. Further, the demand for specialty sheets in food packaging is growing by the day. Hence, we are

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and plastics disposal. Banning is not the solution to all the problems. In spite of these challenges, there are opportunities for growth of the plastic packaging industry as well. The demand for quality plastic packaging is increasing by the day, and consumers in all the segments prefer attractive plastic packages.

What will be the future trends in the plastic packaging industry in India?

trying to develop new products in this segment.

What are the challenges and opportunities faced by the industry?

At present, the major challenge for plastic packaging companies is the various bans on plastics imposed by different state governments. Various state governments in the country have also banned the usage of plastic carry bags. There are restrictions imposed on plastic packaging in one form or the other. All this has highly impacted the plastic packaging industry and will not allow the industry to grow further. In fact, instead of banning plastics, the society at large needs to implement efficient systems for waste management

Modern Packaging & Design July-August 2013

The plastic packaging industry is growing at the rate of 14–15 per cent per annum. Plastic packaging is an indispensible part in every segment – be it pharma, food or fast moving consumer goods. However, the demand for plastics in the food packaging segment will majorly drive the growth of the industry in the times to come. Many food processing companies are coming out with new products in the Readyto-Eat and Ready-to-Cook categories. This will directly impact the growth of the plastic packaging industry as most of these products are packed in flexible pouches and not metal containers. Further, the need for plastic barrier films and containers for packaging of food will define new horizons for the plastic packaging industry. At present, the demand for barrier containers is very low, and almost none of the companies in India manufacture these. The main reason is that barrier containers are expensive, and people want cheaper products. However, the thinking is changing, and people are moving towards barrier containers and their demand will definitely increase in the near future. Email: avani.jain@network18publishing.com


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Business Insights •Technologies•Opportunities

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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 1500 words, while that of a product write-up should not exceed 100 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 be sent a complimentary copy of that particular edition. Published by Network18 Media & Investments Ltd, ‘Modern Packaging & Design’ is one of the leading bi-monthly magazines 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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8 SEEING INSIGHT & OUTLOOK: Packaging consumption

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THE

BIG PICTURE

Anniversary

Packaging is involved in nearly every aspect of human life due to the use of different products. Importantly, it has also been able to meet the increasing needs of customers. This review illustrates the factors, shifts and trends that influence the packaging industry. P V Narayanan

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he economic environment in the country is influenced by four key forces, viz rapid sustained growth, liberalisation, demographics and conducive development of business environs. The demographics in terms of households can be broadly viewed under five major categories, viz ‘Have All’, ‘Have Lots’, ‘Have More’, ‘Have Some’ and ‘Have Nothing’. The ratio is about 0.3:1.3:0.5:10.0:0.3. This is essentially based on annual income. The third and fourth categories are predominant, ie the middle income and higher middle income. Trends in recent years are a clear indication of the shifts observed. These two categories are moving ahead because of increasing personal disposable income and hence better purchasing power to satisfy sophistication needs.

6%

5% 29%

26%

In the earlier years, the growth of the country was measured by the steel sector and subsequently by the electronics sector. Today, the packaging sector sets the index, and probably packaging alone has its shades cast on every walk of the industry and on human life.

All over the world The global packaging industry is estimated at about $ 600 billion, with a contribution of about 29 per cent from the Asia Pacific region, mainly from Australia, Japan and China; 34 per cent from Europe; 26 per cent from North America; 6 per cent from Latin America and 5 per cent from the rest of the world. India is indeed an opportunistic region. Whereas the world packaging industry is growing at 3–5 per cent, India is at an enviable position of about 12 per cent growth. The easiest way to interpret the potential for packaging is by the fact that 80 per cent of packaging is consumed by 20 per cent of the population. In other words, 80 per cent of the population has access to only 20 per cent of packaging. This opens up the reach possible for the packaging sector, and every percentage shift in the 80 per cent would be the index of growth.

Per capita consumption pattern 34%

Asia Pacific Europe North America

Latin America Rest of the world

Percentage contribution of different regions

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The interpretation can further be augmented by the per capita consumption pattern. Whereas the per capita packaging consumption in Europe, North America, Australia and Japan could be over $ 200, and at the higher level of $ 400 in Latin America, it is at the lower ebb in Asia and India. As against the global average of

Modern Packaging & Design July-August 2013

about $ 75, India is only at the level of $ 10. Thus, even if we have to reach the global average, the growth opportunity is over 75 per cent. This is the current situation, and hence, packaging appears to be a sector of opportunity. It is further evident by the fact that the Indian packaging sector had a compounded annual growth of only 4 per cent in the early 1980s. This grew in leaps and bounds to a level of nearly 20 per cent by mid 1990s, and subsequently steadied at about 12 per cent. The major growth sectors are ‘Flexibles’, ‘Folding Cartons’, ‘Thermoforms including disposals’ and ‘Labels’, particularly the pressure sensitive and shrink labels. Alongside will be the processing and packaging technologies. The Indian packaging market is estimated at over $ 1,200 million, and the growth trend is driven by growth in DPI, double/multiple income families, increasing retailing infrastructure, foreign direct investment and increasing investment by fast moving consumer goods multinationals and emphasis on brands. The food sector alone is the single point driver and is set to grow by over 12 per cent. The retail sector today is over ` 40,000 crore and is the eighth largest in the globe. Organised retail will be of the order of 10 per cent from the current level of about 4 per cent. This, along with private labelling, will have a very high impact on packaging. Domestic spending can be an excellent indication on the types and trends in packaging. Food & food products account for 31 per cent of spending. Agriproducts is valued at


Packaging consumption

$ 177 billion, milk & milk products at $ 49 billion and meat & meat products at $ 32 billion. Beverage sales is slated to double by 2015 as is the sales of ready-tocook/ready-to-eat foods. For 2010–2015, the growth rate is estimated at 65 per cent for alcoholic drinks and at 80 per cent for soft drinks.

Packaging consumption Packaging consumption according to the industry segment is governed by the growth of the particular industry, viz processed foods (20 per cent), pharmaceuticals (10 per cent), health & personal care (15 per cent), home care (8–10 per cent), engineering & electronics (10 per cent), software (20 per cent), consumer durables (8 per cent), textiles (7 per cent), chemicals (8 per cent), toys (7 per cent) and incense sticks (10 per cent), besides value added consumer packages.

On shifts and trends Shifts and trends in packaging are influenced by bulk to retail consumer packs, conventional to new systems, long shelf-life to optimum life, ease in handling & convenience, ease in production & distribution, overall economy and adoption of mechanisation & automation. Added facets contributing to the requirements and adoption of packaging and its movement are growing consumer consciousness, consumer convenience, willingness to experiment and pay, branding, facilitating quality claim, value addition, export thrust and disposal & sustainability. Packaging is fragmented due to two specific reasons, viz the wide range of package types and the proximity of supply sources to the user sector. The former also defines shapes, sizes, materials and technologies to suit customers or end users. Availability on time and in desired quantities to avoid a ‘stock out’ situation has become extremely difficult.

Evolving with consumers The life of consumers is changing very fast. Inventions and innovations are

Packaging consumption in the consumer packaging market (percentage values)

Packaging type

Percentage consumption

Rigid plastics

18

Flexible packaging

21

Folding cartons

17

Glass bottles

10

Metal cans

6

Caps & closures

5

Labels

4

Others

19

driven constantly by consumers and technologies. The consumer world has become increasingly uncertain. Consumer thrust is on brands. The increasing literacy level, media explosion and consumer exposition to new products and systems have increased choices. These have also made the market highly competitive and discriminating. Consumer expectations have undergone a sea change. Cost-centric consumers are slowly shifting from ‘value for money’ propositions to higher value offerings. Consumers today are willing to experiment, experience and adopt new products. The articulate consumer has developed aspirational needs, seeking solutions for a price. Quality and reliability are the new buzzwords, although cost is important. The strategy will revolve round a global scope (standardisation,manufacturing optimisation and logistics) and leadership (economy of scale, sourcing facilities, best practices and branding) and focus on specialisation (key development areas, innovation & creativity, closer customer relationships and optimal packaging solutions). Following the shifts and trends, the packaging industry has been on the move and has converted challenges into opportunities, leading to product and business developments. The trends witnessed in the recent years are likely to accelerate through 2013. New trends that would drive growth during the year and the years ahead would be rural & new consumer segments, expansion & new launches, emerging trends and trade channels, sales promotion & discounts and premiumisation. Consumption at the

bottom of the income triangle will grow stronger, and the major contribution will be from the rural sector. Growing consciousness for quality and belief in a brand by consumers in the rural sector will require not only a packaged product but also an attractive well-designed package with built-in convenience. The personal disposable income in the rural sector has enabled these consumers to reach out for packaged products that are preferably branded. Their preference for small quantity packages places a substantial volume increase in packaging materials and forms.

In conclusion The overall situation is indeed encouraging. The package conversion industry would need to be updated and ready to provide innovative, creative and optimally priced packages. Demands will see a quantum jump, and the estimate may touch over 20 million tonne. Is the packaging industry ready to face the onslaught? Will there be acquisitions, joint ventures and sharing of technologies as India becomes a hub for supply of both materials and machinery? (Data in this article has been obtained from various sources) P V Narayanan is a Member of Board in APEDA (Ministry of Commerce). He is also Secretary General - IPMMI and Chief Executive - PFFCA. He is a recognised UNIDO, ITC and CFTC (UK) expert consultant in the field of packaging. Email: pvniyer@hotmail.com

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8

INSIGHT & OUTLOOK: Holistic brand building

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Anniversary

LOOKING BEYONDLOGOS

The concept of branding dates back to ancient times when animals were branded to distinguish ownership. Branding has changed from then to its present form that has evolved to encompass recognition, recall, experience and even a celebration among consumers. Both branding and rebranding have reached a whole new level to stay relevant in the present times. Alpana Parida and Aakriti Goel

D

uring the early stages of the industrial revolution, as a large workforce uprooted and migrated to urban production centres, the local products and services from back home were the only familiar things, and these became the earliest brands of our times. Although the world has changed since then and branding has assumed new meanings and definitions, the idea of having a symbol that is laden with much significance and meaning and which differentiates one generic product or service from another has been constant.

Defining a brand

The concept of branding has been defined and redefined over the ages in various fashions. The old school defines a brand as a name, term, design, symbol or any other feature that identifies one

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seller’s goods or services from others. However, a brand in modern day terms is an embodiment or a set of expectations, memories, stories and relationships that when taken together account for a consumer’s decision to choose one

product or service over the other. Today, brands need constant reinvention to attract consumers. Influential brands, like influential people, make their presence felt and leave behind a vivid imagery for people to remember and recall. With shifting consumer loyalties and an increase in the number of brands, brand managers need to work harder to create brands that are remembered and preferred. A brand needs to function as a singular concept or idea that is owned across various touch-points, which can result in a memorable and complete consumer experience.

Brand recognition

While Lux or Liril is treated like another personal care brand, Dove has been able to etch out a clearly demarcated space for itself amid the cacophonous clutter of the personal care market place. The brand celebrates us – the common people, and says there is real beauty in real people.


Holistic brand building

The premise of ‘1/4th moisturising cream’ coupled with the real beauty concept has been reinforced by the brand across all media and has subconsciously been entrenched in the minds of consumers. The result is a brand that stands for something unique while making ordinary everyday people spokespersons of the brand. This is the magic of holistic branding that supports and brings to life the brand’s core thought across various touch-points so that the core message gets established over and over again in the minds of consumers. Till date, brand owners have equated branding to the creating of a logo. However, holistic branding goes beyond the realms of just a logo and extends itself to all the five senses, hence resulting in a wholesome branding experience.

Creating a compelling story – Standard Chartered

The compelling brand story created by Standard Chartered in harnessing various elements in its branding is an example of wholesome branding. Standard Chartered has not only been able to create a niche for itself with a distinguished logo and a unique colour combination, it has also maintained consistency in its communication across various media. From its illustrations to its website, Standard Chartered has been able to establish a unique identity that is independent from its logo and still distinguishable. In the day and age of increasing competition and occupying consumer mindspace, brands need to capture all the five senses and subconsciously make an impact in the minds of consumers to remain relevant. Tools such as experiential and sensory branding are being used to capture the five senses but have not been used holistically to capture the target audience at large. Be it Mozart’s symphony for Titan, the signature tune for Britannia or the retail kiosks for perfumes, brands have not been able to harmonise ownable elements towards a holistic brand experience.

Keeping with the times – Fastrack

Fastrack, from the Titan stable, was clearly targeting a younger consumer – one who perhaps saw Titan as an older person’s brand, such as the brand worn by parents. Fastrack captures the youth’s philosophy of ‘Move On’ – from its constantly changing product portfolio, to its packaging, to its communication that makes moving forward a virtue. Brands that simply rely on advertising to create a memorable advertisement miss out the chance of intervention at the level of packaging and retail to create a significant differentiation.

Increasing visual appeal – Kurkure

The image in the new Kurkure packaging takes the impulse category to a new place by maximising the tear that perfectly symbolises the light but irresistible snack. The rejuvenated identity was an apt evolution from the previous, and it added a spark of energy not only through the identity and font visual but also through the strong visual mark of the tear.

Rebranding – Amul Ghee

Today, brand managers can leverage packaging to do a lot more to increase market share and ensure shopper preference through innovating packaging in terms of design, structure and substrates. At a time when health consciousness is on the rise, Amul Ghee was contemporised and made relevant. While researching, it was found that ghee was actually good for health and should be used daily. This was communicated through structure innovation. The innovative structure with a leaf facet was utilised to highlight the ‘1 spoon a day’ proposition. The motifs used in packaging were contemporary and modern while maintaining the gamut of colours to cue tradition and reinvent Amul Ghee from being an old brand to being modern and in sync with the audience of today.

The metallic look

The use of metallic substrates or inks has boosted many brands. Taj Mahal

tea has improved perception and has a more premium appearance in terms of perception as a result of the metallic look. Similarly, the new range of Lakme has been revamped to look premium and convey various propositions for the beauty brand, changing its perception from masstige to premium. Cigarette and liquor categories have been using the metallic look for a long time, but now many other categories are adopting the look to evoke the premium feel. From soaps to lipsticks and from tea to deos, metallic has come to symbolise premium. Holistic brand building is an imperative in today’s complex market place, and brands that leverage that opportunity will become market leaders. Alpana Parida is President of DY Works. With over 20 years of experience in retail and marketing communications, she is steering one of India’s largest pure-play branding agencies offering insight-driven solutions across its expertise areas. Email: alpana@dyworks.in Aakriti Goel is Senior Marketing Manager at DY Works. Email: aakriti@dyworks.in

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New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers such as consultants, raw material suppliers, plant & equipment manufacturers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the packaging, printing and converting industries.

Anniversary

Duplex paper Rana Papers Ltd Project type New facility

Project news

Rana Papers Ltd is planning to set up a new paper project at Muzaffar Nagar in Uttar Pradesh. The project involves manufacture of duplex paper.

Project location

Muzaffar Nagar, Uttar Pradesh

Project cost NA

Implementation stage Planning

Contact details: Rana Papers Ltd 8 km Stone, Jansath Road Muzaffar Nagar 251 003 Uttar Pradesh

Kraft paper Magnum Paper Mills India Pvt Ltd Project type New facility

Project news

Magnum Paper Mills India Pvt Ltd is planning to set up a new paper project at Mahaboobnagar in Andhra Pradesh The project involves manufacturing of kraft paper.

Project location

Mahaboobnagar, Andhra Pradesh

Project cost NA

Implementation stage Planning

Contact details: Magnum Paper Mills India Pvt Ltd 3-6-344, Ruby Plaza, Basheerbagh

Hyderabad 500 029 Andhra Pradesh

Paper (machine made) Rainbow Papers Ltd

Packing paper The Canara Paper Mills Pvt Ltd

New facility

Project type New facility

Project news

The Canara Paper Mills Pvt Ltd is planning to set up a new paper project at Kottayam in Kerala. The project involves manufacturing of packing paper.

Project location Kottayam, Kerala

Project cost NA

Implementation stage Planning

Contact details: The Canara Paper Mills Pvt Ltd Chethipuzha, Changanassery Kottayam 686 104 Kerala

Paper & paperboard articles and pulp products Tapovan Paper and Board Mills Ltd Project type New facility

Project news

Tapovan Paper and Board Mills Ltd is planning to set up a new paper project at Aurangabad in Maharashtra. The project involves manufacture of paper & paper board articles and pulp products.

Project location

Aurangabad, Maharashtra

Project cost NA

Implementation stage Planning

Contact details: Tapovan Paper and Board Mills Ltd Nath House, Nath Road Aurangabad 431 005, Maharashtra

Project type

Project news

Rainbow Papers Ltd is planning to set up a new paper project at Mehsana in Gujarat. The project involves manufacturing of paper (machine made).

Project location

Mehsana, Gujarat

Project cost NA

Implementation stage Planning

Contact details: Rainbow Papers Ltd 801, Avdhesh House S G Highway, Thaltej Ahmedabad 380 054 Gujarat

PET bottle and preform Manjushree Technopack Project type

Facility expansion

Project news

Ma n jushree Tec hn o pac k is increasing its capacity from 50,000 MTPA to 80,000 MTPA by constructing its largest PET preform production facility in Bidadi.

Project location Bidadi, India

Project cost NA

Implementation stage Planning

Contact details: Manjushree Technopack Plot No. 60 E&F Bommasandra Industrial Area Hosur Road, Bengaluru 560 099 Karnataka

Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai 400 067, Maharashtra, India Tel: 022-28666134 • Fax: 022-28013817 • Email: parmeet.d@tendersinfo.com

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TENDERS

Latest Popular Tenders brought to you by www.tendersinfo.com Polyethylene bags Org

: Limburg.Net

TRN : 16255742

Desc : Delivery of polyethylene bags

for the selective collection of plastic, metal and drink packages

Desc : Supply of 200 ml

drinking water bottles

BOD : 24 July 2013 Loc BT

: Domestic (NCB)

Dual blood bags

BT

TRN : 16653521

: Belgium

: Global (ICB)

Resistant polypropylene bags Org

: Municipio de Panamá

TRN : 16471166

Desc : Supply of resistant polypropylene bags (3.00 Balboas c/u)

Org

: Department of Defense

Desc : Supply of 90,000 dual blood bags BOD : 25 July 2013 Loc BT

: Syria Arab Republic : Global (ICB)

High-density polyethylene bottles (15 cc)

BOD : 22 July 2013

Org

BT

Desc : Supply of 15 cc

Loc

: Panama

: Global (ICB)

Polythene waste & refuse sacks and bags Org

: Centre Hospitalier de Bastia

TRN : 16459264

Desc : Supply of polythene waste & refuse sacks and bags

: Mysore Paints and Varnish Ltd

TRN : 16254938

high-density polyethylene bottles

BOD : 25 July 2013 Loc BT

: Mysore, Karnataka : Domestic (NCB)

BOD : 23 July 2013

High-density polyethylene bottles and jars

BT

TRN : 16254935

Loc

: France

: Global (ICB)

Polythene covers Org

: Bharatiya Reserve Bank Note Mudran Pvt Ltd

TRN : 16645645

Desc : Supply of polythene covers (size: 110 cm × 70 cm)

Org

: Mysore Paints and Varnish Ltd

Desc : Supply of various sizes of high-density polyethylene bottles and jars

BOD : 25 July 2013 Loc BT

: Bengaluru, Karnataka : Domestic (NCB)

BOD : 24 July 2013

Plastic bags and sheets

BT

TRN : 16597105

Loc

: Mysore, Karnataka : Domestic (NCB)

Water bottles Org

: Maharashtra State Road Transport Corporation (MSRTC)

TRN : 16524125

Anniversary

: Mumbai, Maharashtra

BOD : 22 July 2013 Loc

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Org

: Budapesti Közlekedési Zrt (AK01331)

Desc : Purchase of plastic products, plastic bags and acrylic & vinyl sheets

BOD : 25 July 2013 Loc BT

: Hungary

: Global (ICB)

Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai 400 067, Maharashtra, India Tel: 022-28666134 • Fax: 022-28013817 • Email: parmeet.d@tendersinfo.com

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EVENT LIST

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National

Anniversary Pune

Maharastra

Chennai Ludhiana Tamil Nadu

Punjab

Indore

Madhya Pradesh

Aurangabad Maharastra

Kolkata Hyderabad West Bengal

Andhra Pradesh

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: Network18 Media & Investments Ltd

Network18 Media & Investments Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028 Tel: 022-30034651 • Fax: 022-30034499 • Email: engexpo@infomedia18.in • Web: www.engg-expo.com

India International Printing & Packaging Fair

India International Printing & Packaging Fair exhibits the best solutions for packaging and processing items. The show has proved to be beneficial for the drink, laboratory testing and other relevant sectors. It will involve the participation of more than 150 exhibitors and over 10,000 attendees from several countries and sectors. New product ranges will be launched and attendees will also get to know about the recent developments made in printing and packaging. Leading industries will exhibit their range of modern packaging items; August 6–9, 2013; at Pragati Maidan, New Delhi For details contact: N C Joshi India Trade Promotion Organization Pragati Bhawan, Pragati Maidan New Delhi Tel: 011-23371302/23371540/23371822 Mob: 8860007682 Fax: 011-23371908/23371492

PET + Drink Tech Asia

PET + Drink Tech Asia is one of the major trade shows in India for the industrial packaging and plastics sectors. The show helps eminent industry specialists to meet under one roof and get a closer look at the latest market

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developments. The event attracts an impressive number of Indian and global attendees. Participants also have the option of attending the topical business seminars that are organised. The show draws in well targeted representatives from the dairy, food processing, healthcare and chemical sectors. New and sophisticated packaging techniques will be highlighted at the show; August 31–September 2, 2013; at Expo Centre Noida, Noida For details contact: S K Bhardwaj SCF- 172 Grain Market Sector 26 Chandigarh Tel: 0172-2795067 Mob: 09216129027

Intelpack

Intelpack is known for its highly defined and advanced form of packaging materials and equipment that it displays to global visitors who represent the packaging and printing sectors. Machines showcased here are from the finest engineering companies, and complete security and assurance are maintained during transactions; September 12–14, 2013; at Bombay Exhibition Center (BEC), Mumbai For details contact: Intel Trade Fairs & Expositions Pvt Ltd

Modern Packaging & Design July-August 2013

113, New Sonal Link Industrial Estate Building No. 2 Link Road Malad (W ) Mumbai 400 064 Tel: 022-28803977 Fax: 022-28819008

Pharmapack Expo

Pharmapack Expo is a cost-effective marketing opportunity and an opportunity to meet senior buyers and decision makers from all facets of the user industry. The exhibits will include packaging materials & products, glass & plastic jars and bottles, aluminium & plastic tubes, corrugated & cardboard boxes, dosing machines for liquids & powders, filling machines, blister packing machines, strip packing machines, labels & labelling equipment, form-fill-seal machines etc; September 12–14, 2013; at Bombay Exhibition Center (BEC), Mumbai For details contact: Intel Trade Fairs & Expositions Pvt Ltd 113, New Sonal Link Industrial Estate Building No. 2 Link Road Malad (W ) Mumbai 400 064 Tel: 022-26003977 Email: info@intelexpo.com Website: www.pharmapackexpo.in


EVENT LIST

Print & Pack Print & Pack - Vietnam will display cutting-edge technology on a wide range of printing, packaging, digital media and desktop & electronic publishing. Profile for exhibit include bag filling, making and forming, banding machines, box packaging equipment, computer graphic machinery, core cutting machines, coating machines, diary product packaging, date making and stamping equipment, filling & sealing equipment, flexo-printers, labelling machines, multi-packaging equipment, printing machines, screen printing machines, vacuum bags and vacuum forming machines, products related to the printing and packaging industry; July 18–20, 2013; at Saigon Exhibition & Convention Center (SECC), Ho Chi Minh City, Vietnam For details contact: Dennis Lam Room 2403, Fu Fai Commercial Center 27 Hillier Street Sheu Ng Wan Hong Kong China (Hong Kong S.A.R.) Tel: +86-852-28518603 Fax: +86-852-28518637

Cambo Pack Cambo Pack is an excellent way to get a complete perspective about the packaging industry in Cambodia, which is mainly striving on the agricultural and processed food sector, the main industry operational in the country. Everything related to packaging production, machines as well as package and packaging processes will be on display at this four-day trade show. The event aims to bring together all the stakeholders in the packaging industry in Cambodia including the national and international manufacturers and suppliers as well as the professional and trade consumers of such equipment and technologies.

International

This trade show also includes a number of networking sessions and interactive platforms to catalyse communication between the attendees; August 8–11, 2013; Diamond Island Convention & Exhibition Center, Phnom Penh, Cambodia For details contact: Chan Chao International Co Ltd 3F, No 185, Kangchien Rd Neihu Dist 114 Taipei, Taiwan Tel: +886-2-26596000 Fax: +886-2-26597000 Email: service@chanchao.com.tw; akai@ chanchao.com.tw

Pack Print International Pack Print International is a premier exhibition for the packaging and printing industries, providing a unique platform for manufacturers of packaging and printing machinery, processing companies, designers and suppliers to display their products to a targeted audience. Profile for exhibit include packaging machines & appliances, packaging materials, packaging means, packaging aids, services for the packaging industry, pre-press & premedia, printing machinery, appliances & accessories, book binding, print finishing, paper converting (including packaging production services) etc; August 28–31, 2013; at Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, Thailand For details contact: 3 Harbour Front Place #09-02 Harbour Front Tower Two Singapore, Singapore Tel: +65-6-3329620 Fax: +65-6-3374633

Pack Expo Pack Expo is an event organised for several industrial sectors, and this show exhibits the best solutions for

the packaging and processing segment. The expo is the perfect place where a new range of products is launched, and attendees will also get to know about the recent developments made in this sector. This event serves to be an important platform where the attendees will get to know about the advanced way of preserving the freshness of consumable items. Exhibitors will get to meet potential buyers and develop business contacts; September 23–25, 2013; at Las Vegas Convention Center, Las Vegas, USA For details contact: 4350 North Fairfax Dr Suite, Arlington VA, USA Tel: +1-703-2438555 Fax: +1-703-2438556

World Food Pack World Food Pack is an expo for producers and dealers related to the food packaging industry. The expo will display products such as packaging materials and supplies, consumer goods packaging, filling machinery, food packaging equipment, food processing equipment, industrial packaging equipment, industrial refrigeration, wrapping machinery etc; October 30– November 1, 2013; at Kiev International Exhibition Centre (IEC), Kiev (Kyiv), Ukraine For details contact: Elena Sinitsina 13-B, Pimonenko Street Kyiv, Ukraine Tel: +38-44-4968645 Fax: +380-44-4968646

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 Business Insights •Technologies•Opportunities

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PRODUCT S

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Anniversary

Looking For A Specific Product?

Searching and sourcing products were never so easy. Just type MPD (space) Product Name and send it to 51818

eg. MPD Wrapper and send it to 51818

Pillow pack machine

The model HPPM150 horizontal pillow pack machine has speed ranging from 30 to 150 packets/ min (according to the size of product). The 2-m-long infeed conveyor is provided for easy feeding of the product. Cross-sealing heaters operate on 110 V. The machine is noiseless and trouble-free. Machines for other products with higher dimensions are also fabricated on order. Design registration is done mechanically or with photocell.

New Indo International New Delhi Tel: 011-26693289, Mob: 09810061605 Email: nii@ndf.vsnl.net.in Website: www.newindo.net

Pouch making machine

Flexible packaging material

A wide range of flexible packaging materials and applications to a variety of industries and markets is offered, which increase the shelf life and barrier properties. This includes food packaging (dry foods, frozen foods, liquids & viscous, snack foods, nutritional & health foods, pet foods and other agricultural products) and specialty consumer & FMCG (tea & coffee, confectionary & candy, pharmaceuticals, engineering products & garments). Shako Flexipack Pvt Ltd Mumbai - Maharashtra Tel: 022-40638002 Email: sales@shakoflex.com Website: www.shakoflex.net

Converter

A combination of centre seal and threeside seal pouch making machine to make centre seal, centre seal with side gusset, two/three-side seal pouches, agarbatti pouches with perforation, off centre, centre seal and pouches with side flap insertion is offered. This multi-function pouch making machine is used for making stand up and zipper pouches. The machine converts laminated film to empty pouches and is suitable for companies having their own lamination and printing facilities.

Launched by Baum端ller, b maXX 5000 is a new generation of converters. Highperformance power modules with air and cold plate cooling, a flexible expansion capacity and connection to a universal communication concept are some of the impressive features of stacking technology resulting from the consistent further development of the successful b maXX series. These new converters and controllers with an output power ranging from 1 to 35 kW can be used to implement both standard and complex automation solutions. Machine and system requirements for future compatibility, flexible expansion capacity and simple adaptation to modified production processes have already been taken into consideration during the b maXX 5000 development process.

Primo Pack Machines Pvt Ltd Ahmedabad - Gujarat Tel: 079-22841684 Email: info@primopack.com Website: www.primopack.com

Baum端ller India Pvt Ltd Pune - Maharashtra Tel: +91-20-40160303, +91-9850834273 Email: ashutosh.kulkarni@baumuller.in Website: www.baumuller.in

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PRODUCT S

PVC/PET/PLA shrink tubing, band and bag Shrink tubing is suitable for covering condensers, wire, batteries, poles and medical instruments etc. It serves the purpose of insulation and consolidation of products. Tubing is able to be printed as desired. Company brand name, logo and other illustration can be printed on the shrink tubes. Shrink neck band is used for primarily for tamper-evident protection. When the seal is broken, it cannot be put back in place; this increases customer confidence, especially in food quality and security. The shrink band is available in a wide range of lay flat size from 4 mm to 750 mm with any length. Preformed bands are also available. Shrink straight and dome bags are used for multi-packed items such as irregular shaped objects and containers. The dome bag is available in many shapes and lengths. Allen Plastic Industries Co Ltd Kaohsiung, Taiwan Tel: +886-7-7425708 Fax: +886-7-7427754 Email: morida@ms19.hinet.net Website: www.allenpack.com

Inductive proximity sensors A proximity sensor detects the presence of objects that are placed in the proximity without any point of contact. Since there is no contact between the sensors and sensed object and lack of mechanical parts, these sensors have a longer functional life and high reliability. These sensors work on the Eddy current principle. An alternating magnetic field emanates from the sensing face. When a conductive, generally a metallic object, enters the field, the latter is influenced in a way that can be detected and evaluated by the builtin electronics. It features rugged stainless steel, brass and industrial grade plastic housings with protection for short circuit and polarity reversal. It is applicable in parts counting, speed monitoring and position detection & monitoring.

One must consider the cost of the product before and making a purchase so as to secure definite assured returns over a period of time.

Manisha Kadam (Assistant Manager) Ashok Industry

Mikrosen Control Devices Pvt Ltd Coimbatore, Tamil Nadu Tel: +91-422-4520335/336 Extn. 24, +91-9750029355 Email: vasudevan@mikrosen.com Website: www.mikrosen.com Modern Packaging & Design July-August 2013

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PRODUCT S

Operator panel

To satisfy the stringent standards required in the automation market, especially packaging, label slitting and motion-based robot dispensing, The WebOP-2000T series with 200 MHz ARM9-based RISC CPU and 128 MB flash memory for application software is available. This series also support a variety of LCD sizes from 4.3" to 15" for different applications involving the use of PLCs, motion/thermal controllers, inverters and sensors. It is bundled with WebOP Designer, a software development kit, which helps create application solutions for labour-saving, improved efficiency of manufacturing and easy control of every machine in the factory.

Advantech India Bengaluru - Karnataka Tel: 080-23374567 Email: info.in@advantech.com Website: www.advantech.in

PVC/PET/PLA shrink label/sleeve

Along with the manufacture of PVC/PET/PLA shrink film for printing shrink label/sleeve, both calendared and blown shrink film with high quality, transparent, flat and stable shrinkable are also available which helps in smooth printing. Benefiting by shrink film’s shape-hugging and shrink on characteristic, the sleeve could not only protect packaging components during transport but also assume a shatter protection function or be used as an indicator in technical application. Other products available are variety of sleeve materials and finishing technologies, with a wide range of options for effective decoration of various products made from plastic, glass and metal. Allen Plastic Industries Co Ltd Kaohsiung, Taiwan Tel: +886-7-7425708 Fax: +886-7-7427754 Email: morida@ms19.hinet.net Website: www.allenpack.com

Labelling and sticker machine

The model LBL-100 FB automatic labelling and sticker machine is user-friendly, vertical linear sticker labelling machine, suitable for applying front and back labels on flat/oval/square shape containers with output of

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100 labels per minute depending on products and label size. Product alignment system is synchronised with top holding belt mechanism, with necessary changes in respect to product samples. It meets the needs of major users of modern packaging lines, which requires high efficiency, speed, accuracy and durability. All adjustments are userfriendly and require minimal tools and change parts. Laxmi Pharma Equipment Ahmedabad - Gujarat Tel: 079-25831600, Mob: 09426406754 Email: contact@laxmipharmaequipments.com Website: www.laxmipharmaequipments.com

Horizontal form-fill-seal machine The model PK 90-DRY horizontal form-fill-seal machine has roll width of 520 mm, power consumption of 4.5 kW and packaging film as allheat sealable laminated film. This machine has attachments such as dual product filling system, swab/ tissue filling system, zipper sealing system and batch printing device. It is used is food and packaging industry. The form-fill-seal machine is used for filling of instant milk powder, spice powder, coffee powder, insecticide powder, malt beverage powder, seeds, sugar, salt, pepper, namkeen, etc. Attachments are dual product filling system, swab/tissue filling system, zipper sealing system, batch printing device, etc. Pakona Engineers (India) Pvt Ltd Mumbai - Maharashtra Tel: 022-22854138 Email: info@pakona.com Website: www.pakona.com

Mini-offset printing machine The Autoprint 1520 Colt (single-colour) is a new generation mini-offset printing machine designed especially for entry level printing entrepreneurs, letter press houses, DTP units, large Xerox and screen printing units as well as small enterprises. This machine is Ideal for short run jobs. It has all the features of a mini-offset printing machine. The machine takes maximum paper size of 380 x 254 mm; minimum paper size is 125 x 175 mm and paper thickness is 3-300 gsm. The blanket size is 430 x 500 mm, gripper margin is 8-10 mm and plate size is 400 x 500 mm. Autoprint Machinery Manufacturers Pvt Ltd Coimbatore - Tamil Nadu Tel: 0422-2212416 Email: info@autoprint.co.in Website: www.autoprint.in


PRODUCT S

Digital paper moisture meter

Sleeve wrapping machine

Cole-Parmer India Mumbai - Maharashtra Tel: 022-6716 2222, Fax: 022-6716 2211 Email: response@coleparmer.in

Durapak Chennai - Tamil Nadu Tel: 044-43033533 Mob: 09840050066 Email: hitendra@durapak.in Website: www.durapak.co.in

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 to 18 per cent, for baled paper the range is 5 to 40 per cent, and for the reference scale it is 0 to 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. It finds applications in the print & paper, packaging, food & beverage and manufacturing industries.

Oxygen and CO2 analyser

The Pack Check model 325 is a singlehanded oxygen and carbon dioxide analyser for checking modified atmosphere inside packages. It is an ideal instrument for portable, fast and accurate headspace tests on the packaging line in warehouses or in laboratories. This analyser has the ability to store 400 readings, stored by operator and product name. It is ideal for sample tests with only minimum amount of gas required for the smallest of packs in a modified atmosphere package. Hemetek Techno Instruments P Ltd Mumbai - Maharashtra Tel: 022-26860692, Mob: 09029308058 Email: mum@hemetek.com Website: www.hemetek.com

L a n t e c h revolutionary SW series high-speed sleeve wrapping machine eliminates many of the common shrink wrapping problems that result in poor package quality. The machine significantly improves productivity levels by reducing rework as a result of poor package quality and reduces downtime due to time consuming changeovers. The SW series is available in SW-1000, SW-2000, SW-3000 and SW-5000 models. Features include simple, intuitive mechanical adjustments that make it easy for operators to set up systems, extra large operating sweet spot for time, speed and temperature control significantly improves quality, etc.

Plastic packaging tube Etain is a fully recyclable plastic packaging tube made from a combination of virgin and recycled plastic materials. This tube contains up to 40 per cent PCR HDPE plastic material. The plastic packaging tube is typically used by FMCG companies for packaging various types of hair care, skin care, pharmaceutical and food products, besides cosmetics. This is made from recycled plastic material and is fully recyclable for the same recycling stream. Etain is highly customisable and the amount of PCR can be varied depending on customer requirements and the nature of the product that is contained within the package. Essel Propack Mumbai - Maharashtra Tel: 022-24819000, Mob: 09769410851 Email: preetosh.shrimali@ep.esselgroup.com Website: www.esselpropack.com Modern Packaging & Design July-August 2013

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Sleever machine

The newly developed next generation “two head DSVC450PII sleever machine” has features of flexible operation and completed function. Moreover, its simplicity and convenience provides customer with exactly suitable applications, not needing to pay extra money for unneeded functions. This unique design for two head high-speed sleever provides environmental energy saving and carbon reduction and can be used for long-term. The machine can produce different labels for body and cap sleeve applications in the same production line to help customer to decrease conveyor cost, and save costs of one tunnel’s steam consumption, which means decreasing line operation cost and equipment space allocation, as well as increasing production efficiency.

Dase-Sing Packaging Technology Co Ltd Taiwan Tel: +886-3-5686478, Fax: +886-3-5686375 Email: dasesing@dasesing.com Website: www.dasesing.com

Plastic packing boxes These plastic packaging boxes for cutting tools are used for industrial packaging. These boxes are also used for packing carbide tools, end mills, reamers, tips, insert, tap set, tool holder, etc. Also offered are foam, stickers, screen printing, emboss and designing of logo of company on the boxes. Om Manufacturer Rajkot - Gujarat Tel: 0281-2384444, Mob: 09978500100 Email: ommanufacturers@gmail.com Website: www.ommanufacturers.com

Sleeve applicator (Cap) The machine helps in avoiding adulteration and duplication of products. Compact Auto Sleeve Applicator does the job of pilfer proofing very well, which operates upto 240 upm speed. Moreover this machine can be easily integrated with existing Production Lines. Aurum’s 25 years of rich experience of more than 150 installations all over the India and abroad comes in bundled package with the machine. This is the reason why most of the FMCG’s, pharma companies and distilleries rely on Aurum for their shrink sleeving needs.

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Aurum Packaging Systems Pvt Ltd Thane, Maharashtra Tel: 022-25415807 Fax: 022-25425782 Website: www.aurumpackaging.com

Lable inserting machine The model DSV-600P sleeve machine runs at a high-speed of 600 BPM while using 180mm height label and is set up online with the producing line. This machine is chosen by beverage manufacturers for huge production capacity. The machine also uses colourful human/machine interface controller, which ensures user-friendly operation. Doublelabel holders are adopted too, which ensures easy operation in changing labels. Meanwhile, users can choose optional parts, eg, label unwind, label accumulator, etc. Specially designed knife plate is change-free within the rated specifications. If needed, the knife plate can be changed in just three minute. Shanghai Dase-Sing Packaging Technology Co Ltd Shanghai - China Tel: +86-21-33658333 Email: label@dasesing.com Website: www.dasesing.com

Continuous inkjet printer

Flexible code options, offering up to five lines of text, barcodes and graphics meet traceability coding requirements. This has compact design with plug-in connectors for easy set-up and movement between production lines. Automatic print-head cleaning and printer shutdown minimises the need for manual printhead maintenance and provides error-free power down. Versatile connectivity options, including Ethernet and parallel input/output provide centralised code management and easy integration with production control equipment. Codeinx New Delhi Tel: 09873926230 Email: sales@codeinx.com Website: www.linxglobal.com


PRODUCT S

Ultrasonic sensor

The model U-GAGE M25U ultrasonic sensor is designed for use in sanitary environments. The sensor is rated at IP69K, IP67 (NEMA 6) and constructed of heavy-duty 316 stainless steel, allowing it to withstand recurring highpressure washdowns, severe temperatures and aggressive cleaning chemicals common in food and beverage applications. With smooth barrel housing, free of threads, gaps or seams that could accumulate debris, the sensor allows for thorough cleanup with minimal effort. Additionally, IP68-rated wash-down cord sets and FDA-compliant brackets are available to further ensure reliable, long lasting performance in harsh environments. Banner Engineering India Pvt Ltd Pune - Maharashtra Tel: 020-66405624, Mob: 09322339208 Email: salesindia@bannerengineering.com Website: www.bannerengineering.com

Automatic wrapper

The model WM-4000-B automatic wrapper is good for packing house. It has a 10.4' colour LCD touch panel, automatic film changing, detachable and washable in-feed table and lifts. This automatic wrapper also includes automatic tray identification and centering, freearm labeling and has the capacity of 35 packs/min. The CCD camera automatically identifies the tray as soon as it is placed on the in-feed table. Wrapping conditions and tare weight are set automatically and any fluctuation in commodity tray placement is corrected by the centring conveyor.

Ishida India Pvt Ltd Gurgaon - Haryana Tel: 0124-3854392 Mob: 09971449821 Email: sales@ishidaindia.co.in Website: www.ishidaindia.co.in

Water-soluble film

These water-soluble films are used for handling and dispensing hazardous chemicals and formulations. By using these films, the infection caused by toxic or stimulating materials can be reduced. The films prevent contamination, are fully biodegradable, environment-friendly and widely used in packaging. The films are water-soluble, transparent and lustrous. These films have good gas barrier property, antistatic property, printability, strength and weathering resistance. The water-soluble films are used in packaging of liquid & powder detergents, all-purpose cleaners, disinfectants, agrochemicals, fertilisers, water-treatment chemicals, pigments/dyes, concrete additives, etc. Arrow Coated Products Ltd Mumbai - Maharashtra Tel: 022-26352500 Email: spatel@arrowcoated.com

Case erector

The Model 330 is a heavy duty powerhouse of a case erector built for high continuous production. It is designed for simple control, top flexibility & minimal maintenance. Its continuous motion drive performs case forming and case sealing operations at speeds of 35 cpm. Using electronics to control the operations and document their performance on the machine, this case erector is also operator friendly with touch screen controls. It is superbly forgiving to variations in corrugated boards and inconsistent Case blank quality yet ensures delivery of square formed cases. Case blank magazine design allows for cases to be picked up from Top, without any pressure avoiding most common reason for jams in case erectors. Its features include soft stop, self-lubricating air cylinders, safety guarding, standard fault detection features and extended blank magazine Clearpack India Pvt Ltd Mumbai – Maharashtra Tel: 022-6113 4200, Fax: 022-2838 9360 Email: info@clearpack.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 Business Insights •Technologies•Opportunities

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LIST OF PRODUCT S

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Looking For A Specific Product?

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Product

eg. MPD Wrapper and send it to 51818

Pg No

Adhesives sealants & maintenance product.................35 Air circuit breaker ........................................................ .FIC Air cylinder ........................................................................ 9 Aluminium linear guide ................................................... 51 Aseptic filling ................................................................... 13 Auto sealer series.............................................................. 95 Automatic pet blow moulding machine ........................ 102 Automatic SP – pristine machine .................................. 102 Automatic wrapper........................................................... 99 Barcode verification ...................................................29 Bearing ......................................................................... 4, 51 Cable carrier ............................................................... 4 Cable connector ................................................................. 4 Cam indexer ..................................................................... 53 Capping machine ............................................................. 45 Case erector ...................................................................... 99 Chain.................................................................................. 4 Cleaning technology ........................................................ 13 Cold seal monitoring ....................................................... 29 Color measurement .......................................................... 29 Compact pneumatic cylinder ........................................... 25 Compact valve .................................................................... 9 Connector........................................................................... 4 Contactor & motor starter ............................................ FIC Continuous inkjet printer................................................. 98 Contrast/colour scanner ................................................... 59 Converter.......................................................................... 92 Conveyers belt .................................................................. 65 Conveyor system .............................................................. 39 Conveyor technology........................................................ 13 Counted tablets packing machine ...................................... 6 Counter & power supply .............................................. BIC Cycle parts packing machine ............................................. 6 Cylindrical sensor ............................................................ 59 Digital panel meter ....................................................37 Digital paper moisture meter ........................................... 97 Digital temperature controller.......................................... 75 Double sheet monitoring ................................................. 59 Drive................................................................................. 75 Drive / inverter ............................................................ .FIC Dual channel with modbus .............................................. 75 Dynamic controller .......................................................... 75 Electric actuator & gripper ........................................25 Encoder ......................................................................... BIC Exhibition - Intelpack 2013............................................. 77 Exhibition - Plastivision 2013 ......................................... 71

Product

Pg No

Fastback revolution seasoning system .........................39 Fibre optic amplifier......................................................... 59 Filler ................................................................................. 11 Filling & packaging machine........................................... 11 Filling and closing technology ......................................... 13 Filling machine ................................................................ 45 Filter ................................................................................... 9 Flexible packaging material.............................................. 92 Forked photoelectric sensor ............................................. 59 Gl film & printing technology ...................................31 Glass-in-glass inspection.................................................. 15 Granules packing machine ................................................. 6 Guided compact pneumatic cylinder ............................... 25 Hand type impulse sealer ...........................................95 HMI ............................................................................. .FIC Horizontal form-fill-seal machine ................................... 96 Human-machine interface ........................................... .FIC Inductive Proximity Sensors .......................................95 Inductive switch ............................................................... 59 Industrial automation sensor ............................................ 73 Industrial control & sensing device ................................ bic Injection moulding machine ............................................ 41 Inspection and monitoring technology ............................ 13

Product

Pg No

Photo electric sensor ............................................... 57, BIC PID controller .................................................................. 75 Pillow pack machine ........................................................ 92 Pipe extrusion line for PVC/PPR/PE ............................. 41 Plastic masterbatch........................................................... 27 Plastic packaging tube ...................................................... 97 Plastic packing box........................................................... 98 PLC......................................................................... 75, FIC Positioning system............................................................ 51 Pouch making machine ...................................................... 6 Pouch making machine .................................................... 92 Powder packing machine ................................................... 6 Press control ..................................................................... 29 Process controller ............................................................. 37 Product handling equipment............................................ 39 Profile controller............................................................... 75 Proximity sensor ............................................................ BIC PVC/PET/PLA shrink tubing, band and bag................. 95 PVC/PET/PLA shrink label/sleeve................................. 96 Quality data management ..........................................29 Refrigerated compressed air dryer...............................25 Regulator ............................................................................ 9

Integrated machine safety solution .................................. 23

Rinses and pasteuriser ...................................................... 13

Labelling ................................................................ .BC

Rotary table ...................................................................... 51

Labelling and dressing technology................................... 13 Labelling and sticker machine ......................................... 96 Label inserting machine ................................................... 98 Level controller ............................................................... bic Lionizer ............................................................................ 25 Long bar sealer................................................................. 95 Lubricator........................................................................... 9 LVS .............................................................................. .FIC Measuring & monitoring relay ................................BIC Measuring sensor ............................................................. 59 Mini sensor ...................................................................... 59 Mini-offset printing machine .......................................... 96 Nitrogen extrusion sealer ...........................................95 Non-nozzle type vacuum sealer ....................................... 95 Nozzle type vacuum sealer ............................................... 95 Operator panel ..........................................................96 Oxygen and CO2 analyser ............................................... 97 Packing and palletising technology .............................13 Paper cones machine ........................................................ 28 Paper tubes machine ........................................................ 28

Safety light curtain..................................................BIC Sensor ......................................................................... 57, 73 Servo............................................................................. .FIC Shrink film .................................................................... .BC Shrink warp sealer series .................................................. 95 Skin wrapping ................................................................. .bc Sleeve applicator (Cap) .................................................... 98 Sleeve wrapping machine ................................................. 97 Sleever machine................................................................ 98 Stretch blow-moulding technology.................................. 13 Switching relay .............................................................. BIC Temperature controller ................................ 37, 75, BIC Timer ............................................................................ BIC Ultra sonic flow meter ................................................37 Ultrasonic sensor ......................................................... 59,99 Universal controller .......................................................... 75 Vision sensor ..........................................................BIC Water-soluble film .....................................................99 X-ray inspection system..............................................15

Paperless recorder ............................................................. 37

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

100

Modern Packaging & Design July-August 2013


LIST OF ADVERTISERS

8

th

Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Pg No

All India Plastics Mfrs Association ............... 71

Leuze Electronics ......................................... 59

T: +91-22-28217324

T: +91-80-40854444

W: www.plastivision.org

W: www.leuze.in

E: pvi13@plastivision.org

E: manish.sahay@leuze.in Mettler-Toledo Safeline X-Ray Ltd .............. 15

T: +91-1762-225302

T: +44-1763-257900

W: www.automaticpouchpackingmachines.com

W: www.mt.com/xray-modernpackaging

Heat And Control ........................................ 39

Mifa Systems................................................ 75

T: +91-44-42103950

T: +91-79-26870825

W: www.heatandcontrol.com

W: www.mifasystems.com

E: info@heatandcontrol.com

IFM Electronic India Pvt Ltd ....................... 57

E: sales@mifasystems.com

T: +91-422-4520335/336

W: www.ifm.com/in

W: www.mikrosen.com

E: info@ifm-electronic.in

Mitsibishi Electric India Pvt Ltd ................FIC

T: +91-80-39127800

T: +91-20-27102000

W: www.igus.in

W: www.MitsubishiElectric.in

E: info@mei-india.com

Intel Trade Fairs&Exposition P Ltd.............. 77

Neelkamal Agency Pvt Ltd ........................... 51

T: +91-22-28803977

T: +91-80-26624006

W: www.intelpack.in

W: www.megagroup.co.in

E: info@intelexpo.com

E: neelkamal_agen@dataone.in

Janatics India Pvt Ltd ..................................... 9

Omron Automation Pvt Ltd ...................... BIC

T: +91-422-2672800

T: +91-22-42288400

W: www.janatics.com

W: www.omron-ap.com

E: janatics@md2.vsnl.net.in

E: in_enquiry@ap.omron.com

K.U.Sodalamuthu & Co Pvt Ltd................... 28

Packam Controls Pvt Ltd.............................. 53

T: +91-09810555577

T: +91-22-61206600

E: sales@sodaltech.net

W: www.sodaltech.net

W: www.packam.co.in Prayag Polytech Pvt Ltd ............................... 27

T: +49-231-569-1423

T: +91-11-47262000

W: www.khs.com

W: www.prayagmb.com

Krones AG ................................................... 13

E: delhi@prayagmb.com Procon Technologies Pvt Ltd ........................ 37

T: +49-9401-700

T: +91-79-27492566

W: www.krones.com

W: www.procon.co.in

E: info@krones.com

Our consistent advertisers

E: info@procon.co.in

T: +91-512-2331646 E: customercare@resinova.com W: www.resinova.com Reynders Label Printing India Pvt Ltd.......... 25 T: +91-149-3305400 E: india@reynders.com W: www.reynders.com T: +91-120-4671694 E: dghosh@ra.rockwell.com W: www.rockwellautomation.com

T: +86-21-3365-8333 E: leo@dasesing.com W: www.dasesing.com Shyam Plastic Machinery ............................102 T: +91-79-25841417 E: contact@shyamplastic.com W: www.shyamplasitc.com SS Packaging Industries ............................... 45 T: +91-11-45072942 E: ssgroup@vsnl.net W: www.sspackaginggroup.com Toppan Printing Co Ltd ............................... 31 T: +91-124-4711648 E: dkohno1972@gmail.com W: www.toppan.co.jp/english/ Ultraplast Chainbelts Pvt Ltd ....................... 65

E: sales@packam.co.in

KHS GmbH................................................. 11 E: Jessica.Soepper@khs.com

Resinova Chemi Ltd..................................... 35

Shanghai Dase-Sing Pkging Technology Co., Ltd....................................BC

Igus India Pvt Ltd .......................................... 4 E: info@igus.in

Reifenhauser India Marketing Ltd ................ 29 Anniversary

Rockwell Automation ................................... 23

Mikrosen Control Devices Pvt Ltd ............... 73

T: +91-231-2672770

Pg No

T: +91-22-26862711 E: info@reifenhauserindia.com W: www.comexigroup.com

Gopal Machine Tools ..................................... 6 E: gopalmachine@gmail.com

Advertiser’s Name & Contact Details

T: +91-129-4113187 E: info@ultraplast.in W: www.ultraplastindia.com Windsor Machines Limited .......................... 41 T: +91-79-25841591 E: sales.imm@windsormachines.com W: www.windsormachines.com Wu Hsing Electronics Co. Ltd ...................... 95 T: +886-4-2271-1498 E: wuhsing@ms17.hinet.net W: www.wuhsing.com

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

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