Packaging Review 01 2021

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Issue 01 2021

Review

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contents

The team

Review

EDITORIAL

EDITOR: Abby Vorster +27 (0)71 359 4519 abby.vorster@newmedia.co.za

ISSUE 1 | 2021

LAYOUT & DESIGN: David Kyslinger SUB-EDITOR: Katrien Smit

ADVERTISING

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News

SALES EXECUTIVE: Carla Melless +27 (0)83 260 6060 carla.melless@newmedia.co.za

8 Coroos turns to Cama for alternative solutions

SALES EXECUTIVE: Anita Raath +27 (0)82 976 6541 anita.raath@newmedia.co.za

10 Clomark drives sustainability through innovation

SALES EXECUTIVE: Càndida Giambò-Kruger +27 (0)71 438 1918 candida.giambo-kruger@newmedia.co.za

12 Didget unleashes print possibilities

INTERNATIONAL SALES

Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk

16 IPSA promotes packaging professionalism 18 Italpac innovates with green food-safe plastic packaging 20 All your identification needs covered by TracePack 24 KHS promotes efficient systems for the beverage industry

PUBLISHING TEAM

26 Solutions from Multivac for every packaging process

GENERAL MANAGER: Dev Naidoo PRODUCTION CONTROLLER: Mandy Ackerman ART DIRECTOR: David Kyslinger

JOHANNESBURG OFFICE

New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park, 2092 Tel: +27 (0)11 877 6111, Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg, 2146 Published by New Media, a division of Media24 (PTY) Ltd

MANAGEMENT TEAM

CEO: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis BRAND STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HUMAN RESOURCES MANAGER: Ruth Shogoe CEO MEDIA24: Ishmet Davidson HEAD OFFICE New Media, a division of Media24 (Pty) Ltd 8th floor, Media24 Centre, 40 Heerengracht Cape Town, 8001 Tel: +27 (0)21 406 2002 Email: newmedia@newmedia.co.za PO Box 440, Green Point, Cape Town 8051

DRIVING SUSTAINABILITY THROUGH INNOVATION

14 New tray sealer from Ishida

CIRCULATION

CIRCULATION MANAGER: Felicity Garbers felicity.garbers@newmedia.co.za

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12 UNLEASHING PRINT POSSIBILITIES

28 Small business tackles a major job for international rugby 30 Take control of your packaging needs with OKI

14 NEW TRAY SEALER OFFERS GREATER SPEED AND FLEXIBILITY

32 Omron’s mobile robots deliver autonomous materials handling in critical areas 34 A revolution in digital packaging decoration with packwise-africa 36 New blow moulding technology from Nissei ASB 38 Rotolabel gets serious about sustainability 40 In the jelly kitchen with Syntegon Technology

The views expressed in this journal, other than those specifically stated, are not necessarily those of the publisher.

44 Teqal and Wildtrust establish a plastic neutral partnership

While precautions have been taken to ensure the accuracy of the content and information given to readers, neither the editor, publisher, or its agents can accept responsibility for damages or injury which may arise therefrom.

46 Trempak embraces the future

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MOBILE ROBOTS DELIVER AUTONOMOUS MATERIALS HANDLING IN CRITICAL AREAS

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Ed’s note Review

BACK WITH A BANG TO BOOST YOUR BUSINESS

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ith a long history of over 40 years in the businessto-business magazine category, Packaging Review became a household name in the South African packaging industry. The journal was launched in 1975 and offered readers authoritative reports and opinion on various aspects of the packaging industry – from the supply of raw materials to their printing and conversion into packaging components and containers, and their application in many end-use manufacturing sectors. The packaging industry has changed significantly since then with sustainability now a hot topic. Consumers have become vocal about their concerns; major chemical corporates, FMCG companies, retailers and manufacturers have all made strong commitments to reduce their environmental impact; and governments worldwide are re-shaping policies placing significant responsibility on producers for the treatment or disposal of post-consumer products. The theme of sustainable packaging development is highly evident in our re-launch edition of Packaging Review, which goes to show that the industry is taking the situation seriously. Of course, this is not to eliminate plastic packaging but to find better ways of producing, utilising, recovering and recycling it. For example, Clomark has produced a two-layer laminate for sachet manufacturing which has replaced more complex, unrecyclable and non-compostable laminates. Didget operates carbon-neutral printing presses, which dovetail into the values of environmental preservation and

reducing packaging waste. It also sources raw material options that boast not only recyclability, but also, where applicable, extended barrier and shelf-life properties, which serve to reduce food waste in the supply chain. Rotolabel has been able to recycle its first 21t of glassine liner since establishing a liner recycling partnership with Avery Dennison in 2018, and Teqal is striving to be 100% plastic waste neutral by establishing a ‘plastic neutral’ partnership with Wildtrust. For every kilogram of plastic Teqal converts into packaging, an equal amount of post-consumer plastic waste (PCPW) is collected from the environment and recycled. These positive stories and so much more on sustainable technologies and streamlined equipment are showcased in Issue 1 of our revamped Packaging Review e-book. The digital magazine is interactive, with loads of videos and links to multiple layers of additional content, providing you with all the information you need to boost your printing, manufacturing and packaging conversion business. Enjoy the read!

Ad index Clomark...........................................................11.............................................clomark.com

Omron Electronics (Pty) Ltd..................33..... industrial.omron.co.za/en/home

Didget Printing (Pty) Ltd..........................13.............................................. didget.co.za

Oristovista (Pty) Ltd t/a NSI Label......29.................www.labelandpack.africa/

Gossamer Structures (Pty) Ltd..............15............................www.gossamer.co.za

Pack-Wise Africa (Pty) Ltd.....................35.............................packwise-africa.com

Institute of Packaging SA......................... 17..................................... www.ipsa.org.za

Polyoak Packaging...................................IFC...........www.polyoakpackaging.co.za

Ishida South Africa...................................... 5..................... www.ishida.com/ww/en

Prac-Pak CC.............................................. OBC............................... www.pracpak.co.za

ISW SHRINK....................................................7........................................ iswshrink.co.za

Rotolabel (Pty) Ltd

Italpac (Pty) Ltd..........................................19..................................www.italpac.co.za

Div of Bidpaper Plus (CT)........................ 37.............................www.rotolabel.co.za

KHS Manufacturing SA (Pty) Ltd.........23................................... www.khs.com/en

Syntegon Technology

Mitas Corporation (Pty) Ltd.....................9.............................www.mitascorp.com

South Africa (Pty) Ltd..............................43.............................. www.syntegon.com

Multivac SA (Pty) Ltd............................... 27...............................za.multivac.com/en

Teqal (Pty) Ltd............................................45.................................................teqal.co.za

Nissei ASB South Africa (Pty) Ltd........36....................... www.nisseiasb.co.jp/en

Trempak Trading (Pty) Ltd..................... 47..........................................trempak.co.za

OKI Europe Ltd.............................................31.................www.oki.com/eu/printing/

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News

MCC PAARL BENEFITS FROM TIME-SAVING BENEFITS OF FUJIFILM’S PLATE PROCESSOR Since December 2020, Multi-Color Corporation (MCC) Paarl has been utilising Fujifilm’s Flenex FW and C-Touch plate processor as part of its label production, with immediately impressive results. “Given the stature of our brand, we are always dealing with high levels of demand for our products,” says Michelle Coetzee, pre-press manager at MCC Paarl. “Predominantly, we are producing low volume, short runs with a fast turnaround time to market – this includes premium quality wine and spirit labels, with innovative embellishments and finishes.” Alongside its reliable and highly regarded products, MCC is also known for its dedication to sustainability. The company is striving to reduce its energy and water usage, as well as the waste it sends to landfill. “With our desire as a business to unearth innovations that meet today’s sustainability needs, we know that our own production facilities must reflect that,” she continues. “We became aware of Fujifilm’s Flenex FW plates last year and the waterwash credentials really appealed to us. We in-house tested Flenex FW alongside plates from another

producer and decided to introduce the Flenex FW product into our daily operations. We spoke with the sales team at Fujifilm, who were great to deal with, and they offered us an equipment deal as well, which included the C-Touch processor. Overall, it was a very attractive package.” Coetzee has been impressed with the performance of Flenex FW since its arrival at MCC Paarl in December 2020. MCC Paarl has seen dramatic time savings in platemaking – previously, it could take up to two-and-a-half hours to produce plates with its solvent system, but with Fujifilm’s Flenex FW and C-Touch water-wash system, plates are being produced in 40 minutes. “Thanks to Flenex FW and the C-Touch processor, we’re seeing a quicker turnaround on getting our high-quality products to market, and less downtime on our presses, which have increased our capacity and enabled us to print more labels in a shorter space of time. All in all, we’ve got a green plate alternative for re-make plates that allows us to work much more efficiently with no compromise on quality.”

MCC Paarl’s plateroom team leader, Edmund Hendricks and platemaker, Hein Koen

Tecnocap and BASF seal the deal on metal food closures Italy’s metal packaging manufacturer Tecnocap utilises BASF’s non-phthalate plasticiser Hexamoll DINCH BMB for sealing gaskets within its metal closures. Sealing gaskets ensure leak-proof containers, protects products from contaminants and preserves product quality throughout its long shelf-life. The metal closures of Tecnocap are used by some of the biggest consumer brands in food, baby food and beverage packaging worldwide. Tecnocap is strongly committed to pioneering

innovative and sustainable packaging solutions. Its specialised teams work together with suppliers and the world’s best-known consumer brands to improve existing products and reach sustainability targets. To meet customers’ expectations for transparency and sustainability, the company has chosen BASF’s biomass balanced plasticizer Hexamoll DINCH BMB. “Working together with customers and suppliers like BASF to enhance packaging sustainability credentials is a strategic focus for us. With the introduction of the life cycle assessment approach and obtaining an environmental product declaration, we can measure the environmental impacts of metal closures and reduce their impact according to our sustainability action plan. With this plan, we aim to reduce our CO2 emissions considerably by 2030,” says Michelangelo Morlicchio, CEO and president at Tecnocap Group. Using Hexamoll DINCH BMB contributes to Tecnocap’s ambitious sustainability target as the plasticiser has a lower carbon footprint compared to the regular plasticiser and helps to save fossil resources. The metal closures of Tecnocap are used by some of the biggest consumer brands in food, baby food and beverage packaging worldwide

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To produce the sustainable plasticiser, BASF uses bio-naphtha or biogas instead of fossil resources. These materials are derived from organic waste or vegetable oils. As the renewable raw materials are processed together with conventional feedstock in BASF’s existing efficient production network, the renewable material is allocated to the final product according to the biomass balance approach. Both the allocation process and the product itself are certified by independent auditors according to the RedCert2 standard. The specifications and technical properties are identical to those of the conventional plasticiser. This ensures the proven product quality and sealing performance of Tecnocap’s metal closures remain intact. Wolfgang Bien, vice president of industrial petrochemicals Europe at BASF explains: “BASF shares Tecnocap’s commitment to sustainability. We are currently implementing numerous measures to reach our goal of becoming climate-neutral by 2050. The biomass balance approach is one pillar of our carbon management programme, which has a major impact on CO2 emissions and the saving of fossil resources. Both aspects are crucial to overcome the climate challenges of today.”


News

NIELSENIQ REVEALS THE STATE OF PRIVATE LABEL IN SA South Africa’s private label (PL) sector has continued its upward trajectory amidst the age of lockdowns and an altered consumer reality. This is according to NielsenIQ analysis which shows that the PL sector now commands 24.3% of total basket* value sales in South Africa which equates to R71bn in annual sales (12 months to end May 2021). This served to cement PL’s growth path from 2019, when its share of sales was 22.8% which rose to 23% by May 2020 and 24.6% by May 2021. These insights stem from a new NielsenIQ’s client report The State of Private Label in South Africa, which provides a far-reaching view of the evolution of PL in the local market based on trended data and insights gathered over the last ten years. NielsenIQ South Africa’s MD, Ged Nooy comments: “There’s no doubt that a new generation of private label ‘house’ brands have provided the impetus and created momentum in the local retail sector during one of its toughest times and most difficult trading periods.” In terms of the origins of this uptick, Nooy stresses that the booster effect of South Africa’s initial lockdowns in 2020 should not be underestimated. “For example, in March 2020 just before South Africa’s first and highest Level 5 lockdown, stockpiling

saw private label growth soaring to a peak of 27.2% in March 2021** and this strong double-digit growth was maintained throughout the second quarter of 2020. Interestingly, during this same time frame, named brands saw a decline in sales,” he reports. The big question is why has PL succeeded against all the odds? Nooy explains: “What we have seen is a diversification of PL products which now range from entry level offerings presenting high value for money and middle of the range solid offerings, to a new generation of premium products which represent quality and value. This stems from more investment in the sector which has created the depth and momentum that we see today.” Amongst the many movers and shakers, Frozen Foods has seen the biggest incremental gain of R2bn in sales over the last 12 months. This was mainly driven by consumers purchasing bigger pack sizes and more products. Unsurprisingly, the fastest growing was healthcare with sales up by 34.8% in the last 12 months. Specific product categories that benefited from the buoyancy in PL are clearly shown by NielsenIQ Trade Desk RMS with personal care private label products seeing a consistent gain in value share. This is understandable given the massive shift to hygiene and health and echoed by 69% of consumers who claim to have purchased more private label personal care products compared to a year ago.

Private label products are no longer perceived as ‘cheap’ or inferior quality no name brands ISW_FEEL THE COLOUR 177 x 65 copy.pdf

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* All categories PL participates in, thus excluding Liquor, Cig, categories etc *Nielsen CIP - PRIVATE LABEL - TD - 12 Latest 4 weeks (4 weeks rolling) - Week Ending 29/03/20). **NielsenIQ trade desk retailer benchmark: Woolworths, Boxer, Spar Group, Pick n’ Pay Group, Shoprite Group, Ok Foods, Clicks, Dis-Chem, Food Lovers Market, Game and 2021/09/07 12:20 PMPEP Stores

RECYCLEPAPERZA CALLS ON CITIZENS TO RECYCLE PAPER PRODUCTS

Mpact paper banks are located nationwide for collecting paper recyclables The paper recycling association of South Africa, RecyclePaperZA says that our country recovered 1.1m tonnes of recyclable paper products in 2020, putting the paper recovery rate at 69.8%. On 17 September it was National Recycling Day. RecyclePaperZA took the opportunity to call on homes, schools and businesses to be better at separating recyclables from rubbish. By keeping cardboard boxes, used office paper, newspaper, pizza boxes and other food packaging out of our bins, they are then kept out of landfill. Not only is it better for the environment, but it also supports the economy, especially the livelihoods of waste collectors. If baled, 1.1m tonnes of paper and paper packaging would cover 142 rugby fields or 200 soccer fields, or fill 1 322 Olympic swimming pools. “More importantly, the paper recovered in 2020 saved 3.3m³ of landfill space while the recovered fibre was made into new products that we use every day,” says Samantha Choles, communications manager for RecyclePaperZA. The small act of separating recyclables at home, school and work, makes a big difference to the environment. Visit www.recyclepaper.co.za for more information.

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VIDEO: Sustainability: the bigger picture

CAMA

THE BIGGER PICTURE OF SUSTAINABILITY – FROM MATERIALS TO PACKAGING EQUIPMENT

When Coroos needed to explore alternatives to plastic packaging in order to keep up with market demands, the Dutch family-owned business turned to Cama. Working together with Zacmi, Cama delivered secondary packaging technology that meets Coroos’ sustainability needs in a holistic way.

The Zacmi filling and closing unit in line with the Cama multipackaging machine

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Sustainability is not just about materials; it can also be addressed by machines that offer superior overall equipment effectiveness (OEE) – especially through technology that is designed and fine-tuned to the specific needs of an application. Delivering this capability is Zacmi, a supplier of filling and sealing lines which Oostrom relies upon. Zacmi’s lines are also regularly seen at larger manufacturers too. “We have used Zacmi machines for a long time,” Oostrom explains. “As well as offering higher speeds and machine developments which have always been closely allied to the needs of our products, Zacmi is based in Northern Italy – so I know the quality is there. They also work closely with Cama on a number of other projects, so we Final carton packages designed for have good supplier synergy.” Coroos’ ready-meal cans Oostrom adds that Zacmi is so much further ahead in terms of machine innovation, highlighting that the companies in the region have started to work together, so full lines could be designed with complementary technologies. “This relationship is demonstrated by the close coupling of Cama and Zacmi,” he comments. The previous plastic packaging for Coroos cans

ounded in 1957, Coroos is among Europe’s top three producers of preserved fruits, pulses and vegetables in jars, cans and flexible packaging. Since its first production site was built in 1960, it has put product evolution and consumer tastes at the top of its agenda. Over the decades, Coroos has witnessed constant market and consumer behaviour changes, to which it has had to adapt. One of the most recent packaging trends – driven by consumers’ preference for a reduction in plastic packaging – is the deployment and specification of secondary packaging that exploits easily recyclable cardboard as a replacement for shrink-wrapped plastic. Coroos director George Oostrom was quick to realise that plastic was falling out of favour, so he set about researching the market for an alternative technology. He invited Cama to help solve his sustainability challenge. In addition to environmental concerns, Coroos has to cater to varying consumer demands and packaging variety, hence the requirement for secondary packaging technology that is able to keep pace with these changes.

Did you know

Cama Group and Zacmi are among seven specialised Made in Italy producers which established The Smart Packaging Hub last year. This digital platform provides a virtual meeting place for end-users of automated packaging machines, specifically in the food and beverage industry. End-users are required to register online to gain access to the hub’s wide range of benefits. Go to smartpackaginghub.com/en for more information.

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Look beyond materials to OEE

Aspects of the sustainability equation

“When I look to justify my investments in technology, I don’t consider the capex as the defining factor,” Oostrom explains. “Could I find machines that are cheaper? Probably. But would they offer me the same levels of quality, throughput and wholelife costs? Almost certainly not.” He advises that manufacturers should look at performance as part of the sustainability equation. Being “green” and being seen to be “green” are not only about the materials. It’s about OEE, maintenance costs, consumable consumption and a myriad other factors which come into play when you consider the impact of a machine. “Finally, as a family company, peace of mind and trust play a huge role too – and having two supplier companies that are already good friends is a real bonus,” Oostrom concludes. •

Cama – www.camagroup.com | Zacmi – www.zacmi.com/en


+27 10 020 7221

sales@tracepack.co.za www.tracepack.co.za

Continuous Inkjet Systems Thermal Inkjet Systems Laser Coding & Marking Large Character Printing Print & Apply Labellers Label Applicators Labelling Systems Vision Systems Rejection & QC

We offer a diverse portfolio of solutions from smart packaging, automation and robotics, sustainability recyclable packaging, end of line packaging systems, labelling innovations, inspection & detection, coding and marking, anti-counterfeiting, security features as well as track and trace solutions.


Clomark

DRIVING SUSTAINABILITY THROUGH INNOVATION “Creativity is thinking new things, innovation is doing new things” – Theodore Levitt. This saying rings true with Clomark. Having produced some of the most complex and challenging packaging designs, Clomark services a wide market from food and beverages, pharmaceutical and cosmetics all the way through to the automotive market.

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hyam Chirkoot, managing director of Clomark, affirms that the management team’s sound and in-depth technical knowledge base of packaging development and manufacturing is driven by an extreme sense of urgency. It also thrives on sophisticated and specialised work with more complex materials. “Being highly motivated and supported by an in-house laboratory as well as plastic forming technology make the product development process much easier,” Chirkoot states. “Additionally, we can offer brand owners design and DTP services, as well as approvals for their entire packaging range (cartons, labels and shrink sleeves) in one sitting. Having to deal with one converter only enables customers to save on costs and improves accountability. This particularly facilitates the maintenance of quality and colour consistency across a new range of products.”

Clomark believes that radical packaging design change is needed and, as a member of Packaging SA, is contributing to driving this change in the packaging industry. The industry is under growing pressure to redesign packaging so as to reduce, reuse or recycle material content (the 3 Rs), and rightfully so. In a world in which plastic is now deemed fiendish, the important role of this substrate in the current packaging mix should not be overlooked.

Whilst everyone is under pressure to make products more recyclable, reusable or compostable, the lack of suitable economical green alternatives locally make plastic a necessary evil, at least for the foreseeable future. Plastic packaging preserves and protects its contents and provides tamper evidence, all of which are crucial to consumers. It is much more economical than other packaging options, has high recycling rates in South Africa, and is a source of recoverable fuel and energy. As far as possible, Clomark works directly with customers’ designers, raw materials manufacturers and brand owners to create product designs that are not only innovative but also kind to the environment. “We work with customers to understand their specific intent and design their packaging to achieve the desired result,” Chirkoot explains. Key factors are often a reduction in packaging volume, cost benefit and the use of recyclable materials. Reusability and local recyclability must be considered alongside functionality. The challenge is compounded by the proliferation of laminates combining normally recyclable plastic types with other plastics and metallised layers that are not recyclable. “We have produced a two-layer laminate that has replaced more complex, unrecyclable and non-compostable laminates and has been used to manufacture sachets destined for European markets,” he says, adding that

The EF-Active range of hand and surface sanitisers was brought to market speedily at the onset of the pandemic, thanks to Clomark’s quick turnaround time

Clomark produces the beautiful multicoloured and gold labels for the exciting range of Rose’s cordial

Actively making a change

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Clomark

“We work with customers to understand their specific intent and design their packaging to achieve the desired result” Clomark encourages customers to re-examine their product formulations for complex packaging as modifying active ingredients may make a profound difference. For example, body scrub plastic microbeads – a growing contaminant of water – have been replaced by many customers with organic alternatives such as cellulose, salt and wheat.

An ethical and responsible business

Many countries have adopted a circular economy model, which mimics the biorhythms of nature. Waste is seen as having value and as a resource for a secondary process. While true economic circularity may resolve the problem and create other opportunities, it requires ownership from all players. The government recently adapted its National Waste Management Strategy by making the circular economy central to waste management and introducing the requirement for industry-managed waste plans. Clomark subscribes wholeheartedly to this development.

Clomark prints high-quality labels for bath and body products manufactured by Serendipity Toiletries, which are exported to the UK and US

Clomark recognised the need for responsible environmental practices and a change of manufacturing processes to support environmental sustainability two decades ago when it earned its ISO:14001 certification, becoming a frontrunner in adapting to the circular economy. Every environmental aspect and the related impact is carefully considered, quantified and supported by action plans to continually reduce the company’s environmental footprint. “Our latest investment in solar energy, which powers a substantial amount of the operations, has demonstrated a significant reduction in greenhouse gases. We also have a ‘zero waste’ policy and have introduced Bokashi composting bins in the workplace and in our homes,” says Chirkoot. In a changing market, Clomark prides itself on providing high-quality products and service to its customers. This has been the company’s recipe for success with Clomark celebrating 50 years in business this year, while looking forward to another 50 years! •

CONNECT WITH CLOMARK ON SOCIAL MEDIA:

Clomark – www.clomark.com

Manufacturers of self adhesive labels, shrink sleeves, folding cartons, sachets & wrappers.

quotes@clomark.com

+27(011)-314 5444 www.clomark.com

or

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Didget

UNLEASHING PRINT POSSIBILITIES Relentless innovation, passion for design and functional aesthetics are the drivers behind Didget’s success. Its digital print offering is the perfect platform for SMEs wanting to upgrade to fully-printed packaging, and compete with best-in-class brands.

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he relevance and client and consumer acceptance of digitally printed packaging is evidenced by Didget’s massive growth of over 30% per annum over the last two years. This growth has not just come from new business, but also the massive expansion of existing brands harnessing the advantages of digitally printed packaging. Printed packaging is proven to produce an increase in consumer offtake and encourages distribution into major retailers with a professional offering worthy of listing. The spinoff in growth for SMEs bodes well for job creation and benefits consumers and the economy with a more competitive arena. It also creates additional opportunities for allied goods and services. Fully-printed packaging is often the catalyst enabling businesses to upscale operations further and compete more effectively.

A winning digital partnership

A recent success story of the power of digitally printed packaging was the launch of Clevers by Q-Foods. Didget and Q-Foods have been collaborating on product development and strategy for some time and together developed the brand identity and marketing roll-out for the Clevers range, launched in July 2021. This digital partnership has helped to catapult sales of Q-Foods’ existing brand, Sugarlean, by 400% within two years, going from 10 to 87 SKUs, and allowing expansion into supplying retail in-house brands. Q-Foods managing director Dale Hellon describes the mega success of the Clevers range as “beyond believable, achieving treble our most optimistic sales projections”. “As a business, Q-Foods has expanded to such an extent that we have purchased a second warehouse, invested in two new automated packing machines, created at least six new jobs within our company and are looking to invest in another delivery vehicle. We could not have achieved this without our collaboration with Didget,” says Hellon.

World-class technology investments In July, Didget installed another HP Indigo 20000 to keep pace with the burgeoning demand, almost doubling its capacity. The company now has three HP digital presses, including two HP 20000 wide-web digital presses which are perfect for medium-run, multiple SKU ranges; and the HP Indigo 6800 narrow press geared towards shorter runs, mock-ups and trials, shrink sleeves and labels.

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This latest investment, together with new slitting equipment of over R20m, underscores the company’s belief in the relevance, scope and possibilities of digital printing for packaging. Digital printing is perfect for multiple SKU ranges, offering customers extensive choice. It allows for low-risk range extensions, seasonal offerings and on-pack promotional offers. The digitally printed packaging can be incorporated seamlessly as an adjunct to the rest of the brand which is either flexo or gravure printed.

An eco-conscious business

Combining best-in-class digital printing with the latest developments in sustainability and recycling is high on Didget’s agenda. All the company’s presses are carbon-neutral and dovetail into the values of environmental preservation and reducing packaging waste. Didget has sourced raw material options that boast not only recyclability, but also, where applicable, extended barrier and shelf-life properties, which serve to reduce food waste in the supply chain. The company is also equipped with various converting equipment to convert to a host of packaging formats, such as bags, k-seal pouches and doy-packs, three-side seal pouches, printed perforated lidding and more. •



Ishida Europe

NEW TRAY SEALER OFFERS GREATER SPEED AND FLEXIBILITY Ishida Europe has extended its range of QX Flex tray sealers with the launch of a new model, which meets market demands for a compact, high-performance solution. The innovative model also maximises output, capacity and flexibility for medium- to high-volume production lines.

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he global demand for shelf-life extension to reduce food waste and to provide quality assurance to the consumer continues to drive Ishida’s ongoing investment in its tray sealing portfolio. The company is also committed to ensuring minimal impact of packaging materials. The Ishida QX-900 Flex operates at up to 15 cycles per minute with a maximum of seven impressions, delivering a top speed of 105 packs per minute. The tray sealer is capable of both seal-only and modified atmosphere packaging (MAP) trays and can handle a wide variety of materials and formats, including trays made from recycled or renewable cardboard and mono plastics, and the latest skinpack and skin-on-board variants. The compact footprint of the QX-900 makes it ideal for use as a standalone machine or as part of a fully integrated packing line, with the control and timing of up to four filling systems and a denester all accessible via the machine’s remote control unit (RCU). Careful control of the outfeed simplifies the interface with downstream equipment. A printer can also be incorporated for batch codes, bar codes, production and sell-by dates, as well as pricing information. Other enhancements include a user-friendly film The left web of the QX-900 Flex unwind arrangement, which speeds up film roll changes. A central fixing point for the RCU enables it to be viewed and operated from both sides of the machine.

Durable and hygienic design

The QX-900 retains all the proven benefits of the Ishida Flex tray sealer range, including a 10-minute tool changeover, with a tooling trolley enabling the process to be carried out quickly and safely using a single operator. Up to 99 individual product settings can be stored in the RCU for fast set-up, along with control of vacuum and gas levels for MAP trays.

Did you know

The Ishida QX-900 Flex is adaptable to sustainable tray materials such as cardboard and mono plastics.

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Integrated gas mixing on the Ishida QX-900 Flex

Ishida’s QX-900 Flex has a small footprint The durable and hygienic design of the machine allows full washdown, while the smart belt system ensures belts can be quickly and easily removed for changeovers and cleaning.

A variety of options

Tooling can be specified to meet individual customer requirements, including both outside and inside film cut, with inside film cut offering superior pack presentation and the incorporation of peel tabs. Options include gas mixing and gas analysing with an automatic cut-out should the wrong mix be detected, and Ishida’s unique head redundancy feature, which enables an impression to be isolated during production in the event of a problem. This allows the machine to continue operating until a suitable time when repairs can be undertaken. The QX-900 can also be integrated with Ishida’s award-winning AirScan, which can detect leaks of CO2 from holes as small as 0.25mm in MAP packs at speeds of up to 180ppm. This combined TraysealerAirScan system provides food manufacturers with complete peace of mind, ensuring perfectly sealed trays that deliver extended shelf-life and preserve product quality to enhance and maintain brand reputation. •

Ishida Europe – www.ishidaeurope.com



Institute of Packaging SA

FOCUSED ON PROMOTING PACKAGING PROFESSIONALISM IPSA is an association of individual packaging professionals whose aim it is to promote high standards and professionalism in the packaging industry, to provide opportunities for networking and education and to elevate the recognition of packaging as a profession. The Institute’s Gold Pack Awards, Student Gold Pack Awards and the four-tier skills development programme are key focus areas to achieve these aims.

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he training courses offered by the Institute of Packaging SA (IPSA) are now hosted online, enabling a wider reach as a global centre of education. Lecture facilitators are drawn from industry and are highly knowledgeable in their respective fields of packaging and related subjects. The execution of training using the Zoom platform has quickly gained a high level of respect and confidence from students, who enjoy the fact that they do not need to travel to physical classes to be able to study packaging technology. Breakout sessions, student polling, student/lecturer chat groups, research-based assignments and online “timed” examinations have all resulted in a programme that truly stimulates an online study experience.

Overview to packaging technology

This entrance level short course, also known as OTP, is structured for those who are new to the packaging field and who may have little or no previous knowledge of packaging and, typically, not have had much – if any – technical schooling, packaging background or experience. The OTP course is also aimed at people interested in the field of packaging as a possible vocation, such as school leavers or perhaps newly-recruited employees and first-time workers. It utilises a significant practical training approach during class sessions. On conclusion of the course, OTP students should have a broad grasp of the technologies of packaging and the materials and processes involved in the industry.

A PLACE FOR PACKAGING PROFESSIONALS IPSA prides itself on being a cornerstone of professionalism and expertise in the packaging industry, which is a vital component of modern commerce. Membership is open to all individuals engaged in any aspect of South Africa’s broadly-based packaging industry, to give packaging professionals a sense of belonging and the opportunity to keep abreast of the many important issues affecting the packaging industry. Click here for more information on membership benefits and how to become a member: https://bit.ly/3Abxq4L

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Institute of Packaging SA Popular one-year study course

The one-year diploma in packaging technology (OYD) is the most wellestablished of the local courses and is accredited by the World Packaging Organisation, the IOP: Packaging Society (UK) as well as the Australian Institute of Packaging. The course is currently conducted under licence by certain African countries through the African Packaging Organisation. The OYD course addresses the full multi-faceted discipline and science knowledge required by the packaging specialist to understand both the technical and business-related aspects of the industry. The course is applicable to people in a wide variety of positions including sales, marketing, design, technical, production, quality control, R&D, buyers, warehouse managers and logistics managers. It is popularly attended by retailers, suppliers to the industry, packaging converters and all users of packaging. Offered annually with a duration of about ten months, the course sets a high standard academically. It includes a practical component, in the form of a packaging assignment, spread over a six-month period. Potential students, most of whom are working people, should be aware that the course is no “walkover” academically, and participation needs to be weighed up carefully regarding the student’s employment workload.

Preparation for senior management

The advanced diploma in packaging (APD) is ideally suited for those being prepared, or preparing themselves, for management level positions. The programme is intended to be highly interactive, with the students encouraged to express their own knowledge and to debate the issues raised by facilitators. The course is structured to give the participant a better understanding at a higher level than that of IPSA’s basic OYD course. In addition to the technical aspects of the packaging industry, the course provides participants with insight into business and its inputs so that they can better relate to the entire organisation. The students receive skills and training on presentation techniques, with the intention to enable them to confidently convey ideas, strategies and business proposals in the boardroom.

The highest professional designation

Most recently IPSA established an agreement with the Institute of Packaging Professionals of the US and the World Packaging Organisation to be able to offer the designation of a Certified Packaging Professional (CPP). This is the highest designation for a packaging professional offered by IPSA and is an excellent investment in professional development. The CPP credential defines the packaging professional and enables organisations to seek out and hire the right professional based on verified knowledge, skills and industry contributions. Using the CPP programme to assess and evaluate one’s professional competency validates the individual as a truly qualified packaging professional at an international standard. •

IPSA – www.ipsa.org.za I SSUE 01 // PACKAGING REVIEW

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Italpac

FOOD-SAFE PLASTIC PACKAGING FOR A GREENER TOMORROW Italpac is an internationally-accredited food-safe plastic packaging manufacturer. The company strives to provide the best quality products at reasonable prices. It also prides itself on continually coming up with innovative ways to reduce costs to the consumer.

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aving FSSC 22000v.5.1 as well as ISO14001 accreditation, Italpac feels it is the company’s duty to keep to these high standards. What better way to do so than to ensure its products are not only recyclable but also biodegradable when required by customers. With this new addition to Italpac’s consumer range, the packaging manufacturer ensures that the end user can also do their part in helping the environment. Being ISO9001-certified, the company provides a full traceability system, which ensures that all its products are completely traceable back to the raw material, including the biodegradable materials used for production, using its unique batch identification numbers. When required, Italpac supplies a certificate of compliance to customers to give them peace of mind in confirming the traceability of their product. This also reassures customers that the product is safe and made for its intended use for which it was manufactured.

Innovation that helps customers

As a plastic packaging manufacturing company, it is important to Italpac to continually develop unique ways to help customers. It does this by ensuring that its products are not only environmentally safe, but also food safe. Its products are manufactured from food-safe LLDPE, LDPE and HDPE raw materials and where the customer requires unique printing, Italpac can produce customised prints using food-safe approved inks that are individually mixed in-house to reduce the cost for the customer. Italpac has a range of specialised products which includes anti-static, UV stabiliser, flame retardant, swanky tape and banana blue. It also manufactures the following plastic packaging products: • spine-, lap-, fin-, double-, side-, bottom- and header-seal bags • punched bags

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• • • • • • • • • • • •

perforated bags shrink sheeting, tubing and bags foilene sheets and bags form-fill-seal butcher bags generic vegetable bags co-extrusion film and bags centre fold sheeting and tubing book covers and seat covers bread bags and cake bags ice lolly/pop tubing aprons, smocks, body bags, cap bags etc.

A diverse business serving many industries

Having this wide range of products allows Italpac to supply to various industries, including the food industry (primary and secondary packaging), and the automotive, mining, agricultural and pharmaceutical industries. The company services the individual business owner up to the blue-chip corporate client. Italpac also includes expiry dates and sequential numbering on its products as these are required by its food industry customers. In doing so, the company assists these customers not only in keeping their products fresh, but also in ensuring consumer satisfaction knowing that they can purchase a product which is safe for consumption. Plastic packaging products from Italpac ensure the extended shelf life of its customers’ products. This helps with cost savings in terms of the finished product and the amount spent on the packaging itself, which in turn helps customers to grow their businesses. It also helps reduce costs passed on to the consumer on an essential like food. Ultimately, Italpac is doing its part in providing customers with a unique product which is direct food contact-safe and environmentally-friendly. •

LENDING A HELPING HAND Italpac’s ISO26000 certification has provided the company with a means to help the community. Its refuse bags supplied to the Hennops River Cleaning Initiative are made from in-house 100% recycled scrap materials. Italpac – www.italpac.co.za


Italpac ONE OF SOUTH AFRICA’S LEADING PLASTIC PACKAGING MANUFACTURERS CERTIFIED TO THE FOLLOWING STANDARS:

Contact: 012 541 1610 / info@italpac.co.za


TracePack

ALL YOUR IDENTIFICATION NEEDS COVERED BY ONE SUPPLIER In today’s global environment, a one-stop-shop approach is essential to optimise resources and remain competitive. It means counting on a single partner capable of providing systems and services to manage the entire production process. Not having to coordinate several suppliers saves time, energy and costs, allowing you to enhance your process every step of the way. TracePack’s diverse portfolio of solutions includes systems for smart packaging, recyclable packaging, inspection and detection, coding and marking, anticounterfeiting, security features, and track and trace. It also supplies end of line packaging systems, equipment for labelling and solutions that enable automation.

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ntelligent packaging detects and communicates information about the condition of the product without taking direct action. It can communicate the product attribute information to users or trigger active packaging functions. Manufacturers must mark codes on the packaging of their products, on a wide variety of materials – this is no match for TracePack’s laser coding machines. These machines can mark codes on a wide range of materials, resulting in legible codes marked both cleanly and safely. In addition, its systems can be easily integrated into any production line, with the reserve of an IP65 rating on certain models, greater reliability in adverse production environments is offered. TracePack’s ultra-high-speed laser coding system for smart packaging is the fastest and most complete solution for packaging digitalisation, with a speed of 1 000m/minute. It is the only laser in the world that can continuously mark more than 100 unique QR codes per second of 400 microns per point (which is readable by any scanner). Automated monitoring of beverage line performance is made possible with the Robo-QCS

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VIDEO: The CodeMaster: Ultra-High Speed laser coding for your smart packaging VIDEO: High Speed Steerable Mirror

Automation and robotics

The automation and robotics solutions from TracePack interface with production and inspection machinery without any interference, enabling maximum cross-over time reduction. These systems and the digital infrastructure that governs a production plant are fully integrated with the customer’s Pharmatrack Seal 4.0 management software. The customer can enjoy peace of mind with a turnkey plant designed and built to transform ideas into reliable and distinctive solutions. TracePack’s experience is consolidated in the glass, PET, food and beverage, chemical, pharma and cosmetics sectors. In addition, the company’s ongoing research and technology upgrades allow it to manage any materials handling, palletising, and storage needs. Robo-QCS is a single solution that can monitor your beverage line performances (CP and CPK) automatically, improving and automating quality control process. Carrying out several non-destructive quality control operations at any time during production can optimise the production process and prevent non-conformities, ensuring


TracePack complete product quality. These are some of the results that can be obtained by inserting an automatic robotic system in line. The system allows monitoring of the efficiency of the whole filling and capping process in real-time. Its advanced data analysis system crosses all acquired values by its stations and other installed inspectors, optimising line performance and product quality protection. Reduce your costs through predictive maintenance, manage claims thanks to the historical database and plan production improvements using all the stored information, with the advantages of improved productivity and quality.

Sustainability and recyclable packaging

PHARMACEUTICAL LABELLING INNOVATION Pharmatrack is TracePack’s automatic industrial labelling system for traceability, serialisation and tamper-evident seal label application on the corners of pharmaceutical cardboard boxes (full and sealed packets).

The strength of the track and trace machine is afforded by its very compact For more than a decade, sustainable packaging has been dimensions, which facilitate its installation onto existing packaging lines. a priority for brand owners. Throughout 2021, we have seen This solution is also flexible in that the labeller can be integrated with a relevant and effective activities that address consumers’ hunger for brands that respect the environment. Increased consumer special inkjet marker or laser marker for pharma serialisation. Thanks to awareness continues to drive the sustainable packaging TracePack’s collaboration with leading vision systems companies in the mission of brand owners. Around 74% of consumers say they are pharmaceutical industry, any vision system chosen by the customer can willing to pay an additional amount for products in sustainable be integrated with Pharmatrack Seal 4.0, satisfying the specific traceability packaging. Recyclable packaging seems to matter most to requirements of each country. consumers because recycling is something they can do to contribute to sustainability. no need to budget for consumables. In addition, it In a retail environment, packaging is necessary ensures a cleaner and more hygienic working because goods need a barcode, which is environment thanks to the absence of solvent. generally attached to packaging. Similarly, at As a result, carbon emissions and harmful the supply chain level, produce needs to be waste are eliminated while production lines marked to be tracked and traced enroute are environmentally compliant. As it is to the retailer and at every stage of the extremely affordable, the iCON 3 is ideal for production process. businesses keen to try laser technology for Food grade ink and food engraving are the first time. solutions that have made packaging-free produce a reality, from distribution to the End-of-line systems shelf. Not only do these solutions contribute In a distribution centre, items are typically to saving the environment, but also help to received and shipped on pallets and pallet reduce costs, wastage and shrinkage at the scanning systems are used in many ways. supplier and store level. Tattoos, a popular fashion Incoming pallets are scanned as they enter while choice, are also of great interest in the fresh produce A PVA bag with laser coding outgoing items are scanned as they are placed on segment. Produce ‘body modification’ has become a a pallet, and the pallet itself is then scanned as it is reality and it’s changing the way produce moves from loaded onto a truck. Codes on pallets are used to route items farm to fork. to their appropriate locations and provide information about Non-toxic and compostable, PVA bags break down in water the materials on the pallet. A pallet of boxes can contain many and have very little impact on the environment. With no barcodes, making it difficult to read the right one at the right microplastic waste, these bags, which do not harm ecosystems time. Another challenge occurs when barcodes are covered or contribute to global ocean plastic pollution, are increasingly by reflective material, such as tape or plastic. There is also the used in everyday life. Water-soluble bags are generally used for likelihood that labels could become damaged or fall off during bulk purchases, especially in the food industry. transportation or unloading from the dock. As a result of changing mindsets, trends and legislation, many Using handheld scanners is inefficient when building supermarkets chains now promote ecological bags, offering pallets since the operator must constantly pick up and put consumers ecological and reusable alternatives. However, down the scanner or work with one hand. When an operator the growing popularity of these new materials creates the cannot scan a barcode or rework a pallet manually, this costs challenge of developing and searching for the best technology the facility time and money. With the DataMan 470 and to mark and code them in a legible, permanent and sustainable high-speed steerable mirror, scanning pallets is easier then way. Clean, fast and consumable-free, TracePack’s latest laser ever. Cognex pallet scanning systems, with their large depth the iCON 3 delivers a permanent mark that does not smudge. of field and wide field of view, capture labels on pallets and It works on most substrates, including labels, cardboard boxes, large packages from short working distances both quickly plastics, glass, wood and textiles, and can produce unique and accurately, even when they are degraded, torn, or and highly defined marks such as QR codes. The iCON 3 does covered in plastic wrap. The Cognex pallet scanning system not use inks or solvents, reducing running costs as there is I SSUE 01 // PACKAGING REVIEW

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TracePack

delivers a cost-effective solution, which increases a distribution facility’s efficiency and lowers costs by using image-based barcode reading technology with advanced algorithms to decode 1D and 2D codes, delivering industry-leading 99.9% read rates. Tracepack’s eco-friendly linerless printand-apply systems are installed at the end of the line. The system applies the last label first and can print any code, images and variable data coming from the packaging line. Its labelling systems can also help with using tamper-proof labels and tax stamps which will assist in the traceability of food products. With its robust, reliable laser coding systems, the coding process can be integrated with other processes such as pre-cutting for snack bags or micro-perforation of boxes and packaging, helping to increase productivity significantly. Quick and eco-friendly coding is made possible by TracePack’s software programme specially designed for food chains, effectively controlling traceability to guarantee safety for consumers.

Inspection and detection

TracePack provides a complete range of inspection solutions for the food, beverage, chemical, personal care, pharmaceutical and nutraceutical markets, to identify defects, irregularities and other manufacturing flaws. For inspection, a machine vision system detects defects, contaminants, functional flaws and other irregularities in manufactured products. Examples include inspecting medicinal tablets for flaws, displays to verify icons or confirm pixel presence, or touch screens to measure the level of backlight contrast. Machine vision can also inspect products for completeness, such as ensuring a match between product and package in the food and pharmaceutical industries and checking safety seals, caps and rings on bottles. Machine vision systems designed for inspection monitor the visual appearance of the observed material. The system automatically identifies potential defects in the material’s surface and classifies the defects based on similarity in contrast, texture and/or geometry, using statistical analysis. Most machine vision systems include a library of software tools that perform different inspections and allow you to incorporate multiple inspections from captured images.

“A new range of HACCP direct food contact inks and edible UV invisible inks for fruit and vegetables, baked products and confectionery is now available” 22

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“Clean, fast and consumablefree, TracePack’s latest laser the iCON 3 delivers a permanent mark that does not smudge”

Coding and marking

Today, good coding is a sign of quality and product safety. TracePack is aware of this and takes on responsibility daily – after all, coding stands for trust. Its thermal inkjet solutions were developed in collaboration with its customers to provide maximum dependability for a smoothly run production process. TracePack’s polymer thermal inkjet inks are unique as they contain polymer resins. These inks not only stick to non-porous substrates but are also difficult to rub and scratch off – making them ideal for many applications on plastic, glass and most metals. Both reliable and robust, TracePack’s thermal inkjet industrial printing systems guarantee brilliant prints with up to 600dpi – even at high speeds. They can be operated as standalone printers or in combination with other inkjet marking solutions. In addition, a new range of HACCP direct food contact inks and edible UV invisible inks for fruit and vegetables, baked products and confectionery is now available.

Anti-counterfeiting and security features

Polytij UV invisible ink is visible under UV light. It is perfect for anti-counterfeiting applications where text or 2D barcodes are required for large data applications. This invisible ink can be printed on a wide variety of non-porous substrates such as metal and plastics. Polytrust edible UV invisible and visible inks are unique because they utilise TracePack’s unique polymer thermal inkjet technology, so the ink can be used for printing on fruit and vegetables and will not be rubbed off easily. TracePack’s highly reliable and efficient software solutions are developed in-house. Its easy-to-use level 2, level 3 and level 4 solutions fulfil the requirements of all the traceability regulations around the world, such as DSCSA, EU-FMD, Chestny ZNAK, ITS, ANVISA, EPTTS, and SFDA. With its software solutions, developed by adhering to the ANSI ISA 95 standard, you can achieve maximum data integrity and efficiency using minimal hardware resources. Furthermore, thanks to the customisable structure, the solutions can be easily integrated into other systems. •

CONNECT WITH TRACEPACK ON SOCIAL MEDIA:

TracePack – www.tracepack.co.za


PERFECT SOLUTIONS DO NOT STOP US FROM CONTINUING TO WORK ON OUR IDEAS.

As a leading innovator, we have one prime characteristic: We are never satisfied. At KHS, we are thus always proud of what we have achieved – but we also immediately start to question it and think ahead. With the aim of constantly advancing and always improving – and of providing our customers with new, intelligent systems time and again. Which we then, of course, develop further. khs.com/products


KHS Manufacturing SA

HOLISTIC AND EFFICIENT SYSTEMS FOR THE BEVERAGE INDUSTRY

The KHS Group is one of the leading suppliers of future-oriented filling and packaging equipment. Beverage producers worldwide profit from the company’s more than 150 years of experience and expertise. Its comprehensive portfolio of products and services includes numerous systems that meet various customer requirements, helping to keep production reliable and cost- and resource-efficient for many years.

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hether beer, water, soft drinks or juice, carbonated or non-carbonated, hot or cold – KHS has the right system to satisfy practically every requirement. The turnkey supplier processes a broad spectrum of containers that range from glass bottles and PET to cans and kegs. KHS filling and packaging systems are a key component in a customer’s value creation chain. The group works to continuously optimise all its developments with regard to efficiency and the use of resources. This helps to reduce the carbon footprint of its customers. One example of a resource-efficient solution is the InnoPET Blomax Series V stretch-blow moulder, which consumes up to 40% less energy than comparable models. Thanks to the effective use of materials, the latest generation of KHS stretch-blow moulding technology saves up to 10% in PET

and valuable resources. This is a significant figure in view of the growing trend towards ever lighter containers. In a further effort to consistently pursue this objective, KHS supports its customers with the holistic Bottles & Shapes consultancy programme, which consistently aims for perfect container development and optimisation.

Future-proof secondary packaging systems

Sustainable, consumer-friendly and gentle on resources: these are also key issues KHS focuses on when designing new forms of secondary packaging and further developing existing ones. For instance, its Nature MultiPack combines beverage containers with easy-to-remove dots of adhesive instead of shrink film to form stable packs, saving up to 90% in packaging

Whether for beer, mixed beer beverages, or soft drinks, the Innofill Glass DPG pneumatically-controlled filling system offers cutting-edge precision technology with flexible application capabilities

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KHS Manufacturing SA

KHS attaches great importance to the reliable and standardised connection of its machines with their various controllers and devices to an MES or PDAS

A modern shrink packer, the Innopack Kisters SP Advanced allows you to process a wide range of products from beverages such as soft drinks, water and beer to food products and sanitary items

“An Innopack Nature MultiPack packaging machine … can process up to 108 000 containers per hour” materials. Available for both medium- and high-capacity volumes, an Innopack Nature MultiPack packaging machine running at overcapacity can process up to 108 000 containers per hour. KHS has developed another powerful machine in the new Innopack Kisters Wrap-aroundShrinkPaperPacker Advanced, or WSPP A for short. It packs beverage cans either in paper, cardboard or film and meets every market and customer requirement. Existing Innopack Kisters machines in the Advanced series can be upgraded to a WSPP A. The Innopack Kisters Carton Nature Packer (CNP) is also new. This resource-saving machine applies toppers made of corrugated cardboard or solid board to cans to form sturdy packs.

New standards in filling technology

In the beverage can segment, the mechanical engineering company recently expanded its tried-and-tested equipment to cover both the high- and medium-capacity ranges. The Innofill Can DVD, for example, processes up to 135 000 cans an hour,

The KHS Innocheck offers reliable rejection and redirection of your bottles and cans

with the compact Innofill Can C can filler aimed at SMEs with rates of up to 50 000 cans per hour. Both fillers are convincing with respect to hygiene, flexibility, product safety and low use of resources. KHS also scores with its new generation of glass fillers. With the Innofill Glass DRS ECO the turnkey supplier sets new standards in consumption values and product quality. A number of optional features help to increase even further the machine’s already high level of energy and resource efficiency. Its minimal consumption of CO2 coupled with low oxygen pickup is equally outstanding. •

VIDEO: Coca-Cola Hellenic Bottling Company relies on KHS Group as a partner for their new canning line

CONNECT WITH KHS ON SOCIAL MEDIA:

KHS – www.khs.com I SSUE 01 // PACKAGING REVIEW

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Multivac

Multivac’s RX-line thermoforming packaging machine and the TX-line Traysealer machines all Industry 4.0 ready

A PERFECT SOLUTION FOR EVERY PACKAGING PROCESS

Sustainability is an integral part of Multivac’s strategy. For 60 years, the company’s packaging solutions have ensured that sensitive products globally can be processed efficiently, as well as being packed hygienically, reliably and attractively.

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t Multivac, particular attention is always paid to the packaging process, which is both resource-saving and gentle on the product, so that the customer receives the right machine technology, suitable packaging materials and an optimum pack design. Other significant areas of action are the optimisation of the company’s internal and logistical processes, as well as the sustainable production of packaging machines with a particularly long lifespan. Multivac is also a trailblazer and trendsetter in the industry when it comes to sustainable packaging materials. Examples of this include the development of alternative packaging material concepts with reduced use of plastics, as well as its comprehensive range of PaperBoard materials. These paper fibre-based materials are not only innovative and functional, but also particularly sustainable. They have found a high level of acceptance with processors, retailers and consumers, and they can be recycled after use in the appropriate recycling loops.

High-quality films, materials and machines

Besides its vast range of machinery, Multivac is a leading supplier of high-quality films and food processing and packaging materials. Its packaging range includes MultiCook ovenable packaging, FormShrink films, printed lid and base, flexible lid and base, semi-rigid lid and base, skin lid, base and MultiFresh, vacuum pouches, shrink pouches, special food packaging, special medical packaging, age maturing bags, printed bags, biltong bags, casings, U-Clips, loops and strings. Multivac’s innovative machine concepts set benchmarks in the market. One example is the X-Line machine range, with the RX-line thermoforming packaging machine and the TX-line Traysealer machines all Industry 4.0 ready. Self-monitoring and self-diagnosing, these machines come standard with overall equipment effectiveness calculators and monitors sent directly to the manufacturer’s production office.

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Multivac is a trendsetter when it comes to sustainable packaging materials

All your needs covered

Multivac is among the leading providers worldwide of packaging solutions for the red meat, poultry, fish/seafood, bakery, dairy, fruit and vegetables, and ready meals segments, as well as the industrial and medical industries. The Multivac portfolio covers virtually all requirements of processors and producers in terms of pack design, output and resource efficiency, such as thermoforming packaging machines, vacuum chamber machines, traysealers, marking and inspection, as well as automation solutions, labellers and quality control systems. Its product range is rounded off with solutions upstream of the packaging process in the areas of portioning and slicing. Thanks to its extensive expertise in packaging lines, all modules can be integrated.

Specialist bakery and meat solutions

Fritsch, an expert in bakery technology, is also part of Multivac’s portfolio. With the highest quality, pioneering new developments and tailor-made solutions, Fritsch offers everything that the bakery trade and industry require to produce first-class baked goods. Since TVI Better Portioning joined the Multivac Group in 2017, customers throughout the world have been portioning their meat efficiently, economically, hygienically and reliably with its powerful portioning solutions. Multivac Southern Africa is the agent for Handtmann, which produces world-class vacuum fillers, portioning systems, and linking and dosing systems. Customers can discover new opportunities and realise innovative product ideas and product classics with Handtmann technology. The company also represents Tipper Tie, which is a leading system supplier of processing and clipping machines. With a long history in the meat and poultry industries, Tipper Tie is active in the dairy, confectionery, food ingredients and pet food segments. •

Multivac Southern Africa – za.multivac.com



NSI Label

SMALL BUSINESS TACKLES A MAJOR JOB FOR INTERNATIONAL RUGBY Silat Labels’ partnership with NSI Label placed the label printing business in an ideal position to work with the Dutch brewing company, Heineken, on a significant local labelling project, which transpired a month before the Rugby World Cup, which kicked-off in Japan in September 2019. A labelled bottle ready for the event

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aul Stretton, owner and founder of Silat Labels, explains: “A customer who was very pleased with our service recommended us for the Heineken project. Our quick turnaround time and print quality sealed the deal for Silat Labels.” Heineken, a key sponsor of the Rugby World Cup, initially commissioned 600 labels for a limited-edition beer bottle to mark the start of the event. The challenge Silat Labels faced was the ability to print a stunning transparent label that displayed well on the dark bottle. To do this Silat Labels needed to research a new label printing solution that could deliver on the requirement, within the deadline.

The label printer

Silat Labels looked for an end-to-end label printing solution, which was different from other CMYK only options that it had previously seen or used. It also wanted a printer with a small footprint to fit within the space available, so ideally a desktop printer rather than floor standing. The printer needed to be easy to use for the entire team, and good for ondemand small run printing. About half-a-dozen samples were printed early in week one and were sent to the client for approval. Thereafter, some minor artwork changes and colour adjustments were made, which would have been an extremely costly endeavour with an analogue printing system, but with the OKI desktop printer supplied by NSI Label, the adjustments were a breeze. In week two, Silat Labels fulfilled order for 600 labels.

Upon receiving delivery of the initial order of 600 labels, the client was extremely pleased and promptly ordered a further 20 000, which were produced and delivered over the following two weeks, all in time for the kick-off of the tournament. “Our digital packaging solution made it possible to grow the order from the initial small quantity into a much larger volume. Other technologies wouldn’t have allowed us to adapt to the client’s needs as effectively as we could with our device,” says Stretton.

The partner

NSI Label was a great supplier to partner with for Silat Labels. “We were initially convinced by their knowledge and immense 20-year experience in the labelling industry. However, once we purchased our label solution from them, they really started to shine. They stood with us every step of the way and were always available to assist and support us. Many suppliers say they’ll stand by you, but Shawn Bezuidenhout from NSI Label and his tech team really live it,” comments Stretton. “They were reliable, and it was a great boost to our confidence in an industry we were initially completely unfamiliar with, to have a supplier we could rely on 100% to stand by us through the process.” Stretton adds that it is great to have a partner in the business he can rely on. “The NSI 4 Africa maintenance guys have truly become part of the Silat Labels team and we wouldn’t have been where we are now without them. They made sure we experienced minimal downtime in critical situations, and we were always able to deliver on our promises with their help, even outside of office hours. Teamwork got the Heineken project done on time and allowed us to shine in the eyes of our customer.” • Specialised Heineken labels, printed on OKI’s Pro1050, featuring a combined background of CMYK and spot white

NSI Label – www.labelandpack.africa

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SILAT


DIGITAL LABEL

& PACKAGING PRINTERS

www.labelandpack.africa

Media Width 215mm BIZPRESS 13R Print Width max. 304mm

Print width up to 210mm wide

Max Width 125mm

650

Cut any Size, any shape label DUOBLADE WX. Max media width: 350mm Lamination, cut and waste removal www.labelandpack.africa

Contact: Wim: 082 454 7190 Lindo: 060 998 2295 Office: 011 050 6600


OKI Europe

TAKE CONTROL OF YOUR PACKAGING NEEDS WITH OKI Consumer awareness has been growing about the perils posed by single-use plastics, sparking a need for more innovation in sustainable packaging. The pandemic coupled with worsening climate change have accelerated this trend. OKI – a supplier of professional, cost-effective in-house printing solutions – explores developments in packaging printing coupled with its professional specialist print equipment positioned to meet market needs.

OKI’s Pro9000 Series helps customers meet new market needs for short-run and on-demand prints

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he way a product is packaged has become an important part of the product itself – from providing sustainability to deciphering the visceral and tactical impact of a physical product in the digital space, to telling a great story. The future is even closer than you think – every product will be designed and packaged to create interactive experiences and connect with the consumer. Yet, the cost of the stock commitment for professional packaging doesn’t help brand owners to try new lines, explore new designs or include current or upcoming consumer campaigns. Recipe improvement, batch-specific information and different barcode systems make it very difficult to achieve “in-time” individual consumer interaction when bulk printing your packages. There is also packaging waste and redundancy costs to consider.

An optimal way to produce labels

When attempting to streamline your business, the specificities may appear daunting at first. Over the past five years, OKI has invested heavily to provide products that are designed to alleviate packaging frustrations. Using award-winning LED technology and a superior dry powder ink, the company has succeeded in giving customers access to print professional packaging as they need it. High-end production quality in desktop devices is what’s on offer from OKI. A small office space can provide small to medium and even larger-sized companies the benefits of taking control of their packaging. OKI’s modern units are reliable and easy to use, and they keep you in business without demanding from you to become a seasoned printer. Packed with the latest in OKI digital LED technology, the Pro Series Label Printer takes creativity and flexibility to a new level, with professional four-colour (Pro1040) and five-colour (Pro1050) narrow-format printing across a wide range of materials. Print in white or clear toner on substrates that you would never have thought possible with a short-run printer. Designed to meet the needs of a diverse range of specialist print applications, the Pro9000 Series delivers vibrant, high-

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OKI’s Pro9000 Series delivers vibrant, high-quality colour printing on a wide range of media quality colour printing on a wide range of media. Whether you’re a small business, commercial print provider or anything in between, the Pro9000 Series has something to offer.

Merging digital with traditional technologies

The number of customers moving to digital is growing. In 2020, the digital volume was estimated at around 17.4% with its growth noted at around 3%. Digital printing offers you a lot, including variable data and high print resolution. The need for short-run and on-demand prints is growing rapidly as new markets open up, such as craft food and beverage producers, photo products and cosmetics. Economically, the relative costs are changing based on the new developments in digital and analogue technology. For short runs, digital has lower setup costs and offers competitive pricing. It is important to note, however, that it isn’t an “either-or” approach. Long-run is better suited for analogue or traditional methods, and many companies will utilise both digital and traditional technologies to give their business the best competitive advantage in the market. That being said, the market is shifting towards short-run, leading to digital’s popularity. •

CONNECT WITH OKI EUROPE ON SOCIAL MEDIA:

OKI Europe - www.oki.com/me/printing/


DIGITAL LABEL

& PACKAGING

OKI PRO 9542 CMYK + WHITE (SRA3) Sheet printer

PRINTERS

OKI PRO 9431 CMYK (SRA3) Sheet printer

Prints using C,M,Y,K Wide choice of compatible materials Packaging printing while also capable of office print tasks

Roll to Roll Printer Only roll desktop printer C,M,Y,K+WHITE Prefect for own use and reselling labels. Prints are waterproof, scuffing and chemical resistant.

Cut any Size, any shape label

Printer Consumables

www.labelandpack.africa

Contact: Wim: 082 454 7190 Lindo: 060 998 2295 Office: 011 050 6600


Omron

VIDEO: Omron LD Series Mobile Robots is the modern solution for warehouse facilities

MOBILE ROBOTS DELIVER AUTONOMOUS MATERIALS HANDLING IN CRITICAL AREAS Using a mobile robot, pharma manufacturer Normon has streamlined the transport of medical vials in its A-class cleanroom environment. Built for performance, Omron’s mobile robots handle simple transport, delivery and routing chores so employees can continue with their higher-value responsibilities.

E

stablished in 1937, Normon – based in Madrid, Spain – has been manufacturing high-quality medicines for over 80 years, serving customers in the pharmaceutical and healthcare sectors throughout Europe and the US. The company prides itself on its advanced technology and innovation, and its ability to produce affordable medicines in a sustainable way.

on the market and became particularly interested in autonomous mobile robots, also known as AMRs, but they didn’t meet our criteria. However, we then came across an impressive AMR produced by Omron, which was suitable for work in cleanrooms.”

A solution for cleanroom environments

The Omron LD mobile robot could be personalised to meet Normon’s specific needs and was very easy to install in the plant. The entire implementation process took just three days and was carried out by Mipelsa, an integrator that specialises in the implementation and maintenance of electronic products, including those involved in industrial automation. Omron worked closely with the system’s integrator throughout the whole process. The installation and start-up at the Normon factory were extremely fast, thanks to everything being tested previously

Normon has been using automated guide vehicles (AVGs) within its production process. However, following a change in the environment in which the robots needed to be deployed, the company discovered that the AGVs were too large to be used in certain cleanrooms. Robots used in cleanroom environments must meet stringent requirements to prevent them for acting as a source of contamination. A specific type of robot is required for cleanroom applications and, as without robots, highlyqualified operators would have to transport the products within cleanrooms, instead of focusing on their own tasks. Normon’s head engineer, Jose María Urdillo, comments: “We investigated a few different solutions Omron’s mobile robots in use at the Normon pharmaceutical plant in Madrid, Spain

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Customised and easily commissioned

“Normon now operates one of the first and largest mobile robot fleets in Europe, with 18 mobile robots in service”


Omron in the Mipelsa laboratory after building a replica of the customer’s work area. Finetuning took place during the testing phase to fulfil all of Normon’s performance and safety requirements. The end result from Normon’s point of view saw commissioning take place in just one week, while working in production mode. The customer was pleased with the help and advice provided by both Omron and Mipelsa, including the redesign of a tray holder to include a slight bend in one of the tubes holding the structure, which resulted in a more robust construction. This application-specific customisation was the most relevant to reduce the presence of humans in an A-class working area as specified by the requirements of the FDA. No modifications within the environment were needed when integrating the robots, which were ready for trials within a week.

Improved productivity

“Since the initial implementation of Omron mobile robots in 2018 and 2019, Normon now operates one of the first and largest mobile robot fleets in Europe, with 18 mobile robots in service. According to Normon, the project was a huge success with the robots demonstratively boosting production after one month in operation,” says Omron’s project manager, Miguel Ángel Esteban.

Did you know

FDA regulations stipulate that no people may be present in an A-class cleanroom area. Thanks to Omron’s mobile robots, Normon is able to comply with this requirement.

The family of autonomous mobile robots from Omron This proved to be the case as productivity was significantly improved – 111 000 vials could be transported in 40% less time than before, reducing the length of stay in the plant’s A-class cleanroom area. In other words, a production process that previously took one-and-a-half shifts can now be completed in less than a shift. Following the introduction of the robots, employees can perform more specialised tasks and functions within the cleanroom, adding more value to their work and ultimately the company. What is noteworthy about this specific project is that no employees have been re-deployed or made redundant by the introduction of the cobots in Normon’s A-class cleanroom area.

Future prospects

As the Omron robots have exceeded Normon’s expectations, additional implementations are being planned for the future. Esteban concludes: “Intralogistics solutions such as this are key to meeting the needs of our pharmaceutical customers, especially in cleanroom environments. With the newest additions to our mobile robot fleet, including mobile robots capable of transporting heavy loads, we can offer a solution for a wide range of applications.” •

CONNECT WITH OMRON ON SOCIAL MEDIA:

Omron – industrial.omron.co.za

Flexible Production Integrated Robotic Solutions

• Autonomous teach and go and self-recharging • Automated can fit within a line or factory to achieve end to end automation and traceability • Intelligent can optimize travelling path and work within a fleet of up to 100 robots • Safe fully collaborative and operate along people Would you like to know more? +27 (0)11 579 2600 info_sa@omron.com industrial.omron.co.za

flexible_production_177x65mm_ad_enza_01_d02.indd 1

07-09-21 13:57

I SSUE 01 // PACKAGING REVIEW

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packwise-africa

A REVOLUTION IN DIGITAL PACKAGING DECORATION The Fourth Industrial Revolution is having a profound impact on production and consumption, fundamentally changing packaging – because it touches all products. packwise-africa explores advances in digital inkjet printing technologies and how best to utilise these solutions for next-generation packaging printing applications.

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hree factors have significantly changed the traditional way of packaging decoration over the last few years. These factors and the change process are often referred to as the Fourth Industrial Revolution. 1. Rapid digitalisation of communication between consumers and brand owners allows brands to connect their clients via packaging (QR codes) and to create a much closer brandclient interaction and relationship. 2. Rapid digitalisation of packaging decoration has not only simplified and accelerated the decoration (printing and embellishing) of packaging (corrugated boxes/cartons, labels, shrink sleeves and flexible packaging), but also enabled variable data and security feature printing for short production runs. 3. A rapid change of the market environment, like the pandemic, has disrupted the market and increased the pressure on brands to attract consumer attention both online and at the point of sale. Promotional, eye-catching packaging is required to connect closely with consumers, leading to more design changes and shorter just-intime production runs.

Digital print solutions

The Fourth Industrial Revolution is a fusion of advances in artificial intelligence, robotics, digital production, the Internet of Things, genetic engineering, quantum computing and more. It opens new opportunities for brand owners to improve their time and cost to market using digital packaging decoration.

Did you know

Digital inkjet printing is the most versatile and cost-efficient digital printing technologies available today. It is technically simpler (requiring less maintenance and resulting in less downtime). It is also faster (up to 180m/min) than most other digital printing technologies and offers a significantly lower variable cost structure. This results in a lower cost of ownership and faster return on investment, which is why digital inkjet printing is exponentially growing its market share globally.

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HanGlobal LabStar 330 digital UV-inkjet press for labels

Hanway REVO2500W multipass digital inkjet press for corrugated boxes

Today, corrugated boxes and cartons, labels and even flexible packaging can be digitally printed. Digital printing substantially reduces or eliminates the time and cost of printing forms, mixing ink, press setup/washup and setup/production waste. Packaging may either be traditionally preprinted with generic content and digitally post-printed with variable content, or completely digitally printed just-in-time. packwise-africa has digital print solutions for corrugated board/cartons, labels/shrink sleeves and flexible packaging. One of packwise-africa’s partners for digital inkjet printing is the Hanglory Group. Hanway, the business unit for corrugated boxes and cartons, has built a global install base of 300 presses over the past ten years – incorporating 75 single-pass and 225 multi-pass models. There are currently three multi-pass presses installed in Africa – one in Cape Town and two in Alexandria, Egypt.


packwise-africa

The Hanway digital inkjet board press range comprises of four presses – the Glory 1604 and 2504 high-volume, single-pass digital inkjet presses for aqueous inks; and the Revo 2500W and HighJet 2500B multi-pass digital inkjet presses for aqueous ink. The Glory can achieve production speeds of up to 180m/ min, resulting in a maximum output of 27 000m2/hour, which is faster than many post-print application presses. The Revo 2500W is the market’s fastest multi-pass inkjet printer for board with a maximum output of 1 200m2/hour. HanGlobal, Hanglory’s business unit for label printing, has built a global install base of 21 presses over the last three years, of which one was recently installed by packwise-africa in Cape Town. The HanGlobal LabStar 330 is an industrial highresolution inkjet press achieving 1 200 x 1 200dpi. It prints CMYK+W at 50m/min, resulting in an output of 990m2/hour. It is designed to print on self-adhesive papers and films, boards and unsupported flexible films.

Miyakoshi MJP30-AXF digital inkjet press for flexible packaging

Digital inkjet solutions

Miyakoshi, packwise-africa’s digital inkjet partner for flexible packaging, has evolved from litho to digital printing presses. Its latest model, the MJP30-AXF digital inkjet press for aqueous printing inks, can print flexible films from 12µm to 100µm up to a width of 750mm with a resolution of 1 200 x 1 200dpi and at a speed of 50m/min, resulting in a maximum output of 2 250m2/ hour. Its unique priming and drying technology in combination with its aqueous inks allows printing of direct food-contact flexible films. To enable packaging converters to utilise existing traditional press technology for variable data printing, packwise-africa has digital inkjet retrofit printers. Jetsci has developed a range of digital inkjet printers for UV inks and aqueous inks. These printers allow monochrome variable data printing up to a speed of 200m/min. Due to their compact design, they can be easily retrofitted into almost any type of press and are suitable to print on paper, board and film. Besides variable data, security elements can also be printed with special inks or varnishes. packwise-africa has more than 30 years’ experience in packaging printing and offers a holistic consultation service with turnkey solutions supported by local technical and application aftersales support for its digital printing solutions. •

+27 (0) 60 327 0472

VIDEO: HanGlobal LabStar 330

VIDEO: Hanway Revo 2500W

VIDEO: Hanway Glory 2500

VIDEO: Miyakoshi MJP30AX:

VIDEO: Monotech Jetsci packwise-africa – packwise-africa.com

uwe@packwise-africa.com www.packwise-africa.com

digital inkjet presses/printbars • flexo/gravure/offset presses • digital finishers • slitter rewinders • die cutters • shrinksleeve converters • plate mounters • web inspection systems • plate/anilox/print cylinder cleaning machines • anilox rollers • print cylinders/ sleeves/adapters • magnetic die cylinders • flexible dies • paperbag making machines

labels & shrink sleeves • flexible packaging • corrugated packaging

I SSUE 01 // PACKAGING REVIEW

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Nissei ASB South Africa

FORM YOUR VISION WITH NEW BLOW MOULDING TECHNOLOGY With a leading share of one-step injection stretch blow moulding machines installed worldwide, the history of PET containers is the history of ASB. Today, its machines and moulds are able to produce PET containers with advanced features. Compact, versatile and efficient ASB70DP The ASB series consists of one-step stretch moulding machines with excellent moulding flexibility supplying the greatest cost efficiency for their users. The origins of the ASB-70DP model range can be traced back to 1986. Since then, there have been continual improvements in the form of the ASB-70DPH v4 and ASB-70DPW v4. Compact, flexible and efficient, the ASB-70DP series consists of the best-selling machines in its class with over 1 700 units having been delivered to customers worldwide. Applications include cosmetics, pharmaceuticals, infusion bottles, detergent, mouth wash, baby feeding bottles, spice, salad dressing, food, liquor, PET can, mineral water and industrial containers such as those used for photocopy toner. The following bottle

shapes can be produced on the series: plain round, non-round, wide-mouth, oval, ultra-light, thick-wall etc.

Highly energy-efficient ASB12M

The ASB12M offers the best energy efficiency in its class, as well as excellent versatility and low noise. With a higher specification than the ASB-50MB, the ASB-12M is ideally suited to more demanding applications offering a wider range of moulding options for pilot or full-scale production. The machine has set new standards for higher cavitation with lower energy consumption through the use of servo driven hydraulic pumps. Moulds from previous models can be fitted to this machine with simple modifications. With ASB’s Vision1 machine control system, the ASB-12M v2 makes a giant leap in terms of factory integration and ease of use. Applications include wide mouthed jars for a variety of food and non-food applications, cosmetics (mascara, lotion, cream etc.), pharmaceuticals (eye drops, medicine, pills etc.), baby feeding bottles, spice, liquor, carbonated drinks etc. Suitable materials include PET, PP, PC, PLA, PEN, PS, PES, PPSU, recycled PET etc. Plain round, wide-mouth, oval, nonround and ultra-light shapes can be produced on the ASB12M. •

Nissei ASB South Africa – www.nisseiasb.co.jp

ASB NISSEI ASB SOUTH AFRICA PTY, LTD

OUR EXPERIENCE WILL FORM YOUR VISION Energy efficiency, Versatility, Low-noise, ASB-12M improved in every aspect. The ASB-12M has been developed as an upgrade model from the entry level ASB-S0MB, which has sold more than 2000 units and remains in our line-up as one of our best sellers. It is a compact one-step injection stretch blow molding machine with improved jar capability, advanced energy efficiency and a wide variety of molding materials.

You(D

www.youtube.com/user/NisseiASBMachine

www.nisseiasb.co.jp

NISSE! ASB SOUTH AFRICA f PtyJ LTD

NISSE! ASB PTE. LTD.

Unit 2 The Shields, 33 Victoria Link, Route 21 Corporate Park, Nelrnapius Drive, Irene Ext.30, 0062, 0157, South Africa TEL 27( 12) 345 4924 E-Marl sales@nisserasb .mza

1 Boon Leat Terrace, #08-03, Harbourside Building1, Singapore 119843 TEL• 65-6778-4633 FAX 65-6778-9440 E-Mail sales@nisserasb.com.sg

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Rotolabel

SERIOUS ABOUT SUSTAINABILITY IN THE LABEL PRINTING SPACE Rotolabel is passionate about the environment and focuses on minimising any negative ecological impact of its products. Its label of trust extends to pushing the boundaries in sustainability to ensure a greener future for generations to follow and the company therefore subscribes to the four Rs of packaging sustainability: responsible sourcing; reduction of materials; recyclability and increased recycled content.

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s a leader in sustainable innovation within the South African label printing space, Rotolabel has introduced some notable initiatives.

Responsible Sourcing

Responsible sourcing is one of the cornerstones of sustainability – and while paper can be biodegradable and easily recyclable, it can also be the product of deforestation or poor forestry practices. The Forest Stewardship Council (FSC) is an international certification and labelling system that enables people to identify responsibly sourced wood, paper and other forest products. As the original pioneers of forest certification, FSC has over 25 years’ experience in setting the gold standard for sustainable forest management. In today’s world there is no excuse for paper to not be sourced responsibly, which is why Rotolabel became FSC Chain of Custody-certified (FSC-C119866) back in 2015 – and was the first label printer in South Africa to achieve this certification.

Liner recycling and raw material reduction initiatives

While self-adhesive labels are a great option for product labelling, recycling of the glassine liner remains a challenge in South Africa. In partnership with Avery Dennison, in 2018, Rotolabel ran a pilot project in Cape Town for the first ever glassine liner recycling programme in South Africa. Despite many challenges, Rotolabel has been able to recycle its first 21t of glassine liner, which is a significant step in reducing waste to landfill. One of the critical pillars for a more sustainable future is to reduce. Although pressure-sensitive labels form less than 3% of the overall packaging on a product, reducing the use of resources can have a significant impact on the environment. By reducing raw materials, Rotolabel can now offer thinner and lighter films with less grammage, without compromising

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on label performance. Using less raw materials also generates less waste and creates a reduction of total consumer packaging – and that also means higher efficiency for brand owners. The Avery Dennison ‘Lite’ range includes PP cavitated, PP clear and semigloss options.

Labels with recycled content

A key driver in the circular economy concept is for raw material suppliers to use recycled content in their virgin products. Avery Dennison now offers an array of materials with up to 100% recycled content – conserving resources such as water, energy and greenhouse gasses. rCrush wine label paper is a range of paper facestocks made from 30% to 100% recycled content and responsibly sourced crop materials with unique finishes ready to inspire creativity. With 15% post-consumer waste, rDT direct thermal paper is the first recycled non-top-coated direct thermal paper on the market. It’s a solution for thermal applications that focus on sustainability and provides similar performance as that of a standard grade. Made partially from recycled PET plastic, at 23 microns rPET recycled liner is currently the thinnest film liner on the market.

“Rotolabel has been able to recycle its first 21t of glassine liner, which is a significant step in reducing waste to landfill”


Rotolabel And you can reduce your environmental footprint even further with liner recycling options.

Clean separation solution for recycling PET

Rotolabel has recently started garnering positive results from an 18-month collaboration of the commercialisation of CleanFlake with Avery Dennison. CleanFlake is a unique pressure-sensitive adhesive technology that facilitates PET (polyethylene terephthalate) recycling through a clean separation during the sink/float of the recycling process. On a planet awash in plastic waste – and with regulators responding accordingly – every recycled package counts. But label contamination prevents proper recycling of hundreds of millions of food-grade PET packages every year, resulting in downcycling or no recycling at all. CleanFlake technology ensures that labels and adhesive separate from PET every time, increasing the yields of pure PET flakes. CleanFlake products have passed the most stringent tests of the Association of Plastics Recyclers. The technology has also been endorsed by Extrupet as a suitable solution for recycling PET bottles back into food-grade rPET (recycled PET) in its facilities. Through this initiative, Rotolabel hopes to share the benefits of CleanFlake and its recyclability of not only bottles made from PET, but also other packaging formats – helping to set an example for others in the industry.

Biodegradable and compostable labels

Demand for compostable packaging is increasing across many business segments due to tightening legislation on the use of plastic. Avery Dennison’s ClearIntent compostable range offers a combination of facestocks and adhesives that can be reintroduced into nature. It helps brand owners, retailers and converters meet growing consumer demand for sustainable solutions while addressing the anticipated legislative requirements on landfill and sustainable packaging.

VIDEO: Rotolabel Sustainability It’s important to note that when applying biodegradable and compostable labels to packaging, the packaging must also be biodegradable and compostable, otherwise it defeats the purpose. Also, most compostable packaging needs to be decomposed by industrial decomposting, and South Arica currently has a limited infrastructure and resources.

Phasing out fossil fuels

Renewable solutions can help to reduce carbon emissions and mitigate climate change. UPM Raflatac has created Forest Film – a unique white or clear plastic label solution based on wood-based residue materials – which allows you to take the first important steps in phasing out fossil fuels. Forest Film uses UPM BioVerno naphtha, a 100% wood-based solution originating from sustainably managed forests, which gives new life to residue from the pulping process. UPM Raflatac is constantly trying to find ways to speed up a transition from virgin fossils to bio-based raw materials. PP White Food FTC and PP Clear Food FTC are specially designed for rigid packaging for food end-use and suit the majority of PP labelling applications. PP Food is part of the sustainable SmartChoice portfolio that helps to reduce one’s carbon footprint and mitigate climate change. It also minimises the amount of virgin fossil raw materials by using thinner and resource-optimised components. Combined with R307 adhesive and FSC certified (FSC-C012530) HD Lite-FSC backing paper, PP Food is a labelling solution that takes rigid plastic packaging in a more sustainable direction. PP Food enables brand owners to lower their carbon footprint, increase the sustainability of their packaging and to be a sustainable leader in their market. •

Rotolabel – www.rotolabel.co.za I SSUE 01 // PACKAGING REVIEW

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Syntegon Technology

IN THE JELLY KITCHEN – A SWEET PARADISE FOR MANUFACTURERS

The dynamics of the confectionery industry are nowhere more apparent than in the jelly market. There seems to be no limit to colours and shapes, and manufacturers are constantly developing bright new creations. Jellies enriched with vitamins and nutritional supplements for children and adults are among the ongoing trends. For producers who want to prevail over the competition, this fast-moving market environment triggers the need for efficient and flexible process technology. By Laura Kossmann, sales and marketing, Makat Candy Technology

T

he jelly market is diverse, colourful and characterised by ever new trends. If manufacturers want to keep up with these trends and withstand constant price pressures, they must continuously develop creative ideas while maintaining cost-efficient production. To implement these ideas, they need a partner who can support them with creative solutions, comprehensive expertise and innovative technologies from the very beginning.

Innovative equipment for sustainable production

In addition to the value-determining raw materials, the kitchen is the starting point for the production of high-quality jellies. Here, process requirements are high. The entire

Makat Candy Technology has been providing turnkey solutions for all steps of the jelly production process for over 90 years, and recently added innovative kitchen technologies to its portfolio

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production environment must meet maximum hygienic standards. A high degree of precision is also required for the continuous dosing and mixing of valuable ingredients such as vitamins and minerals. Especially when it comes to very small quantities, volumetric dosing and mixing stations are best suited. The kitchens also have membrane pumps with flow control and a high dosing accuracy of up to 1%. “Sustainability is an equally important issue in jelly production. Using our patented Rapidsolver for dissolving jelly mass, we enable significant energy savings in this process step,” The starch depositing process is the established standard for manufacturers who want to respond quickly and flexibly to new consumer demands or market trends


Syntegon Technology

explains Dr Sandra Link, product manager at Makat Candy Technology. “By expanding the Rapidsolver with the patented Energy Recovery System, also known as ERS, producers can achieve energy savings of up to 50%.” The Rapidsolver’s optimised design enables a reduction in steam pressure of up to 0.5 bar. This not only reduces energy consumption within the dissolving process, but also reduces the heat load on the mass and protects the quality of the end product. Extensive research has also resulted in the geometry of the Rapidsolver’s mixing elements, which are especially adapted to the needs of gummy and jelly. It ensures a first-in-first-out principle and reduces dead corners, which in turn reduce cleaning times. The hygienic design and specifically adapted cleaning-in-place (CIP) system with integrated rotating spray balls facilitate the thorough cleaning of the equipment.

High accuracy for a perfect result

Once the suspension has been mixed, dissolved and preconditioned for further processing, another decisive step is required – depositing the jellies. Here, the starch depositing process is the established standard for manufacturers who want to respond quickly and flexibly to new consumer demands or market trends. “The Makat high-performance mogul, or HLM, works particularly precisely. Thanks to its reproducible and accurate

“Using our patented Rapidsolver for dissolving jelly mass, we enable significant energy savings” The kitchens feature membrane pumps with flow control and a high dosing accuracy of up to 1%

depositing result, it ensures consistently high product quality – whether you want to deposit 500kg or 6 000kg of jellies per hour,” Dr Link explains. The stamps used to form the negative moulds in the starch can be flexibly and easily exchanged to create a wide range of variations in size and shape. The Makat HLM also features a robust design and PLC-controlled process monitoring. Its scalable production system is also ideally suited for the use of Industry 4.0 solutions. Sustainability also plays an important role. For example, the brushless RNC 6000 tray edge-cleaning system reduces not only the starch losses, but also production waste, cleaning effort and costs.

TURNKEY SOLUTIONS FOR JELLY MANUFACTURING Makat Candy Technology, a Syntegon Technology company, has been providing turnkey solutions for jelly manufacturing for over 90 years – now also including innovative kitchen technologies. By bundling its jelly competencies, Makat offers jelly manufacturers individually tailored process solutions for cooking and moulding their products from a single source – a “one-stop shop” for all needs. The optimal solution for jellies of all kinds starts at the Makat application technology centre: from developing a new product in test kitchens to planning new equipment or modernising production processes. After commissioning, Makat ensures the constantly high availability of machines and systems. There is virtually no limit to the colours and shapes of products in the jelly market – manufacturers are constantly developing new, colourful creations and therefore rely on efficient and flexible process technology

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Syntegon Technology

The Makat Candy Technology application technology centre in Dierdorf, Germany

The starchless innovation

In addition to reliable quality, innovation is a key factor in jelly production. Manufacturers must always be able to offer new product variants and respond promptly to changing consumer wishes. New products require innovative manufacturing processes, such as starchless depositing, a process that is particularly suitable for the production of jellies enriched with minerals or vitamins. “Starchless depositing eliminates the need for starch. Instead, the jelly mass is poured into special reusable moulds,” comments Dr Link. “We have optimised our equipment in order to ensure a high-quality depositing process of masses with a high dry substance content.” After depositing, the product moulds with the jelly mass pass through an integrated cooling tunnel and are brought to the

“The starchless depositing process has several advantages”

required demoulding temperature. Depending on the recipe, the jellies are cooled and form-stable already after 20 minutes of cooling time. Once the jellies have been demoulded, the empty moulds return to the depositor and the process starts all over again. “In the traditional starch-based depositing process, the starch trays have to remain in a curing room for up to 72 hours,” she explains. “The starchless depositing process has several advantages. It reduces production time and the products no longer have to leave the machine for cooling. In addition, jelly producers save the space and energy costs for the curing rooms, as well as all expenses for starch handling and conditioning – which also eliminates expenses for ATEX protection.”

Everything from vitamin bears to collagen drops

“The use of product moulds somewhat limits the design options,” she mentions. “Nevertheless, starchless depositing can be an attractive option for the mass production of jellies in simple, uniform shapes. In addition, it is suited for the production of jellies as dietary supplements enriched with vitamins or other additives.” Dr Link is convinced that “starchless jelly production will currently not replace mogul technology. Rather, it is an excellent addition to the portfolio, enabling us to respond even better to the individual needs of our customers and to find the best possible solution for them.” When it comes to deciding on the most suitable process for their gummy and jelly products, Makat supports confectionery manufacturers right from the start. “At the application technology centre at our site in Dierdorf, Germany customers benefit from the knowledge of our experts. Our team works with our customers to develop innovative products and processes, advises them on how to optimise their production processes and, if necessary, trains their employees on the use of new processes,” Dr Link concludes. •

Syntegon Technology – www.syntegon.com

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The numbers speak for themselves. Wherever the journey may take you – you will never walk alone. At Syntegon, we are there for you from the very first idea to the installation of your system and beyond. Our focus: Satisfied customers and high-quality products. Be it packaging materials, machine applications or new recipes: our first-class technologies and customized consulting services help you to forge your path.

Syntegon. Formerly Bosch Packaging Technology. syntegon.com


Teqal

TEQAL AND WILDTRUST

ESTABLISH A PLASTIC NEUTRAL PARTNERSHIP

As a packaging manufacturer, it is essential for Teqal to actively contribute to reducing the environmental impact of plastic when it accumulates on land and in our waterways and oceans. The company recently established a ‘plastic neutral’ partnership with Wildtrust through its Blue Port project.

B

ased in KwaZulu-Natal, Teqal produces quality packaging for the cosmetics, personal care and industrial markets. Its manufacturing plant, situated at the Dube TradePort SEZ, adjacent to King Shaka International Airport, houses some of the most energy- and production-efficient servo-driven packaging machinery available worldwide. Teqal’s strengths include the strategic registration of functional and technical designs and patents, along with inhouse high-end packaging, tool-making and design experience – all of which are vital in generating value in the personal care and cosmetics industry. In an effort to be 100% plastic waste neutral, for every kilogram of plastic Teqal converts into packaging, an equal

The Teqal team at the Durban Port pictured with Wildtrust CEO and Wildoceans Blue Port project team. Standing left to right: Wendy Dunn (Blue Port project supervisor), Junior Mthembu, Anele Shabane, Nomzamo Ntini, Renee Kirkham, Sean Kirkham, Roelie Kloopers (CEO of the Wildtrust), Ntombifuthi Dlamini, Sihle Mdakane, Sabelo Mbatha (Blue Port boat skipper), and Rachel Kramer amount of post-consumer plastic waste (PCPW) is collected from the environment and recycled. The Blue Port Project is an initiative of Wildoceans (a programme of the Wildtrust), with the aim of creating action-based research and the implementation of strategic interventions to reduce plastic waste in the Durban Port and ultimately restore the Durban Bay to its natural functioning state.

A local innovator

The Wildoceans Blue Port project seeks to progressively clean up the Durban Port ecosystem and returning it to a healthy, natural state

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Thanks to funding received from the incredibly supportive Industrial Development Corporation, Teqal is experiencing a very high growth phase in the business. The company recently relocated to substantially bigger premises within the Dube TradePort and has invested in new technology to increase capacity in various areas of the business. Teqal already actively uses recycled content in its packaging products, some of which are also biodegradable. The company’s biodegradable Reflections jar was launched in July last year, marking a first for cosmetics packaging produced in South Africa as it is 70% biodegradable and 100% recyclable. The challenge here is that biodegradable or compostable packaging needs to end up in the correct environment in order to biodegrade or compost. Conditions in home composters and in the open environment are very different compared to industrial composting plants and this


Teqal

SUCCESSFUL INTEGRATION OF DEAF EMPLOYEES Since December 2020, Teqal has been partnering with eDeaf on the successful placement and integration of deaf employees within its workplace. eDeaf strives to improve the social and economic lives of the deaf community. Its value-adding efforts create employable deaf individuals who are able to contribute to the economy. The successful integration of the deaf employees not only required effective communication measures to be put into place at Teqal and but also a workplace where their health, safety and accessibility are guaranteed. Along with learning basic sign language, the Teqal team was trained by eDeaf while the company has made changes to its IT systems to make the transition to an inclusive manufacturing plant.

affects the rate and extent of breakdown. The correct disposal and treatment of biodegradable, compostable and biobased plastics are also crucial for these types of sustainable packaging solutions to be effective.

Enabling a circular economy

Plastics are a key material in modern life. They are versatile, light and can be produced at relatively low cost. In a circular economy, all plastics should be recycled into new plastics in the first instance. This is why Teqal has turned to Wildtrust to effectively contribute to enabling a circular economy, initially in Durban with the hope of growing the project’s reach further afield in KZN. “As a company, we are trying to find ways to reduce our environmental footprint – and striving to be plastic neutral is certainly a big stride in that direction. Until the partnership with Wildtrust, this goal was not going to be easy to achieve,” explains Sean Kirkham, sales and marketing director of Teqal. Rachel Kramer, Blue Port project manager, adds: “This agreement gives Wildoceans an opportunity to have sustainable finance streams which allow for progression within these projects, by increasing the teams’ operations in the port. They also allow for continuing long-term research and exploring different opportunities.”

A vision for sustainability

Kirkham adds: “Consumers are becoming more educated about problems linked to plastic pollution and they are beginning to push brands, which in turn push suppliers to be more environmentally conscious. We are now leading the pack in driving the message of being waste neutral. Government has also played a part in putting legislation in place that lets producers and retail companies know that they are also responsible for the waste generated by the plastic that they sell.” Renee Kirkham, CFO of Teqal, is equally passionate about the ‘plastic neutral’ partnership. “Plastic is highly recyclable and highly reusable,” she says. “If we can get to a point where we ensure plastic is reused and recycled, we can continue to reap the benefits of the solution it provides in packaging – but do it in a way that is sustainable. As a converter of plastic, it is important that we contribute to this initiative.” •

Teqal – teqal.co.za I SSUE 01 // PACKAGING REVIEW

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Trempak

EMBRACING THE FUTURE Over the past two years, Trempak has forged ahead with major expansion, investing over R30m to increase its capacity in bagmaking, pouching, slitting and warehousing. The company has employed 11 additional people during this period and plans to create more employment opportunities, whilst also creating work through the upgrading and expansion of its premises. A further R11m has just been spent on a state-of-the-art laser perforator, placing Trempak at the cutting edge of micro- and macro-perforation technology and capability. For clients in the ‘fresh prepared’ and other fresh food sectors, improved turnaround and precision will be significant. Reducing environmental impact

The hot topics of plastic pollution, waste and sustainability have been embraced holistically by the company, where it continues to focus on these issues from two angles: 1. reduce, re-use and recycle 2. shelf-life extension and reduction in food waste. This two-pronged approach not only addresses the environmental issues of pollution and resource sustainability, but also the dire state of malnourishment and starvation in South Africa. The solutions Trempak develops for, and with, clients give cognisance to this bigger picture. Another aspect of the company’s commitment to reducing its environmental impact is its investment several years ago in a solar energy system, which supplies 60kW daily to power its offices and some of its smaller machinery.

World-class international principals

Trempak represents a number of world-class international principals including Smipack, Proseal, Bollore, Audion Elektro and Tenax. Exciting developments in the Proseal and Smipack offerings are detailed below with video links for more information and insights. The Proseal Halopack tray system is the first fully hermetic cardboard MAP packaging. The trays are made from over 90% recycled cardboard and incorporate high barrier properties that maintain product quality and with the right conditions can extend shelf-life. The Halopack system addresses the primary protective function of packaging and serves to reduce food waste while reducing the amount of plastic used by up to 42%. Proseal Skin2 is a new skin packaging technology, which increases cycle speeds over existing skin processes while

VALUES AND IDEALS True to its mission statement, the company strives to action and embody these values and ideals: • Trempak is a spirited and innovative packaging solutions company. • Our business journey is one of respect and integrity, driven by our passion for excellence. In the Smipack FW series, a new range of flow pack machines has been introduced consisting of six models

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• We are fully invested in our customers, our people, the community and our planet.



Trempak

reducing unit and equipment costs. The system can use both flat sheets or trays, depending on suitability for product and aesthetics. Proseal’s entire range of tray sealing machines is readily equipped to handle the widening range including board Graham Finke, managing director of Trempak and pulp, enabling manufacturers to adopt new formats without excessive or costly additional investments. In the Smipack WPS series, a new tuck-and-fold case wrapping machine has been introduced with a host of applications, such as a six-pack beverage casing and multiple detergent packs. In the Smipack FW series, a new range of flow pack machines has been introduced consisting of six models. Designed to pack a wide range of products with irregular shapes and small dimensions, the machinery allows for easy switch-over between pack sizes and shapes and can achieve outputs of between 60 and 200 per minute depending on the model. Click on the links for more info: • Proseal Board and Pulp Material • Halopack Packaging • Halopack Packaging – Proseal video • Proseal’s tray sealing machine range • Smipack WPS Series • Smipack website for machine specs and ranges of models or special applications • Smipack YouTube channel

A one-stop shop

Trempak is an AA accredited BRC packaging facility which has been in business for some 35 years. The company has the products, expertise, back-up support and passion to service every aspect of flexible packaging. From machinery and specialised laminates including fully-recyclable options, to ready-made bags and pouches, lidding, polyolefin shrink film, MAP expertise and design services, Trempak is a one-stop solution for all your flexible packaging needs. •

“R11m has just been spent on a state-of-the-art laser perforator, placing Trempak at the cutting edge of micro- and macroperforation technology and capability”

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In the Smipack WPS series, a new tuck-and-fold case wrapping machine has been introduced


South African journal for food and beverage manufacturers

www.foodreview.co.za It’s the only one of its kind in the country to target decision makers in the manufacturing of food, beverages and their related industries. It offers incisive and authoritative reports on all aspects of the process, from raw material sourcing, to manufacturing and packing, right down to the distribution and marketing of finished goods. FOOD REVIEW informs readers about the introduction of new ingredients, equipment, products and packing, and provides objective commentary on cuttingedge local and international market trends and issues. To contribute editorially contact Tennille Aron Tennille.Aron@newmedia.co.za

For advertising enquiries, contact Anita Raath anita.raath@newmedia.co.za +27 82 976 6541 or Carla Melless carla.melless@newmedia.co.za +27 83 260 6060 Candida Giambo-Kruger +27 (0)71 438 1918 candida.giambo-kruger@newmedia.co.za

New Media, Ground Floor, Media Park 69 Kingsway Avenue, Auckland Park, 2029 PO Box 784698, Sandton, 2146 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 713 9024

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1 READ STREET ♦ CNR HARRIS DRIVE ♦ OTTERY ♦ CAPE TOWN ♦ SOUTH AFRICA

Converters of flexible packaging materials and allied products • Polypropylene (BOPP) / Cellophane • Bio-degradable starch based film • 3 side sealed laminated pouches • Stand-up pouches, with or without zipper • Stand-up pouches, with or without spouts

Tel: (021) 704 1135/6/7 | Fax: (021) 704 1210 | Email: pracpak@iafrica.com | www.pracpak.com


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