Packaging Europe Issue 10.1

VOLUME 10.1 – 2015

Converting NestlĂŠ on how brand owners think Print innovations Colour management Pharma serialisation Behind the scenes at Tetra Pak Small pack nuances CEPI on breakthrough technologies Laminated with Cosmo Films velvet thermal lamination film

Packaging Europe | i |

| ii | Packaging Europe

Contents

VOLUME 10.1 – 2015

The front cover of this edition has been laminated with a special BOPP-based ‘velvet touch’ thermal matte film supplied by India –based global group, Cosmo Films Limited which is a leading provider of laminating solutions & polypropylene films.

3

Editorial

4 10 12 16 18 22 24 26 30 32 34 36 38 43 44 46 50 52 56 58 60

News, Analysis & Comment European Headlines World News Business News Innovation News Design News Sustainability News Nestlé interview: A brand owner’s perspective Upcoming packaging events easyFairs: The UK’s Biggest Packaging Show is Back Innovation time for Huhtamaki in Birmingham Packaging design: Honeybell Soap How to make a big impression with small packs Tetra Pak: Innovating to protect what’s good Complying with the EU falsified medicines directive Pharma serialisation: Are we on the brink of a mass extinction event?

Print innovations overview Colour management: From chaos to control Big Interview: CEPI’s Marco Mensink Innovation in aerosols Intellectual property: Protect your packaging The rise of printed electronics

62 67 68 72 75 80 84 88 92 94 97

Industry Profiles Toyo & Deutsche Aerosol Connecting values Coda Plastics Delivering complete solutions Fleming Gulf Passion for plastics and polymers Manuli Stretch Group Stretch and grow Mettler Toledo Safeline Avoiding risk – in challenging applications Hunkeler Innovations in paper processing Vibac Global leader in the packaging industry Waddington Europe One to watch Gietz Gietz AG celebrates two jubilees Illig Maschinenbau Trailblazers in thermoforming technology Matrìca Novamelt The success of green chemistry

100 108 112 115 118 122 126 130 136 140 144 149 154 158 162 164 168 172 176 183 186 189 192 194 196 200 204 208 211 216

219 220 226 228 232 236

Gualapack Flexible packaging specialist with a global reach Elopak Innovating freshness Crown Van Gelder Paper Potential mall//herlan Even better shape FlexLink Improving total efficiency Dupont Teijin Films Innovation leading the market Ilapak Ilapak invests in innovation Eson Pac Lean cooperation Lantech The bigger picture Plastotecnica Keeping up with the times Procap Exceeding expectations Radpak Complete packaging systems supplier IMP Leading the way Albertazzi Innovation, quality and service Atlas Packaging Strength in design Afa Dispensing Flair for success Della Toffala Know-how and style in beverage sector Plasticos Romero Innovative plastics-based packaging PACE Europe’s premier networking event Abriso Extrusion experts Parkside Flexibles Evolve and solve Viappiani Printing Leaders in IML labelling Windmöller & Hölscher Passion for innovation Graco A pioneering tank-free hot melt delivery system FPE Associations Focus on flexibles Petainer A passion for sustainable innovation Arti Grafiche Network The complete solution to shape the business Duran Dogan A perfect combination Atlanta Stretch Leaders in pallet wrapping Mitsubishi Electric Innovation in packaging applications with Mitsubishi Electric’s motion control technology Mesago SPS IPC drives Corex Board but never bored Smurfit Kappa Opening the future Zaugg Maschinenbau Swiss precision Amsterdam Metallized Products Rise and shine Hagmaier Etiketten & Druck A new generation

Packaging Europe | 1 |

Advertisers Index A ABG International Air Control Industries Alaska Plus Altratech AmbaFlex Ampac Flexibles Anixter Component Solutions Arnott Handling Equipment Artigrafiche Asahi Machinery A Schulmann International Ashton Jig & Tool Co Ltd Athena Graphics ATS-Tanner Banding Systems Automha

F 239 7 8 163 121 199 77 79 207 163 13 76 182 83 106

B Bericap Bisio Progetti Bizerba Boxon Branson Ultraschall

23 103 66 135 13

C Camozzi Carcano Cartiera dell’ADDA Cartiera Di Laveno CGP Flexibles Clariant Coda Plastics Collins Inkjet Comital Comparato Nello Cosmo Films Crown Cork Crown Van Gelder

129 179

E easyFairs ECO Group Elba EPPS International Holdings

P 146 71 121

G Gallus Grafe Advanced Polymers

135 156

H Herzog-Heymann HP HT Board Huber Group

29 222 241 234

Julius Schulte Söhne

Radpak Repsol Robaech Robatech Rouxel

227 171 8 203 19 174 175

S

222

K K3 Syspro Kodak

79 181

L Legnobotti Leuze Electronic Lic Packaging

74 212 157

191 117 202 178 171 147

N Nordson

139

O Optima

Sabic Nordic Schulman, A Sefar Siegwerk SN Maschinenbau Sonoco Alcore SpanTech Europe Starlinger Sumitomo Sun Chemical

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TFP Thermoplay TM.I.P. Trufab

147 142 166 206 64 73, 161 242 180 105 133, 234

33 104 87 77

U 239

V Vacuum Formers Ltd Verbano Film Videojet V Tech SMT Ltd

76 107 151 76

W Waterline Windmöller & Hölscher WL Gore & Associates

102 240 167

Z Ziegler Papier

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150 15 137 231 146

T

UPM Raflatac

M Macchingraf Mall//Herlan Max-Logistik Mayr-Melnhoff Karton Gesellschaft m.b.H. Mestriner & Piccoli Meyer Seals

61 65 83 213 111 125 238

R

I Il Recycling Inoxtubi Padova International Paper Invista Ipack Ima IQAP Masterbatch Isolago

PakTech Pamasol Petratto Pneumax Polyketting Porvair Filtration Group Prati

132 5 157 142

J 127 102 223 225 185 ii 67 82 106 170 21, 35 182 114

D Dansensor DSN

Farpi-France Flemming Gulf Flexlink

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Editor Tim Sykes Deputy Editor Victoria Hattersley News Editor Elisabeth Skoda Journalists Libby White Profile Writers Emma-Jane Batey Alessandra Lacaita Felicity Landon Romana Moares Barbara Rossi Piotr Sadowski Abigail Saltmarsh Marco Siebel Julia Snow Vanja Svacko Philip Yorke Art Director Gareth Harrey Art Editor Paul Abbott

Designers Claire Bidle Rob Czerwinski Leon Esterhuizen IT Support Jack Everson

Tim Sykes

EDITOR

Web Development Neil Robertson Production Manager Kamila Kajtoch Administration Amber Dawson Kayleigh Harvey Senior Account Managers Kevin Gambrill Jesse Roberts Features Managers Mauro Berini Jamie Gibson Clayton Green Matthew Howe Emma Kerton Dominic Kurkowski

Art Administration Tania Balderson

Packaging Europe

Alkmaar House, Alkmaar Way, Norwich, Norfolk, NR6 6BF, UK Telephone: +44 (0)1603 414444 Fax: +44 (0)1603 779850 Email: Editorial: editor@packagingeurope.com Studio: adcopy@packagingeurope.com Advertising: jr@packagingeurope.com, kg@packagingeurope.com Website: www.packagingeurope.com Facebook: www.facebook.com/PackagingEurope Twitter: www.twitter.com/PackagingEurope

© Packaging Europe 2015 No part of this publication may be reproduced in any form for any purpose, other than short sections for the purpose of review, without prior consent of the publisher.

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elcome to a new edition of Packaging Europe magazine, which in 2015 enters its tenth year. As we celebrate our jubilee, we are unveiling a fresh magazine design and concept. Each of this year’s six issues will focus on a key area or topic for the packaging industry, with articles exploring the theme from multiple angles.

Our subject this month is converting. Today’s packaging converters have to respond to an array of market pressures and drivers – price of course, sustainability, shifting regulations, and the needs of end users who are interacting with packaging in different ways as their shopping and consumption habits change. Shedding light on how a brand owner navigates this complex web of demands, Nestlé’s Alison Ingle discusses packaging development from the point of view of sustainability and other major innovation drivers.

Elisabeth Skoda surveys the most significant innovations in print technology over the past year that are pushing forward the boundaries of converting. Meanwhile, Patrice Aurenty of Sun Chemical talks us through the nuances of colour management and LOPEC’s Wolfgang Mildner shares his views on the ways printable electronics are set to impact on packaging.

The EU Falsified Medicines Directive represents a major new regulatory challenge for pharma brands and the packaging converters supplying them. Lee Henderson of Asia Pulp & Paper discusses the new serialisation burdens, while Ian Haynes asks whether we are heading for a significant shake out in pharma manufacturing. Libby White reveals that aerosol converters have had a particularly innovative year, and Hervé Turpault explores the opportunities thrown up by the growing trend for smaller pack sizes.

We take a look back at the biggest packaging industry developments over the festive season and look forward to two of the most important events this year for packaging converters: Packaging and Converting Executive Forum (PACE) and the exhibition ICE Europe. Last and certainly not least, Marco Mensink of CEPI graces our Big Interview with the latest on breakthrough technologies for paper, while my account of a visit to Tetra Pak in Modena headlines another selection of instructive and inspiring success stories from around the European packaging industry.

The Packaging Europe team wishes you a happy and prosperous 2015!

Tim Sykes ts@packagingeurope.com @PackEuropeTim

POSITIVE PUBLICATIONS

A Square Root Company

Packaging Europe | 3 |

Headline News Test Bed Aiming at New 3D Paper Products I

nnventia has been granted SEK 2.75 million from VINNOVA for the establishment of a full-scale test bed for processes that create highly deformable paper. This will enable verification of new product concepts and lead to a decrease of non-biodegradable waste streams and more energy efficient production processes.

In January 2015 a rebuilding of Innventia’s FEX pilot plant with new units for producing highly deformable paper starts. The pilot units will be modular and can be used separately or together with the FEX pilot paper machine. This will be the start of a new project called PhD-paper which aims to establish a full-scale test bed for processes that create highly deformable paper. These processes will, on one hand, broaden the design window for forest based raw materials and, on the other hand, create opportunities for verification of new application areas and markets.

With the help of an industry consortium and Innventia’s gathered knowledge base and machine park, new technologies that are industrially viable will be made available for verification of new product concepts. During the project, value chains for new products as well as for commercial products with extended properties will be identified. One possible application is 3D packaging. Traditionally, paper has only been used to manufacture packages with flat surfaces. What restricts the use of paper for 3D packages, i.e. with curved surfaces, is the lack of industrial processes to produce paper material with a high level of stretchability in the cross direction.

“The idea with this investment is to enable testing of new energy efficient production concepts for paper qualities that will, for example, make it possible to replace some of today’s 3D packages in plastic and thereby reducing the amount of nonbiodegradable plastic waste,” says project manager Mikael Magnusson.

The PhD-paper project runs for two years with a total budget of SEK 8.1 million of which VINNOVA, the Swedish Innovation Agency is financing 2.75 million. The project partners are Innventia, Gruppo X di X Gruppo, BillerudKorsnäs, Stora Enso and Tetra Pak. Visit: www.packagingeurope.com/News/61547

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Constantia Flexibles Sold to Wendel F

unds advised by One Equity Partners (OEP) and the H. Turnauer Foundation have agreed to sell their 100% stakeholding in Constantia Flexibles, one of the world’s leading manufacturers of flexible packaging products and labels, to the Wendel Group. Wendel’s offer values the group at around EUR 2.3 billion. OEP acquired the company in 2009, when it took over the majority of Constantia Packaging AG, and holds 75% of Constantia Flexibles, the remaining 25% belonging to the H. Turnauer Foundation. The latter intends to remain a significant shareholder of the company and is currently discussing with Wendel a potential re-investment.

“We are very happy with the way that Constantia Flexibles has developed over the last five years under the ownership of OEP. Thomas Unger and the management team, along with all the employees of Constantia Flexibles, have done an excellent job. On behalf of OEP, I would like to say thank you for the outstanding cooperation,” said Melchior von Peter, MD at OEP. Constantia Flexibles supplies its products to numerous multinational companies and local market leaders in the food, pet food, pharmaceuticals and beverage industries. Constantia Flexibles employs over 8000 people in almost 80 Group companies and delivers to over 3,000 customers worldwide. In 2013, the company achieved sales of EUR 1.63 billion and earnings of EUR 233 million. Since OEP’s investment, sales have grown by 73% and earnings by 76%.

Thomas Unger, CEO of Constantia Flexibles, remarked: “In recent years, Constantia Flexibles has developed from a regionally-focused provider in Europe into a globally-active group present in the most attractive and fastest growing markets for flexible packaging. We have positioned the company outstandingly for further profitable growth, and we will be working with our new owner to realise this potential in the future.”

The purchaser Wendel is a leading European investment firms, which invests internationally in leaders of their respective field, such as Bureau Veritas, Saint-Gobain and Materis Paints. Wendel plays an active role as industry shareholder in these companies.

The transaction is subject to approval from the relevant antitrust authorities and is expected to be closed in the first half of 2015.

Visit: www.packagingeurope.com/News/61568

Packaging Europe | 5 |

IMA Group Acquires OYSTAR Group from ODEWALD T

he international I.M.A. Industria Macchine Automatiche S.p.A., headquartered in Bologna, Italy, has acquired the operating business of OYSTAR Group, a globally leading producer of packaging machines, from the private equity firm ODEWALD. The operating companies of OYSTAR Group – Benhil, Erca, Gasti, Hamba and Hassia – will be transferred into the newly founded holding company IMA Dairy and Food GmbH. Under the umbrella of IMA Group, they will continue to act independently and continue their growth. There are no material consequences for the group‘s customers, employees and production locations following from the change in ownership.

The closing of the transaction, which is expected in the first quarter of 2015, is subject to approval of the cartel authorities.

IMA Group will hold 80% of the shares in IMA Dairy and Food GmbH, while ODEWALD will continue to support the companies with a minority participation of 20%.

For the 20% of the shares remaining with ODEWALD, put and call options have been agreed upon, planned to be exercised in the years 2017 and 2018. With more than 850 employees, the companies now acquired by IMA expect consolidated revenues of approx. EUR 185 million and an EBITDA of around EUR 15 million in fiscal year 2015.

IMA Group is world leader in the design and manufacture of automatic machines for the processing and packaging of pharmaceuticals, cosmetics, tea, coffee and food. The Group has approx. 3,700 employees and 24 production plants in Italy, Switzerland, the United Kingdom, the United States, India and China as well as a global sales and service network. IMA Group is active in more than 80 countries. For fiscal year 2014, IMA Group expects revenues of EUR 850 million and EBITDA of ca. EUR 130 million.

Alberto Vacchi, chairman and CEO of IMA Group, said: “With this acquisition, the IMA Group is taking another important step towards the future. The product range of the companies being acquired is complementary to our presence in the food industry and positions us, worldwide, among the most important group leaders in food packaging. The combination of Italian and German excellence, internationally recognized as the leading edge in this field of technology, opens up new and interesting prospects for the IMA Group. Italian creativity and design, in a framework of production flexibility, combined with solid German technical expertise, undoubtedly result in creating a unique and successful mix for our key markets, generating a model for combining already competitive industrial expertise in different parts of the Europe.“ Markus Ehl, CEO of OYSTAR Group, said: “Our strategy has been and will be to focus and build on our strengths. ODEWALD’s support over the past years in growing our business has been outstanding. We are looking forward to continue our successful growth path under the umbrella of IMA Group.”

Visit: www.packagingeurope.com/News/61511

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SIPA Acquires Automa PET Bottle Production Activities S

IPA, a leader in PET container production and filling technologies, has officially acquired all activities related to production of injection-stretch-blow moulding (ISBM) equipment at Automa S.p.A., another Italian company well-known in the PET packaging sector.

The acquisition represents an important strategic move for SIPA. It will enable the company to extend its existing offering in single-stage ISBM systems; it will provide it with a stronger position in the market for equipment producing specialty products, such as containers for pharmaceuticals, cosmetics, personal care products, and spirits; and it is fully in line with SIPA’s objective of becoming a leader in the development and supply of complete solutions for filling and packaging.

Automa ISBM machines are designed for production of containers in smaller lots than SIPA’s existing units, with features that enable quick change-overs between different product configurations. They are also characterized by their compact lay-outs and high energy efficiency. The three-station ISBM 50SR unit, for example, with a 500-kN injection clamp force, has a rated power consumption of just 18.5 kW/h for machine, hot runner system and PET loader. The 800-kN ISBM 80SR, which has four stations (separate stations for stretch-blow and discharge), consumes 20 kw/h.

Enrico Gribaudo, General Manager of SIPA, says the company intends to exploit synergies between SIPA and Automa’s ISBM operation, in three areas in particular: firstly, in packaging development; secondly, in research and development of the ISBM process and containers, which is already a major SIPA strength; and thirdly, in technical support, which SIPA now provides through 18 branch offices and 23 technical assistance centres across the globe, complemented by a hot line covering all products.

SIPA has specialized for more than 25 years in complete manufacturing lines, including moulds, for PET containers. It has production operations in Italy and China. The company’s offering includes preform and bottle design, engineering and industrialization up to the supply of injection and blowing moulds for any type of PET machines in the market.

Visit: www.packagingeurope.com/News/61273

Headline News Variable Gripping Based on Human Hand E

xpanding on the company’s ‘inspired by nature’ research, Festo’s MultiChoiceGripper concept is an adaptive, flexible handling system that employs the concept of opposable thumbs to ensure maximum stability when gripping. Typical applications for the MultiChoiceGripper are wherever a variety of different objects are gripped; for example, in auxiliary robotics, for assembly tasks or in production facilities where various products are made.

“To cope with the complexity of parts to be handled, shape, mass, surface, fragility, etc. there are countless corresponding gripper designs,” explains Steve Sands, product manager at Festo. “The MultiChoiceGripper combines two development fields – adaptive finger technology using Festo’s Fin Ray structures and a clever mechanical linkage that changes the position of the fingers from ‘opposing’ to ‘surrounding’.”

Depending on requirements, between two and six finger elements can be fitted to the MultiChoiceGripper. Due to the adaptive nature of the Fin Ray structure, the it is not only variable in terms of the direction of grip, the fingers themselves can adapt to a wide variety of shapes. It can therefore grip differently shaped and also very sensitive objects without the need for additional sensor or control technology. In addition, the Fin Ray structures are made of food-compliant polyurethane, which means they can be applied within washdown environments in the food industry. Besides the Fin Ray fingers, two other types of fingers can be attached.

“Future applications for the MultiChoiceGripper are widespread in assembly and robotic tasks,” concludes Sands. “Until now, gripping multiple parts has required either time wasting tool changing, weight increasing multiple heads or even multiple handling arms.”

Visit: www.packagingeurope.com/ News/61451

Huber to Purchase Crown General Line Activities T

he family owned business Huber Packaging Group from Öhringen will be purchasing Crown general line tinplate packaging locations in Switzerland (Aesch), Finland (Helsinki), the UK (Liverpool) and France (Rouen), as soon as the local and European consultation procedures (if applicable) and necessary formalities have been completed. Crown is a global provider of packaging products headquartered in Philadelphia. The acquisition is scheduled to close by the end of the first quarter of 2015. The parties have agreed not to disclose information about financial details and purchase price.

With this acquisition, the Huber Packaging Group is pressing ahead with the further development of the company, expanding its market share in its core business sector and in establishing market access to fields in which the company has not yet been active. Huber is currently developing an integration plan for the assets to be purchased.

Visit: www.packagingeurope.com/News/61441

Packaging Europe | 7 |

Seeing the lighter weight advantage!

The announcement in 2014 of International Paper’s completion of the $60m investment and upgrade at its Kwidzyn mill in Poland has resulted in the development and launch of a new lightweight, GC2 folding boxboard packaging grade, Alaska Plus. Coupled with the investment programme, Alaska Plus is offering extensive benefits to customers and end-users.

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ackaging Europe talks to International Paper’s Commercial Director for Coated Paperboard and Recycled Specialities, Michael Krüger, about the investment and to find out how Alaska Plus has been received and the plans for the future.

What is the lightweight product, Alaska Plus, and what kind of benefits does it offer?

Alaska Plus is a GC2 board that has a notably reduced weight than many other standard GC2 products on the market. Thanks to its lighter basis weight, Alaska Plus offers a multitude of interesting benefits to packaging converters and brand-owners. These include environmental benefits as due to lower weight of the packaging fewer resources are being used in production, the packaging is lighter to transport and the weight of packaging waste is reduced. Alaska Plus also provides economic benefits thanks to a better yield, meaning that our customers get more square meters per tonne. And with lighter packaging, the waste is also lighter, resulting in lower disposal fees. These are benefits which many customers and end-users of packaging find attractive today and they respond with interest to a product offering them.

How is Alaska Plus different from the standard Alaska grade? Other than being lighter in basis weight, are there any differences in other quality aspects?

The main difference is indeed the basis weight, Alaska Plus being 6%-7% lighter weight than Alaska. And that’s it when it comes to differences! All other quality aspects of Alaska remain similar also in Alaska Plus, such as a high consistency in the quality of the product and production efficiencies in printing, converting as well as packing lines.

Alaska can be replaced by the equivalent Alaska Plus grade without any issues in the complete printing, converting or the packing process, and also none during transporting or the shelf life of the packaging. Our customers trust the brand Alaska based upon the good experiences that they’ve made with the product in the past – and we have also converted many new customers onto the new Alaska Plus grade, which is testament to the quality of the new grade and its performance.

How long will the standard Alaska keep existing next to the new Alaska Plus product?

Alaska will exist until the end of June 2015, allowing sufficient time for customers to test and qualify the new Alaska Plus product. From July 2015 onwards Alaska Plus will then be the only GC2 product in our portfolio.

How has Alaska Plus been received by customers so far?

Overall there has been a significant amount of interest towards Alaska Plus since we launched it to the market in July 2014, together with the media coverage which has helped to spread the message. Not only are existing Alaska customers moving to using Alaska Plus, but it is also catching interest from converters and brand-owners, some of which have been less familiar with our standard Alaska product in the past. At the same time we have also converted new customers into using Alaska Plus, who are new finding out for themselves how the grade performs and the advantages that they can attain.

Alaska Plus represents a step-change in light weighting and based on the feedback we hear from the market, it responds directly to today’s needs of economically attractive and environmentally sustainable packaging solutions. | 8 | Packaging Europe

Are you seeing any one segment leading the way in taking up Alaska Plus?

One of our main target segments is the pharmaceutical and healthcare packaging, where Alaska is a leading brand in Europe. This is thanks to the high quality stability as well as the reliability and efficiency in production, which are important aspects in the pharmaceutical segment. We also offer some key characteristics for the pharmaceutical segment such as best-in-class 2D Data matrix codeability.

Other key segments are cosmetics and beauty care, chocolate and confectionery as well as the dry food segments, all of which are important for Alaska Plus, and it has been noted that our customers are switching to Alaska Plus across all the target segments.

Can you explain how the weight reduction on Alaska Plus was achieved, whilst still maintaining all other quality aspects as before?

The production of Alaska Plus was enabled as a result of the board machine modernization which took place early in 2014 at our Kwidzyn mill in Poland. We invested over $60 million to rebuild the machine and to allow the development and production of the lightweight GC2 board. The rebuild included several modifications along the board machine, but the main part focused on enhancing the calendaring equipment that allows us to maintain the stiffness, thickness and bulk of the board. In other words, with this new calendaring technique we could reduce the basis weight of Alaska Plus whilst keeping surface smoothness, stiffness and strength of the board on the same level as in the standard Alaska product.

Can you tell us what else did this investment include?

In order to maximize the opportunities and capabilities of this modernization we also invested in other auxiliary equipment, most notably two new sheeters to debottleneck the finishing operations and enable even greater service flexibility. Our service offer includes a flexible sheeting service, known as Kwidzyn X-Press, which allows for the production of small order volumes, starting from one tonne in bespoke sizes, together with a guaranteed turnaround time of just four days, plus transportation time. With the new sheeters we can meet the increasing demand for quick and flexible service, and Alaska Plus is of course available through Kwidzyn X-Press too.

So what will be the next developments for International Paper in terms of your coated board products?

Our intention is to keep looking to develop and work on maintaining and improving our service offerings wherever possible across Europe. The investment we have made at Kwidzyn further underlines our commitment towards the folding boxboard market in Europe.

One new development we are working on right now is the replacement for our 200gsm Alaska grade with an equivalent in Alaska Plus.

Packaging Europe | 9 |

Labelexpo South China Attracts 5000 G

uangzhou’s Pazhou Exhibition Center played host to the biggest Labelexpo South China yet with 2014’s December edition reporting a 4% increase in footfall. Around 150 exhibitors showcased their latest products and services. New product launches included presses from Nuova GIDUE, Venture Electronics and WeiFang DongHang Precision Machine Co. The exhibition was also supported by a two day conference. Well-attended and received, conference program highlights included the keynote presentation given by Jari Haavisto and Heini Lehti of UPM Raflatac along with John Li, senior packaging development manager at Johnson & Johnson Consumer Group Asia-Pacific. Both companies have collaborated to find sustainable labeling solutions and gave their practical insight into how sustainability must go together with profitability in everyday business practises. Another big draw was an overview of the latest smart products being used to encourage consumer interaction and spending with presentations by Top Print Labels, Peng Cheng Li Cultural Technology and Sun Chemical.

The interactive Live Technology Clinic which made its debut at this year’s show also proved popular as two hour-long sessions gave show visitors access to one to one discussions with a panel of label and package printing experts. At the clinic, experts from companies including Kinglabel Adhesives, YUPO and the Printing and Printing Equipment Industries Association of China (PEIAC) amongst others, were on hand to advise on all aspects of label and package printing technology as well as help printers realize their potential, solve challenges and increase their opportunities.

John Davy, divisional director of Labelexpo South China said: “The team has again worked incredibly hard to build, improve and ultimately deliver the show. Labelexpo South China 2014 has been an even more valuable event for Chinese printers with the addition of the Live Technology Clinic, while the conference program’s content once again appeared to resonate with the audience. Achieving our highest ever onsite rebook rate in South China to date with 31% of the space signed up for 2016, Labelexpo South China continues to go from strength to strength in what is a formidably competitive marketplace.”

Visit: www.packagingeurope.com/News/61473

Monadnock & Smart Planet Enter Strategic Partnership M

onadnock Paper Mills has entered into an exclusive licensing agreement with Smart Planet Technologies for use of its extruded EarthCoating® technology for adhesive beverage labels in North America.

“We are pleased to be expanding our Envi Portfolio® of products through our partnership with Smart Planet Technologies,” said Richard Verney, Chairman and CEO of Monadnock. “As consumers become more eco-conscious with a continued push to reduce plastic in packaged goods, and while brand owners look for improved performance in labels, the timing is perfect for this new extension to the Envi line.”

EarthCoating, used as a plastic lamination replacement, provides a unique option for demanding wet label applications. Cost effective EarthCoating minerals enhance fibre bonding strength and surface tack with pressure-sensitive and other adhesives in labelling.

“Monadnock is a leader providing premium, cost effective, and environmentally advanced products to the label converting industry. Their innovative culture is very exciting and we look forward to a long term technology partnership” says Chris Tilton, Chief Technology Officer of Smart Planet. www.packagingeurope.com/News/61502

O-I and Constellation Brands Enter into Joint Venture O

wens-Illinois has completed the formation of a 50-50 joint venture with Constellation Brands to own and operate a glass container production plant in Nava, Mexico. The companies announced their intent to form the partnership, which was subject to regulatory approval, in October. Approvals from the Mexican Federal Competition Commission and the U.S. Department of Justice have been received.

The joint venture will operate the glass container production plant in Nava that it recently purchased from Anheuser-Busch InBev. The plant operates under the name IVC and produces bottles exclusively for Constellation’s adjacent brewery, which makes an expanding portfolio of Mexican beer brands for export to the United States, including Corona Extra and Corona Light. The state-of-the-art plant employs about 250 people and first began operating in February 2014.

To accommodate Constellation’s current and growing need for glass bottles, the joint venture will expand the capacity of the plant from one to four furnaces over the next three to four years. A team of engineering and manufacturing experts has already begun working on the expansion. In a related matter, O-I signed a long-term supply agreement with Con| 10 | Packaging Europe

stellation to supply additional bottles to the brewery. Supply under the agreement begins in late 2015, ramping up significantly in the following year.

“This is an exciting and promising venture for us,” said Chairman and CEO Al Stroucken. “We are pleased to support Constellation’s growth in a way that allows both partners to optimise their expertise and capabilities. Through the joint venture and the long term supply agreement, we can participate in the outstanding growth these brands are experiencing in the U.S.” Visit: www.packagingeurope.com/News/61543

World News

NatureWorks & Natur-Tec Begin Sales of Ingeo in India N

atureWorks and Northern Technologies International Corporation (Nasdaq: NTIC) announced today the companies are collaborating on marketing and sales of Ingeo™ in India and surrounding countries, including Bangladesh, Pakistan, and Sri Lanka. This is the first major sales initiative on the Indian subcontinent for Ingeo, a naturally advanced bioplastic with a host of commercial uses including rigid and flexible packaging, foodservice ware, personal care products, textiles, in-home durable products, appliances and electronics, and the latest innovations in 3D printing.

Natur-Tec India Pvt. Ltd., a subsidiary of Northern Technologies International, is leading the marketing and sales effort in India and the subcontinent. Northern Technologies has been manufacturing and marketing a range of biobased and compostable flexible films, rigid injection molded materials, and engineered plastics in India since 2006, initially through a joint-venture and since 2013 through the subsidiary.

Under this new agreement, NatureWorks is supporting Natur-Tec India’s sales efforts by participating in joint sales meetings with multi-national corporations, providing technical expertise and marketing support, and supplying resin in bulk for distribution

by Natur-Tec India.

Initial sales and market development emphasis are focused on flexible films for packaging such items as food and branded consumer goods, paper-based packaging where a thin film of Ingeo provides barrier properties, rigid containers for such products as yogurt, and foodservice ware. Natur-Tec and NatureWorks will also be working with regulatory agencies on waste reduction demonstration projects.

“Success in a market as diverse and complex as India requires finding the right commercial partner – a partner that knows the market and our Ingeo products, has the respect of local customers, and shares similar values to your own,” said Rich Weber, Asia-Pacific commercial director, NatureWorks. “NatureWorks has worked with Northern Technologies International for years in North America. We know and respect the management team, and see this new multifaceted collaboration with Natur-Tec India as an extremely positive commercial development.”

“I agree with Rich,” said Vineet Dalal, VP and director of Global Market Development for Northern Technologies International. “Natur-Tec India’s product and market knowledge in close collaboration with NatureWorks’ technical and commercial support sends a very positive message to customers that they will receive innovative products and an exemplary support infrastructure.”

Visit: www.packagingeurope.com/61327 Indeo-based products by Natur-Tec

Packaging Europe | 11 |

Management Buy-Out of Vos Logistics T

he management of European logistics service provider Vos Logistics and Scheybeeck Investments have together acquired all the shares in Vos Logistics. The change in shareholder structure is a logical step in the company’s strategy. The transaction has been approved by the Dutch Authority for Consumers and Markets (ACM).

The trade unions have been informed and the works council has issued a positive opinion.

In the coming years, the strategy will be directed at optimising goods flows in cooperation with customers in order to create clean and efficient logistics and transport solutions; further optimising the cost of international transport networks for packed goods and dry bulk; realising controlled growth in customer-specific logistics services both organically and through selective acquisitions.

The new shareholders will invest further in this multiyear strategy. They will receive financial support from Delta Lloyd Mezzanine Fund in the form of a long-term subordinated loan. The equity position will be strengthened by € 52.5 million and the debt position will be reduced by EUR 45 million. The solvency ratio at the end of 2014 will come to almost 25%.

For Vos Logistics, 2014 was a better year than 2013. The upward trend reported in the second half of 2013 continued in 2014. Cargo and Logistic Services performed particularly well. Vos Logistics made substantial investments to strengthen the company in 2014. It

invested 15,000 hours in staff training and education, and added 120 new trucks and 275 new loading units to the fleet. It also took a new sustainable distribution center into operation in Oss with a warehousing capacity 25,000 m2. Vos Logistics will close 2014 with a profit on slightly higher turnover and a positive cash flow from operating activities.

Frank Verhoeven (CEO) and Ben Vos (CFO) of Vos Logistics are delighted with the new shareholder structure: “Scheybeeck Investments is a solid shareholder that is a good complement for Vos Logistics. They are giving us an opportunity to build independently on the foundations we have laid in the past few years, while retaining our own identity. With a good strategic plan, a strong team and the necessary financial muscle we are looking to the future with confidence.”

Dick Burger of Scheybeeck Investments describes Vos Logistics as “a fantastic company with a lot of potential. The acquisition is an excellent match for our investment philosophy.

Vos Logistics has an enterprising management team and a clear long-term vision. We are pleased to support them. We understand the complex world of transport and logistics and were impressed by the transformation Vos Logistics has undergone in recent years. We believe in the strategy that was put to us and have every confidence that Vos Logistics’ management will make it work.”

Visit: www.packagingeurope.com/News/61544

AURELIUS acquires ECO Plastics A

URELIUS, a pan-European investor, has announced its acquisition of ECO Plastics, the reprocessor of recyclable materials. In line with its standard investment approach, AURELIUS will supply both its highly specialised operational improvement capabilities and financial support to the company’s current operations, with a core focus on the long-term strategic development of the business.

ECO Plastics operates one of the world’s largest and most sophisticated plastic reprocessing plants, capable of sorting 150,000 tonnes of mixed bottles per year and representing around 35% of the total UK bottle collection in the UK every year. Since 2000 ECO Plastics has played a leading role in the UK’s plastics recycling sector with the development of new recycled plastic (rPET) products, which have delivered value to local authorities and the waste management industry through feedstock contracting, and by working in partnership with major companies.

Tristan Nagler, managing director of AURELIUS in London said: “AURELIUS is delighted to have acquired ECO Plastics which has a strong position in the UK marketplace. For customers, suppliers and partners it will be business as usual, and we are committed to working with the Company to deliver long term, sustainable growth. AURELIUS has a strong track record in the industrials sector, providing both operational improvement as well as financial support to businesses. We are extremely excited about the future prospects of this business.”

ECO Plastics’ founder and deputy chairman Jonathan Short, commented: “This news is not just a vote of confidence in the future of ECO Plastics, but a vote of confidence in the promising future of the fast growing recycling sector. Working with AURELIUS will take the ECO Plastics story to the next level. This new owner will not only bring in new expertise and financial resources, but also a shared commitment to the development of a more sustainable, circular economy in the UK.” Coca-Cola Enterprises Ltd released a statement asserting, “We are pleased that ECO Plastics has found a buyer to support the next stage in the development of the UK’s most important supplier of food-grade recycled PET. As part of the financial agreement, Coca-Cola Enterprises Ltd has agreed not to continue with the joint venture, Continuum Recycling. In return, CCE has entered into a long-term agreement to source rPET from Eco Plastics. This new arrangement will ensure that CCE continues to use a minimum of 25% rPET in our plastic bottles in Great Britain, allowing us to deliver on our commitments to set the standard for sustainable packaging.”

Visit: www.packagingeurope.com/News/61464 | 12 | Packaging Europe

Business News

Jayplas Completes Investment J

ayplas, the UK’s largest plastics recycler, has completed its installation of a new extrusion and printing plant and the creation of a new packaging division as part of the company’s long term strategic investment to grow its nationwide recycling infrastructure.

The 200,000 sq ft manufacturing facility in Worksop is supported by a new LDPE wash plant in Loughborough which recently installed an Erema 212 to increase the company’s output of recycled plastic granules by 20,000 tonnes. The processed plastic packaging products offer a closed-loop solution by turning plastic waste into a range of retailer packaging products.

The new division is a direct response to the UK retail industry’s drive for greater levels of sustainability within their own supply chain through increased use of recycled plastics.

For the first time it will allow them to reduce their carbon footprint by keeping all the stages of recycling – from collection to distribution – in-house and in the UK. Previously, a high percentage of plastics have been exported to Asia for reprocessing.

The new packaging division will offer organisations a complete range of sizes and types of recycled plastic bags – from bags-on-a-roll to Plastic Bags for Life – designed and produced in the UK to their own specifications as part of a unique closed-loop re-cycling process. As part of the process, Jayplas segregates and sorts the plastic waste that is washed, reprocessed and converted to recycled pellets at state-of-the art plants in three Jayplas UK locations. These pellets are then extruded into film before being converted into finished products as part of a total UK-based process.

Visit: www.packagingeurope.com/News/61542

Stora Enso: New Organisational Structure for Renewable Packaging S

tora Enso’s Renewable Packaging Division has been split into two divisions: Consumer Board and Packaging Solutions, as of 1 January 2015. Stora Enso has appointed Jari Latvanen as EVP, head of Consumer Board and as a member of the Group Leadership Team. A Finnish citizen, Mr Latvanen and has held several leadership positions within the food industry. Since 2010 he has worked as CEO for Findus Nordic operations. Before that, Mr Latvanen enjoyed a long international career within Nestlé group.

“Jari Latvanen has a long and relevant experience from working with strong brands and corporate strategies. I am convinced that he will be a valuable contribution to the team and strengthen our customer focus even further,” commented Stora Enso CEO Karl-Henrik Sundström.

Hannu Alalauri, currently SVP Packaging Solutions Stora Enso, has also been appointed as acting head of Packaging Solutions. The new structure in the packaging business is a further step towards strengthening Stora Enso’s focus on customers, business performance and growth. It will also mean greater transparency in financial reporting.

Visit: www.packagingeurope.com/News/61551 Packaging Europe | 13 |

Business News Clondalkin Announces Major Investment T

he international producer of high value-added packaging solutions Clondalkin Pharma & Healthcare has installed its first mass carton serialisation capability at its Cherry Orchard facility in Dublin, Ireland. The installation of the Atlantic Zeiser Digiline 300 provides customers with a solution to one of the biggest challenges currently facing the pharmaceutical industry - the introduction of track and trace technology for new serialisation standards.

The investment will support track and trace capability for product movement as well as providing authentication, improved brand protection and increased consumer confidence.

The finished cartons are fed into a coding stream that utilises a print head and UV dryer allowing fast coding speeds, while the twin vericam camera data inspection system verifies application. This facilitates application, code verification to the master data and readability.

An automated rejection process is also included.

Mark Rooney, COO for Clondalkin Pharma & Healthcare Specialist Packaging Division (SPD) highlighted the flexible nature of the equipment: “Many pharmaceutical companies

are responding to the challenge of serialisation standards by upgrading or installing lines capable of applying a track and trace identifier, but this is often confined to 2D barcoding and batch specific data.

“We have the capability to individually code products of various sizes including flat cartons both glued and unglued. The system can receive and manage multiple data files and print multiple code. The wide print head with multiple image print capability in direction of feed allows 2d matrix and code 128 possible in separate locations once within same print width profile. Should the need occur additional print heads can be added to extend the print location capability. The two separate camera verification scanning units ensure quality of code read and verification of code, or multiple code to the master input data” Malcolm Farnan, sales and marketing director for Clondalkin Pharma & Healthcare SPD Europe added: “Continued investment is required in order to respond and provide solutions that make it easier for our customers to meet regulation without compromising on efficiency and quality. Our customers approach us to provide solutions from regulatory changes to efficiencies. There are both mass market and niche market demands that are best supported by a competent and experienced packaging supplier rather than in house.”

Since the installation of the equipment Clondalkin have been approached by several pharmaceutical companies that have identified it as a good fit to their in house capability and avoids costly line reconfiguration and downtime.

From its three facilities in Ireland Clondalkin Pharma & Healthcare produces a wide range of printed components from cartons, labels and leaflets to clinical trial extended content labels to customers across Ireland, the UK , Europe and the US. Globally Clondalkin Group’s Specialist Packaging Division has 24 production sites throughout North America and Europe and includes folding cartons, labels, leaflets, literature and inserts/outserts businesses, along with paper packaging and printing components. It operates across an extensive range of markets including pharmaceuticals, cosmetics, toiletries and confectionery.

Visit: www.packagingeurope.com/News/61456

Quadpack Group Inaugurates Manufacturing Division F

ollowing extensive renovations and upgrades, cosmetics packaging provider Quadpack Group has officially inaugurated its Manufacturing Division in Torrelló, Catalonia, Spain. The state-of-the-art facilities now boast five separate areas, including the wooden component factory of Technotraf and the specialist decoration plant of Krampak. The new division reflects the group’s industrial strategy as an end-to-end provider of differentiated packaging solutions.

Quadpack Group CEO Tim Eaves said: “We have consolidated all of our industrial capabilities on the same site, to create a single, streamlined Manufacturing Division, where we pool our talent and share our knowledge to create great new packaging concepts.”

The 10,000m2 site comprises five areas: the wood manufacturing plant of Technotraf Wood Packaging; Krampak’s decoration facilities; the ‘Inspiration

| 14 | Packaging Europe

Room’ product development suite; a 110m2 sample warehouse; and new warehousing facilities.

Over €500,000 has been invested in upgrading the current facility; a brand-new, purpose-built 650m2 decoration area has been built to house Krampak, along with the latest screen-printing, tampo-printing and hot stamping equipment to cope with increased demand. Throughout the facility, new employee dressing rooms and a canteen have been installed and the existing spray-painting facility has been upgraded.

The sample warehouse stocks over 1000 different packs from Quadpack’s standard range in controlled conditions, ready for shipping to anywhere in Europe within 48 hours.

The warehousing capability stores semi-finished products for decoration on demand, dramatically reducing lead times.

Visit: www.packagingeurope.com/Packaging-Europe-News/61554

Packaging Europe | 15 |

Smartstak System to Indicatorium to Cap the Bottle Market Commercialise UPM’s S Food Freshness Indicator Innovation

martstak, Loadhog’s Queen’s Award-winning glass bottle containment system, now has another dimension with the launch of a product designed to optimise the transport of glass bottles and jars, particularly in Europe.

The new element introduced to the patented Smartstak concept is the ‘Smartcap’ - a universal plastic reusable capping tray. When used in conjunction with the Smartpad - a vital Smartstak component - the Smartcap creates another complete, intelligent glass bottle packaging system which eliminates cardboard capping trays used predominantly in Europe, in addition to shrink wrapping.

The Smartpads are injection moulded, waved edged layers in the Smartstak system which ensure pallet stability and allow bottles to be added to each layer or even complete layers added to a pallet. The Smartcap is said to improve hygiene and wet weather performance by providing a waterproof barrier with no spoiled pallets and is washed and handled in the same way as Smartpads.

Smartcaps are washed after every trip at Loadhog’s wash plants in Sheffield, UK, and Pegoes, Portugal, which utilise reverse osmosis water. The plants do not to use any detergents and are tested to stringent hygiene requirements.

According to the manufacturers, thanks to an active hinge feature, the Smartcap requires no assembly, thereby eliminating manual labour or erection equipment costs, which are associated with existing cardboard trays. It retains the top layer of bottles, holding the necks securely in place and avoiding deforms during shrouding to protect bottles. The added benefits of using reusable Smartcaps rather than cardboard capping trays, say Loadhog, are that inventory can be reduced; fewer products and less storage space are required and there are also significant, storage and stock cost savings.

Visit: www.packagingeurope.com/News/61557

U

PM and Indicatorium Oy have entered into an agreement for the international commercialisation of the food freshness indicator technology developed by UPM. Food freshness indicator is a smart label that reacts to certain chemicals and helps to determine whether a food product is still fresh and safe to eat. Indicatorium is aiming to introduce food freshness indicator to the global markets. The Finnish Funding Agency for Technology and Innovation (Tekes) will finance the initial stage of the project.

“The Innovation Mill programme funded by Tekes is a great way for UPM to find partners to commercialise ideas and patents that are outside our key competence areas. We are constantly looking for innovative partners for co-operation on bioeconomy projects and the utilisation of by-products, developing new business models and utilising patents that would otherwise be neglected”, says Jyrki Ovaska, executive VP, Technology at UPM. This agreement is UPM’s first commercialisation project within the Innovation Mill programme, which is managed by Spinverse Ltd. “Innovation Mill was originally developed with Nokia, and since then the programme has been a huge success based on both the amount of projects and their success rate. It is great that large corporations have been actively participating in the programme and can benefit from the internationally ground-breaking practices developed by it”, says Kari Tilli, service Director at Tekes.

Since 2009, Innovation Mill has been involved in the commercialisation of more than 100 technologies developed by large corporations, which in turn has created over 1000 new jobs. “We are currently renewing the programme to cover the extending network of small and medium-sized enterprises and large industrial partners so that ideas and products can move in both directions”, says Pekka Koponen, CEO at Spinverse Ltd. Visit: www.packagingeurope.com/News/61550

Holfeld scoops WorldStar for lightweight rPETeCO H

olfeld, now part of Waddington Europe alongside Par-Pak Europe, has won acclaim for its lightweight, low carbon rPETeCO material. Already the laureate of three major awards and with another three ‘Highly Commended’ placings, it has been crowned a WorldStar winner in the ‘Food Packaging’ category amongst some 69 global contenders.

Holfeld uses 20 per cent less plastic bottles to blend their rPETeCO material - only 8 out of 10 waste plastic bottles used. rPETeCO is a multi-market robust tactile lightweight low carbon material using 90 per cent recyclate, each bottle weighing an average of 20gms or approximately 50,000 bottles to the tonne. The material has a non-plastic appearance where added value is required. Meanwhile, Holsorb in the base eliminates the need for a soak pad.

Representatives from 17 packaging associations, members of the World Packaging Organisation (WPO) judged 265 packaging projects from 37 countries. In the Food category some 36 out of 64 entries were selected as winners against multi-disciplinary and functional criteria.

Visit: www.packagingeurope.com/News/61438 | 16 | Packaging Europe

Innovation News Mondi Launches Rain Resistant Splash Bag IN

response to lively customer interest for rain-repellent paper bags, Mondi has developed the Splash Bag, which is said to resists rain for up to two hours and withstands humidity better than a standard paper bag.

Standard paper bags for packaging cement and other powdery products are generally vulnerable to rain. To tackle the issue, Mondi, working in collaboration with major cement producer Lafarge, has developed an innovative rain-repellent bag particularly suitable for cement. The new wet-strengthened, machine-finished Splash Bag is designed to absorb less moisture than conventional bags. Its outer ply of Mondi Advantage Protect sack kraft paper has a water-repellent surface and is formulated to keep high tensile strength even in a wet environment. It also helps prevent moisture ingress if conditions are damp or humid during storage. Advantage Protect sack kraft papers have a water-repellent surface and are formulated to have high tensile strength, to help prevent rupture. For example, Advantage Protect in a grammage of 80 g/m2 has a tensile strength of 5.6 kN/m in the machine direction – an impressive figure.

Splash Bag’s water-resistive properties are immediately apparent in side-by-side visual testing versus standard paper cement bags (test conditions simulating direct exposure to rain). “Water gathers on the bag’s surface without being absorbed, then evaporates over a period of several minutes, leaving the bag essentially dry,” explains Claudio Fedalto, Deputy COO Mondi Industrial Bags. “By contrast, the standard bag absorbs the water, weakens as a result and may potentially rupture if exposed to extremely wet conditions,” he adds.

Results of Cobb tests, which measure the amount of water absorbed into the surface by sized paper over a set period of time, indicate that Splash Bags are resistant to rain for nearly two hours. If inadvertently left in damp (rather than wet) conditions, e.g. on damp sand, Splash Bag resists moisture ingress for up to 12 hours.

Even after two hours of direct exposure to rain, Splash Bags can be moved, handled and emptied without any difficulties. Bag breakage rates are significantly reduced, leading to genuine cost savings: fewer broken bags translate to lower vehicle and site clean-up costs, fewer trips from warehouse to site, as well as time savings for logistics and site managers.

Excellent moisture resistance can also mean better protection of the filling good if conditions are damp or humid at the warehouse.

Importantly, none of these advantages comes at the expense of filling speeds or deaeration rates, which match those of standard bags (in tests performed on Mega Gurley

equipment at Mondi’s Bag Application Centre in Austria). According to interviews carried out at construction sites, Splash Bag has already won generous plaudits from construction workers for its ability to resist rain and moisture when used to package cement. The construction workers surveyed were particularly impressed that the bag shrugs off rain and remains strong and easy to handle even under damp conditions.

Visit: www.packagingeurope.com/News/61488

Safe Label Material for Drug Packaging IN

addition to glass containers, pharmaceutical manufacturers are increasingly using primary containers made of plastics. In the case of soft plastics, there is a risk of migration. Schreiner MediPharm develops customer-specific, low migration labels for plastic containers that do not compromise the medicines contained in them. Therefore, special adhesive systems, materials, and inks were qualified to develop the ideal label design for each particular plastic container.

To ensure that harmless materials are used for each particular label design, Schreiner MediPharm conducted a study with a renowned, independent test institute to analyse, calculate, and evaluate the migration tendency of various label compositions. The results make it possible to specifically develop low migration label solutions for each application, without any major expenditure of time or investment by the pharmaceutical manufacturer. Furthermore, the use of verifiably harmless low migration labels increases the probability of a smooth approval from the respective drug administration authorities and ideally the approval process can be shortened.

Visit: www.packagingeurope.com/News/61536

Packaging Europe | 17 |

Thematic Display Lines from Pixartprinting P

ixartprinting’s new project features themed, ‘espresso’ made-to-order print solutions for showroom, point-of-sale and location displays. First off the blocks is the innovative Land of Ice project inspired by polar icescapes. This range of unique products, with optional preset graphics, is perfect for creative winter decorations. As W2P specialist, Pixartprinting is always keen to make its customers’ lives easier. That’s why it has created Pixartprinting Project to cater specifically for small businesses, retail chains and agencies seeking versatile one-stop solutions for customisable themed displays. Land of Ice is already available on the Company website and will shortly be joined by three new, mixable lines: Forest Walk – inspired by the magic of the woods, Christmas Carol - for an emotion-filled Yuletide, and Fantasy Tales – the realm of the imagination.

“This new project was conceived as a ‘ready-made’ range offering predecorated, easy-to-assemble products,” explains Andrea Pizzola, Pixartprinting’s sales & marketing director. “It’s a formula particularly appreciated by our cus-

tomers for certain products, for example when they need last-minute solutions for temporary displays.”

Based on the concept of dynamic storytelling, the campaign takes users on an interactive journey of discovery through Land of Ice, accompanied by high-impact images that morph into the new products. Interactive communication is used for direct product presentation at our e-shop: polar bears gambolling in the snow become customisable, easy-toassemble 3D profiles, cuddly shivering penguins come to life in free-standing digipaks as a skier, a snowboarder or even a ‘house penguin’. Visitors can follow as they discover Land of Ice is set in dreamlike landscapes that shift from fantasy to reality on shapeable honeycomb cardboard panels and vinyl canvases depicting snow-covered mountains and cosy igloos. To marvel at these magical places, just make yourself comfortable among the display cubes, gifts packages and ready-customised window stickers. Look up at the magic of transparent plexiglass, forex or BCA cardboard hanging ice stars.

Visit: www.packagingeurope.com/News/61317

King Oscar Reigns at the Oscars 2

014 has ended with double success for the team at Ardagh Group behind the production of the King Oscar seafood can. The eye catching container was recently honoured at the Canmaker Summit in Hong Kong where the King Oscar Easy Peel ® lid from Ardagh won Silver in the Ends, Caps & Closures category.

At one of Europe’s most prestigious packaging awards, King Oscar shared a name with the award title. At the Oscar de l’Emballage 2014, the aluminium can produced by Ardagh for the Norwegian seafood firm King Oscar, claimed an Oscar for best product in metal.

The jury was particularly impressed with Ardagh’s Easy Peel® aluminium opening solution that gives the consumer an easy and quicker means of opening the can while significantly reducing any risk of spatter. Also praised were the weight reduction, 50 per cent lighter than a standard end, its safety with no sharp edges to contend with, and its role in rejuvenating the club mackerel can category.

Patrick Savouré, commercial director, Seafood at Ardagh Group’s metal division, was absolutely delighted with these latest achievements, adding: “The awards demonstrate that striking design and excellent functionality are a perfect combination.”

Visit: www.packagingeurope.com/News/61505 | 18 | Packaging Europe

Design News

Stolichnaya elit™ Launches Final Edition J

DO Brand Design & Innovation has partnered with SPI Group and the elit™

by Stolichnaya® brand (the highest rated white spirit in the world) to create the latest and final edition in the elit™ pristine water series: Andean edition. First introduced in 2011 with the Himalayan Edition, followed by the New Zealand Edition last year, the elit™ pristine water series captures the brand’s unrelenting pursuit of liquid perfection as the vodka maker continues its quest to explore and bring to life the subtle tastes of exemplary vodka, beginning with the most pristine of all ingredients: water.

This year they trekked to the crystal clear waters of Colico Lake in the La Araucanía Region of Chile, to a natural spring flowing from the foothills of the Andes Mountains. This water was added to the Russian Alpha Spirit of elit™ by Stolichnaya® to create the final vodka in this rare series. With only 250 bottles set for global distribution, this new, highly limited edition spirit is the jewel in the crown of a series of unique vodkas of unprecedented perfection and exclusivity.

The limited edition vodka comes in a hand-cut crystal bottle by Glencairn® Crystal, one of the world’s leading crystal houses, designed to refract light and enhance the liquid’s clarity. Every exquisite bottle is sealed with a silver medallion overlaid with gold and crowned with a ruby depicting the elit™ by Stolichnaya® flame. The bottle is then nestled in a sustainable Chilean Black Cherry wood case that is lined with leather. JDO took inspiration from the native woods and the metal textile designs of the local Mapuche tribe who attribute their great health to Colico Lake’s pure water.

Paul Drake, JDO creative director said, “It’s not often that you get the opportunity to work on such a prestigious brief and with such beautiful materials. We feel that we’ve truly been able to tell the story of this Andean edition elit™ pristine water series.”

Ilse Wolfe, global brand manager, elit™ by Stolichnaya® added, “The final elit™ pristine water series needed to be the ultimate expression of the elit™ by Stolichnaya® brand and JDO has managed to capture this perfectly with their beautiful and impactful design.”

Visit: www.packagingeurope.com/News/61531 Packaging Europe | 19 |

Design News RPC Jar the ‘Essence of Beauty’ T

he latest innovation in anti-ageing products from Dr Pierre Ricaud, part of the Yves Rocher Group, is using a Diamond Jar from RPC Bramlage’s standard range to help convey the product’s luxury premium image. The Essence de Beauté Indulgence Body Balm is a “genuine anti-ageing product specifically designed to activate five keys to a younger skin, while treating the skin with a bewitching and irresistible nectar texture.”

To reflect the indulgent feel-good nature of the product, the injection moulded double walled 150ml Diamond Jar features a highly transparent outer layer, manufactured in Styrolux, complemented by a coloured inner layer in polypropylene. This eye-catching high quality appearance is continued with a metallised PP lid.

Available in a range of sizes from 50 to 200ml, the Diamond Jar has the flexibility to be tailored to the precise requirements of each customer with a choice of materials for the outer layer and a wide variety of personalisation finishes, including colour matching, labelling, hot stamping, lacquering, metallisation, silk screen printing, sleeving and pad printing.

Visit: www.packagingeurope.com/News/61476

STI Group Wins WorldStar E

very year the most inventive and effective packaging solutions receive a prestigious WorldStar from the World Packaging Organisation, in a global competition that has been running since 1970. Previous winner STI Group has once again impressed the jury to win this highly coveted award. STI Group’s award-winning packaging concept was developed for international coffee and tea company, D.E. Master Blenders 1753.

Tea drinking is not just about the product, it’s about the whole ritual – from preparation to consumption. With selected Pickwick flavours now available in single packs, opening the package has become the essential first step in creating a special tea experience.

Capturing the concept of functional beauty, these distinctive single packs with their clever leaf-shaped opening tabs clearly communicate that they contain something special.

Protection during transport and storage is critical to keep the packs looking so inviting, so they are placed into a divided tray and enclosed in an offset-printed consumer pack. Both the individual and the consumer packaging are manufactured from sustainable FSCcertified raw materials, reflecting the natural speciality teas inside.

Visit: www.packagingeurope.com/News/61410

Tetra Pak’s New Size for Smaller Households T

etra Pak has extended its award-winning Tetra Brik Aseptic Edge family with the launch of Tetra Brik® Aseptic 500 Edge, designed to meet the needs of smaller households.

Austria-based dairy company Berglandmilch is first on the shelf with the new package, using it for its premium milk brand, Formil.

Josef Braunshofer, Managing Director of Berglandmilch said “In the recent years we have witnessed a significant shift in the way consumers buy their milk –many more are looking for smaller pack sizes due to the decreasing size of households. The new Tetra Brik Aseptic 500 Edge is exactly what we have been looking for. We were delighted to see the success of the product during its pilot launch, and hear directly from consumers | 20 | Packaging Europe

that they not only love the milk but also liked the overall look and feel, the ease of use and the way the product fits with their lifestyle.”

By 2020, the average number of children globally per household is forecast to be 1.0, down from 1.9 in 1980.

Single person households and couples without children are forecast to experience the highest rate of growth, almost doubling to top 330 million during the same period[1], the result of changing lifestyles, reduced fertility rates and the climbing cost of raising children.

Berglandmilch is packing Formil using a Tetra Pak® A3/ Flex DIMC filling machine with QuickChange™, which allows the company to switch between 1000ml and 500ml packages in just 15 minutes.

Visit: www.packagingeurope.com/News/61350

Packaging Europe | 21 |

Industry Responds to Dropping of Circular Economy Measures T

he announcement, made during the European Parliament’s plenary session in Strasbourg in December, that the European Commission is withdrawing the Circular Economy proposal has met with contrasting responses across the packaging supply chain.

The association Plastics Recyclers Europe (PRE) has stated that it regrets the delay announced on Tuesday for the EU’s Circular Economy Package. “Today is an unfortunate day for sustainable growth in Europe,” commented Ton Emans, PRE President. “A direct implementation of the Circular Economy would have enabled the creation of 120,000 jobs in plastics recycling alone.”

However, he greeted the promise to revisit the issue in 2015: “We look forward to the ‘more ambitious Circular Package’ announced by vice president of the Commission Frans Timmermans today. The Commission must keep its word to make this revised proposal in a speedy manner. As underlined in the Commission’s green paper on plastic waste, increased recycling in Europe will lead to a more sustainable and circular economy.”

Meanwhile, some voices representing the packaging supply chain have been arguing for some time that, while the Circular Economy principles are sound, care must be taken to implement new measures in a fair and feasible manner, with realistic targets. Two months before the announcement, EUROPEN (the European Organisation for Packaging and the Environment) had stated: “The packaging supply chain… supports the overall aim to further transition to a Circular Economy, and believes that any new packaging waste targets must be achievable, comparable and measurable, taking into account current performances in the 28 Member States. Currently, it is unclear whether the proposed packaging waste targets can be considered feasible because, at the same time, a new calculation method has been proposed, which would impact Member States’ current reported rates. EUROPEN therefore calls on EU policymakers to fully understand the impact of the new proposed methodology for calculating packaging recycling rates on Member States’ current reported rates before discussing new and restructured targets.”

EUROPEN also released a joint statement with other stakeholder organisations urging any new regulations, among things, to fully assess with a cost/benefit analysis the impact of any changes to the way packaging recycling targets are measured before discussing new and restructured targets; set a clear and enforceable harmonised method for measuring and reporting packaging recycling rates; and maintain the current method of counting recycling of composite packaging towards the rates and targets of the predominant material.

The Commission announced it was shelving the Circular Economy regulations in December 2014. “We are proposing to withdraw the existing proposal to make way for a broader and more ambitious approach that can be more effective,” said Timmermans. “This means that we will withdraw the present waste proposal and come back with a more ambitious proposal that will cover the whole of the circular economy. We will do this in 2015 - we will not drag our feet with this because we want the circular economy to be in pole position when the Junker plan is being put into effect so that the economy that can profit from investment is smack in the middle of the circular economy.”

RLC Offers Climate Neutral Packaging T

he rlc | packaging group is intensifying its efforts to reduce climate change. Support through internationally recognised climate protection projects now enables rlc customers to offset greenhouse gas emissions resulting from the production of their orders. Emission values are measured using a CO2 calculator developed by rlc in cooperation with climate protection experts at ClimatePartner. The production of carbon neutral packaging adds another important element to the rlc sustainability portfolio.

Environmental protection, social accountability and sustainable business practices are all key elements of the rlc approach to packaging responsibility. As a comprehensive system supplier, rlc has been dedicated to the success of its customers for more than 150 years. In line with its company-wide lean production concept, rlc has integrated a continuous improvement process aimed at minimising waste across all manufacturing operations. This includes the efficient use of valuable resources in packaging development, production and supply chain management.

“Sustainable action and thinking are firmly anchored in our corporate strategy.

This way we also create an important added value for our customers,” explains rlc | packaging group CEO Hans-Christian Bestehorn. “For many years, we have relied on

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modern supply chain concepts. We continuously invest in the safety and security of our employees and implement our lean production concept to achieve both economic and eco-logical objectives.” The company pays close attention to optimum material utilization. This includes the use of raw materials from renewable re-sources or recycled products. And as part of its ‘Green Chic’ concept, rlc implements laser gloss and other resource-saving inline finishing technologies.

Working in cooperation with ClimatePartner, rlc has developed a company-specific CO2 calculator based on a dynamic analysis model. This tool computes greenhouse gas emissions for specific orders, taking into ac-count all factors related to the carbon footprint of a packaging. Emissions can be offset with emission certificates from internationally recognized climate protection projects. Using the results from the CO2 calculator, rlc plans to offer customers even more targeted advice on sustainable pack-aging design and production.

The carbon footprint for each of the rlc sites in Hanover, Aachen and Ber-lin has also been certified. “We are currently looking for other potential options to further reduce CO2 emissions. This reflects our ongoing commitment to eco-sustainability,” Bestehorn adds.

Visit: www.packagingeurope.com/News/61437

Sustainability news

Red Dot Seal for Ecover’s Ocean Plastic Bottle T

he Ecover Ocean Plastic Bottle has won the sought-after Red Dot Award: Communication Design 2014 for Packaging Design, one of the largest and most respected international design competitions. The bottle was chosen ahead of more than 7000 entries and the coveted first prize was awarded at the ceremony in Berlin. The project saw cleaning pioneer Ecover join forces with Logoplaste Innovation Lab who conceived the design and produced the washing-up liquid bottles made from ocean plastic waste. The combination of this revolutionary sustainable packaging concept and tactile design, based on natural principles has already been recognized by five other industry awards. This is a promising result less than half a year after the project launch in June 2014.

Ecover wants to turn the tide on plastic endangering our seas and oceans, as well as creating the conditions for a systematic clean-up of the waste that’s already there. Current estimates state that one million sea birds and 100,000 sharks, turtles, dolphins and whales die every year from ingesting plastic. Fish in the middle depths of the Northern Pacific Ocean are ingesting as much as 24,000 tonnes of plastic each year - equivalent to 480 million two litre plastic bottles, or the weight of 132 blue whales. Not only does the reduction of waste plastic in the ocean make for healthier fish and sea mammals, it would ultimately also reduce the levels of micro plastics in our food and drinks.

That is why Ecover created the Ocean Plastic Bottle, the first ever bottle made from waste plastic fished out of the ocean. This limited edition bottle contains Ecover washing-up liquid and is made entirely from recycled plastic, with 10 per cent of that plastic coming from the sea. The washing-up liquid itself has been developed with a special ‘sea lavender and eucalyptus’ fragrance – bringing the scent of the sea to consumers’ homes. Ecover produced 15,000 Ocean Plastic Bottles, of which 10,000 were distributed in the UK. To emphasise the importance (and wonders) of our oceans, the design of the bottle was inspired by the skeleton structures of diatoms and radiolarians. These are single celled organisms found in our oceans that are able to create extreme lightweight yet solid skeleton structures. By applying the same principles of that skeleton structure, Ecover was able to create an aesthetically pleasing plastic bottle that uses 15% less plastic without losing mechanical capacity.

This year, Ecover used one tonne of ocean plastic and aims to increase that number every year. Conversations with project partners are ongoing about improving the amount of recyclable ocean plastic (e.g. through the use of additional sources like beach clean ups). It is also crucial to get an insight on the composition of the plastic soup, floating in our seas and oceans, to optimise the recycling process in the future.

Visit: www.packagingeurope.com/News/61382 Packaging Europe | 23 |

The Brand Owner’s Perspective Alison Ingle, group packaging manager at Nestlé UK & Ireland, tells Tim Sykes how the giant brand owner approaches packaging development from the point of view of sustainability and other major innovation drivers.

TS AI

What are the defining characteristics of Nestlé’s sustainability policy and how does overarching policy inform the packaging development process?

To improve the environmental performance of our products, we need to assess and improve their environmental impacts from the moment we begin to design them.

This means getting a clear understanding of the environmental life-cycle impacts of our products – from agricultural production and the sourcing of ingredients through to what happens at the end of a product’s life – across the value chain.

The packaging of our products is crucial to prevent food waste, guarantee our high quality and safety standards and inform our consumers. Nestlé takes a life cycle approach to its products and packaging. Nestlé are committed to: • Optimising the weight and volume of our packaging; • Leading the development and use of materials from sustainably managed renewable resources that meet packaging, product and environmental performance requirements; • Supporting initiatives to recycle or recover energy from used packaging; and • Using recycled materials where there is an environmental benefit and where it is appropriate.

Within product development we use eco-design tools (which follow Life Cycle Assessment methodology) to support our packaging and product development teams. This allows a detailed comparison of the environmental impacts of different packaging choices, including packaging end-of-life, across a range of environmental indicators.

Nestlé in the UK are a key member of the consortium with Enval Limited. Enval has developed a method of recycling aluminium-plastic foils, i.e. pet-food pouches or coffee packs. The technology separates the material into its different components, producing clean aluminium ready for introduction into the secondary aluminium supply chain and hydrocarbons that can be used for fuel or chemical feedstock. | 24 | Packaging Europe

Nestlé UK & Ireland is partnering with Coca-Cola Enterprises, Tesco and waste partners Enval, SITA UK and LRS Consultancy, having received funding from the Department for Environment, Food and Rural Affairs (Defra) to explore options for collecting flexible laminate packaging containing aluminium, so that the plastics can be recovered and converted into fuel, and the aluminium recycled. Trials are due to begin in 2015.

TS AI

Can you give any examples of successful packaging development projects Nestlé has recently undertaken that have resulted in significant environmental gains?

A good example is the 2012 launch of the Nescafe refill pouch, which with the compact format uses 34 per cent less packaging than our previous refill pouch and requires 50 per cent fewer lorries in transportation. This was communicated to consumers through the messaging on back of pack and through billboards such as the below.

TS

How does the organisation mediate the trade-offs that need to be made between sustainability goals, marketing priorities, cost and functionality? Is it the job of people like you to find the sweet spot somewhere in between these considerations?

AI

Within packaging development we are always looking to find the ‘sweet spot’ with a packaging solution which meets the required brief, has sustainability benefits and has the required functionality. We use both eco-design tools as described above, as well as using industry guidelines on design for recycling and inclusive design methodology within packaging development to try to ensure we consider all key aspects. We always aim to ensure that consumers are delighted with the end product experience.

TS

Speaking more generally about innovation, to what extent are packaging concepts driven by new technologies and products available on the market or initiated internally? (I’m sure there is a mixture of both and variation according to the product, but I’d like to get at how the relationship between Nestlé’s packaging specialists and external suppliers functions, and what factors can tilt the balance.)

AI

Within Nestle we have dedicated research and development resources for each different business that drive innovation globally. Innovation can come from a variety of sources either initiated internally through our R&D community, through close collaboration with suppliers or from new technologies available. To be able to deliver the right innovation to the market it is important to understand clearly what the consumer needs and values in the specific market you are developing the product for.

TS AI

To what extent does Nestlé formulate broad, long-term packaging policies to think through responses to megatrends?

For packaging, we have defined five focus areas which are related to consumer & customer centricity, technology master ship, operational excellence, sustainability and compliance. For each focus area we have long term views, strategies and consequently related global policies and processes in place. Aging population for example is covered within the area of consumer centricity.

TS

Could you name some of the most significant consumer trends which are shifting the kind of packaging you use - and the formats that are growing in popularity as a result?

AI

Demographic changes like aging population, growing single households and urbanisation have a major influence on our packaging formats. We have to adapt the functionality of our packages to the needs of the elderly people, smaller pack sizes and snacking formats are growing due to the change of household sizes and urban life styles. Over-nutrition is a major concern in our western society; packaging plays a major role to inform consumers on portion guidance but also on potion control via adapted pack sizes or reclose-ability features.

New technologies like smart phones offer revolutionary new ways to connect and engage with our consumers via packaging and related formats. On the other hand, affordability becomes more and more relevant for European consumers, so the pressure on reducing packaging and distribution cost is getting even higher in order to address these consumer needs.

TS

International brands face a choice around the balance between consistency and communicating with consumers in local markets. How does Nestlé approach this dichotomy? How much central control is there over branding and packaging design?

AI

We don’t see this balance as a dichotomy – instead we see it as leveraging the best of both worlds where global strategy is adapted to be relevant to local consumers. We do this by balancing centralisation and decentralisation through establishing set principles for strategy and execution – and in so doing we build strong global brands through creating alignment between the Strategic Business Units and the markets.

As a result we aspire to one global strategy that may have different expressions in different markets depending upon the situation or consumers in that country. For brand identity and packaging design, we provide guidance in the form of standards which help ensure the brand’s strategy is understood locally and translated well into execution.

Packaging Europe | 25 |

Diary PACE Forum

Date: 10 - 12 February Visit: www.arena-internarional.com

Pharmapack

Date: 11 - 12 February Visit: www.pharmapack.fr

Venue: Brussels, Belgium

Venue: Paris, France

Packaging Innovations Date: 25 - 26 February Visit: www.easyfairs.com

Meeting Pack

Date: 25 - 26 February Visit: www.meetingpack.com

LOPEC

Date: 3 - 5 March Visit: www.lopec.com

Venue: Birmingham, UK

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Venue: Valencia, Spain

Venue: München, Germany

Personal Care & Homecare Ingredients Date: 12 - 14 March Visit: www.pchi-china.com/en

Propak East Africa Date: 17 - 19 March Visit: www.propakeastafrica.com

Anuga Food Tech Date: 24 - 27 March Visit: www.anugafoodtec.com

Venue: Guangzhou, China

Venue: Nairobi, Kenya

Venue: Köln, Germany

GulfCan Conference

Date: 14 - 16 April Venue: Dubai, UAE Visit: www.worldcanconferences.com/gulfcan

Plast 2015

Date: 5 - 9 May Visit: www.plastonline.org

IPACK-IMA

Date: 19 - 23 May Visit: www.ipack-ima.it

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PACE Europe

Venue: Milano, Italy

Venue: Milano, Italy

he Packaging and Converting Executive Forum (PACE), taking place in Brussels, 10-12 February, is the packaging industry’s key invitation-only event, giving solutions-hungry professionals a platform for collaboration to keep up with the ever-evolving challenges facing us all.

In a context of viewing packaging as an investment conflicting with the constant demands to do more for less, the tenth edition of PACE Europe will be focused on the future of an industry under pressure. With new packaging technology and solutions providing unparalleled opportunities for companies, participants can discover how to harness innovation in the best possible way and for optimal results.

PACE Europe is a cross-industry event where executives from brand owners such as Coca-Cola, GlaxoSmithKline, Procter & Gamble and Mars rub shoulders with converters in workshops, case study sessions, one-to-one meetings and presentations. Over the years the event has proved it has an uncanny knack of putting its finger on the very most important questions of the day for packaging converters, while providing invaluable insights into the way brand owners integrate these into their packaging development processes. Some of the topics in this year’s agenda include: • How to land innovation that has the scale required for effective solutions • Reducing costs while maintaining quality • Working with the retail environment: Cooperation for all-round success • Functionality as the point of difference: The customer as king • Sustainability and food waste: An opportunity and a challenge to the packaging industry • Digital printing and customisation: The opportunities for packaging today and tomorrow • Advances in technology to achieve weight reduction in packaging: What barriers still exist?

• Intelligent packaging: Combining innovation and cost reduction • Demands for convenience: How consumer changes are necessitating a new world of packaging • Social networks and changes in consumer buying behaviour: Creating and maintaining brand loyalty through packaging • E-commerce and packaging: Reverse logistics and the associated costs to your business Visit: www.arena-international.com/pace

EVENTS Nicola Hamann, Managing Director, Mack Brooks Exhibitions 1. What makes the ICE premise distinct from the many other trade shows serving the packaging market?

5. What do you expect to be the hottest topics under discussion among visitors to ICE 2015?

ICE Europe, International Converting Exhibition, is not primarily targeting the packaging market in general, but more specifically the converting industry within the packaging sector.

The focus of the event is the conversion of flexible web-based materials, such as paper, film, foil and nonwovens. The exhibiting companies present a comprehensive range of machines, materials, accessories and services for the converting industry. Of course, the packaging industry is a core target group as the users of these machines and services. However, ICE Europe also attracts a variety of other industry sectors, such as the pharmaceutical industry, the automotive industry and the textiles and nonwovens industry. This makes the show special within the environment of packaging events; it is a vertical technology exhibition for the converting industry offering a highly specialised exhibition profile.

Environmental sustainability is a key trend for materials as well as the conversion of materials. Another challenge is energy efficiency, which becomes ever more important with increasing energy prices. There is a marked trend for added-value products and individualised end-products. Here, digital print applications and innovative conversion solutions play an important role. Key topics at ICE Europe 2015 are, therefore, efficient production processes, enhanced quality and environmental sustainability.

2. How many exhibitors and visitors are you expecting to attract in 2015?

Currently the exhibition features more than 400 exhibitors from 23 countries and covers a net exhibition space of more than 10,000 m2. Three months ahead of the show, ICE Europe 2015 is, therefore, already as big as the previous exhibition and we are still receiving a large number of stand enquiries from companies across the globe. Major exhibitor countries are currently Germany, Great Britain, Italy, Switzerland and the USA. The previous event, ICE Europe 2013, was the biggest international converting exhibition ever. A total of 6,600 visitors from 64 countries came to Munich to find out about the latest products and technologies in the converting sector. We had a very positive feedback on the previous show and from our current marketing campaign for ICE Europe 2015, we are confident that ICE Europe 2015 will, once again, be very successful with regards to visitor attendance.

6. Which areas of innovation do you anticipate will be among the most exciting among the exhibitors?

Technologies that offer solutions for the above mentioned key topics. We will publish a Show Preview in January 2015 where exhibitors give detailed descriptions of their products and services on display at ICE Europe 2015. Visitors will be able to access the Show Preview on the exhibition website - www.ice-x.com/europe - or order a printed version of this publication. You will see that most of the innovative solutions on display in Munich from 10 – 12 March 2015 will focus on environmental sustainability, enhanced production processes, new materials and cost-efficiency.

3. From the feedback you receive from exhibitors, what would you say are the most significant demands facing converters?

There is a marked trend for individualised and value-added products in the highly developed markets. Younger consumers expect product solutions that are at the same time attractively designed, practical to use and environmentally-friendly. The increasingly older population requires easy-to-open packaging solutions with a clearly visible signage. Suppliers demand cost-efficient and light-weight transport packaging and retailers modern and easy-to-use POS solutions. Stricter health and safety regulations play an important role for consumer products such as food and pharmaceuticals. Next to all of these requirements from consumers, the supply chain, retailers and governmental bodies, the converting industry have to adapt their production process to a changing industry environment. High energy costs and the need to meet the demand for an ever increasing product variety require efficient and flexible fabrication processes.

4. For each of the drivers above, how are packaging converters responding?

For the converting industry these challenges represent a great opportunity. They are a driver for technological innovation and open up a big market potential for the converting industry.

As a highly flexible and innovative industry branch, converters quickly adapt their production processes to changing market requirements. Our exhibitors invest in R&D to offer cutting-edge technology, intelligent in-line solutions and innovative systems to the converting industry. The use and processing of new, environmentally-friendly materials and technical developments, such as printed electronics and advanced digital print solutions, are just a few examples of how converters continuously respond to the latest market trends.

Packaging Europe | 27 |

EVENTS

Packaging Segment and Conference Track Returns To PCHi 2015

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ersonal Care & Homecare Ingredients (PCHi) 2015 trade event is the largest cosmetics & personal care ingredients sourcing platform in China now expands its reach into the global personal care industry with a stronger focus on cosmetics and personal care packaging and machinery. The show, an essential trading hub for any CPC manufacturing business, will be held at the Guangzhou Poly World Trade Centre, from 12 to 14 March 2015.

“We recognise that packaging and product formulation go hand in hand in the creation of a winning product,” shared Elynn Xu, project manager, RSE. “With that in mind, the Packaging and Machinery Segment and conference sessions were planned around providing cosmetics packaging designers and formulation scientists with a more holistic platform to innovate, collaborate, and develop premium products. Building on our previous experiences and on feedback received, we will present an improved and more comprehensive CPC packaging focus at PCHi 2015.”

Launched in 2013, the PCHi Packaging and Machinery Segment of the exhibition was first established to meet the specific needs of global cosmetics and personal care product manufacturers, designers, and formulation scientists. At PCHi 2014, PCHi collaborated with leading research firm Mintel to develop the Packaging Innovation Zone, which showcased the latest innovative beauty packaging solutions. Returning to the show again next year, Mintel’s Packaging Innovation Zone will feature the latest packaging design trends, manufacturing technologies, and packaging material innovations for CPC markets. Packaging specifiers can also expect to connect with established packaging materials and technology suppliers, including plastic bottles, tubes and cups manufacturers, plastic raw materials manufacturers, and label printing companies.

In addition, the PCHi 2015 Conference Programme will feature a series of packagingrelated seminars led by distinguished partners including Euromonitor, Mintel, China Cos-

| 28 | Packaging Europe

metics Review, Shanghai Jiao Tong University, Packaging Update, and Printing Equipment Industries Association of China (PEIAC).

Attendees of the packaging conference will hear from these global packaging experts about the latest packaging trends such as packaging regulations, labeling requirements, and industry standards in beauty packaging. The confirmed list of packaging-related talks at PCHi 2015 includes: • Packaging Market Trends Conference • Cosmetics Packaging Design Trends Conference • Packaging Sustainability and Innovation Conference • Label Technology Conference “The 2015 PCHi Packaging and Machinery Segment has already garnered interest from internationally acclaimed companies including Amway, Lancôme Paris, Avène, Johnson and Johnson, Nivea, and Kao,” Xu related. “Visitors at PCHi 2015 can look forward to interacting with these established companies at our various networking sessions. With our expanded activity around CPC packaging and machinery, we hope to bring greater value and benefit to the global audience that see PCHi as an essential hub for cosmetics and personal care information and technology.”

PCHi 2015 is now open for pre-registration at www.pchi-china.com/en/Visitors/ Visitor-Registration. Pre-registration is free through 9 March 2015, after which only on-site registrations will be accepted at a fee of RMB165 per visitor. Over three days the highly anticipated trade show will host a myriad of new launches, an outstanding conference programme, and networking activities for industrial professionals.

Visit: www.pchi-china.com

Packaging Europe | 29 |

The UK’s Biggest Packaging Show is Back easyFairs is set to celebrate its tenth anniversary on 25 and 26 February 2015 at Birmingham’s NEC. The flagship packaging event will operate under three core brands, Packaging Innovations, Empack and Label&Print; aligning the full easyFairs packaging portfolio across Europe under the same brand concepts.

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lison Church, Event Director for easyFairs’ UK packaging events, says: “It’s amazing to think this coming February’s edition will be our tenth show. Since opening its doors in 2006, the show has tripled in size with over 350 exhibitors. It has become the key calendar event for the packaging industry. All different types of companies that supply into the packaging industry are here, and if you really want to know what’s going on in the industry, you need to be here.”

Exhibitors will not only be represented by the UK, but major names from territories such as Germany, Austria, Poland, Italy, France and The Netherlands have signed up for the 2015 show, including names such as Hewlett-Packard, Xeikon, Esko-Graphics, GMUND, Seufert Transparente, EPSON (UK), Compact and Bale, Fujifilm and Atlantic Zeiser. | 30 | Packaging Europe

The show also extends its reach beyond mainland Europe. For instance Bedford Industries, from Canada and Ever Rich International, from Hong Kong have also confirmed that they will be showcasing their latest products and services.

Amongst the exhibitors will be Future Pak, launching its ‘HOT FILL PET’ for Thermoforming, which enables material to be filled with liquid or solids of up to 95 degrees centigrade. Perfect for jams, sources, candles, soaps and medical purposes just to name a few.

For those looking to sparkle, Seufert Transparente will be unveiling its new PET promotional packaging with light effects for the drinks market. It combines packaging made of a coloured, transparent PET film together with an LED module. When the packaging is picked up, approximately 80 light-points light up in a pre-set sequence of red, white and yellow.

The show has a strong representation within the cosmetic and pharmaceutical markets, with AE Adams who will be celebrating its 50th Anniversary, Chester Medical Solutions and Chesapeake Pharmaceutical and Healthcare all set to present their latest innovations and technologies.

Dieter Bakic will be showcasing its new packaging, The Laurie bottle, for Head & Shoulders, its innovative UNITY cap design. Plus MIMOSA, a make-up compact, where the base and the lid are divided by a wavy curve that interweaves both parts creating dynamic and emotional appeal, especially when decorated or colored separately.

Measom Freer will be launching its Swithland bottle range. Distinctive plastic bottles, which are conical and cylindrical in shape, versatile in material, size and colour, providing great shelf presence for a wide range of product sectors.

Promens will be launching its Prestige Wooden Caps, set to enhance brand identity and positioning in the luxury beauty sector. It will also be showcasing Slidissime, a tactile ‘touch & slide’ pump with revolutionary airless technology and three new families of PET bottles providing prestige for the masses.

First time exhibitor, Bech Packaging, will be showcasing its specialised range of plastic packaging, designed for the cosmetic, food and pharmaceutical industries.

Also making its show debut is the GABRIEL-CHEMIE Group who will be exhibiting its latest packaging solutions, such as oxygen scavengers to actively help keep food fresh, and colour indicators to show consumers when food is no longer fresh. Whilst Sirane

will be showing Siralon, its range of top-quality nylon food packaging materials that can be oven-cooked, microwaved and cooked sous-vide.

Durst will be showcasing its Tau 330 digital UV inkjet print system for the food industry and fully-automated industrial production. Atlantic Zeiser Ltd will be presenting MEDTRACKER a flexible and modular software solution dedicated to pharmaceutical Track & Trace and authentication applications. Whilst, AMS Ltd will be demonstrating its colour label printer, the M1C Labelmaxer.

This year’s show will feature its first ever Pharmaceutical Symposium, providing organisations with the opportunity to gain inspiration and a greater understanding of how to tackle the key issues within packaging, labelling, coding and marketing for pharmaceutical products.

Also launching at the show will be two additional features – The Drinks Symposium and The Retail Symposium, providing exhibitors and visitors from all spheres of the packaging and print world with a unique programme of valuable and insightful content.

The BIG Print Debate will be returning alongside show favorite, Lions’ Lair, there will be a full learnShops programme addressing all of the hot industry trends, plus live 3D print demos enabling designers, engineers and educators to test and perfect work with 3D modeling.

For anyone interested in exhibiting, more information can be found at www.easyFairs.com/PIUK, www.easyFairs.com/EmpackUK and www.easyFairs.com/Label&Print or via the show team on +44 (0)20 8843 8800 or PackagingUK@easyFairs.com.

Packaging Europe | 31 |

It’s time for Innovation at the Huhtamaki stand G41 in Birmingham Ronsberg, January 2015. The visitors to the Huhtamaki Flexible Packaging Europe stand at Packaging Innovations can look forward to a wide range of innovations: From efficient aluminium lid solutions to reseal features on a roll, Huhtamaki shows its continued tradition of innovation.

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he flexible packaging specialists from Huhtamaki are attending Packaging Innovations with the motto “Time for Innovation” - with new and improved ideas which bundle and focus Huhtamaki’s knowledge gained from within the global Huhtamaki network. Huhtamaki wants to share these ideas about packaging solutions with their customers and will support their customers optimally through their next steps. Huhtamaki’s purpose is to be there for their customers and to work hand in hand. In this way, Huhtamaki can give the best support possible in developing customer’s growth plans and in developing tailored solutions to customers innovation needs.

One of these solutions is Easy Tear EverywhereTM – this modified laminate material for stick packs and sachets enables easy, controlled, linear tear opening and perfect portioning.

In this way, Huhtamaki is contributing to convenience trends like easy handling and opening as well as meeting customer needs. Thanks to a special modification of the polyester film, it is easy to tear at every position along the long side of the packaging, even without a tear notch.

The application spectrum is highly diverse. No matter whether it’s used in hygiene and medical applications or in the construction or food industry: Easy Tear Everywhere™ offers real innovation with a high degree of customer benefit in every application area.

With Integrated Reclose®, the Bavarian based flexible specialists are presenting a revolutionary resealing concept for bags, which together won the Deutscher Verpackungspreis (German Packaging Award) in September 2012. As usual, the packaging material is supplied on rolls. What is new is that everything needed for the easy opening and resealing is already integrated into the roll. This means multi-serve products can be packaged in a user-friendly and differentiating manner, without having to modify existing plant machinery.

Huhtamaki is rounding off the range of new ideas with the presentation of its new extrusion line that opens up a wide range of options in extrusion lamination and coating and offers a high level of added value. Thanks to intensive development work, Huhtamaki is now able to offer paper-free, 100% plastic composites in addition to our current speciality, namely, paper/barrier layer composites.

Helping great products reach more people, more easily – Huhtamaki wants to partner with their customers and develop tailored solutions. Huhtamaki is looking forward to seeing you at the fair at stand G41.

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About Huhtamaki Flexible Packaging Europe Huhtamaki is one of the world’s leading suppliers of innovative packaging solutions. As a centre of competence within the corporate group, Huhtamaki Ronsberg is specialised in the production of flexible packaging material - with a focus on new projects and innovative packaging solutions. In Southern German Ronsberg and Italian Tortona, Huhtamaki produces pioneering packaging for the pharmaceutical, cosmetics and food industries.

HUHTAMAKI FLEXIBLE PACKAGING GERMANY GMBH & CO.KG Heinrich-Nicolaus-Str. 6, 87671 Ronsberg, Germany For further information, please contact: Gerhard A. Hartmann, Marketing Director Flexible Packaging Europe T +49 (0)8306 77456, E gerhard.hartmann@huhtamaki.com Visit: www.huhtamaki.com

Packaging Europe | 33 |

Design Opinion Jack Pearce, joint creative head of Silk Pearce, tells the inside story of the thinking that informed the packaging design created for the Honeybell Soap Company.

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have not heard the words ‘I am not influenced by packaging design’ for a long time now, but you may be surprised to know that this view was not uncommon back in 1984 when we started our business. I can still remember the sinking feeling when in the middle of a design presentation somebody would attempt to use this as the nuclear option for avoiding change.

These days most people willingly acknowledge that they are indeed influenced by packaging, particularly when focused through the lens of ‘brand’. And of all the design disciplines, packaging comes closest to having an immediate effect on us in either a positive or negative way. Of course packaging must be functional in protecting the contents, but it is likely to be judged on the shelf or screen in an entirely emotional way. Choose this and reject that.

With the new range of packaging for The Honeybell Soap Company, defining the qualities of the brand was of paramount importance. Although the company’s previous packaging had routinely been described as pretty and attractive, what it lacked, however, were the qualities that are less easy to define: such as the care that is taken in making these high quality products, the authenticity of the ingredients, the fact that they are handmade

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in England. In addition, it was important to add a contemporary twist to what had been a traditional brand – the ‘this will look good in my bathroom’ factor rather than ‘this is an inexpensive present for an older lady’.

Of course buying Honeybell as a present for an older lady is still important, but in its new packaging customers will be equally happy to buy the products as gifts for anybody including themselves. And that is it. Packaging can change the way we think about the products and the brand as a whole. But that power cuts both ways. It can delight, reassure, satisfy... or disappoint.

The latter point is interesting because we have all bought goods on the strength of the packaging only to be disappointed by the contents. In the case of Honeybell, the reverse was true – the products were far superior to the promise offered by the packaging. The bar and liquid soaps, body lotions and candles are all handmade from the finest organic or natural ingredients. And it was clear that the products would be at home on the shelves of many of our best department stores and gift shops if the packaging projected the right qualities.

Our approach to the design was to comprehensively elevate the packaging in all respects in terms of quality, and along with it the brand itself. This meant that all aspects had to be considered: the Honeybell logo, the pattern illustrations, the choice of colours, the use of fonts and, importantly, the paper stock.

I think it is no exaggeration to say that Honeybell were blown away by our presentation.

This was the first serious foray into design by the company that started life as a hobby – the previous designs having been developed in-house. We presented a number of viable designs but our client, Honeybell MD Jenny Gould, wanted to strike a balance between contemporary and tradition. She also wanted to maintain the colourful approach for which Honeybell were known by their customers – not to throw the baby out with the bathwater.

We designed a classic roundel for the logo using a honeybell flower. The logo works as a foil to the 18 different patterns that were taken and redrawn from Victorian, geometric

references. The patterns which are printed in a coordinated colour palette are designed to mix and match and to work well together when products are bought as sets.

The choice of paper was crucial and we decided on Favini Twill in Bright White – which is actually quite a soft shade. The colours of the patterns are warmed by the off-white paper and the subtle ribbed texture provides a tactile reassurance of quality and that homemade feel.

Initial reactions to the revamped range are extremely positive with enquiries from several big chains and increasing international interest, including a significant deal with a Swiss company that was attracted by the ‘Englishness’ of the products. Proof if any were needed that people are indeed influenced by packaging design – but thankfully these days that is something that most of us know already.

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Making a Big Impression with Small Packs Hervé Turpault, Perception Research Services, Vice President, Europe.

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cross many categories, from sweets and gum, to pet food and health and beauty (HBA) products, consumer goods are appearing in smaller packs. And this is a trend taking place in developed, as well as developing markets. In 2012, for example, more than half of all new product launches in the prepared food sector in the UK were single serve packs.

Why is the smaller pack on the rise?

More people living alone The trend of more people living in single households although not new, continues to be an important driver. In the UK, for instance, that in 2013, 29 per cent of the population were living in single person households compared to 17 per cent in 1971.

Avoiding price increases With the cost of the raw ingredients and the manufacturing of the consumer goods going up – in many categories significantly – many brand owners have chosen to downsize rather than pass the increased cost on to consumers. Coca Cola, Pepsi and L’Oreal, for instance, reduced the size of products in China to cut costs as a way of keeping the price the same. Studies in US supermarkets have shown that almost 10 per cent of products have become smaller with prices remaining the same. While some of the shrinking could go unnoticed, consumer watchdogs have identified products that have been downsized, in some cases, by as much as a quarter. Examples include Birds Eye Beef Burgers (25 per cent less), Thornton’s caramel shortcakes (17 per cent less), Nestlé’s Superfruity Shredded Wheat (10 per cent less), and Walkers crisps (six per cent less). In the US instances include Tropicana Orange Juice (eight per cent less) and Haagen Dazs ice cream (12.5 per cent less). | 36 | Packaging Europe

Looking for more ‘on the go’ convenience and portion control At the same time, consumers have been looking for smaller, individual and one time portion sized goods of everything from snack foods to toiletries. According to a study by The Hartman Group, 47 per cent of all eating occasions in the US are solitary. Beverage makers are just one category of increasingly exploring single serve options. Coke’s mini can – 7.5 oz – was a standout performer for the company in North American during the second quarter of 2014.

Best Practice for presenting small packs The smaller packages face various challenges when competing in-store. To be successful, packaging needs to break through clutter and generate shopper consideration and at the same time, to help people find the right product quickly and accurately. Both of these challenges become more difficult with smaller packs, as their visual impact is typically modest when seen from several feet away, within a cluttered aisle. In addition, due to their limited size (and their instability), these packs are often compromised on shelf (knocked-down, turned sideways, etc.).

What, then, do marketers need to counter these issues and help ensure a strong shelf presence? The core challenges for smaller packs (visibility, shop-ability and communication) are parallel to those facing all brands at retail. But, the difference is that smaller packs have less “room for error” – and a greater need to rely on design, rather than words – due to their limited space.

The importance of leveraging colour Colour is the most powerful and accessible tool for driving visibility and delineating across varieties. Marketers face a fundamental question regarding its use: either to ‘own’ a

In the pet food category, secondary packaging creates a much larger “billboard” on shelf.

colour to define a brand (i.e. Colgate red or Danone’s Green) or to use colour to delineate varieties (as with M&Ms and Doritos). Both strategies can be successful, but from PRS’s experience, brand-blocking in a single colour can be particularly critical for smaller brands with relatively few different products in their portfolio.

At the brand level, going ‘against the grain’ can be very effective, but at the variety level, it is nearly always advisable to stay within established category colour codes.

Shape and structure are underutilised A unique ‘footprint’ such as the Pringles canister can be very effective in differentiating brands from a distance and creating both visibility and immediate recognition. The effective use of shape can also be powerful in differentiating across product forms or tiers.

Getting the shape right is also important for ensuring that the product sits securely on the shelf in the right way.

When working with smaller packs, it also pays to think creatively about shape in the context of multi-packs. In the pet food category, secondary packaging creates a much larger “billboard” on shelf.

Finally, marketers need to remember that many smaller packs typically “live” in store within outer packs, carriers or SRP (shelf-ready packaging). Thus, it is important to develop packaging and SRP concurrently to work effectively together. Ensuring that the outer pack highlights the packaging, rather than blocking it and compromising legibility – or allowing packs to fall over when the carrier is half-full.

images are far more consistently seen than copy. Therefore, it is important to make the visuals both engaging and informative (in conveying product form or user imagery).

People will often have multiple packs in hand, attempting to compare them, understand product differences and confirm they have the right one for them. To facilitate these comparisons, it is best to use a consistent layout across packs (and sub-brands), so that shoppers “know where to look.” Similarly, grouping key information (flavour, form, quantity, etc.) in one place makes shopping far easier.

Finally, the most important guideline for the communications on a small pack is to keep it simple. Generally speaking, small packs allow space for only 2-3 primary design elements, which often correspond to branding, variety information and perhaps a single visual or message. We would encourage marketers with small packs to find ways to reduce front-of-pack design elements (by showing the product through the pack, for example) – and to use the back panel, POS materials or digital links to convey more detailed information.

Clear and simple communications As a smaller package has less room to “tell a story” (via claims, visuals, etc.), there is a premium on clear, concise communication – and on effective design. As with shelf presence, there is not a single solution, but PRS can offer several principles, drawn from its experience: The first priority is product information. Generally, shoppers will have identified the brand from a distance (via colour, shape, brand mark, etc.) – and they will now give a package about 5 seconds to convey product information (and provide any necessary reassurances) – or they will move to another “safer” selection. Thus, variety information must be prioritised (and clearly conveyed) on the front label.

Given limited space for messaging, it is particularly important for smaller packs to connect emotionally, ideally through pack shape, texture or visuals. An ‘ownable’ shape (or a premium finish) can convey the desired imagery without words, as seen quite clearly with many cosmetics products. And from eye-tracking research, we know that on-pack Packaging Europe | 37 |

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Innovating to protect what’s good When Tim Sykes visited Tetra Pak’s Research & Development centre for aseptic packaging in Modena, in Italy’s engineering heartland and packaging valley, last month he was treated to a behind the scenes glimpse of how the world’s most famous packaging company approaches the market.

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reating entirely new market categories through packaging innovation ever since the 1950s, Tetra Pak occupies the unique position of a packaging brand that enjoys widespread household recognition. It is perhaps no surprise then that the company places a special emphasis on understanding both consumers and brand owners. The Modena launch of a new on-the-go carton featuring an ergonomic shape and the latest closure technology gave Tetra Pak the opportunity to expand on the nature and scale of research which stands behind each innovation.

Consumer intelligence Everyone at Tetra Pak emphasises that innovation is driven by requirements rather than solutions so it is natural that R&D begins at the broadest level – with the study of global megatrends and their implications for the kinds of products demanded by today’s and tomorrow’s consumer. Michela Vallalta, global director of consumer intelligence, cited urbanisation (which is set to reach 60 per cent by 2030), the growing middle class, and the tripling of the over-60s population over the next decade among key tendencies Tetra Pak is closely monitoring. Such research yields important discoveries, such as the revelation that 35 per cent of global consumers are prepared to pay more for products that make their lives easier, and 48 per cent rely heavily on products that help them save time. Meanwhile, there is a mass of data emphasising that a large number of consumers want products that are tailored to their individual needs.

“Such intelligence is fed into our annual Strategy Cycle process, which defines Tetra Pak’s strategic direction for the following three to five years,” Ms Vallalta explained. “This involves assimilating consumer data with information from the various market segments, such as juice and dairy, also taking into account valuable direct market feedback from our customers.”

This serves to set product development priorities, such as on-the-go convenience and age-friendly pack formats. In addition, it identifies a range of future scenarios and market conditions, in anticipation of which Tetra Pak can look to develop technologies that address market needs likely to arise.

State of the art R&D This is where innovation centres such as Modena and Tetra Pak’s Development and Engineering hub in Lund, Sweden, come in. The company draws on staggering resources – investing some 350-400 million Euro per year in innovation and employing some 500 R&D staff in Modena alone. This buys Tetra Pak formidable strength across the range of disciplines from market research through product development laboratories and prototyping facilities to consumer testing centres across the world, which have to date carried out some 40,000 tests on 1240 packs in 40 countries.

It also means investment in the cutting edge thinking, such as the research of Professor Lena Lorentzen, global authority on inclusive design. Prof Lorentzen has pioneered the collection of data on hand strength in order to properly understand the range of consumers who interact with packaging. “Traditionally, design was a male-dominated field, and male designers tended to produce packs which were suited to their hand size and strength,” she remarked. “This didn’t take into account the fact that women and children on average have lower hand strength, nor those with reduced hand function.”

In the context of a fast growing global senior population, among whom 50 per cent report difficulties in opening packaging and a significant proportion suffer from conditions such as arthritis, Prof Lorentzen’s work provides Tetra Pak’s R&D centres with matrices against which to measure the accessibility of a pack and in particular its closure. This has become a focus of innovation within the company and already ten advanced packaging formats have received accreditation from bodies such as the Swedish Rheumatism Association (SRA).

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Innovative closures More generally, closures have been a major focus of innovation in recent years, not least in relation to the on-the-go trend. The Modena unveiling of a shapely Tetra Prisma® Aseptic 330ml carton showed off the latest iteration of the easy-open Dreamcap™ closure series. The Dreamcap™ is a post-applied closure which is rather strikingly positioned over the edge of the carton. As I discovered when invited to test its performance in the Tetra Pak’s Modena consumer lab, this positioning is designed to provide an outstandingly smooth flow during consumption. Moreover, the low-force, one-step opening action seemed sure to please the analysts from the SRA. However, Tetra Pak’s portfolio is wide and not exclusively about value-added functionality. “We are present at different entry points in different markets around the world,” explained Fabio Thomazelli, product manager, opening, closure & straw. “Between ourselves and our customers the task is to find the sweet spot between functionality and cost, as determined by the particular conditions of their market. With over 4000 cap/closure combinations in our catalogue, the widest selection on the market, we can offer a host of options: pre- and post-applied, one-step and two-step opening, various sizes and designs, and optimised for various consumption occasions.”

Indeed, cost reduction is a primary USP behind another recent closure, the LightCap™, which is designed to keep plastic use to a minimum, making it particularly suited for larger sized closures.

Environmental protection Sustainability is one of the megatrends that Tetra Pak identifies as of especial importance to consumers: its research indicates that 50 per cent of global consumers say they would like to do something about the environment, but don’t know how, while | 40 | Packaging Europe

74 per cent expect companies to take environmentally responsible actions. As such, this is a hugely significant focus of the Tetra Pak’s investment in innovation.

Its environmental innovation strategy is three-pronged. The first aim is to reduce impacts across the value chain – reflected in significant reductions in energy consumption and a halving of water consumption in Tetra Pak machinery since the year 2000. The second element is working to increase the recycling levels of beverage cartons, which reached 60 per cent in kerbside collections in the UK in 2014.

The third prong of the strategy – sustainable product development – is perhaps the most interesting, as it puts Tetra Pak at the forefront of bio-based plastic packaging. “Of course, paperboard is the main component of all of our packages and we are working with the most reputable forest certification system, The Forest Stewardship Council (FSC) to increase the availability of responsibly sourced paperboard,” said Christina Chester, product director, carton gable top at Tetra Pak. “However, we are working to replace the non-renewable elements of our packages – such as conventional plastic, with renewable alternatives, in this case bio-based plastic derived from sugarcane.”

The business has been working with Brazil’s Braskem to secure supply of biobased HDPE, resulting in the introduction of bioplastics caps to the Tetra Pak packaging portfolio in 2011. This was followed by the roll out of other initiatives, including bio-based coatings to all packages produced in Brazil in 2014.

“A very recent development is the launch of the industry’s first 100 per cent biobased package – a new version of our popular Tetra Rex® gable top chilled package,” continued Ms Chester. “We are expecting our first customer launch, which means that completely bio-based beverage cartons will shortly be appearing on European supermarket shelves.”

An educated guess would be that the exciting announcement Tetra Pak expects to make sometime in 2015 has its roots in the Hyperspeed Concept first introduced at Anuga in 2012. Predicted at the time to become available within a three to four year timeframe, eBeam non-contact and dry sterilisation are said to offer faster operating speeds, reduced energy consumption and carbon emissions while increasing line capacities. eBeam sterilisation, based on low voltage electron beam (LVEB) technology, also allows customers to simplify their plant operations by removing the need to handle bulk chemicals and simplifying quality control.

When launched, eBeam sterilisation will also play a significant role in the new Tetra Pak A3 filling machine for super high speed packaging – the Hyperspeed Concept – to assure the complete sterility of products while keeping mechanical complexity low and increasing capacity. With a redesigned jaw system and an innovative final folder based on linear guides that handle packages firmly until the point of final delivery to the belt, the Hyperspeed Concept is expected to reach speeds of up to 40,000 packages per hour. In addition, it aims to decrease customer operational costs on portion packages by up to 30 per cent in some configurations.

High performance

A symbiotic partnership

When pressed on the most exciting product launches scheduled for 2015 Ivano Selmi, managing director of the whole Modena operation, bound to secrecy offered a sphinx-like smile and the observation that “the biggest innovations are often those that are not seen by consumers”, but rather those that raise the bar in terms of performance earlier in the supply chain.

According to Mr Selmi, the successful launch of new systems and packs relies on maintaining strong relationships with customers. “It is our customers who introduce our products to the market and share with us their unrivalled knowledge of the needs of the particular consumers they serve,” he remarked. For their part, Tetra Pak’s customers have time and again transformed their offerings with the help of a new carton concept.

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Monther Al-Harthi, CEO of Al Rabie Saudi Foods Co. Ltd, a market leading Saudi food and beverage brand and long-time customer, testified to the value of the partnership. “Being an early adopter of Tetra Pak solutions has effectively created new products for us,” he said. “For instance, when we introduced an onthe-go juice pack using the Tetra Prisma® Aseptic 330 carton, it was so popular that consumers were prepared to pay a substantial premium. It redefined pricing assumptions for this market.”

Similarly, Tetra Recart® (the first retortable carton package designed for shelfstable products traditionally filled in cans, glass jars or pouches) was the vehicle for the launch Al Rabie’s ‘Awal Qatfa’ range of ready-to-eat healthy foods. Free of preservatives, artificial colours and cholesterol, the Awal Qatfa brand marketed itself as a radical solution for modern life, delivering not just healthy ingredients but convenience and the security of state-of-the-art sterilisation systems. According to Mr Al-Harthi, the brand revolutionised the Arabian food market, with the modern packaging an integral part of its identity.

Redefining markets Asked where Tetra Pak is likely next to create new market categories, Mr Selmi pointed out that its products are already used to package many hundreds of foods and beverages around the world, often unique to geographical markets.

“As an example, in China we have contributed to the emergence of the drinking yoghurt market, popular with the growing middle class,” he said. “In fact we have a small team dedicated to technologies for drinking yoghurts containing small particles. We have moved into numerous new market segments over recent years, including wine, water and sauces.”

Indeed, the Modena facility was founded in order to work on diversification.

“In 1980 when I joined the new Modena site we had a staff of around just 25,” Mr Selmi said. “Our primary task was to find technical solutions to diversify the range of applications for cartons – working on liquids of various densities, solids, viscous products, shakeable contents, etc.”

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Mr Selmi’s experience of ‘growing up at Tetra Pak’ provides insights into the distinctive, Nordic culture of the company. “When I went to Sweden for training over thirty years ago I was immediately struck by the strong focus on the individual,” he said. “There was an attention to the comfort of employees and to things like ergonomics, which I had never encountered before. Tetra Pak wanted to engender a stimulating and challenging environment where everyone feels freedom and accountability, which is an ethos we try to replicate here. In Modena we are competing with lots of packaging engineering companies for the best talent and young people are not only motivated by salary, so we try to pay attention to little details (for example, taking delivery of employees’ internet shopping) that make this a pleasant environment to work in.”

Mr Selmi concluded: “I feel privileged to work for a company whose products you come across in the most remote corners of the world. More than that, the innovation we are engaged with is meaningful. Our motto ‘Protects what’s good’ and our mission to make food safe and available reflects the fact that what we do has a positive impact on the world – and there are still regions where we are not yet established in which making more food safe and available can enhance lives.”

Visit: www.tetrapak.com

Complying with the EU Falsified Medicines Directive The European healthcare supply chain is to have a new set of packaging guidelines for pharmaceutical companies. The EU Falsified Medicines Directive (EU FMD) and Delegated Acts have been designed to prevent the entry of falsified medicines into the legal supply chain and will require that manufacturers package and distribute their drugs to a new set of standards. Lee Henderson, European director of sustainability and stakeholder engagement at Asia Pulp & Paper, talks us through the issues.

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ll evidence suggests that there is a growing need for such new measures to counteract the prevalence of illicit medicines. According to the World Health Organisation (WHO), the global pharmaceuticals industry is expected to grow from US$300 billion a year to US$400 billion a year by 2017, and it is becoming an ever more lucrative target for producers of counterfeit drugs.

Growth in the sector has led to an increasingly complex supply chain, presenting more opportunities for illegal products to enter distribution. It is already estimated that up to 1% of medicines available in the developed world are likely to be counterfeit, rising to 10% globally and even reaching 33% in some of the most impoverished developing countries, thereby causing concern that this figure could grow without an industry-wide response.

The European Union is therefore introducing a number of measures in 2018 that will transform the way drugs are distributed and dispensed, putting greater emphasis on how the products are packaged. New requirements will be enforced which require the outer packaging of medication to clearly display the product number, the batch or lot number and the expiry date.

Most notably, though, all medications dispensed must feature a tamper-evidence seal which includes a random serialisation number that acts as a unique identifier. This identifier will ensure full traceability and enable the pharmacist to know instantly the status of the medication, including whether it has been dispensed before and is therefore a counterfeit product, or if there has been a recall or notice against the batch.

The implementation of the tamper-evidence seal and the unique identifier marks a major step in progressing patient safety. All medicinal products placed in the EU market, including imported products, will have to comply with the new measures and the net effect should be to reduce the amount of counterfeit or tampered products available on the market.

However, while these new measures are a welcome safeguard for patient security, the widespread changes can bring significant challenges for the packaging industry. Early participation in the system has already revealed difficulties in the implementation, especially in generating, printing, reading and storing the unique identifiers, and further complications can be expected to arise as the guidelines are more widely adopted.

For example, functionality of the packaging must be taken into account when implementing some of the new requirements such as the tamper-evidence seal. While products must cater to the needs of an ageing population and offer easy-access containers for medicines, this must be balanced by the need to protect children. Developing a product which is easy to open for older users and difficult to access for children highlights a clear need for the packaging industry to develop innovative solutions for dual-purposes.

Ecobliss Holding B.V., a manufacturer of blister packaging, has already gone some way to overcoming this challenge and have developed the first ever child resistant cartons for medicine called Locked4Kids. The cartons contain hooks that must be pressed simultaneously to release the medicine and are located at a distance that is too far for children’s hands to manage. The carton is also coated with a tear resistant laminate so that children are not able to simply break their way in.

Similarly, ADENTS, a software developer based in France, has responded to some of the challenges presented by the new measures, particularly over the requirement to provide full traceability of a medicine. The company has produced its Pharma Suite solution that can identify and process all randomised serialisation numbers, quickly adapting to all types of existing packaging systems to ensure efficiency and maximum productivity while keeping costs to a minimum.

Addressing the challenges presented by the EU Falsified Medicines Directive will have some important implications for the industry. Firstly, it will be essential for packaging companies to work closely with their pharmaceutical customers to completely understand what is required of the product. A sense of collaboration during the development phase can help maximise on the expertise of the customer and ensure that the end-product aligns with their expectations.

Secondly, the industry must be mindful of the timescales involved. Manufacturers will have to act quickly to ensure they have adequate solutions in place to meet the new regulations as they are introduced, as any packs of medicine that do not have the unique identifiers will no longer be able to be sold within the European Union.

Moreover, even though the EU Falsified Medicines Directive takes effect in 2018, some of the large pharmaceutical companies such as AstraZeneca, Novartis and GlaxoSmithKline have already started to comply with the regulation. They will be looking to establish long term partnerships with suppliers now, and if the packaging industry is slow to engage with the pharmaceutical industry at this point, the sector could forfeit the opportunity to place themselves at the centre of a valuable market going forward.

The packaging industry should therefore welcome the EU Falsified Medicines Directive.

By providing a tamper-evidence seal and unique identifier, the consumer – in this case the patient – will benefit from procedures that aim to ensure their safety through the prevention of counterfeit medicine. It is also an opportunity for the industry to provide better solutions to functionality and forge better relationships with customers.

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Pharma Serialisation: Are we on the Brink of a Mass Extinction Event?

Many pharma companies are dangerously behind in their implementation strategies to achieve compliance with the new EU Safety Features regulations in the EU’s Falsified Medicines Directive (EU-FMD). 3C Integrity’s Ian Haynes, a thought leader in coding and serialisation for the pharmaceutical industry and formerly AstraZeneca’s serialisation expert, asks whether we are heading for a significant shake out in pharma manufacturing.

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here are thought to have been five mass extinction events in the history of the earth – sudden, catastrophic surges in the rate of extinction where, by some estimates, over 90 per cent of existing species are wiped out overnight - at least in geological terms. While there is debate amongst scientists about the causes of these events, each mass extinction leaves the world a profoundly changed place; previously successful organisms are wiped out, opening up opportunities for others to exploit.

The losers are soon forgotten, whilst the winners make the most of the freed-up ecological niches suddenly there for the taking. And this leads me to ask whether serialisation will become the cause of a mass extinction event in the pharmaceutical industry.

The bare bones of serialisation Serialisation is increasingly being adopted as a key weapon in the fight against counterfeit and illicit trade in pharmaceuticals. The provisions of the EU Falsified Medicines Directive, for example, have the potential to re-shape the situation in Europe. | 44 | Packaging Europe

From 2018 onwards, a globally unique pack identifier in the shape of a 2D data matrix code will be scanned in the pharmacy at the point of dispensing. It will contain the product code (and possibly national healthcare reimbursement number), the batch/lot number, the expiry date and a highly randomised serial number. Within a fraction of a second a series of automatic checks will be carried out against a Europe-wide medicines verification infrastructure of systems.

The dispensing pharmacist will get instantaneous feedback about the status of the product; can the unique identification of the pack be verified as genuine? Has it been previously dispensed and could it therefore be a counterfeit? Is it still within its expiry date or is it subject to a recall?

This represents an enormous step forward in terms of patient safety as stated in the aims of the European Falsified Medicines Directive, 2011/62/EU ‘Safety Features’ provisions. But achieving it requires a huge amount of work on the part of pharmaceutical manufacturers supplying the 28 EU Member Countries, whether they’re

original brand owners, generics manufacturers, contract packers or re-packagers or parallel importers.

However, this task cannot be avoided: complying with the EU-FMD requirements – and similar requirements in many other markets around the world – is now a capability that pharma companies have no choice but to master. Those who don’t and fail to meet these requirements in time will, by definition, go out of business – they will be driven to extinction.

Not a bolt from the blue The last, and best known, of the five mass extinction events that have occurred throughout history is the Cretaceous-Tertiary (or K-T) event that wiped out the dinosaurs. As to the cause of this mass extinction event, there are many different theories, but it’s the impact hypothesis that is most popular.

Researchers agree that a major factor triggering this extinction was an asteroid about 10 kilometres in diameter, striking what is now the Yucatán peninsula in Mexico; a catastrophic event, sudden and completely unforeseeable. The dinosaurs did not see it coming, and even if they had had a warning, there was nothing they could do.

However, unlike the dramatic appearance of a meteor in the sky - a literal bolt from the blue - the legislation now confronting the industry has been a long time in coming indeed.

In the EU, in particular, early discussions started in the middle of the last decade and the direction, likely scope and shape of the requirement in the EU has been there for all to see since the EU directive 2011/62/EU became law just over three years ago. The industry has had plenty of warning, and plenty of time to prepare and act.

Driven by earlier similar compliance requirements in markets such as Turkey and China, companies such as AstraZeneca, Roche or Boehringer-Ingelheim - the big beasts if not dinosaurs of the pharma industry - have well-established implementation programmes in place. They find themselves in the relatively comfortable position that - with considerable additional time, effort and investment - they will be able to meet the requirements of the EU-FMD, the US Drug Supply Chain Security Act (DSCSA) and the many other requirements announced or anticipated in a steadily growing numbers of global markets.

But if we look at the smaller pharma companies, a very different picture presents itself.

True, there are mid-sized and smaller firms that have embarked on the march to compliance and have put credible implementation programmes in place; some, even, who are positioning themselves not just to survive the coming storm, but to be ready to pick up the business of those who have not moved and will go under.

However, observers of the industry agree that these companies are still in the minority.

There are many companies, particularly in some parts of Europe, who are still not moving forward fast enough, and others not at all, despite having all the means at their disposal to take action, get ready and prepare.

What is clear to the observer - if not the decision makers in charge - is that these companies are wilfully or unintentionally putting their businesses at risk. The question one might ask is: Will this lead to a significant shake out in the industry - and maybe even a mass extinction event?

Many companies seem to be in a state of denial regarding the requirements, despite recent updates from the European Commission via Europe Direct, the European Union (EU) information service that gives the clearest indication yet when the Delegated Act is to be expected.

The Commission has stated it aims to adopt the Delegated Act by the end of 2014 with publication in the OJ (Official Journal of the European Union) in the first half of 2015. This sets the three-year compliance clock ticking and gives manufacturers the unambiguous message that inability to comply will prevent them selling their non-compliant products in Europe.

Some companies are hoping for a soft start to the requirements in Europe, but again the EC has made it clear that the three years between the issuing of the DA and the compliance date is to be considered enough of a transitional period, so only products that comply fully with the EU-FMD requirements can be manufactured and supplied to any of the 28 Member States (or the estimated 25 member states with no equivalent safety features) after the compliance date of early 2018.

That message should be clear enough, yet it still seems not to be heard everywhere. To many smaller companies, 2018 still seems a long way off and they are banking on their agility to enable them to implement their serialisation programmes much more quickly than the published timescales of the ‘dinosaur’ large company early adopters.

Learning from history Ignoring the experience and warnings of the early adopters, however, is dangerous – and whilst smaller companies may be able to move more quickly, they will have problems of their own that will slow execution.

Another barrier to implementation arises out of the way the message is – or is not – being circulated within the industry. Looking at the guidance and updates being given to the industry via information events, one sees a pattern in some markets where wishful thinking, a lack of focus by industry associations and preoccupation with other (admittedly important) aspects of the EU-FMD combine to dilute the message that urgent action is now required and unavoidable.

Add to that the complex politics being played out between different participants in the industry, as they fight to protect their interests, the observer wonders if winning a skirmish in the short term can warrant losing the battle for survival in the long run.

History shows us that Mass Extinction events generate losers but also winners. Pharma companies who want to be the latter need to get onto the ‘front foot’ with respect to serialisation; those that recognise that it is now a core capability will have the potential to survive and even flourish, taking advantage of the niches that open up as companies who have not understood the urgency of the need to act are forced to abandon some of their business.

It seems likely that a number of established businesses today will not survive serialisation other than in the fossil record. But unlike the impact of the K-T event, it appears as though the approaching Pharma Serialisation Mass Extinction Event may count the Big Pharma beasts amongst the survivors, while at least some of the smaller companies – whose size and agility should predestine them for success in responding to gamechanging challenges - will this time be counted amongst the losers.

Breaking down the barriers So why, then, is there this apparent brinkmanship on the part of some, mainly SME pharma companies, in the face of serialisation requirements? After all, serialisation is a compliance requirement and as such a core capability for all pharma manufacturers who need to maintain their license to operate.

But it seems, when it comes to serialisation and traceability requirements, that things are different - why?

Uncertainty is often cited as a key barrier. Until the publication of the ‘Safety Features’ Delegated Act expected later in 2014, managers can hide behind the lack of certainty as a reason not to act. This is particularly noticeable with regulatory managers whose inability to deal with the ‘shades of grey’ in serialisation requirements effectively prevent projects getting off the starting blocks.

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Focus on packaging printing The last year has seen a wide range of innovations in the packaging printing industry, from printing onto glass, folding cartons and corrugated to digital label printing and waste and energy saving solutions. Elisabeth Skoda picks out some of the highlights.

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ccording Smithers Pira’s report “The Future of Package Printing to 2019”, the global package printing market registered a positive growth of four per cent between 2012 and 2013, reaching €370 billion and is forecast to advance at an annual average rate of seven per cent over the period 2014–19. Flexography is the most used process in package printing, followed by offset and gravure. Digital printing is forecast to show by far the highest growth rate, at an estimated 17 per cent per annum between 2014 and 2019.

Digital label printing press innovation Switzerland-based Gallus Group presented a new generation digital printing press for labels at the “Gallus Innovation Days 2014” at its headquarters in St. Gallen in the autumn.

At the event top specialists revealed the latest trends and technical developments in narrow-web label printing. Mark Hanley, President of IT Strategies, explained the importance and impact of digital printing in the label business, while Jason Oliver, digital printing manager at Heidelberger Druckmaschinen AG, predicted a fundamental change in the printing industry over the next few years as digital printing takes hold in print shop pressrooms.

The new Gallus DCS 340 digital inline label printing system (DCS = digital converting system) with its native resolution of 1200 dpi, print speed of 50 m/min and maximum | 46 | Packaging Europe

register accuracy was unveiled. This digital press is the result of a co-project involving Heidelberger Druckmaschinen AG and its expert partner in inkjet technology, Fujifilm, in response to the ever greater demand for short runs and customised or versioned labels.

These trends have inspired a growing willingness to invest in digital print technology that enables Gallus to tap into new growth potential in this particular segment.

“We are not going to stop at the current printing speed of 50 m/min,” reveals Stefan Heiniger, COO Label Business, “but want to improve even further upon what is already a very decent rate by the time the Gallus DCS 340 goes to market a year from now. Our aim is to create the most attractive digital printing system on the market.”

Folding carton printing A major hub for innovation in the area of packaging printing was the Emballage trade fair in Paris in November 2014.

For its first time attendance at Emballage, Xeikon showcased its enhanced Folding Carton Suite that now offers a basic press configuration where the print stations are equipped with orange toner, in combination with CMYK. The extended colour gamut achieved with this configuration ensures the accurate production of a wider range of brand colours. Producing folding cartons digitally is perfect for specific seasonal packaging,

intensive test marketing, just-in-time delivery contracts and customisation of shorter runs and appeals to smaller geographic and demographic market segments. With the Folding Carton Suite, Xeikon offers a ready-to-use package, making it easy to configure an efficient and cost-effective set-up for the digital production of folding cartons. It is the ideal solution for packaging converters who need to add high quality cost-effective short runs of folding cartons to their mix of offerings as well as for commercial printers looking to enter the packaging market.

“Eager to provide the best end-to-end digital printing solutions to the market, and address the changing needs of brand owners and packaging converters, our Folding Carton Suite allows to digitally produce the same high quality packaging but for a whole range of new applications, allowing them to build new revenue streams with higher profit margins,” says Filip Weymans, director segment marketing and business development, Labels & Packaging at Xeikon.

Print quality and waste saving Also at Emballage QuadTech showcased print quality and waste saving solutions for packaging printers and converters. Karl Fritchen, president, QuadTech comments: “Brand owners are becoming more and more demanding when it comes to colour quality and controlling costs. In today’s market, having a firm grip on your margins is essential to success.”

Stephan Doppelhammer, QuadTech’s marketing manager for packaging, speaks about industry trends: “We observed a growing demand for absolute repeatability from press to press and plant to plant, with documented proof of print quality results. This stems from the globalization of brands and the desire for a consistent image worldwide. Here, there is also the demand for higher quality and faster turnaround times, as well as the pressure to fulfil shorter runs. Another trend and challenge is the expanding range of complex and problematic substrates, especially for flexible packaging converters using transparent and opaque

films. These thin and reflective materials often lead to tension variation and print quality is difficult to measure. When faced with these challenges and trends, it is paramount that converters do everything they can to maintain high productivity and efficient workflows to maximise profit margins.”

Offering an integrated solution for colour control, the QuadTech® Colour Quality Solution utilises the expertise of QuadTech, X-Rite and leading ink manufacturers. The system combines inline spectral colour measurement, ink formulation data and ink dispensing technology to ensure accurate colour matching. Customer-defined colour targets are prepared and a spectral colour curve is created and loaded into X-Rite’s Ink Formulation software, which creates an ink recipe. This recipe is added to a colour database that then feeds information to the dosing machine for preparation of an ink can, ready for the press.

The colour targets are loaded into the QuadTech Colour Measurement System with SpectralCam™ which collects and maintains live spectral data inline, at full press speeds.

Deviations, measured in Delta-E values, are captured and the spectral data sent back to the X-Rite Ink Formulation software via a CxF file. This automatic measurement and reformulation maintains colour quality while reducing waste and downtime.

Quality assurance is also guaranteed with the QuadTech Inspection System, which inspects 100 per cent of the web 100 per cent of the time. The system can be used with opaque, translucent and transparent substrates as well as on reflective materials, and detects process faults (streaks, hazing, colour variation and mis-register) as well as random defects (spots, mis-prints, hickies).

Possibilities for digital printing on corrugated Attractive, well-designed and innovative packaging adds to the customer appeal of health and beauty products by reflecting their opulence – a marketing advantage that can be further enhanced thanks to pioneering printing technology available to the corrugated industry.

Digital packaging is growing, due to its ability to provide high quality, variable graphics with short lead-times and lower stock costs. Image is critical for personal care goods.

Packaging Europe | 47 |

Protection, brand identification and differentiation are all key elements for packaging and exert a significant influence on purchasing power.

In order to cater for this, SUN Automation Group® launched state-of-the-art, costeffective digital printing equipment that allows corrugated to move away from traditional specifications for cosmetics. With CorrStream®, corrugated aligns more closely with opportunities for unique and customised packaging that engages consumers with eyecatching colours, seasonal and promotional strategies.

SUN Automation’s range of new digital printers – CorrStream 66, 40 and 20 – provide the corrugated packaging industry with higher output, reduced operating costs, efficiency and better print quality. This presents inkjet as a real alternative to conventional analogue methods for mainstream applications.

CorrStream brings an extra dimension to brand owners and retailers through the print on demand of high quality, colourful shelf ready packaging (SRP) in smaller batch runs. Without a minimum order requirement, state-of-the-art, cost-effective digital printing equipment helps corrugated to accommodate seasonal, regional or event-based promotions.

SUN Automation’s global product manager for CorrStream, Sean Moloney, said: “This equipment brings corrugated in line with other packaging formats for the personal care industry – if the perfume label can be customised so can the outer box. Revamping packaging for beauty products has never been easier.”

Thermal inkjet coding and marking Speaking about trends in the packaging printing industry Mr. Neuschäfer, managing director at REA Elektronik lists Industry 4.0 demands on data exchange between devices without any further adjustments as well as the replacement of many continuous ink jet systems that are still widely in use.

In all sectors, the trend towards ever shorter product cycles is unbroken. Flexible production with modularised components is therefore becoming increasingly important in the area of coding and marking. This is incorporated in the development of new coding | 48 | Packaging Europe

and marking system REA JET HR 4K by REA Elektronik: The high-resolution thermal inkjet printer offers a print height of up to 50.8 mm, can be adapted quickly and easily to any requirement and it can operate under humid or dusty environmental conditions.

With the expansion of its HR series REA JET has responded to the demand for more printing height in the field of product marking. HR 4K can be equipped with a total of four print heads, each generating up to 12.7 mm in print height. The variable printing of up to 50.8 mm in height, for example, is asked for when marking of packaging has to be well legible to the human eye as well as automatically readable when barcodes and data matrix codes are printed.

The REA JET HR 4K is based on the well proven HP printing technology. The thermal inkjet technology with its proven track record in the office field has now established itself in the factory, replacing many continuous inkjet systems.

Technologically advanced printing At their Print Technology Centre in Offenbach in Germany, Manroland Sheetfed GmbH unveiled the new ROLAND 700 EVOLUTION press. The latest generation ROLAND 700 incorporates many new technological developments and enhancements, aimed to give printers unprecedented levels of efficiency, productivity, operation and quality.

Manroland Sheetfed CEO Rafael Penuela said: “The ROLAND 700 EVOLUTION is the latest ground-breaking new press which we believe will be yet another milestone in the evolution of print technology.”

The newly designed central console with state-of-the-art touch-screen panels give detailed graphical information in a user-friendly interface offering enhanced operation, flexibility and comfort, with options for left-handed and right-handed operation as well as customisation for different operator body heights. The new feeder pile transport brings appreciable productivity benefits with smooth upward motion of the pile-carrying plate and highly improved sheet travel from the feeder to delivery. This leads to fewer interruptions, less start-up waste and reduced walking distances to the feeder.

Solid fixing of the suction head reduces vibration and wear while ensuring safer sheet separation and higher average printing speeds.

The brand new press also boasts completely redesigned cylinder-roller bearings. Separate bearings for radial and axial rotation provide better absorption of vibrations with fewer doubling effects and ultimately, much longer bearing life and significant improvements in print quality as well as a new three-phase AC motor which combines highest power output with lower energy consumption.

Printing on glass The current trend towards personalised packaging is not the only reason for the growing popularity of digital glass printing. Digital printing is a broad field. Both UV-curable inkjet inks, suitable for fast and clean print results on glass and PET bottles, and Marashield liquid coatings proved very popular. At Glasstec 2014, Marabu presented screen, pad, and digital printing inks for the glass industry.

The enquiries at Marabu’s stand at this year’s Glasstec underlined the current trend in the glass industry towards UV-curable primers, including combining them with hot stamping, and digital glass printing solutions, especially full coverage of glass surfaces using roller-coating with the new Marashield UV-CGL shades. Marabu has positioned itself as a strong partner for both digital and analog methods.Hot stamping with UV inks to create glossy gold and silver effects.

Marabu also presented an alternative to high-cost ceramic inks to achieve glossy gold and silver effects – hot stamping with UV inks. The visual is screen printed on the glass surface using Ultraglass UVGL primer, and also functions as a hot stamping cliché. The foil adheres to the UVGL primer-treated areas. The result is high-gloss gold and silver effects at a significantly reduced cost. Marabu also showcased the solvent-based MGL Maraglass screen printing ink and TPGL Tampaglass for pad printing. MGL is suited to high-gloss decorative printing on flat glass or on curved surfaces. TPGL inks are highly versatile and durable. Both products can be used on a wide range of substrates, and feature brilliant, precise shades.

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From Chaos to Control:

Transforming the Packaging Industry with Colour Management

By Patrice Aurenty, business leader, Colour Management at Sun Chemical.

Patrice Aurenty, Business leader

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rand owners are constantly looking to secure a productive, dependable and profitable value chain from their suppliers. Central to this value chain is the package printer, and for the package printer, consistency of colour output is one of the most critical factors. That and being logistically located for ease of supplying the package to the brand owners’ facilities.

Due to the high cost of printing technology, as well as the amount of space and training required to operate it, colour specifications communicated from the brand’s designers have traditionally been handled by experts within the value chain.

Harmonisation of colour for brand integrity Naturally, brand owners strive for a harmonisation of colour across all substrates, applications and geographies to communicate their brand equity consistently to consumers on a worldwide basis. However, this is often very difficult to achieve, not just in terms of the accuracy of colour management itself, but also due to regulatory issues, logistics and economics all being incohesively managed.

In addition, the complexity and high cost of investment in new product development also acts as a barrier to innovation, which is so vital in the competitive FMCG market. This is especially significant when taking into consideration the cost of reworks required to secure colour consistency to safeguard the integrity of the brand.

In the packaging industry, regardless of the vertical market, the same business issues float to the surface in most discussions with brand owners and their suppliers. Brand consistency across formats, substrates and geographies is a business-critical objective, tied in with the desire to streamline processes, introduce efficiencies where possible, manage cost by eliminating waste, and accelerate time to market.

Without a doubt, colour inaccuracy and inconsistency can be major causes of delays and bottlenecks in the process. The universe of different individuals involved in reviewing and approving colour for a particular job can be vast and geographically disparate, making it hard to communicate effectively and get a grip on something as slippery as ‘correct colour.’ | 50 | Packaging Europe

Of course, the packaging community has taken steps to take out the guesswork around colour. In the field of process colour, that has mainly been a question of introducing and enforcing standards such as ISO for the participants in the supply chain to adhere to.

The difference is that the colours are created by mixing them on the press rather than pre-mixing as a spot colour. Here the requirement is for the ink manufacturer to produce inks to the colour specification set that meets the standards for the appropriate printing technology in ISO2846.

Then the converter must set up and control their press in line with ISO12647 and profile the press so that the colour created from it is both measurable and predictable.

This enables the creation of a good quality and consistent image that matches the original brand owner design.

The science of colour management Where spot colours are concerned (and that’s often a key consideration for brand owners with their brand- or product-specific colour palettes), the challenge has been greater. The Pantone book remains the default reference for spot colour. Yet in practice, ‘colour management’ is often a mix of gut feel, operator experience and the somewhat inconsistent use of measurement tools and samples of uncontrolled origin representing the standard where the Pantone guide is unavailable or not specified in the first instance.

When trying to map colour management processes in many packaging supply chains today, the picture is pretty chaotic, with inter-communication going in many directions, and often around in loops of approval and re-approval.

It’s a recipe for error, inefficiency, and excess cost.

Of course, there are readily available software tools for colour management, but the challenge remains that they are often deployed inconsistently by individual links in the supply chain, looking more like disconnected islands of solutions than an industry standard reference.

What is more, they may be supplied by small entrepreneurial software developers with good technical credentials, but without the infrastructure and expertise to support the deployment of products across large global companies and multiple disciplines (design, pre-press, converter, etc.).

While colour management software might remedy the problem at one site, it fails to address the wider issue. In order to take the guesswork out of colour in packaging, every participant in the supply chain must be working from the same, scientific point of reference: the spectral data of a colour.

The solution lies in the DNA of colour Happily, there is a remedy for the chaos, and the prize is worth having. Far greater efficiency, streamlined product delivery, and optimal colour accuracy and consistency across different packaging types, and from country to country. Colour is not subjective; every colour that can be printed can also be measured, and its characteristics stored as a spectral curve that acts as the “DNA” of the colour and serves as an exact specification for further reproduction.

There is a supporting system that enables printers to reproduce any colour as faithfully and efficiently as possible, whether on paper, board, film, plastic or any other substrate that can be thought of.

The key for such a system is to develop multiple libraries of colours that cover the majority of substrates used in the packaging industry, including corrugated kraft, transparent and white films, laminated films, carton board, paper and labels.

These libraries can capture the spectral curves of any colour on the relevant substrate – from a physical print– and hold it in a database on the cloud, which can be referenced at each step of the packaging workflow when a brand owner needs to reproduce that colour. The additional key enabler is a digital color communication tool that can link every part of the packaging workflow and share this color “DNA” with every participant.

The brand owner specifies the right colour digitally. The designer creates the design file using that exact same colour signature. Prepress adapts the file to the specific printer configuration based on that same colour spectral curve. The ink manufacturer matches spectrally the right ink to that digital colour specification. The printer ultimately reproduces the colour on the final product and controls its quality by comparing directly to the original colour spectral curves, as specified by the brand owner. This closes the loop for a seamless colour approval process. Furthermore, this type of system allows everyone to work from the precise and unique colour definition stored on the cloud and enables users to operate seamlessly in a fully digital workflow. Accurate output can therefore be produced that will match the original specifications established from real colours on real substrates.

This tool has the scope to remove the margin for error in colour reproduction from one packaging material to another, and to bring about a far greater consistency through brand families and across multiple territories where substrates are often inconsistent.

Implementing colour management throughout the workflow However, the key to true colour management is to deploy this science right through a particular packaging production workflow by ensuring that all participants in the process are working, communicating and ultimately printing with the same colour data. This type of solution completely overturns old colour management practices by delivering significant, quantifiable improvements for brand owner and their suppliers.

Total colour management in packaging is no longer the elusive Holy Grail – the data and the systems are already here that make it a reality. The packaging supply chain has actively embraced the potential of digital technology in so many other areas of the workflow, but colour somehow remains a magical element which too many packaging printers still prefer to leave to visual evaluation by “experts”– with a heavy cost to all parties.

By applying logic and science to the magic, digital colour management has the power to answer the prayers of brand owners.

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The Big Interview Marco Mensink, director general of the Confederation of European Paper Industries (CEPI), talks to Tim Sykes about developing the breakthrough technologies that will enable the paper industry to hit carbon reduction targets while remaining economical.

TS

CEPI’s Forest Fibre Industry 2050 Roadmap poses the question of how to achieve 80 per cent reductions in fossil-based CO2 emissions while creating 50 per cent more added value. In what context were these targets set?

MM

In March 2011, the European Commission published the EU ‘Roadmap for moving to a competitive low-carbon economy in 2050’, a discussion document to explore the future of climate change policy. The CEPI roadmap attempts to lay out the future of the forest fibre industry and its potential to meet emission reduction in line with the modelled overall industrial reduction of 80 per cent by 2050, compared to 1990 levels.

It is the start of a wider debate and has grown into a platform for the industry to discuss the future. We have clearly built upon the European Commission’s document and our Roadmap has been embraced to the extent that we have already distributed 7000 copies and several print reruns. It has been present on every management table throughout the industry within the last two years.

The CEPI Roadmap concluded that the breakthrough technologies the industry needs in order to meet an emission reduction of 80 per cent by 2050 are not available today.

To achieve an 80 per cent CO2 reduction, breakthrough technologies would need to be developed and available by 2030. 2050 is two paper machines away, meaning two investment cycles maximum. A reduction of 50 per cent CO2 by 2050 is possible in the right circumstances, however the industry needs to be able to invest to make the changes and meet the targets.

TS MM

What are the implications for the paper industry if the targets are not met?

There are a lot of ‘ifs’ depending on the predictions of the European Commission. Of course, no one predicted the economic crisis, and no one is certain what the future European economy will look like. We clearly included the targets as a goal to work towards but also acknowledge that these are based on a reality that might or might not be in the future.

However, it is clear that the climate change agreement is still moving forward. The European Commission just set a minus 40 per cent emission reduction target by 2030 in-

| 52 | Packaging Europe

line with its aim to achieve a minus 80 per cent target by 2050. It is clear to us that if the rest of the world does not come along, the second part of this period will see very heavy debates in the developments between the competitiveness of European industry vis-à-vis global obligations.

What happens if we do not manage our energy intensiveness over the years? There is awareness within the industry that if we do not tackle our energy intensity, we will face an uphill battle for years to come. We will become uncompetitive with regards to cost compared to other materials, or other regions in the world. There is no clear penalty yet, but the carbon cost and the energy cost will increase, and in order to stay in business we need to improve. The industry needs to use technologies that will not only decarbonise, but also add value or reduce costs.

TS

One of the conclusions CEPI reached was that breakthrough technologies would be needed by 2030 in order to achieve the targets. Are you able to quantify the gap between gains we expect to make through resource/energy/conversion efficiency and the 80 per cent target, which must be bridged by new technologies?

MM

An important point we have made to the policy makers is that they have to understand the way investments work in this sector. In the past, policy never really considered how investment cycles in the industry work. The investment into a paper machine will be there for 20 to 30 years. So efficiency can indeed improve over the years but the major share of the energy consumption is pretty much fixed from the moment the machine is bought.

The old equipment of today will either be out of business or replaced by 2050 and as long as industry keeps investing in Europe by upgrading and replacing; efficiency will improve. The same will happen through ongoing consolidation.

You can already see the efforts we are taking as we have reduced absolute emissions by 22 per cent since 2005. This is partly due to a shift towards the use of biomass, or of combined heat and power. The fuel mix used now is slightly more than half biomass based, 40 per cent natural gas and CHP, four per cent oil and four per cent coal. That is around the limit you can now reach in Europe for fuel efficiency.

The next step to be taken is that the electricity grids should also be decarbonised. Then there is still the breakthrough technology gap left which needs to bring the difference from the minus 50 to the minus 80 reduction. For some of these technologies, if they were implemented throughout the entire sector you would see possible carbon reductions of 20% and energy reductions of 40%.

TS

CEPI organised the Two Team Project as a means to identify areas where breakthrough technologies could be developed. Why the concept of two competing teams and where did they look for inspiration?

MM

We thought that with only one group investigating, we would end up with something like a consultant’s report. We were looking for a way to keep up the enthusiasm in the sector and to get the best ideas out. Two competing teams was a new concept to the process and a way to challenge people. Both were unaware of each other’s activities until after the jury’s decision.

Paper producers, suppliers, customers, and complete outsiders were spread between the teams and we specifically broke existing links between them to encourage the competition. We held our meetings in unusual places such as in Atomium in Brussels. This added to the success of the project and raised awareness.

The teams were left to develop their own ideas, on the condition that they delivered their concepts (not specific technologies) within a year to the jury and demonstrated a broad Packaging Europe | 53 |

idea of how to turn the sector around. They were asked to investigate both the value and carbon reduction, and to quantify the results in the same manner as the other team.

The logical step was to look at technologies that can alter the papermaking process, which is where the biggest loss of energy through water evaporation occurs, and the biggest use of energy occurs through the pulping process (either by cooking or grinding).

TS MM

Could you tell me about some of the most interesting concepts that were generated from the project?

Many of the approaches looked at how natural or technological processes distinct from our industry could be applied to paper making. The first concept is using Deep Eutectic Solvents, which are produced by plants to protect against water stress.

We tracked down a professor who was studying this and she explained that DES could dissolve biomass at room temperature into lignin, cellulose and hemicellulose in half an hour. This came as quite a shock to the industry, raising the prospect of significant energy savings in the pulping process.

The technology is already operating at a laboratory scale and the promise is such that 17 companies have formed a consortium. All the big industry players have come together for the first time in history to pay for two PhD students to develop this further. It is a completely new breakthrough pulping technology using biomass. Mimicking nature has the potential to take out 40 per cent of the energy consumption of the sector.

A second concept looked at DryPulp for cureformed paper. Here we again looked at mimicking nature. When Penguins swim, air-bubbles are formed on their feathers, reducing friction in the water and speeding them up. The Russians copied this concept for their torpedoes and Boeing applied it to its Dreamliner. In papermaking bio-based substances could be used to modify the viscosity around fibres. Combined with cureforming, which allows the formation of a thin sheet, it is possible to produce the sheet as a layered product, in response to demand for certain properties and with the means to add new functionalities, while drastically reducing the amount of water needed. | 54 | Packaging Europe

A third concept is Supercritical CO2, which is neither liquid nor gas. This is used in the decaffeinating coffee process and also by clothes manufacturers, where liquid C02 is used to dye fabrics – and to dry them as it evaporates. This is another technology that eliminates water and it can be applied to paper production as a means to dry pulp and paper without the need for heat and steam, as well as dyeing paper and removing contaminants in the same process.

TS

Some great ideas emerged from this project. How does the industry and society as a whole make sure further R&D takes place with the necessary investment behind it? What has happened in the 12 months since the teams reported back?

MM

CEPI ended up owning patent applications. We were able to publish our findings and we licensed out all the rights. We built consortia around most of the concepts, either through carrying out research or developing projects for co-funding by governments.

The transformation process over the next fifteen years is something we are looking into.

It could be very small companies coming in and pushing big companies off the market or very big companies owning the technology and not allowing small ones to compete on the market due to capital cost. All of those processes will determine which technology will win in the end and we think we will see a mix where not all of the eight winning concepts will make it to the finish line. It will ultimately be the market that decides.

We have taken the next step by developing the consortia and at CEPI we are focusing on innovation policy and how governments can support projects. In the past Europe was very good at supporting research, but when it comes to developing pilots and demonstration plants, these tend to be invested in elsewhere, such as the US. The role of CEPI now since the Two Team Project is to help create funding opportunities and keep these technologies in Europe. Alongside other sectors, the Biobased Industries Consortium has been built to develop pilots, demos and flagships. It is worth 3.8 billion euros (one billion euros paid by the European commission). This is a big step forward and

we are now looking to the next round of funding for after 2020 to continue the development of these ideas.

The risk to a company to be the first one using a completely new technology is enormous. Which company wants to take that risk? There is a good example in the steel industry which has also developed breakthrough technology. One of those technologies is at Tata Steel in the Netherlands. The big question is will it be developed here in Europe or in India where there are growing markets.

The biggest hurdle for the industry in Europe is to safeguard and ensure breakthrough technologies are developed here on European soil. To ensure this we need to work very closely together with governments and continue to look into EU innovation policy and national innovation policy.

TS MM

Apart from the particular technologies the teams considered, did they come to any conclusions about changing the industry’s approach?

In the packaging industry corrugated board is bought by the square metre, whereas paper is bought by the tonne. If you look at the technology of lightweighting as an example, when you make the paper lighter it is beneficial for the environment, however the specific energy consumption per tonne increases.

So in this case, if you calculate in tonnes only, you cannot see the benefits of the innovation. Therefore, perhaps tonnes are not the best measurement. Selling by the square metres and according to functionalities may be more appropriate. In the end the paper industry should not be producing tonnes, we should produce value.

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Innovation is key to the aerosol sector Despite the recent tough economic climate, the aerosol sector has remained buoyant and has consistently introduced innovations in its design and packaging that keeps the format fresh and modern, contributing to the continued success of aerosols. The British Aerosol Manufacturers’ Association (BAMA), which represents the industry and has approximately 80 members ranging from fillers, marketers, valve suppliers, can makers, ingredient and machinery suppliers and consultants, shares the latest trends in the aerosol industry with Packaging Europe and highlights some of the best innovations to hit the market in recent years.

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ccording to BAMA, the trend in recent years towards use of aluminium has continued with now a virtual 50:50 split between aluminium and tin-plate for aerosol manufacturers. Significant areas of growth were air fresheners, already an important category, some personal care segments, hard surface household cleaners and industrial aerosols. Following two years of strong growth year on year in 2013, 1466.5 million cans were filled in total within the UK. The UK fills the most aerosols in Europe.

A retailer perspective At the recent BAMA forum 2014, discussion circled the future of aerosols from a retailer perspective. Clare Norman, Waitrose Technical Manager for Household, Baby & Pets, was invited to share her opinion and advocated that it’s all about working collaboratively with aerosol suppliers trying to see through the retailers’ eye. She represents Waitrose on The BAMA Retail Liaison Group which consists of technical representatives from many of the UK’s major retailers including several of the largest grocery, pharmacy and DIY groups.

“Our customers expect us to offer something different, so our suppliers need to think of the bigger picture. One way for suppliers to succeed is by offering us something exclusive in the UK - perhaps selling the same concept in Europe but allowing us to offer that point of difference here,” she advised.

Ms Norman’s presentation at the annual BAMA Forum covered a number of retail topics including the importance of keeping the aerosol offer compelling, to keep up with customer expectations, through differentiation whilst minimising the impact of legislation and environmental perceptions. Highlighted challenges faced by the retailer and aerosol manufacturers, included the transportation of aerosols becoming more complex and the requirements of additional legal text on product. | 56 | Packaging Europe

Ms Norman said that new initiatives in aerosols will always be considered if the offer is compelling. “The challenges of increased and complex legislation regarding the transport of aerosols from the EU can be viewed as beneficial to UK manufacturers of aerosols selling in Britain,” she told BAMA members and their guests at the Forum.

The presentation also stressed that retailers were now keen to help act as the customers’ conscience. “The industry should all play their part in promoting to consumers that empty-aerosols are recyclable by looking to carry the message on packs and in-store,” Ms Norman advised.

Dispensing control Advancements in design and technology have allowed for new innovations to change the face of dispensing, enhancing both consumer convenience and ease of use. Aptar Beauty & Home has for example developed ‘Runway’, a dual action trigger accessory.

The new actuator offers consumers a choice of spray action, either vertically or via the trigger for maximum ease of use. The company advises that the standard vertical actuation is suited for short, precise applications whereas using the integrated trigger is the most convenient choice for longer use. Aptar says that Runway gives better dispensing control with its dual spray actuation feature and, combined with their Bag-on-Valve technology, allows the flexibility of 360° actuation. The company claims that this new dual action trigger offers multiple benefits across many product applications including: sun care, body lotion, hair sprays and cleaning products.

Runway can be locked securely utilizing Aptar’s integrated twist-to-lock technology.

The lockable system with non-removable pieces provides portability for transport and the bold and distinctive look helps shelf-appeal as the two colour option enhances brand differentiation.

Packaging differentiation is enormously important for hair styling and sun care brands and ease of use through the dispensing function is key. An innovative example is the Aptar’s Jazz Aerosol, characterized by a unique design for ease of use when spraying. The directional spray nozzle offers many insert options to enable fine-tuning. No hood is needed because of the convenient twist-lock with audible click.

The dispensing of a product can also be improved through the latest technologies, by offering 360 degree use. Colep achieved a ‘Special Distinction’ accolade for its Natural Foaming Cream with CO2 – which launched at the Aerosol & Dispensing Awards in Paris earlier in the year.

The Natural Foaming Cream product is a new organic aerosol cream and has foaming properties which result from the addition of CO2 to the formulation using a special mixing technology. This Bag-On-Valve product uses compressed air as the propellant, with CO2 directly added to the formulation, creating a gentle foaming cream. The product is not only propelled by compressed air, but also has Natrue certification, recognising its organic formulation. The aerosol pack brings its own generic advantages which include an extended shelf life, protection from oxygen and light due to it being hermetically sealed, portable and durable.

The Bag-on-Valve Aerosol brings additional advantages, mainly in the form of extended preservation, due to the separation of the product from the propellant, as well as 360 degree use. Colep says that this application answers the need not only for new textures, but combines product innovation, (through technology), and a sustainable approach, recognised by its Natrue Certification.

Design and functionality The last ten years have seen an array of design ideas and functional benefits hit the shelves across markets. BAMA highlights that Swallowfield turned aerosol cans on their head by introducing a change in the usual cylindrical shapes and Alcan’s Transfer Can incorporated the visual appeal of aluminium with the benefits of seamlessness and rust-resistance, and could be assembled with most standard caps and closures used on tinplate cans. The advantage of the new cans was that they could keep the same cap or closure across a product range where aluminium and tinplate were both used.

Crown Aerosols Europe launched an easy-to-grip shaped aerosol for SICO’s KING tyre repair and inflator which included an image of a tyre pressure gauge embossed on the front of the pack. In the same year the CosoCan® launched with The Lindal Group and Unilever involved in the development where laser seam welding was used for the first time

in large-scale production. Welding the cap, body and bottom of the can with a laser created a particularly smooth transition at the joints and produced a high premium finish. The new technology enabled the production of small can diameters of less than 10mm, and opened up new markets for tinplated steel.

Beiersdorf UK Ltd introduced the Spray Plaster and in conjunction with Colep Ltd, launched NIVEA VISAGE Oxygen Power which, for the first time, formulated oxygen into a cream. This was achieved by perfecting a bag-on-valve system technology that ensured the oxygen was contained and protected within the aerosol until dispensed.

In the same period, Unilever’s Lynx presented a new ‘twist’ mechanism for its male grooming brand.

Less is more Ball Corporation announced a metal technology breakthrough that enabled the use of recycled aluminium in the manufacture of extruded aluminium packaging for aerosols. The resulting new metal alloy exhibited increased strength and allowed light-weighting of the container without affecting package integrity.

Unilever’s recent ‘compressed’ can innovation resulted in half-size deodorant aerosol cans that last just as long but which it was claimed have on average a 25 per cent lower carbon footprint per can. The launch of the range has meant 50 per cent less propellant gas and 25 per cent less aluminium per can, 35 per cent reduction in transport emissions and 53 per cent more products on a pallet. Albedo100 launched a Reflective Spray designed with safety in mind, enhances visibility in low light.

The compressed aerosol can technology which caught the attention of the BAMA judging panel, making it the Aerosol of the Year 2013, has recently been extended across its entire range of male deodorant brands including: Sure Men, Dove Men+Care, Lynx and Vaseline Men variants. Launched in February 2013, with the simple consumer proposition ‘lasts as long with less packaging’. The launch of the range has resulted in 50 per cent less propellant gas and 25 per cent less aluminium per can, 35 per cent reduction in transport emissions and 53 per cent more products on a pallet. Unilever originally launched the range of compact aerosols within the women’s Sure, Dove and Vaseline brands.

Aerosols is clearly a packaging type rife with innovations in materials, technology, design and functionality. Dr John Morris, Chief Executive of BAMA concludes, “As an association, we are proud to see impressive and exciting innovations.”

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Protecting Your Packaging With competition increasingly fierce in every sector, companies know that having a brand that is both recognised and well-regarded is critical to success. Familiarity breeds content, as one saying goes, and busy consumers often plump for a recognised brand, believing it will be reliable, rather than always looking for the cheapest – writes Jackie Maguire, CEO, Coller IP.

IT

makes sound business sense to protect the brand, and its underlying intellectual property, especially as over 80 per cent of most companies’ value now stems directly from intangible assets.

Design, branding and trade dress (characteristics of the visual appearance of a product or its packaging that denote the source of the product to consumers) potentially contribute greatly to increasing the value of an organisation’s intangible assets and its intellectual property.

Packaging is of course a vital way to explain, represent and enhance a brand. However, branded packaging, as has been well-reported, is under threat both from legislation in the form of some products – notably cigarettes – perhaps being required to be sold in plain packaging, as in Australia – and from illegal copying which can detract from the value of the brand. France is set to bring in plain packaging for cigarettes in 2016, and the UK is set to do likewise in the not-too-distant future although all these rulings are likely to be subject to legal challenges.

One argument against such a law is that generic packaging would make it harder to prevent smuggled and counterfeit products entering a market, and that the restriction of valuable corporate brands by any government would risk placing it in breach of legal obligations relating to intellectual property rights and international trade.

Counterfeiting and piracy has increased hugely over the years, and large-scale manufacturing plants now exist that can produce, for example, cheap and realistic-looking, and sometimes therefore dangerous, copies of goods such as drugs and associated packaging.

The counterfeit market in the UK is estimated to be worth around $21.6 billion each year – US$663.5 billion globally according to the Anti-Counterfeiting Group UK. The packaging industry should and is fighting this threat.

A growing number of retail products that look like those from brand leaders – with similar packaging, size, type and shape of container with virtually identical graphics and brand name are causing concern in the industry as the aim is clearly to piggy-back on the carefully-built reputation of the brand leader. To try to prevent this, the UK government in 1994 exercised an option under European Law and introduced provisions in the Trade Marks Act which prohibit the use of branding which, without due cause, takes unfair advantage of the distinctive character and reputation of well-known registered trade marks.

The British Brands Group who has found that misleading “parasitic” packaging is on the rise with around a third of shoppers admitting to having accidentally brought the wrong product because of its similar packaging.

According to the British Brands Group, “It is very difficult in the UK to take action against parasitic packaging. The designers of such packaging tend to ensure that they do not infringe intellectual property rights such as trade mark and design rights and a passing off action is very difficult and expensive to bring. The Consumer Protection from Unfair Trading Regulations (CPRs), introduced in 2008, have provisions addressing misleading practices but these are not being enforced by the authorities (companies are not able to use the Regulations themselves to bring civil rights of action).

However, a range of intellectual property and intangible asset tools, including trademarks, can help in the war against counterfeiting. | 58 | Packaging Europe

An intangible asset benchmark and audit is often the first stage in a company understanding the importance of its intangibles, and established benchmarking processes are normally used to assess how a company can enhance its market value. This will include examining the robustness of the protection already in place, as well as investigating extending from the use of the trademarks and trade dress that differentiate the brand to other innovative technical developments such as novel packaging materials.

Trademarks are words, logos, and devices – ie, distinctive features that can be represented graphically and can distinguish goods or services of one business from those of another. They can include logos, sounds, colours, gestures, brand names, and slogan and even the shape of goods and their packaging.

Having a good trade mark portfolio to protect a brand can secure the real monetary value that has often been invested in the creation of that brand. It is a definite asset that can ensure that the real value of a business is recognised when it comes to seeking additional funding or when making plans to sell.

Patents protect the functionality of new, unique inventions on a country-by-country basis through national patent offices. There are also some regional systems for filing, such as the World Intellectual Property Organization (WIPO) or the European Patent Office (EPO). A patent protects the inventor’s right to its exclusive use. Food packaging is a buoyant area of patenting where the rate of filing has been steadily increasing over the past 20 years.

Coller IP has identified around 15,000 patent families relating to aspects of food packaging that have been filed over this period.

Copyright can cover the artistic aspects of product packaging. In contrast to a patent, copyright protects an expression of a work rather than the idea underlying it. The good news is that UK copyright is automatic and does not require registration. Under UK law, a business would by default own the copyright of work created by its employees.

An area of IP that is particularly useful to the design professional is registered and unregistered design rights. Registering a design gives the creator of the design additional legal protection. A registered design protects the overall visual appearance of a product in the geographical area in which it is registered for up to 25 years. In order for it to be registrable, a design must be both new, and have ‘individual character’.

Unregistered design rights can offer free automatic protection in the UK for the internal or external shape or configuration of an original design. What is often not recognised however, is that although it protects shapes, it does not protect the two dimensional aspects of a design such as patterns or decoration. Such an aspect is protected by a registered design right.

New Trends Environmental concerns continue to impact on the packaging industry and novel clean technology solutions are therefore of particular interest. Consequently, it is no surprise that bioplastics packaging is an area where patents are increasing. In order to identify key trends in patenting activity in the bioplastics sector, we conducted a search of major patent databases (including US, European, Japanese and Chinese patent documents and international (PCT) applications). This search used keywords relating to bioplastics or common bioplastic feedstocks in combination with patent classification codes relating to organic macromolecular compounds. This search identified around 10,000 patent families which

have been published within the last 20 years. We believe the results from that search are a good representation of the patenting activity in the bioplastic sector. From analysis of these results it obvious that patenting in bioplastics is growing overall, with an over 300 per cent increase in annual patent filings from 1994-2013.

According to Smithers Pira,* the bioplastics share of the packaging sector to grow from 0.2 per cent in 2013 to 2.4 per cent by 2023. The company claims that, driven by both biorenewability and biodegradability trends, the demand for bioplastics in packaging is expected to grow to about 9.45 million tonnes by 2023. This represents a global CAGR of 33 per cent, according to their recent study.

According to the report, worldwide consumption of all polymers is valued at more than $650 billion in 2013. In geographical terms, North American and European global shares are both slightly under 25 per cent each, while Asia (including Japan) represents about 40 per cent global share. The remaining 13 per cent share is consumed in other regions. By 2023, the Asian share of global biopolymer demand is expected to increase to 34 per cent, while both Europe and North America decline in share of global packaging demand for this type of material.

This general shift towards bioplastics, says the report, is driven by both environmental concerns and the increasing costs for fossil fuel products. Growth is closely linked to the relative competitive prices for traditional polymers (petro-polymers) based on fossil fuel products such as oil, natural gas and derivatives. Therefore, bioplastic acceptance and growth in packaging are driven by the dynamics and economics of the fossil fuel industry on a global basis.

A UK company claims to have produced a new type of packaging that not only is 100 percent recyclable, but also actively removes CO2 from the atmosphere.

The new Polyair material developed by Polythene UK is made from sugar cane and uses photosynthesis to capture CO2 and release oxygen. The company claims that for every ton of the product manufactured, 2.5 tons of CO2 will be removed.

Trading Internationally Protecting breakthroughs such as those in bioplastic packaging could therefore be critical to the success of those developing the new materials involved. If the developments and the related IP is not protected (or not protected thoroughly enough, for example in each significant country where it may be at risk) there is a real possibility that the commercial edge that they provide will be lost to others operating in the market. Wherever possible a company should promptly register its IP rights in its key geographical markets.

The chart below represents an analysis conducted by Coller IP looking at the country of origin of bioplastic patent filings. This information provides an indication that USA, EU and Japan lead the bioplastic sector with regards to innovations, in that respective order. The figures for Europe include the top individual countries (Germany, France, UK and Italy) as well as European Patent Office filings.

Caption: An analysis of the patent document set relating to bioplastics. The chart shows the country of filing of the first (priority) application within each patent family identified.

The IP landscape for bioplastics has been investigated. A patent landscape map is generated through an analysis of the most frequently used words and phrases within a document set and allows us to see the key areas of patenting activity within a sector and the active parties in a specific area of development. Coller IP uses such IP landscapes as a strategic tool to guide market developments and investigate trends in innovation within a market sector.

Analysis of the patent landscape shows a particular focus for bioplastics is biodegradability. Whilst all bioplastics may not be biodegradable, this landscape evidences the fact that many bioplastics are biodegradable to some extent and patent applicants wish to emphasise this element during patent filing. It therefore appears that biodegradability is a key driving force of bioplastic innovation.

It is also clear that the most common forms of bioplastic are derived from starch or cellulose, with a lesser, but still significant, focus on other organic materials included under the biomass label. The importance of starch and biodegradability in innovation in the

bioplastics sector is evident from the high number of patents within the landscape relating to these aspects. One smaller but surprising area of patenting activity within the area of natural polymers is the patenting of natural rubber composites with biologically derived fibres or bioplastics .

Patents relating specifically to packaging formed from bioplastics represent a small area of the landscape (around 300 patent families). However, biodegradability is a characteristic which is particularly relevant and suited for packaging, and many of the biodegradable bioplastics detailed in the patent filings may be intended for or ultimately be used in bioplastic packaging. Whilst it is not possible to be definitive about the extent of patents in this area which may be relevant to bioplastic packaging, it does appear that, in line with the overall trend in bioplastics, the rate of filing of patents relating to bioplastics and packaging has increased steadily over the last 20 years.

The developments however are being led by US patent filings and an opportunity appears to exist for greater innovation led from Europe. A European Patent can be used to provide protection across the EU states. When launching products, however, it is also important to consider distribution strategies. This is because in the EU, different trade restraints apply, and it is especially important to consider competition law, which covers the free movement of goods around the EU and the avoidance of the abuse of a dominant position in the market.

Recommendations for the exact route to choose will depend on the countries to be covered, the stage of development of the technology and the nature of revenue streams and cash flow.

Because patent protection overseas can be complex, we recommend taking advice at an early stage to ensure pitfalls are avoided, opportunities maximised and costs are kept to a minimum. It can be time-consuming and costly to sort out errors later.

Intellectual property tools are powerful business assets for those involved in packaging, and like other assets they need to be looked after, protected and applied effectively, ever more important in an increasingly competitive world.

1%

5% 15% 36%

Patents

by Country 21%

22%

• US

7359

• JP

4176

• KR

1092

• EU

4431

• CN

2954

• WO

264

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Printed Electronics and Packaging LOPEC 2015, the seventh International Exhibition and Conference for Printed Electronics, takes place at the Messe München trade-fair centre on March 3-5. With the field of printed electronics attracting ever more serious attention from brand owners, packaging applications will be a significant focus at the show. Here Wolfgang Mildner, LOPEC general chair and vice chairman Europe of the OE-A (the Organic and Printed Electronics Association), discusses the smart future of packaging.

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hat are the aims of LOPEC and what can a packaging manufacturer or a brand owner interested in packaging expect to gain from attending?

The concept of smart and intelligent packaging has been around for quite some time.

LOPEC 2015 will showcase many solutions demonstrating how packaging manufacturers and brand owners can use new technologies to implement this idea into their future packaging concepts. As before, LOPEC will show concepts for sensor-based quality control, communication and interaction with the user. All of these concepts will be key elements of this year’s conference programme.

What are the most interesting existing applications of printed electronics in packaging?

We are seeing a wide variety of applications coming to fruition, including: • Enriching the visual appearance and attractiveness of packages by using interactively enabled lights and colours (see the example of Bombay Sapphire Gin with illuminated packaging).

• Quality control for temperature sensitive goods, from long-term logging to Low/High temperature alarms.

• Intelligent packaging for pharmaceuticals to help, for example, customers to comply with the recommended use of their medication.

In which end-use markets do you think we are most likely to see widespread adoption of printed electronics in packaging?

Frankly, the use of printed electronics in packaging is unlimited and some early applications are already here: • Pharmaceutical goods – At next year’s conference we will get to hear the initial feedback from field trials as one of the plenary talks. Readers should check out: www.lopec.com/en/conference_speakers_plenary_session/speaker/1540 • High value consumer goods such as perfumes, liquors, cigarettes and so on to attract the customer’s attention.

• The oe-a (www.oe-a.org) is working on a roadmap for printed electronics, with specific chapter on healtcare and pharma which describes the future development.

How quickly are the costs of these technologies decreasing?

Is cost the number one barrier to adoption in packaging at the moment?

Understandably, cost is the driving factor for adoption in lower cost goods and, as costs come down, new markets will emerge. Until now, however, performance has been the major barrier and the industry’s ability to deliver and integrate in the appropriate format is constantly pushing that barrier aside.

What kind of new functionalities do you expect to emerge in packaging?

What are the next technological challenges for the industry and the most exciting areas of primary innovation at the moment?

Ease of use - Future Packaging will have its own intelligence and will help the consumer towards a better product experience - for example with interactive handling instructions. As packages will become a part of the Internet of Things (IoT) – they will be connected and will be interactive.

In the foreseeable future we will see the introduction and increasing use of “communicating packages”, enabled by standards like Near Field Communication (NFC).

The link between the digital world and the package is very exciting and will enable many interesting and useful functions and values to customers.

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Christian Czech & Yuichi Takayanagi

Connecting Values An interesting new joint venture, Toyo & Deutsche Aerosol GmbH is bringing the spirit and experience of Japan’s leading aerosol contract filler Toyo Aerosol Industry Co., Ltd together with the strong European reach of Germany’s Care Connection GmbH. Emma-Jane Batey spoke to the managing directors of both companies to find out how this is being achieved.

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oyo & Deutsche Aerosol has been created following the strategic joint venture between Japan’s leading aerosol contract filler Toyo Aerosol and Germany’s highly respected Care Connection. The partnership is the perfect balance of knowledge and a strong European footprint, bringing together two of the most wellknown companies in their fields to create a truly unique aerosol expert, which aspires to improve the life’s of consumers with smart, innovative aerosol technologies.

Toyo Aerosol, headed by president Yuichi Takayanagi, is the largest contract filling manufacturer in Japan and part of the Toyo Seikan Group Holding, the world’s seventh largest packaging company. As a pioneer in the aerosol field, Toyo Aerosol is truly an innovator. Managing director of Toyo & Deutsche Aerosol, Akira Tada spoke to Packaging Europe to explain more about the company’s strengths and its plans to bring its unique experience to the important European market. Mr. Tada said, “We are a key part of the

huge Japanese Toyo Seikan Group, which is listed on the Tokyo Stock Exchange, employs more than 20,000 people and has over 100 facilities worldwide. As the largest contract manufacturer of aerosols in Japan we have a terrific reputation for creating, manufacturing and delivering high quality, innovative aerosol packaging for a large range of customers worldwide.”

Ready for action Mr. Tada noted that the joint venture with Care Connection, which was initiated beginning of this year and started operations in April, is a major step forward in Toyo’s global expansion. He said, “We decided to establish the joint venture corporation with Care Connection in Germany as a base for manufacturing and selling aerosol products in order to expand our business in Europe. We’re now here and ready for action!”

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Bizerba Bizerba offers its customers in industry and logistics a globally unique solutions portfolio of hardware and software around the central value “weight”.

The customer base includes globally operating companies in trade and industry as well as retailers, bakeries and butcheries.

One of the many diverse solutions offered by Bizerba is a dynamic checkweigher for maintaining precise nominal filling quantities. The calibratable CWF checkweigher combined with a Varicon metal detector can check up to 400 packages per minute and detect metal components in the product. Like other Bizerba systems, the CWF is also compatible with the _statistics.BRAIN software, which enables comprehensive documentation of production processes.

Working closely alongside Mr. Tada is Christian Czech, CEO and 49 per cent shareholder of Toyo & Deutsche Aerosol. His extensive experience in the packaging industry makes him a valuable part of the newly-formed company. Mr. Czech told Packaging Europe, “I was born in an aerosol can! Along with my family, I established and developed the CZEWO, one of Europe’s biggest contract manufacturing groups, which we sold some years ago. Now I am purely dedicated to our exciting joint venture by bringing my knowledge and connections of the European aerosol packaging market together with the huge scale of Toyo’s investment and global reach.”

Both Mr. Tada and Mr. Czech explained how the name Toyo & Deutsche Aerosol is key to representing the marriage of the two operations. Mr. Czech said, “The ‘&’ between Toyo & Deutsche is very important; we’re connecting values and combining the best of two cultures... all the customers, the opportunities and the innovations. It’s a connection of two like-minded operations into one company that can deliver truly exceptional quality and service, but more importantly can improve the life’s of consumers with smart, new aerosol technologies.”

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Incredible foundations Collectively, the joint venture brings over 100 years of contract manufacturing experience in the aerosol packaging industry with more than 60 years of solid presence in Japan. Mr. Czech added, “We know aerosols by heart. We’re bringing together the best values and technological advances of Asia with the innovations and on-the-ground knowledge of the European packaging industry. We will be bringing our customers the very best possible experience of developing, manufacturing and filling all types of aerosols – all with an innovative twist.”

That innovative twist is expected to reap big rewards for Toyo & Deutsche Aerosol. It’s fresh-thinking, award-winning DUAL aerosol is a truly new introduction to the market: an aerosol can that combines two bags into one can, the DUAL has quickly become successful. Mr. Czech explained, “The DUAL is a game-changer.

With this two bag, one-can solution, it is possible for the first time for products to be mixed and dispensed at the same time. They can be kept separate in the can until the exact moment they are required to be mixed. The DUAL is proving highly valuable for products like glues and hair colours, where the product stays fresh and can be used a little at a time, just as needed.” The DUAL is an ecologicallyresponsible offer too. Totally reusable and recyclable, it is also supporting a ‘less waste’ focus by allowing products to be used as required rather than all mixed with only a little used.

The Toyo & Deutsche Aerosol joint venture is based in Neutrabling, Germany, in the Bavarian countryside not far from Munich. By the end of 2015 the company’s state-ofthe-art facilities will be totally finished, representing a €12 million investment in premises, technology and machinery. Mr. Tada added, “It’s a serious investment for a start-up, but Toyo & Deutsche Aerosol is not any start-up! We have decades of high-end contract aerosol experience gained across the world. We also have the strength of a global group with production facilities and blue chip customers across the world and the passion of a respected figurehead. We’re ready to go!”

Visit: www..tokyo-pack.jp

Delivering Complete Solutions As one of the largest independently owned plastic packaging manufacturers in the UK, Coda Plastics Limited continues to innovate and expand into new markets with its award winning solutions and bespoke offerings. With a global reach, Coda Plastics operates from a modern, purpose-built facility based in Norfolk, UK. Libby White spoke with Sales Director Simon Girdlestone to find out about Coda’s winning combination of high manufacturing standards and custom-made designs.

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r Girdlestone remarks, “Coda was established in 1973, so our expertise is based on a long history. Our knowledge is well recognised by the industry which leads us to design and manufacture the most innovative and challenging products.”

Bespoke Packaging One of Coda’s main strengths is that it can offer its expertise to both start-up companies and well-known leading brands. “From concept to design, we work alongside our clients every step of the way throughout the product development process, delivering bespoke solutions that will set them apart from their competitors,” Mr Girdlestone is proud to point out.

Coda Plastics offers concept design and rapid prototyping to low or high volume plastic packaging manufacturing across the personal care, household, pharmaceutical and food markets. The company counts leading brands such as Imperial Leather, Carex, Charles Worthington, St. Tropez and Revlon amongst its customers within the personal care market, in which it has held a strong position for many years. It has also worked alongside such leading names as Proctor & Gamble, Jeyes Parazone and the Bin Buddy.

High Standards Utilising the latest manufacturing processes and equipment ensures Coda can achieve the highest manufacturing standards. Mr Girdlestone explains the company continuously invests in its machinery, “We have recently purchased new KraussMaffei injection moulding machines to increase our capacity and we are about to install a new extrusion blow-moulding machine.”

Successfully expanding into the food market, the company has achieved high standard certifications in the last few years from approved bodies to support this growth. Mr Girdlestone comments, “We achieved the British Retail Consortium food packaging standard and were accredited an A grade status as a direct food contact packaging manufacturer.”

Coda has worked alongside companies in the food & beverage sector such as Britvic, and is a Coca-Cola accredited manufacturer. “We also provide our packaging for Nespresso® compatible coffee pods. Our main client for these is CaféPod which is developing into one of the largest Nespresso® compatible brands in Europe,” Mr Girdlestone adds.

Also meeting the needs of the pharmaceutical market, Coda has developed products such as crash-box packaging for hypodermic syringes. Mr Girdlestone says, “For this market, we have been audited by a number of our large customers to a high level pharmaceutical standard.”

Company growth The company’s main market is the UK, however as a truly global manufacturer, it supplies its packaging across the whole of Europe, and as far afield as East Africa, Indonesia, India, Australia and the U.S. Coda will continue to maintain organic growth within its established markets. “However our recent investments and certifications achieved for our high standards puts us in a strong position to advance into the food and pharmaceutical markets,” Mr Girdlestone concludes. “We are currently working on a number of confidential new and innovative medical developments.”

Visit: www.coda-plastics.co.uk

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Passion for Plastics

and Polymers Gulf Plastics and Polymers Show (GPPS) is an exciting new launch event for Fleming Gulf Exhibitions, an experienced events coordinator that has been organising world class events since 2005. Under the slogan ‘Linking Business with Intelligence’, Fleming Gulf has 10 international offices and organises over 100 events across the Middle East, Africa, Europe, Asia, North America and South America.

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he first edition of the exhibition will run from 8–10 September 2015 at the impressive and dedicated exhibition venue of the Abu Dhabi National Exhibition Centre (ADNEC), with the mission of bringing together plastic raw materials, machinery, equipment and finished goods under one roof. Alex Heuff, exhibitions director, talks about the highly-anticipated event and the huge impact it will have on the industry.

Networking platform The aim of GPPS is to provide thousands of the world’s leading suppliers and buyers a business platform to network, learn and capitalise on the multi-million dollar industry.

“We are expecting our exhibitors to be showcasing the latest technologies and solutions to help our visitors – i.e buyers – improve their manufacturing capabilities and increase their output,” Mr Heuff comments. “Through our seminars and conference, exhibitors also have the opportunity to speak to a captive audience, educating the market on the latest techniques available within the industry.”

Visitors and delegates will have the opportunity to network and learn about the latest technologies and innovations within the industry – whether it relates to polymer development, plastic converters, end users, machinery or recycling. Delegates will be able

to listen to thought provoking speakers and interact through panel discussions. Visitors have the opportunity to see the latest products and services and have the opportunity to improve their manufacturing and production capabilities by purchasing the products and services on display.

wood to become more economical,” Mr Heuff remarks. “Other technology areas would focus on selective dissolution and the splitting of the resins into recyclable plastics.” GPPS provides the ideal platform for the industry to address these issues and showcase the technologies to overcome them.

Key trends

Dedicated product zones

When researching and speaking to the market about the feasibility of organising GPPS, Mr Heuff uncovered some very interesting insights and trends about the market, which will be explored throughout the show.

He explains that two key areas reoccurred in discussions: “Sustainability and bioplastics and the technology around making bio-plastics a more attractive proposition over the more traditional fossil fuel and chemical based polymers.”

The shift from fossil fuel based polymers to plant based polymers, which are more sustainable and environmentally friendly, is an area the industry is exploring. However, the costs involved in the development of plant-based polymers are higher than the relatively cheaper costs for fossil fuel polymers.

“On the other side of sustainability, there is mounting pressure on the industry to reduce the environmental impact of the final products and increase the use of biodegradable materials. We all know that there has been a worldwide drive and government initiatives to reduce greenhouse gas emissions and increase recycling. Consumers are becoming more environmentally friendly and conscious of recycling so the industry needs to react to these trends.”

Related to the area of sustainability is the development of bio-plastics and plant-based polymers. According to Mr Heuff, in 2012 bio-plastics were worth US$4 billion and are forecast to grow further between now and 2018. However, there needs to be further improvements in the manufacturing process to reduce the costs and allow bio-plastics to become more mainstream.

“We are expecting some of the technologies to focus on how to make second and third generation cellulose conversion from non-food crops such as horn husks, grass and

“Over the next five years, the number of polymer products produced within the GCC will double and by 2018 the total polymers capacity within the GCC is expected to reach 35.9 million tons. During the same period, 11.3 million tons of additional polymer capacity will come on stream and 22 per cent of this will be from new products,” Mr Heuff points out.

To ensure that GPPS is focused, catering for the needs of this vast market, the show is split into five dedicated product zones: Plastic Converters; Machinery, Lab and Control Equipment; Polymers and Materials; Printing Solutions; and Plastics Products for Packaging and piping.

Initially GPPS will cover 3000 square metres of ADNEC’s exhibition space, providing thousands of the world’s leading suppliers and buyers with a platform to network, learn and capitalise on the multi-billion dollar industry. Mr Heuff remarks, “The potential for GPPS to grow and develop over the years is enormous. Trying to ensure that the first GPPS achieves its full potential is a challenging task but we are confident that, as the market grows, so will GPPS.” With the bulk of the GCC’s polymers being commodity plastics, Mr Heuff expects a fair proportion of the audience to come from consumer packaging. However, as the industry is so vast within the region visitors are also expected from the following sectors: construction, industrial packaging, textiles, consumer goods, agriculture, automotive, appliances, electrical and medical.

Mr Heuff comments, “Our exhibitors can expect to meet with both C-Level decision making professionals, distributors, trader, consultants and agents as well as the more technical and specialist chemical professionals from around the region.”

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Strategic venue Abu Dhabi the capital of the UAE, with a GDP per capita of over $41,000 is a wealthy, dynamic and vibrant cultural city with strong business acumen thanks to its substantial investment in free trade zones and international business parks. Visitors will be able to see the many attractions on hand ranging from the Yas Marina Formula 1 track, Ferrari World Theme park, Guggenheim Museum, Abu Dhabi Grand Mosque, countless golf courses with over 130+ hotels.

ADNEC is ideally located with ease of access for both internal and local businesses looking to exhibit and visit GPPS. “We believe that the potential for the event is enormous considering the size and value, not just of the local market, but also the regional market,” Mr Heuff remarks.

“Currently polymer sales within the GCC stand at US$23.8 billion and this is growing at an annual rate of more than 20 per cent, which demonstrates the sheer scale of the industry within the region and the market potential for suppliers looking at conducting business within the region.”

Abu Dhabi, the capital and business hub for the United Arab Emirates, has been strategically chosen as the venue for the exhibition for a number of reasons. Mr Heuff explains why he believes there is a strong market demand for an event such as GPPS: “Abu Dhabi is home to one of the fastest growing plastics business parks within the region – the Abu Dhabi Polymer Park located in the Industrial City of Abu Dhabi (ICAD). With a total output capacity of no less than 1 million tonnes per annum, the Abu Dhabi Polymers Park creates sustainable value within the economy through the conversion of readilyavailable domestic and regional products.

“By leveraging Abu Dhabi’s existing up- and midstream presence in petrochemicals, the Park is well placed to participate in higher margin downstream production so as to broaden its manufacturing base and product mix. In addition, it creates opportunities for international and regional private investment in developing downstream products for the construction, infrastructure, packaging and OEM segments.”

He continues, “Looking beyond the UAE and Abu Dhabi, the Middle East’s plastics and polymer global market share is set to soar by 17 per cent by 2020. This growth is helped by the investment the region is putting into the industry. Along with the Abu Dhabi Polymer Park in the UAE, Saudi Arabia has two massive projects under development – firstly there is the Rabigh Conversion Industrial Park (RCIP) where Petro Rabigh is building another plastics converting park similar to its existing site based in Jiddah.

Petro Rabigh is a joint venture between Sumitomo Chemical from Japan and Saudi

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Aramco. Secondly there is the expansion of the Plaschem Park, which is managed by the Royal Commission of Jubail and Yanbu, where Saudi Aramco are developing a plastics park in Jubail next to Sadara Chemical.” These three major projects in the region demonstrate the investment and importance of the plastics and polymers industry, and its need for a comprehensive show.

Conference aims The conference will be held over two days of the exhibition and provides more than 20 industry experts to educate the market with the latest trends. It will include presentations, workshops, panel discussions and roundtable discussions allowing both the speakers and the delegates to interact. The conference aims to cover five key areas.

One of these key areas is polymer development in the region and forecast on new product development along with the impact on the converter sector. According to Mr Heuff, “The Middle East is host to some of the world’s largest downstream players such as Tasnee, Sipchem, Sabic, Aramco, Petrorabigh and Sadara Chemicals. With huge forecasts of over 2 million tonnes of polymers to be produced p.a. in the GCC alone, polymer players are poised to develop new materials such as EVA that will promise to open doors to new and fresh applications in plastic manufacturing.” GPPS will be an ideal platform to host technical workshops from leading material players to raise awareness and make an informed business decision.

Secondly, the conference will throw light on the burgeoning growth promised by converters through innovations in packaging, materials and supply chain efficiency that will lead to good quality products at competitive price. The focus will be on packaging but also on automotive, construction and medical. “The GCC is host to around 1000 plastic converters with the majority of them present in UAE and Saudi Arabia. UAE accounts for 19 per cent of the region’s output and the country also ranks second in total plastics manufacturing capacity, representing 10.2 per cent of the area’s polymer capacity,” Mr Heuff explains. “The growth is led by major companies such Falcon Pack, Obeikan Group, Savola Plastics and NAPCO Group, all of whom we expect to be in attendance.

“The GCC has a growing FMCG sector with high growth in Construction, Medical and apparel as well. All these sectors lead to a high demand for packaging materials and plastics and polymers for their end manufacturing.” Therefore the conference will also host presentations from leading FMCG and construction companies and end users to discuss their requirements and future packaging innovations. Companies such Al Marai will be focusing on sustainable packaging materials.

Visitors to the show can also expect to find solutions for their machinery requirements. Mr Heuff points out, “There is an ever-growing demand for large-scale machines and technologies that enhance production output at lower costs in the MENA region, home to many large-scale downstream and converting plants, resin raw material manufacturers, plastic converters and companies that use packaging which need advanced machineries and technologies for their manufacturing facilities.”

The conference will also aim to cover the important topic of plastic recycling. “The government is increasing awareness through regulations for environmentally friendly activities and companies are looking at eco-friendly and sustainable materials for plastic packaging,” Mr Heuff comments. GPPS will have leading companies that offer recyclable material packaging solutions to present and raise awareness through workshops and presentations.

For more information, visit www.gpps.ae

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Stretch and grow Globally-active BOPP film manufacturer Manuli Stretch Group has consistently developed innovative ways to meet the changing needs of its customers. Emma-Jane Batey spoke to CEO Jean Claudio Bassano to learn more.

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ounded in Milan in 1934, Manuli Stretch Group was established when Dardanio Manuli developed an electrical insulation tape that quickly proved popular. Over the following decades the company continued to maintain its position at the technical forefront of the BOPP industry, becoming the global market leader in totally recyclable linear low density polyethylene (LLDPE) stretch film.

Today Manuli Stretch Group is one of the world’s biggest producers of stretch film, with the group comprising three focused business units that all work together to deliver a sustainable product to customers worldwide. The three units are the European operations, European distribution and the Latin American operations and distribution. With the global headquarters in Milan, the European manufacturing hub in Leipzig, Germany and additional manufacturing sites in Argentina, Brazil and Chile, the company has a strong global footprint.

Safe and sound CEO Jean Claudio Bassano spoke to Packaging Europe to explain how the company’s structure serves both the business and its customers. He said, “Our group manufacturing is centred on our three main plants in Schkopau near Leipzig, Buenos Aires and Curitiba in Chile, giving us an excellent capacity and availability for customers wherever they are in the world. Together, our plants produce nearly 200,000 tonnes of stretch film every year from a total production area of around 40,000 square meters. So by having a sound company foundation and three state| 72 | Packaging Europe

of-the-art manufacturing plants, we have worked hard to create a globally-active company that consistently meets the needs of our customers.”

At the Manuli Stretch plant in Leipzig, which was built from scratch in 1999 using the very latest technologies and has continued to be upgraded ever since, the company operates 14 extrusion lines. There are a further four extrusion lines plus a tapes coating line in Argentina and another three extrusion lines in Chile.

“All our plants are second-to-none in terms of the latest machinery and equipment,” Mr Bassano continued. “In Leipzig our key technologies are industrial stretch film extrusion, stretch film orientation and conversion, cast polypropylene (CPP) extrusion, stretch hood extrusion and CPP film conversion. Our continual upgrading of this European facility has seen us install a new capacity for stretch hood extrusion and we’ve built an extension line upgrade for CPP. We have also recently installed a new slitting line for CPP conversion.”

With the Argentinian and Chilean plants also operating the very latest extrusion and conversion machinery, as well as tapes coating lines and new tapes slitting lines, it is safe to say that Manuli Stretch lives up to its promise of delivering quality stretch films. Mr Bassano added, “We do have some further expansion and investment planned for the near future but it is currently confidential.”

All of the Manuli Stretch Group’s facilities are accredited with the ISO 9001, ISO 14001 and ISO 15001 certificates. The company is committed to operating in an environmentally-sound manner as well as being efficient in terms of process

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manufacturing. The sustainability focus certainly extends to its product development activities too, with its latest innovation achieving a reduced thickness while retaining the high-quality mechanical properties expected by the Manuli brand.

Mr Bassano explained, “We’ve been very successful in reducing the thickness of our film through smart use of technology and clever integration of research. It means that customers can use fewer polymers to wrap or palletise their products but they keep the performance and reliability of our films. It’s better for the environment and better for our customers.”

Always developing The innovative developments from Manuli Stretch Group can be attributed to its ‘Touch Centres’ - dedicated research and development centres at each of its plants that employ highly skilled process engineers that follow market trends and lead in-

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novative projects. Mr Bassano added, “It is here that we’ve been working on a really fresh new film for food packaging. It’s currently top secret but I will certainly tell Packaging Europe readers all about it as soon as it’s launched.”

As an Italian family company based in Germany, Manuli Stretch Group has an interesting mix of efficiency and flexibility, taking the positive traits from its heritage and balancing it with the benefits of its location. “Our German plant is great at coming up with a good idea and running with it in an effective manner, while the Italian part is then flexible about getting it to market,” said Mr Bassano. “We’re always asking the question ‘what is the best way we can solve this?’. It’s about being fast in the market but, above all else, it’s about being reliable. Reliable quality, reliable service and reliable as a partner. We’re really into mutual exchanges of ideas with our customers, our suppliers and our staff.”

As Manuli Stretch Group continues to grow, the company is continually increasing its efficiency in order to stay the market leader. Currently working to adapt all its facilities to ensure it is always one step ahead of the latest certifications in its fields, the company is very positive about the future. Mr Bassano concluded: “The European market is not so buoyant at the moment, but as a global company with a strong footprint we are able to move quickly and grow in countries where there is potential. By keeping close to our customers worldwide, we are always ready when the market picks up and, thanks to our constant innovation, we always have new solutions available that are tailor-made to our customers’ needs.”

Visit: www.manulistretch.com

Avoiding risk – In Challenging Applications Mettler Toledo Safeline is the global market leader in industrial metal detection for the food and pharmaceutical processing and packaging industries. Felicity Landon reports.

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Vacuum Formers Ltd are a British company with our factory based in the heart of Macclesfield, Cheshire. Vacuum Formers are specialists in creating moulded plastic components using thermoforming (vacuum forming) techniques. Vacuum Formers are ideally located to serve our customers throughout Cheshire and the UK. Vacuum Formers are a family run business and our success is largely due to our very flexible and creative approach to plastic moulding and plastic fabrication. We are specialists in the manufacture of replacement roadside and amenity lighting and a wide range of general purpose industrial plastic mouldings, including for pharmaceutical machines.

We utilise many types of plastic moulding materials such as Petg and polycarbonates with food grade options for the vacuum forming process.

A complete in-house development service is carried out on the premises by our team of experienced plastic design engineers. From initial drawings, we can provide realistic lead times for prototypes and production quantities.

We can also provide “cut to size� panels, fabrication and welding.

If you have a project to complete or a problem that needs solving please contact us. We are always happy to discuss your plastic vacuum moulding requirements with absolutely no obligation.

01625 428389 - info@vacuum-formers-plastics.co.uk - www.vfplastics.co.uk

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or food and pharmaceuticals companies the world over, brand and reputation means everything. A product recall can cost millions of dollars, without even taking into account the knock-on effect of the bad publicity. And no company wants to make the headlines because a customer has found a piece of metal in their breakfast cereal or ready meal.

This is where Mettler Toledo Safeline, and its sister companies in the group’s product inspection division, provide critical services and solutions. Incredibly sensitive instrumentation can detect rogue items even where volumes are huge and flows extremely fast.

This is, however, no ‘ordinary’ detection. “Our Profile Advantage metal detector sets the benchmark in sensitivity for difficult-to-inspect products in the food industry, while our Pharmaceutical systems can detect specks of stainless steel that the eye can’t see,” says Alan Purvis, managing director of Mettler Toledo Safeline. “We can find those specks at a processing speed of 200,000 tablets an hour. And we don’t just make the detector – we make the material handling system to provide the right solution, including a failsafe reject mechanism.”

It is, says Mr Purvis, all about avoiding risks – not only putting in detection at critical points in the process but also avoiding false alarms which bring production to a halt.

“Reliability and uptimes are absolutely critical for our customers,” he says. “But at the same time, compliance must be watertight. Companies value their brand and reputation extremely highly. We sell the high technology inline instrumentation to help food producers and retailers, and the pharmaceutical sector, to protect their brand, comply with international standards and maximise productivity at the same time.”

World leader Safeline was set up in Salford in the UK 25 years ago; it grew fast and was acquired by the Mettler Toledo group. “The Safeline name is recognised by food producers for providing high quality inline instrumentation – but we would not have been able to grow and invest to the level that we have without the support of our parent group,” says Mr Purvis. | 78 | Packaging Europe

The company holds a global market share of about a quarter – and its export figures are remarkable, exceeding 95 per cent of its output from the UK. “We are the global leader in terms of installed basis and turnover in the metal detection business,” says Mr Purvis. “And we intend to grow. The global food industry is enormous, and the proportion of the world’s population that is able to buy mass-produced, packaged food is growing every year, particularly as the population becomes more and more urbanised.”

Unique solutions A key factor of Safeline’s expertise is in its attention to detail. There are so many potential and varying applications in the industry that the company doesn’t make to stock or sell off-the-shelf solutions. “We assess the application, which means that our sales people have to be experts,” he says. “Nearly 90 per cent of what we sell is made to order. You have to understand what the customer needs before you can explain to them what you can provide, before they decide to buy it. There is a whole value chain of expertise involved.”

A good metal detection system provides improved brand and customer protection; compliance with international food safety standards and retailer codes of practice, or pharmaceutical standards; cost reduction; and increased productivity. But as well as all of these, a good system can improve overall equipment efficiency (OEE). “There is a lot of information inside metal detection that most customers wouldn’t normally consider,” he says. “They only want to know – can it protect/reject? But the information gathered in the detector can also help optimise manufacturing and processing by reporting throughput, yield and system availability.

“I believe we are the only metal detection supplier that offers OEE displays, and these are incredibly valuable to our clients’ quality engineering teams. They can track OEE, detector set-up, product rejects and Performance Verification (PV) routines. With this

phone: +44-161-876-4498 www.k3syspro.com

K3 Syspro At K3 Syspro, we understand that industrial packaging businesses need an ERP solution that is tailored to meet their manufacturing and distribution needs. And just like there is no one-size-fits-all solution for packaging, the same is true for ERP. You need a solution that helps you overcome the daily challenges that you face every day; whether it’s labelling multiple units of measurement, connecting shopfloor and e-commerce, or rebate tracking, we give you the tools you need to do your job more effectively. ERP packaged around your individual business needs can really help your company deliver.

type of system you can demonstrate compliance much more quickly than if you send people out with clipboards to write things down.

“Our systems also monitor the electronics. We build in predictive diagnosis and condition monitoring, so the client can pre-empt maintenance issues – for example, if the system starts to drift out of calibration. More and more companies are using this feature to reduce their production costs. In the future we will develop further in this area.”

Safeline metal detectors can inspect food products in all formats, and are built to provide the best solution for each type in order to pick up on ferrous, non-ferrous and difficult-to-detect non-magnetic stainless steels.

Its rectangular aperture metal detectors detect contaminants in conveyorised, loose or packed product applications and can be used, for example, for meat, poultry, fish, bakery and ready meals, as well as sacked/crated produce, blocks of cheese or bulk meat packs.

For some products, however, something different is needed. How does a factory producing millions of packets of crisps every week enable an efficient inspection? The cooked crisps are fed into a giant hopper, weighed and then dropped down a chute into the individual bags which are themselves metallised, so are clearly not suitable for metal detection at that point. Safeline produces vertical packaging metal detectors to fit neatly into this type of operation. As the crisps head through the final process, the system detects for metal – before they go into the bag.

For bulk powder or granular products, Safeline supplies gravity fall metal detection systems. And for liquid, paste of slurry type products – think jam, baby food, sausage meat – Safeline supplies a pipeline detector.

facility in China. To augment that, because you can never have enough innovation, we sponsor a department at the University of Manchester which is focusing on electromagnetic research.

“In the past three years, we have innovated substantially and have had really significant successes, including several patents.”

Safeline is about to bring to market the most sensitive metal detection solution it has ever produced. Mr Purvis described the ‘Profile Advantage’ as the company’s biggest step forward for a decade, and a significant moment also from the market point of view.

At present, Mr Purvis says, there are 80,000 Safeline detectors installed in the world.

An estimated 1.5 trillion packages of food go through Safeline metal detectors every year.

In terms of the company’s markets, approximately 40 per cent of sales are into Europe (including the CIS countries), 40 per cent to the Americas, and 20 per cent to Asia, which is the fastest growing market as global companies look for ‘global reach and local excellence’.

That means that a branded chocolate bar should be exactly the same standard, whichever country it’s made in bought in. “We can support these companies in their growth plans,” he says.

In 2012, Mettler Toledo Safeline received the Queen’s Award for Enterprise: International Trade, in recognition of its exports and also the company’s longevity and reputation. The award also recognised Safeline’s impact on society, says Mr Purvis proudly.

“Food safety is so important. Through our equipment, we are making a hidden and secret contribution to the welfare of billions of people.”

The importance of innovation

For more information on how to detect and reject metal from “challenging applications” in your production line, download Mettler-Toledo Safeline’s white paper: http://uk.mt.com/gb/en/home/supportive_content/White_Papers/product-organizations/pi/ understanding-challenging-metal-detection-applications.html

R&D is, of course, a vital part of the company’s ongoing success. “It is critical that we continuously innovate,” says Mr Purvis. “We invest in R&D people primarily based in Manchester, near our factory, but we also have R&D people at our satellite production

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Innovations in paper processing “Anyone who processes paper and print knows our name as a byword for excellence in paper processing.� Behind this claim stands the brand Hunkeler, an independent, family owned business based in Wikon near Lucerne, Switzerland.

Julia Snow gives a preview of the Innovationdays in Luzern – an event organised by the company and due to take place in February 2015.

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unkeler has gathered more than nine decades of expertise in the paper processing industry since its foundation in 1922. The company offers advanced pre- and post solutions for high performance digital print systems covering print on demand, computer centres and direct mailing, as well as web finishing services. It also offers modular systems to produce application-based, organisational, communication and advertising media. Around 250 employees are working at its recently built corporate headquarters in Switzerland as well as in subsidiary companies in Germany, Italy and Hong Kong; more representations can be found worldwide.

Hunkeler Innovationdays Being held from 23–26 February 2015 for the 11th time, the Hunkeler Innovationdays event in the Swiss city of Lucerne is described as “the event for trendsetters and technology leaders who will influence and set the pace for the next stage of industry innovation.”

The list of exhibitors includes all the top names in the printing industry, and the event is expected to break attendance records. Visitors will have plenty of opportunities to have in-depth discussions, make new contacts and discover innovative ideas and solutions dealing with every aspect of digital high-performance printing and paper processing. In the two new ultra-modern trade show halls in Lucerne,

Hunkeler will show more than 40 real-world production solutions. More than 80 exhibitors – from wide-ranging areas including prepress, print and finishing, printing substrates, consumables and finishing materials as well as software – will all be in one place to provide visitors with expert advice.

Reaching the summit together The Innovationdays event slogan ‘Reaching the summit together’ refers to the convergence of important customers, technology and worldwide experts who will be present at Lucerne. The event invites users, manufacturers and specialists to inspect Hunkeler’s broad state-of-the-art product portfolio for the digital printing sector.

With their own eyes visitors can experience the high efficiency of end-to-end workflows over the entire value creation chain – from software to finished books, from idea to solution. Inline, nearline or offline, with tried and proven digital printing or mapping the transition from conventional printing environments.

The latest in automation Hunkeler and its partners will also use the event to present exclusive world premieres and leading-edge developments for improved automation, including: A new generation of winding and unwinding modules with fastroll changes and

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Petratto Petratto is a manufacturer of original folding gluing machines, able to process most of the jobs that are not feasible with traditional folder gluers. Equipped with many innovative accessories, our machines can perform various processes: from the application of double side adhesive tapes, tear strip, up to inserting 3D objects inside boxes or envelopes.

The main novelty of 2014/2015 is given by the new line of die cutting machines, Pdf. The leading machine is Pdf 75 that differs from other similar equipments in the market: in fact it had been specifically designed for digital jobs.

It’s a fully automatic machine that allows carrying out the following processes: die cutting, hot foil, embossing and holograms.

production speeds over 300 metres /min; a book production line with automated format length changeover; dynamic finishing technology for perforating, punching, gathering, chip-out, cutting and stacking; as well as new ease-of-operation with new control platforms and software modules such as PerfEditor and LaserEditor.

Innovations from coating to book binding The new Hunkeler ‘Primer Coater’ Module expands the range of conventional substrates that are eligible for inkjet printing and can also add post-print gloss to inkjet-printed products.

In the area of digital newspaper finishing Hunkeler will show a new folder and collecting module for enhanced efficiency when producing tabloid and broadsheet formats – also perfectly suited for producing inserts.

Also, book production solutions can be inspected in a variety of workflows – from highly flexible nearline solutions to highly-automated book production lines and from the white roll to the finished book. Examples include short-life budgetbound books and efficient adhesive binding to quality thread stitching, as well as the full spectrum from small to medium scale production runs.

Visitors will find efficient production solutions for digitally printed brochures with dynamic content and variable numbers of pages. When it comes to the dynamic perforation and punching of payment forms, tear-off coupons, mailings and security applications, Hunkeler solutions now offer even greater functionality and production speed.

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More security with laser Laser finishing is for perfect security printing, including highly dynamic punching, perforating and engraving of complex logos, shapes, text and numbers. Easy operation is guaranteed with an advanced LaserEditor for producing forge-proof checks, IDs, lottery tickets, coupons and much more. Hunkeler’s quality control and document tracking meets the latest standards for reliable production monitoring, compliance and reporting.

Listening to experts – finding experts The Innovationdays will also be supplemented by high-level on-site forums: DOXNET (The Document X-perts Network), Interquest and EBDA (European Business Document Association) are sure to attract attention with fascinating technical presentations and discussions.

Digital printing means that offset quality can often be achieved or even exceeded in many applications. Choosing a competent partner, who not only accompanies developments but also actively helps to shape them, is vital in order to stay ahead in the digital printing world. The Innovationdays 2015 are set to offer a unique platform to find such partners.

Up to date information, timings and a registration facility can be found at www.innovationdays.com.

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Masking Tapes – The perfect solution for Body Repair and Car Refinishing

The Vibac Group is one of the world’s leading producers of speciality packaging films and pressure-sensitive adhesive tapes. Eugenia Fiusco talks to Carmela Magno, product manager of the Film division, Andrea Sentimenti, global marketing director, and Giovanni Gaballo, sales director of the Film division, about the latest developments at the company.

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Carton sealing tapes – Products and solutions for any Packaging need

Global leader in the packaging industry V

ibac was set up 1968 and since the very beginning has built a strong reputation for its production of adhesive tapes. In the 1980s the company, thanks to investments in a new production line and strategic acquisitions, consolidated its position as the leading group in the packaging and labelling industry. In less than 50 years the group has achieved an annual turnover of €300 million, set up five production plants in Europe and the Americas reaching an yearly production output of over 3000 million square metres of adhesive tapes and 110,000 tonnes of film.

The Group consists of two main divisions: The BOPP Film Division (Biaxially Oriented Polypropylene) and the Tape Division. The former is dedicated to flexible packaging and labelling, with production lines including clear, metallised and white opaque biaxially oriented polypropylene films. The latter, meanwhile, is focused on the manufacturing of pressure sensitive tapes with different supports: BOPP for carton sealing and other purposes; Paper (masking tapes) for various applications such as automotive and DIY; and PVC. “Thanks to a new production line located in L’Aquila, specialising in BOPP film coating, Vibac has strengthened its position on the market. We offer a comprehensive range of products that appeal to customers thanks to their innovation and quality,” says Mr Gaballo.

Ms Magno, meanwhile, comments on a recent innovation from the Film division: “We have introduced a special film that prevents contamination from mineral oils. In particular, MOSH and MOAH are mineral oils commonly used in industrial inks, notably for printing newspapers. Since newspapers form a significant part of the paper/carton recycling stream, recycled paperboard often contains a mixture of MOSH and MOAH. A potential health hazard if ingested, while waiting for E.U. new legislation on the subject the German Government is legislating to strictly regulate the migration of mineral oil from packaging to food. We would also like to underline the fact that we are ready to supply coated, metallised and coextruded products free of phthalates, in line with a European law that will become effective in 2015, additionally all our BOPP films are already BPA free.”

Apart from the ISO 9001 and ISO 14000 certifications, Vibac is also implementing the OHSAS 18001 standard. “Undoubtedly, Vibac’s quality standards are amongst the highest in the industry and so are the efforts and investments made to ensure our group grows in a sustainable way.”

Geographical presence Vibac recently invested €60 million in setting up its latest production plant, due to be up and running some time in 2015. The plant is located in Serbia and will consolidate

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Masking Tape production line

R&D - IR Spectrometer

the group’s presence in eastern Europe, strengthening business relationships with the neighbouring Russia, Turkey, the Middle East and some African countries. It will thus apply the same winning strategy it has used beforehand in Canada where it set up a tape sales and production site.

“In a global market, a company cannot afford to be unable to serve their customers efficiently wherever they are,” explains Mr Sentimenti. “In terms of growth and development, America and Europe offer the greatest potential for us. That is why we wanted to strengthen our presence in those areas. Our products are now used by clients in 130 countries all over the world. We are leaders in countries that are 18,000 kilometres away – for example Australia – and we don’t intend to stop there.”

Tape production – Packaging line

BOPP Film – Product Range selection

Research & development The Vibac group carries out its research and development activities in a modern research centre equipped with state-of-the-art instruments for performance evaluation. Thanks to its research activities, Vibac is able to design and develop innovative films and tapes for numerous areas and applications.

“Research & development are key stages in the production process. Investing time and effort in those two key areas is vital for the success of the end product on the market,” explains Mr Gaballo. “Vibac works in collaboration with two excellent centres for films and tapes, each of which boasts a superb team of highly qualified researchers.”

In terms of its future goals, Vibac has always combined organic growth with acquisitions and it intends to maintain this winning strategy in the years to come.

“In the future, we aim to concentrate our efforts on the development of products for highly specialised applications,” says Mr Sentimenti. “Our market also includes commodities and that is a big opportunity for us in terms of profit and ongoing improvement of products and processes.

Visit: www.vibacgroup.com

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BOPP Film-Slitting Line

Masking Tape – The tape sticks at a touch and stays positioned providing outstanding paint lines, hugs curves and perfect contours even on sensitive surfaces

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One to Watch

The Waddington Group is a major global manufacturer and supplies a broad range of packaging for the food processing and food service markets. The Group has grown substantially over recent years, operating 14 manufacturing sites across the USA and Canada and ambitiously growing its European market presence. Packaging Europe’s Libby White reports.

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he Waddington name will be familiar to many in Europe as a major UK based packaging and printing company, renowned for producing board games such as ‘Monopoly’ and ‘Cluedo’ . The company was acquired in 2000 and subsequently divided. As a part of the break up, Waddington’s US division was sold to the management and a group of financial investors. Together and under the original Waddington name they have steadily built the business to become the powerhouse it is today. In 2013 the Waddington Group acquired ParPak of Canada. ParPak is a large thermoforming company based in Toronto, Canada, with operations in Houston, Texas, and Milton Keynes in the UK. This gave Waddington its first foothold back into the European market. They recently used the ParPak Europe business as the springboard to acquire Holfeld Plastics in Co. Wicklow Ireland. The two businesses are now being operated under the Waddington Europe banner and are poised for significant further European expansion.

The combined businesses have a turnover in excess of €50m and have well over 200 employees. The businesses are led by managing director Kevin Ingram, who has enjoyed previous experience of Waddington, having worked for the Group in the early 1990s. I recently met with Kevin Ingram and other members of the management team when

I visited Holfeld’s site in Ireland to learn more about the future plans and strategy of the newly combined companies and the track record of innovation and achievement into which the Waddington Group has bought.

Kevin explained that with two plants in northern Europe and a shared dedication to innovation, greatly encouraged by its new US based partners, Waddington Europe can lead the way forward in European growth in thermoformed packaging.

European expansion “After initially acquiring Par-Pak Europe (PPE) in June 2013, swift advancements were then made through PPE’s subsequent acquisition of Holfeld Plastics,” Kevin Ingram explained.

“This is only the beginning of a major growth strategy: the Waddington Group will continue to invest further in both European sites and look towards future acquisitions.”

Based in Milton Keynes, UK, PPE’s core competencies lie within the bakery, confectionary and dairy sectors. Its clients benefit from concept development, lead time compression (i.e. speed to market from concept to full scale production), flexible manufacturing capabilities, and an extensive library of designs for immediate use or as a basis for NPD.

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“We are well invested both in terms of our staff and our manufacturing resources,” remarked Kevin Ingram. “Much of our team has developed its skills within PPE but we have also brought into the company experience and expertise from other industries and backgrounds. We have and, under the ownership of The Waddington Group, continue to benefit from an on-going investment in new manufacturing technologies.”

Holfeld Plastics employs similar thermoforming technologies but is predominantly active in the protein and produce markets. As an additional service, Holfeld shares the benefit of its expertise with on-site tool making and extrusion.

“Together the businesses offer a broad portfolio and demonstrable expertise across key markets,” commented Kevin Ingram. “It is an extremely complementary combination that provides a solid foundation for the Waddington Group to grow into Europe.”

Promoting the portfolio and manufacturing capabilities on a European scale, both companies are already well-regarded and well-known in the European arena. “We aim to become truly pan-European,” said Frank Coleman, site director at Holfeld Plastics. “Our packaging can be seen on the shelves of major leading UK supermarkets and increasingly so in continental Europe, for example, we have are supplying a leading French retailer. We offer a direct route to the European market for the Waddington Group.”

Customised creativity PPE’s focus is on creating bespoke designs that are functional, use environmentally-friendly materials, and offer striking on-shelf differentiation. The most recent example is shelfready packaging PPE has developed working closely with the Cornish brand Rodda’s to boost the visibility and personality of its clotted cream products in the retail environment.

“PPE were challenged by our customer to provide a shelf ready packaging solution for branded clotted cream,” explained Kevin Ingram. “The tray had to hold two different pack sizes, protect the product through the transit process and arrive on shelf to maximise the visual appearance of the Rodda’s brand.”

The solution is easy to merchandise with simple shelf replenishment and optimisation of critical shelf space. The packaging, produced in recyclable PET, is strong enough to endure the challenges of the supply chain. The design makes for easy, customer friendly shopping. The solution, which was successfully launched ahead of the Christmas season, adds value for both the brand and the retailer through encouraging impulse purchases while minimising handling through the supply chain and within the store – and this is just one example of the innovation PPE can bring to its clients.

Another high profile and successful innovation is the rPETeCO from Holfeld Plastics.

This is a new range of lightweight, low-carbon footprint sustainable trays accepted in the recycling waste stream and exceeding Courtauld 3 objectives. The new trays are suitable for a number of applications in the protein, meat and fish and fresh produce markets with wider applications in the airline catering, bakery, games and perfumery sectors. Holfeld has invested substantially in new thermoforming and extrusion equipment to support the production of this new range.

The packaging contains at least 85 per cent food grade post-consumer PET recyclate and is available with a PE sealing layer with the potential to provide high gas barrier | 90 | Packaging Europe

in Modified Atmosphere Packaging applications. Barrier protection of rPETeCO mono material is approximately 90 per cent of that of standard PET but more than 30 times higher than standard polypropylene. The range is particularly suited to applications such as the organic food market, which seeks a natural feel and appearance to trays. The range also demonstrates the same characteristics and material properties as virgin PET with excellent chill impact properties and top load performance.

Award winning innovation The achievement of rPETeCO has garnered wide recognition within the industry, resulting in a number of highly regarded awards more recently a shortlisted winner in the World Star Packaging award for the low carbon rPETeCO material. In awarding a Starpak Gold in the Greenstar sustainable packaging category, the judges felt that rPETeCO delivers long term financially viable and environmental benefits and is a truly sustainable range of multi-purpose packaging. In addition, the innovation has scooped the Repak sustainable packaging design award 2013/14, won the top Packaging Solutions Gong at the Food Processing Appetite for Engineering Awards 2014 and was a finalist at the Plastics Industry Awards for best technology application and best recycled product. Most recently it was highly commended at the UK Packaging Awards for Best Rigid Pack of the Year.

Among other recent innovations is Hydrozorb, an offering specifically targeting the mushrooms sector. “Mushrooms are traditionally packaged in polystyrene or polypropylene,” explained Frank Coleman. “However, these materials are not readily recycled through current collection systems and are therefore currently non-sustainable. The Hydrozorb can be made from up to 100 per cent post-consumer material, meets food safety regulations, and has a low weight and also surface tension to avoid moisture build-up, as mushrooms are notorious for sweating in the pack.”

Shelf-ready packaging and bespoke promotional decoration are other areas in which the business believes it can add value to the market. It is also developing innovations in hermetically sealed skin-pack technology to offer extended shelf-life and ensure food safety. “To add further value to the skin-pack, we are developing bespoke formats for difficult-to-package or delicate products that are more demanding and challenging applications,” Frank Coleman revealed.

In summary recent developments reflect a focus on providing innovative, sustainable, and customised solutions – an ethos which is set to be underpinned in the future by considerable investment from the Waddington Group.

Spotlight on R&D Research and Development is central to the strategy of PPE and Holfeld. In terms of focus, food safety is the key foundation of innovation, with sustainability coming a close second in importance. The recent sequence of acquisitions makes these exciting times for the businesses, with technological synergies being exploited and more to come.

“The integration of Holfeld and Par-Pak gives us the opportunity to develop and innovate in a stronger union drawing from the knowledge and expertise of both parties,” commented Kevin Ingram. “Furthermore, under the umbrella of our parent company in

the US we can draw on the Waddington Group’s technological capabilities and harness them to suitable applications directed at the European market. It can be a challenge to introduce new technologies into Europe from outside markets. However, there is a tremendous opportunity to add value to the European market through the extensive US portfolio of the Waddington Group.”

An interesting feature of Holfeld Plastics is that it is entirely self-supported with regards to tooling and the company also makes the sheets from which it thermoforms its trays. “Our innovation goes beyond that of a normal thermoforming business or converter,” Frank Coleman revealed. “It goes into the raw materials we are using, and we invest a lot of time in materials development. Similarly, PPE invests time in tooling development as well. We have vertical integration and are self-sufficient so we can control factors in terms of cost and time-to-market.”

Waddington Europe The combined product ranges and merged technical resources enhance both companies’ capacity to serve the needs of their existing and new market sectors.

Bryan Ford, sales and marketing director of both European sites, observed, “PPE and Holfeld Plastics already share the same values, and a commitment to customer service

excellence and innovation. We pride ourselves on offering the core values of agility, innovation, and responsiveness. We strive to continually exceed our customers’ expectations. By combining our sites we are convinced we can bring new opportunities to the market through ongoing investment in R&D, materials and technology and increased thermoforming capability.”

Indeed since the acquisition of PPE, the Waddington Group has continued to invest into the Milton Keynes site, and the further acquisition of Holfeld Plastics was the second major investment of an ambitious growth strategy.

Kevin Ingram concluded: “The Waddington Group aims to be one of the leading players in the market through both the organic growth of Holfeld Plastics and PPE, and further acquisitions. This is a company with huge aspirations – it was not present in Europe until 2013, and after entering the market with the acquisition of Par-Pak it virtually doubled its capacity within a year with the subsequent acquisition of Holfeld Plastics.

The two companies will, in the future develop as ‘sisters’ under the umbrella of Waddington Europe. Our US parent is keen to see the growth and development they have enjoyed in North America replicated here in Europe, and the enthusiastic support being given to the n current businesses is testament to this.”

Visit: www.parpak.co.uk and www.holfeldplastics.com

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Gietz AG celebrates two jubilees Switzerland-based machinery manufacturer Gietz AG supplies first-class foil stamping machines as well as machines for the gluing and forming of conical trays to the graphic and packaging industry all over the world. All machines are built exclusively in Switzerland. Today the company is run by Ms Claudia Gietz Viehweger and Mr Hansjörg Gietz, who represent the 5th generation of the founding family.

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ounded in 1892, Gietz AG opened its new production site in Gossau near St. Gallen in 1964. Today, its headquarters are still located there.

On 25 and 26 September 2014 the company invited customers, partners and employees to celebrate two jubilees: The handover of the 50th hot foil stamping machine Gietz FSA 1060 Foil Commander; and 50 years since the establishment of the Gossau production site.

10 years after the introduction of the hot foil stamping machine Gietz FSA 1060 Foil Commander, the 50th machine was handed over to the long-time customer Gräfe Druck GmbH from Bielefeld (DE), a company well known for its activities in the print and print finishing sectors.

The celebration Some 70 international customers and partners from Japan, France, Germany, Russia, Spain, Italy, Poland, Serbia, Turkey, UK and Switzerland arrived in Gossau on the afternoon of the 25 September 2014.

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After a speech from managing director Mr Hansjörg Gietz, the 50th Gietz FSA 1060 Foil Commander was officially handed over to Mr Frank Denninghoff, managing director and co-owner of the company Gräfe Druck GmbH. As a mark of appreciation of the trust and good cooperation between the two companies, Mr Gietz handed over to Mr Denninghoff a specially engraved Appenzell cowbell.

In 2005 Gräfe Druck GmbH was the first company to invest in the innovative new Gietz FSA 1060 Foil Commander technology. Perfect stamping results, huge production output and very high durability made the decision to invest in the 50th Gietz FSA 1060 Foil Commander for Gräfe Druck GmbH an easy one.

In the assembly hall the 50th Gietz FSA 1060 Foil Commander was set up to produce a jubilee poster featuring a large combined foiling and embossing impression, an example of which was signed by all participants.

To celebrate Gietz’s commitment to the production site in Gossau and its Swiss heritage, four Alphorn musicians in traditional Appenzell dresses accompanied the handover, giving it the ‘Swiss Touch’.

That evening, at the Werk 1 restaurant in Gossau, the guests were able to view the photo exhibition ‘50th Gietz FSA 1060 Foil Commander & 50 years company location Gossau St. Gallen’. Afterwards some very informative presentations took place: Mr Markus Hoffmann, member of the managing board of Leonhard Kurz Stiftung & Co. KG from Fürth (DE), opened the symposium with a view on new perspectives and challenges in the foil stamping industry.

Mr Keith Campbell, global technical director at Amcor Tobacco Packaging, spoke from the customer viewpoint about the unique aspects of the Foil Commander and gave an overview on the future trends in the tobacco packaging industry.

Mr Heinz Artmann, founder of ART-Line Projekt GmbH and international consultant for the high security industry, spoke about his long-term experience in the high security industry and the application of Gietz technology in the banknote printing industry.

Playing local musical melodies, the yodel group Hirschberg-Appenzell opened the celebratory banquet. As a special musical treat Valerie Schindler dazzled the guests with her skilful performance on the dulcimer, her performance being enthusiastically applauded by all participants.

Additional greeting messages came by video from England, the USA, Nigeria and Brazil.

To conclude proceedings, on 26 September 2014 there was a group excursion to the top of the Säntis mountain.

Visit: www.gietz.com

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Trailblazers in thermoforming technology Based in Heilbronn in the south of Germany, ILLIG Maschinenbau GmbH & Co. KG is an industry leader, offering the most comprehensive range of machinery and tools for the thermoforming and packaging industries world-wide. Elisabeth Skoda visited the company’s Open House on 30 October 2014, and spoke to managing director Karl Schäuble and head of marketing communications Wolfgang Konrad to find out more about what makes the company a benchmark in quality.

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LLIG was founded in 1946, and since its beginnings has been at the forefront of thermoforming innovations. The company headquarters are located in Heilbronn in Germany, ideally situated between Stuttgart and Frankfurt. Machines are exclusively manufactured on site in Heilbronn. As a global player, ILLIG has sales offices in 80 different countries, and 80 per cent of its business comes from exports. More than 750 employees develop and produce complex production lines. ILLIG prioritises pioneering inventions and innovations, as Mr Konrad explains.

“About 100 members of staff, over 10 per cent of the workforce, develop forwardthinking solutions into research, development and design, securing ILLIG’s position as an innovation leader. Having such a high percentage of employees working on development gives us a competitive edge.”

Complete thermoforming solutions As a market leader, ILLIG is proud to be the only manufacturer to offer a complete thermoforming portfolio under one roof, as Mr Konrad points out.

“We are the only company to offer a complete range for various industries, including sheet processing machines; automatic roll-fed machines for forming and punching and also for separate forming and punching; skin and blister packaging machines; and form, fill and seal lines. Our competitors offer some of the machine functionality, but none of them offer the entire range under one roof.”

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“We have competitors in individual sections, but nobody else offers the complete range in thermoforming. Thanks to this, we can offer from synergies in-house, and the customer benefits. For example, when we work to fulfil the high requirements for coffee capsules, the insights gained in the process can be applied to other areas, thereby optimising processes. Our synergies, complete lines, training and service are the key points that set us apart from the competition,” Mr Schäuble adds.

Packaging applications include items such as cups, blisters, lids, inserts and trays, bottles, hinged packs, trays and skin packs. Automotive is another major industry served with a product range from headrests to instrument panels and inner door linings being thermoformed. Refrigerator insides, model making, stacking pallets, plates, housing and laminated parts complete the application portfolio.

ILLIG not only develops machines, but also tools in-house, which makes the company an ideal partner for machinery development together with customers.

“This enables us to offer a wide spectrum of products and customers benefit from receiving the complete product from one source,” Mr Konrad adds.

“ILLIG’s name has become synonymous with quality. Many of our suppliers and even competitors advertise the fact that they manufacture tools in ‘ILLIG quality’, which is a great recommendation but also keeps us on our toes to keep ahead of the game with innovation.”

Better machine operation with ILLIG IC One of ILLIG’s success stories is the introduction of its IC Intelligent Control System. The name evolved out of ‘ILLIG Intelligent Control Concept’, following market demands for a simpler way to operate increasingly complex machines.

“Modern thermoforming machines have increasingly complex requirements, necessitating an intelligent operating concept. An example might be the technology used in smartphones which offer a lot of features but are still easy to operate,” says Mr Konrad.

Mr Konrad explains that IC offers six key features: thermo line control, dynamic process optimisation, compensation of ambient influences, accelerated mould change, a self-adaptive start-up phase (sas-up®), and ILLIG NetService.

ThermolineLineControl allows central management, monitoring, optimisation and controlling from a panel at the forming station, providing increased operator convenience, saving time and effort during a mould or format change, thereby increasing machine productivity, facilitating fault analysis and troubleshooting in case of a malfunction. The second feature is dynamic process optimisation via a motion control system.

The machine recognises material and calculates parameters for production, facilitating the task of selecting the right machinery settings. When settings are changed, operating sequences are re-calculated and adapted while pre-set process parameters are maintained, with downstream stations being integrated into the system. ILLIG achieves an average performance increase of around 42 per cent using standard tools.

The third key feature that sets the IC system apart from the competition is the compensation of ambient influences.

“Previously, a machine frame would heat up as production progressed, resulting in temperature non-uniformity of the material band. A compensating controller is now used to ensure a constant film temperature via continuous automatic adaptation of the heating element temperature or heating time, respectively. At the same time, the forming air pressure, temperature and cooling water throughput are monitored inside the mould. These features promote a constantly high product quality and save energy,” Mr Konrad adds.

Another feature is fast mould changing. A structured help system displayed on the control screen guides the operator through the mould-change process, saving time, increasing the machine’s availability rate.

The ‘sas-up® - Self-Adaptive Start-Up’ mode provides a reduced cycle rate and optimised settings, slowing down the start-up phase, thereby allowing the operator to observe processes and make the necessary changes, which means a reduction of waste. Finally, ILLIG’s NetService provides the option for remote servicing and trouble shooting, allowing technicians to review system components via the internet anywhere in the world, and provide trouble shooting.

“This also allows for preventive maintenance – the system recognises when a part is nearing the end of its life, and we can send a replacement before the part is actually broken,” Mr Konrad says.

Showcasing the company ILLIG regularly exhibits at trade shows, and makes sure it is present at all the major fairs such as K, Fakuma, Interpack and Anuga Foodtech, and a range of trade fairs in countries where plastics products are popular, such as Germany, France, UK, Italy and Spain. Further afield, important trade for ILLIG include Chinaplas, Plastica in Russia and of course Pack Expo in Chicago and Las Vegas. Regular Open Houses are another way of keeping customers and potential customers up to date with ILLIG’s latest developments.

On 29–30 October 2014, ILLIG held its 13th Open House at its headquarters in Heilbronn, presenting high performance machines and recent improvements and innovations. Amongst the machines showcased were newly developed thermoformers of the IC Generation, such as the models IC -RDK 80 with servo A/B stacking and IC - RDKP 72 with DSB and stacking. Further highlights included a RDK 90 with double handling.

Also showcased was the potential to interlink machines, with the IC-RDKP 72 and the STAL 90 punch and die press.

Visitors had the chance to see the machines in operation. Presentations summarising technical highlights and market trends, with a focus on IML applications and the coffee capsule market, concluded the event.

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At the last Fakuma, ILLIG presented an old classic. In response to many requests it reintroduced the previous generation of today’s UA 100g sheet processing machine into its portfolio – the UA 100Ed machine which had been built for two decades up to 2002. It is a completely servo driven and process controlled sheet processing machine and meets all current demands in terms of flexibility, cycle speed and product quality. But thanks to its smaller size and easy operation it is of great interest to contractors, training institutions, workshops as well as material manufacturers and tool makers.

“People are keen to own an ILLIG machine, and the 100Ed is perfect for entry level customers,” Mr Konrad adds.

International focus The company has achieved continuous growth over the years, as Mr Schäuble explains.

“Recent years were marked by an ever growing international focus, expanding to more markets outside of Europe. Standards in packaging and demands on hygiene are increasing. As megacities in developing countries grow further, demand for higher hygiene standards through packaging will also grow. Therefore it is important to be present in developing countries with operations and services. Growth will follow.”

Technological advances and sustainability go hand in hand, as Mr Schäuble adds. “Of course there has been some discussion about replacing plastics with other materials in order to be environmentally friendly. We think however that in order to fulfil the hygiene requirements of the modern world, plastics are here to stay. Technological advances, allowing optimised thermoforming which results in the minimal amount of materials used for the best possible product will lead the way to a sustainable future.”

Mr Schäuble uses ILLIG’s coffee capsules as an example. “The coffee capsule market continues to grow. Thermoformed coffee capsules offer a long product life thanks to being hermetically sealed, preventing contamination and saving the need for outer pack-

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aging. In-mould labelling is another example of thermoforming as an environmentally friendly technology: since label and container are made from the same material, recycling becomes a lot easier. Improving the quality of in-mould labelling again helps to reduce the need for extra packaging, for example in the case of a six pack of yoghurts. When the product description is clear on the containers, extra cardboard wrapping is not necessary.”

Process optimisation as described in the term Industry 4.0. is of key importance, and this is why ILLIG focuses on innovation, investing a large share of turnover back into product development, as Mr Schäuble points out.

“It is important to us to very watch market trends very closely. It takes around two years to develop an entire line. Big form, fill and seal lines have huge technological requirements, and we have to be an expert in almost the entire supply chain, as our machines can be linked up with other machines in the supply chain.”

ILLIG follows a strategy of concentrating on its in-house core technologies and exploring development potential in new applications for thermoforming. “Important areas for additional growth are in-mould labelling and packaging lines with decoration technology – a major USP for us. We will continue to bring new solutions to the market,” says Mr Schäuble.

With an international presence already, ILLIG makes 60 per cent of its turnover from outside of the EU. “Our machines are used all over the world, and one of the important challenges for the future is finding out how to adapt machines so that they work well for the different requirements of other countries. A range of applications were originally developed together with European customers, with good possibilities for transfer to countries outside Europe. Looking for new applications which are initiated in Europe and trying to distribute these applications outside Europe once we have a suitable distribution n and service structure in place is of key importance,” Mr Schäuble concludes.

Visit: www.illig.de

Matrìca: The success

of green chemistry In October 2014 Matrìca hosted an international open day in Porto Torres (Sardinia) to present its green chemistry plant to European stakeholders.

Catia Bastioli, CEO of Novamont and Matrìca and Daniele Ferrari, CEO of Versalis and chairman of Matrìca talk about the project and the importance of building bridges with institutions, local government and farmers in order to be successful and promote the circular economy. Alessandra Lacaita reports.

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The joint venture Born in June 2011 as a 50/50 joint venture between Novamont and Versalis (ENI), Matrìca managed the successful project of the reconversion of the petrochemical plant of Porto Torres (Sardinia) into a green chemistry plant. Leveraging Novamont’s knowledge in biotech and green chemistry and Versalis’ engineering know how for the industrialisation process, Matrìca identified local sustainable production of oleaginous products crops, created a research centre and started its production of bio-based products.

Catia Bastioli explains that Matrìca continues on the line of the Novamont’s research. She states: “Our main objective at the beginning was to use low impact crops available in the local areas in order to respect biodiversity, to use marginal areas without wasting large volumes of water, to reuse deindustrialised sites and integrate a range of technologies into the bioplastics chain. In the bioeconomy we have to think not only about bio-based products but about systems and about territorial regeneration and so the way a product can face societal challenge.”

“In the chemical industry,” Daniele Ferrari emphasises, “we have always thought about energy platforms, alternative energies, sustainability, an intelligent market and bio-based chemistry, which are the European mega-trends for the bioeconomy.

Today in Europe there is a need for infrastructures and political support to face challenges which can unlock the potential of green chemistry. Moreover, in order to be successful in the green chemical industry we have to think about three main business growth accelerators: chemical industry, crop science and biotech, and the way we can exploit these.”

According to Mr Ferrari, as a joint venture Matrìca possesses these points of strength and it has the support of the local Institutions and the local Goverment, which on 26th May 2011 signed the ‘Memorandum of understanding for Green Chemistry in Porto Torres’.

Plants and production Matrìca has globally invested 180 million Euro in its project. In 2012 it opened its Research Centre in Porto Torres consisting of an analytical laboratory and seven pilot plants covering a total area of 35,000 square metres.

In addition, Matrìca has three big plants with innovative technologies for its production. The Bio-monomers plant represents the most important part of the project, as it produces intermediates such as azelaic and pelargonic acid which are not produced in Europe at all. The Azelaic Acid is the monomer of bioplastics and

“Our main objective at the beginning was to use low impact crops available in the local areas in order to respect biodiversity, to use marginal areas without wasting large volumes of water, to reuse deindustrialised sites and integrate a range of technologies into the bioplastics chain. In the bioeconomy we have to think not only about bio-based products but about systems and about territorial regeneration and so the way a product can face societal challenge.”

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“In the bioeconomy it is important to establish a relationship between industry and agriculture and this is what Matrìca did, through the joint venture between Novamont and Versalis”

the monomer for the synthesis of some polymers and it serves for the production of plasticisers and lubricants and for pharma-cosmetic formulations. Pelargonic acid is a raw material for ester production in applications such as bio-lubricants, cosmetics, personal care and food fragrances.

The second plant is specialises in Rubber and Additives, and produces plasticisers and oil extenders for rubber. The third plant is dedicated to esterification, that is, production of esters for different applications.

“All these products can contribute positively to the environment,” Catia Bastioli explains. “Polymeric plasticisers are a replacement for phtalates; bio lubricants reduce the consumption of lubricants, which disperse oil in water and soil; thistle oil replaces palm oil, with less deforestation.”

Matrìca’s main crops for the production of bioplastic is the thistle, with a total of 400 hectares on which 40 farmers work.

institution: we started locally, involved the government, university, research centres and trade unions. We spoke a lot about the employees, who are the most important factor for a successful realisation.” Today Matrìca employs around 120 employees (rising to 145 by the end of 2014) but, for its first project installations it had 400 people working on the construction of the site, with peaks of 700 per day. “We always put safety at first, from the beginning to the last. The major achievement was to deliver this project with no accidents.”

Matrìca is now working at six different sites in Italy producing new technologies n for the bioplastics chain.

Catia Bastioli, CEO of Novamont and Matrìca

Building connections “In the bioeconomy it is important to establish a relationship between industry and agriculture and this is what Matrìca did, through the joint venture between Novamont and Versalis,” Ms Bastioli asserts. “Matrìca is the result of a new concept: from a product based company it becomes a system based company as it tries to integrate the biorefinery plant into the local area. Matrìca is in fact a green plant which produces chemicals and bioplastics from different plants, in order to respect a different biosystem. It uses low impact technologies and plants as well as marginal lands and de-industrialised sites.”

She also explains that in the creation of a start-up it is really important the upstreaming integration, as it requires research and financial support, engineering activities and connection with institutions and farmers: “A project like this cannot be done alone but with lots of partnerships. It is important not to build cathedrals in the desert but to create connections with the local area in order to create a specialised chain which enables crops to survive in an environment like the northern part of Sardinia. Matrìca creates these connections.”

“I think Catia and I can claim a masters degree in Institutional Relationships after this experience,” Mr Ferrari jokes. “I believe we have spoken with all kinds of Packaging Europe | 99 |

Flexible packaging specialist

with a global reach The Gualapack Group is a global leader in flexible packaging, founded in 2010 through the joining together of two leading Italian companies: Safta and Gualapack. Today the group is part of an international network involving joint ventures, partners and research centres. Packaging Europe looks at the qualities that have contributed to its rapid growth.

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he Gualapack group, with a turnover of €180 million in 2013, has become a world leader in flexible packaging technology after the successful combination of two firms with a long industrial pedigree: Safta (a pioneering Italian producer of multi-layer flexible laminates founded in 1925 in Piacenza, Italy) and Gualapack (a world leader in premade flexible packaging solutions with spout and cap, founded in 1986 in Alessandria, Italy).

“Safta is a well-established and highly reputable, fully certified Italian converter of flexible packaging, well-known for the quality of its multi-layer laminates and for its tailor-made packaging solutions,” says general director Michele Guala. “For more than 50 years Safta has been an expert in advanced flexible packaging. The range of our products covers nearly all food and non-food segments with complex structures up to five layers, for critical applications such as vacuum packaging, chemical or mechanical resistance, hot filling or sterilisation. Gualapack is a global leader in premade flexible packaging with its stand-up pouch and spouted pouch packaging solutions These are supplied to customers with their spout and a separate cap, to be screwed to the spout after filling.”

International network And the offering does not stop there. “Gualapack Systems also offers filling lines specifically designed for our range of spouted pouches,” he adds. The group, which employs 900 people across its different locations, has also built up an international network involving joint ventures, partners and research centres.

The global network is made up of three plants in Italy, one plant in Romania, one plant in Costarica and two joint ventures (Secure Packaging in China and Cheer Pack North America in the USA).

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A network like this brings synergies, explains Mr Guala: “The Gualapack Group enhanced its expertise and efficiency by merging the business units involved in Cheerpack production; from Safta producing the laminate reels to Gualapack producing Cheerpack and manufacturing the filling lines.

Safta in return benefits from Gualapack’s outstanding capacity in pouch-making to offer a complete range of Stand Up Pouch for dry, fresh or retort product. Moreover, strong synergies were created within the Gualapack group, both technical and economic, with its existing joint ventures by expanding its sphere of activity in other areas.”

Targeting market segments Thanks to its unrivalled expertise, the group is increasingly focusing on liquid products and products that demand thermal treatments. This results in a focus on food, but also on medical, pharmaceutical and cosmetics. “We are actually focusing on constant product and process optimisation, to serve today’s end-use markets even more efficiently, especially with regards to safety, cost effectiveness and sustainability. Equally important is the creation of a ‘positive feeling’,” Mr Guala explains. “Our products must create feelings, and therefore we focus on innovative pouch designs and features and on surface effects.

Needless to say, we also emphasise maximum efficiency in terms of waste reduction, high processing speeds, maximum functionality and user-friendliness.”

Market leadership qualities The Gualapack group’s mission is to provide integrated, efficient and safe packaging solutions. The group’s strengths comes from a total control of the whole process,

Gualapack, Alessandria (Italy)

Safta, Piacenza (Italy)

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Thermoplay

Thermoplay, with its HQ in the industrial area of Pont-Saint-Martin in Aosta, Italy, is a specialist developer and manufacturer of hot runner systems for plastic injection moulding. The product range, designed and built exclusively in-house, includes a vast selection of standard and special hot runner systems, including complete hot halves, temperature and sequential control units, flow analysis, tailored made projects, simultaneous injection of different colours and materials, and sequential injection with pneumatic or hydraulic valves, in order to satisfy all configuration needs for any market or application.

Since their foundation, Thermoplay and Guala Pack have shared philosophies, immediately creating a close collaboration that has brought unique results in product innovation and in productivity increase.

More than thirty years of experience in the design of hot runner systems and the know how acquired in multicavity applications for the packaging sector, combined with continuous research of proper innovative solutions to increase the performances of toolings and manufacturing, have contributed to a series of products that deliver the fast moulding cycles and maximum aesthetical and functional quality necessary for Guala Pack product typology.

This close collaboration becomes ever more strategic, not only to strengthen the partnership in the proposed solutions, but also to offer the best support to all production sites.

Thermoplay and Guala Pack combine the same passion and daily attention in all their activities, creating above all the best environmental and human conditions to be able to guarantee the client the maximum satisfaction.

Thermoplay S.p.A., Via Carlo Viola, 74, 11026 Pont Saint Martin (AO), Italy www.thermoplay.com

from PE film blow extrusion to pouch filling. Customers can count on a comprehensive technology portfolio, as well as on its ability to develop tailor-made solutions – everything backed up by the assurance of the highest quality and safety standards certified according to ISO and BRC. “A company is measured not only by numbers, but also by its courage to innovate and try new solutions in order to meet customer expectations,” says Mr Guala. “In an increasingly complex and varied market we consider the needs of sustainability and respect for the environment.” Over the years, the Gualapack Group has been investing in R&D, developing new projects like NEXT, LamiNEXT or Baby’Clips®.

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Gualapack Group recently launched the ‘NEXT’ project, which stands for ‘New EXpertise for Tomorrow’. This is a set of initiatives aiming at reducing the LCA (Life Cycle Assessment) of packaging in minimising waste as well the impact of the company’s activity on the environment. A brand new development is the LamiNEXT range of films that are bio-compostable or made with bioplastics derived from renewable resources.

A further innovation is called Baby’Clips® – the first clip-on spoon for baby food pouches. With a width of less than 2cm, the spoon is designed specifically for a baby’s mouth. It encourages the transition from bottle-feeding to spoon and provides a clean, pleasant and effective learning experience. The spoon snaps quickly onto baby food pouches, and can be used anywhere and anytime.

Verbano Film

Verbano Film, is a production Italian company specialized into CPP film production.

PP film is used into several application fields such as Laminates for Food & Medical applications, Flexo & Roto Printing, Textile & Flower bags, Stationary, Automotive and Adhesive tapes.

Films are produced by 4 lines highly automated, equipped with self-diagnosis system to keep production and quality parameters into defined tolerance range.

Nominally, production out-put of the lines is set around 15.000 t/year.

Produced films may have: • Thickness range from 25 my to 280 my • Max width 2700 mm • Max rolls diameter up to 1000 mm Verbano film is certified in compliance with the ISO 9001 and BRC/IOP Regulations.

AUTOMHA

AUTOMHA is a leading global provider of innovative logistic solutions and material handling for the optimization of the supply chain, distribution centers, and manufacturing operations.

With the ability to achieve solutions for each industry, AUTOMHA develops cost effective and efficient products for the multi-deep storage as tailor made solutions of automated storage and picking, including AS/RS, Miniload, material handling, WCS-WMS software and services.

Each automatic system is designed and manufactured 100% by Automha facilities.

Automha is the key partner for your warehousing needs!

Visit: www.automha.it

Baby’Clips® was voted best innovation of the year in 2013 and 2014 by parents visiting the eight Baby shows in France and comes in a variety of colours.

Europe and beyond At the time of writing, Mr Guala had just been voted president of GIFLEX, an Italian Association that joins 36 producers of printed flexible packaging. The group is part of the Italian Manufacturers’ Association, a part of the National Association of Printing, Paper and Converting Industries, and belongs to the EAFA division FPE (Flexible Packaging Europe). “I think GIFLEX has been playing an important role in Italy, and now thanks to its participation in FPE will extend its

influence at European level, where more and more regulations will be decided,” he says.

But the company’s vision for the future does not stop at Europe, as Mr Guala confirms: “We think of Europe as our home market, and we develop our strategy in Europe first.

We do not distinguish between different European countries, because we compete equally across all of them. But our recent strategy is also bringing us outside Europe, where we have been developing fast in recent years thanks to local joint ventures, trying n to follow the growth of our customers around the world.”

Visit: www.gualapackgroup.com

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Innovating liquid carton packaging Highly innovative carton packaging for dairy and juice products – this is the world of Elopak. Julia Snow reports on the company and the newest member of its product family.

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oday a carton has to be more than just a generic package for liquid. With over 13 billion produced annually, Elopak’s paper based packaging solutions are top of the class in terms of design, functionality and innovation. The company offers complete packaging solutions, including blanks, closures and filling lines with maintenance and service.

Based in Norway, and wholly owned by the Ferd Group (one of Norway’s largest privately owned industrial groups) Elopak is continually developing its packaging expertise to match the changing demands for packaged food. Over half a century of continuous expansion and growth has turned it into a global corporation operating on every continent.

Through a network of market units and associates in more than 40 countries, the Elopak Group is able to bring its international expertise and product technology to new markets.

Trendsetting in Aseptic: the new generation of filling lines With the development of the first fully aseptic gable top system, Elopak is pursuing the strategy of highly functional packaging concepts, offering convenient and cost-attractive packaging solutions for products in ambient distribution.

Elopak´s new aseptic filling machine (E-PS120A) sets new standards in the market and ensures fully aseptic filling technology. It benefits from its modest space requirements and high effectiveness with an output capability of up to 12,000 cartons per hour.

The machine offers a multitude of unique benefits in manufacturing, assembly, operation and maintenance. The versatile design makes it capable of processing high as well as low acid products.

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Pure-Pak® Sense: Next generation gable top carton

Contributing to a more sustainable future

Brand new in 2014 is Elopak’s latest carton innovation for fresh products: the Pure-Pak® Sense carton. The name has been derived from the fact that the design is focused on an appeal to the senses. This latest highlight is a result of thorough market research and analysis as well as internal workshops across Elopak’s technical, design and development departments. It was developed to appeal to consumer preferences and enhance brand differentiation through both its look and innovative functional features. It has a new, eye-catching design that communicates better on-shelf, and improved functionality with more convenient handling.

Elopak aims to replace all fossil-based raw materials with renewable alternatives and is working in partnership with key customers wanting to boost the environmental merits of their packaging. An increased use of bio-based PE helps reduce the use of fossil-based materials. In addition, this reduces one of the largest sources of CO2 emissions in the beverage carton value chain.

“The beverage carton is the environmentally superior packaging choice, consisting of at least 75% renewable paperboard derived from responsibly managed forests. The remaining materials are mostly made of polyethylene, a polymer usually produced from fossil-based raw materials. Renewable PE brings us much closer to our vision of a 100% renewable carton. At the same time, we are further reducing the carbon footprint of the carton; a footprint which was already best in class within beverage packaging”, says Kristian Hall, Director Corporate Environment at Elopak.

In addition, the bio-based PE is certified through the entire value chain, by the International Sustainability and Carbon Certification system (ISCC PLUS). ISCC PLUS sets strict requirements for sustainability and traceability through the entire value chain, with chain of custody certification based on a mass balance system.

Visit: www.elopak.com

Differentiating on shelf The carton features an arched top fin with a print option that provides a tool for better range navigation and enhanced communication of promotional messages. This carton both looks and feels different with an embossed ‘first touch’ zone on the top sides of the pack, giving consumers a new tactile experience with better handling.

Reflecting the global trend to combat food waste, the Pure-Pak® Sense carton features new easy-to-fold lines. The feature enables consumers to fold the carton and squeeze out more of the product from the pack which is ideal for high viscosity products. The easy-tofold lines also enable convenient flattening of the empty carton, reducing volume in waste or recycling facilities.

Elopak has developed this latest solution as a cost-efficient and flexible option running on existing filling lines with a minimal investment in a retrofit kit. Customers could run both the new Pure-Pak® Sense carton and the Pure-Pak® Classic carton on the same line. Importantly, the technology gives users the flexibility to switch from one carton format to another with minimum changeover time. In a marketplace that demands ever-increasing diversity and innovation, this is a key enabler for business growth.

The Pure-Pak® Sense carton has been tested and launched in several Beta sites across Europe with a strong positive response from customers, retailers and consumers.

The Greenest Pure-Pak® carton ever Elopak is the first company to offer beverage cartons with renewable coating to the European market. As an industry first, Elopak uses second generation renewable polyethylene (PE), made of European-sourced biomass not in competition with food supply.

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Crown Van Gelder:

A tradition of innovation Packaging partner Crown Van Gelder is committed to developing and manufacturing speciality papers. Emma-Jane Batey spoke to Eric Guern, speciality packaging products manager, to learn how this dynamic company is growing in more ways than one.

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ndependent paper manufacturer Crown Van Gelder is based in Velsen-Noord close to Amsterdam in the Netherlands and is listed on Euronext Amsterdam. Employing nearly 285 people and generating a turnover of around €160 million, the company develops and manufactures specialities for graphical and industrial applications using state-of-the-art technology.

Crown Van Gelder’s speciality packaging products manager Eric Guern spoke to Packaging Europe to explain how the company stands apart from the competition. He said, “It’s not just the fact that we have the very latest technology; we have great expertise too. We are always able to get the very best out of our equipment as we employ people who know speciality paper inside out. We are experts in industrial processes to produce speciality papers.”

Industrial expertise This expertise is clear from the Crown Van Gelder portfolio. Based on the three core areas of digital, packaging and label, all of its products are of the highest quality. Mr Guern

continued, “We always want to stand out in the markets and being in close contact with our customers where we operate. As a medium-sized, modern and versatile paper manufacturer we are able to respond flexibly to our customers’ requirements. By distinguishing ourselves as a true partner in speciality papers in each of our core areas, we can be sure to stand as a leader in our industry.”

Crown Van Gelder’s strapline of ‘bringing paper to life’ highlights the vitality of its portfolio. The company started developing paper products especially for high-speed inkjet printing over a decade ago and this continues to be an important activity. Mr Guern added, “With our Crown Letsgo Inkjet range we have the world’s most extensive product portfolio. We have gained a leading position in the field of high-speed inkjet printing, in terms of volume as well as knowledge and technology.”

One area where Crown Van Gelder is enjoying considerable growth is in its product range. In addition to continually adding new options to help customers expand their business, the company is able to develop and manufacture custom solutions, with a range of finishes for transactional, promotional and publishing market segments.

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The issue of sustainability is important to Crown Van Gelder and it is also another area where its achievements are growing. Mr Guern explained, “Alongside our expanding product portfolio runs our focus on sustainability. We are constantly working on new ways to reduce the raw materials used whilst retaining the high quality we are famous for, as well as creating exciting new solutions using the most innovative materials. These also allow sigificant reductions in the further production proces of our customers. Although much of what we’re working on is top secret, I can tell you that we are engaged in very strong research of biopolymers as barriers to be applied on papers. This will provide excellent protection against gas, moisture and so on.”

Retail opportunities A further growth area for Crown Van Gelder’s portfolio is the field of shopping bags.

Long active in this sector, the company is finding that the ever-changing European regulations on plastic shopping bags are working in its favour. Mr Guern noted, “Shopping bags are an important growth area for us and one in which we are very pleased to be seeing strong growth; it’s great to be part of a more ecologically-sound alternative.” Crown Van Gelder also works closely with a number of converters active in the food packaging sector and as such holds all of the required global standards for food contact. Crown Van Gelder is also producing paper for corrugation (fluting and liner) for the markets

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of takeaway food and cosmetics. Moreover, high quality paper for the making of icecone wrappers is also an speciality that requires the needed expertise and continuous attention.

Crown van Gelder is also strict when it comes to employing good forestry standards across its suppliers. Mr Guern noted, “We have a clear sustainability message. We believe in paper: it’s a good substrate to work with as it’s renewable, biodegradable, recyclable, compostable – all with the highest forestry standards of course.”

In terms of its geographical footprint, Crown Van Gelder is also experiencing growth.

Primarily active in Europe and especially northern Europe, its domestic and near neighbouring markets account for around 85 per cent of its turnover. Working closely with carefully-selected partners in North America, Asia and Australia is increasingly bringing new opportunities for sales further afield and this is a key part of its plans for continued success. Mr Guern concluded, “We predict strong organic expansion in the coming years in our three focus area’s: packaging, label and digital. With the announced acquisition by Andlinger Company we will be able to utiilise opportunities even quicker in the future and develop innovations suitable for our customers. This will strenghten our strong position in the High-quality Inkjet printing papers, in the European Self-adhesive paper markets and our growth in the Packaging paper specialties.

Visit: www.cvg.nl

Even better IN SHAPE If you hold an aluminium aerosol can or tube in your hand, it was probably made on one of mall//herlan’s production lines. Felicity Landon talks to managing director Roger Schmidt, who is leading a major overhaul at the group.

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ore efficient, more cost-effective and with a clear strategy to remain the market leader – these are some of the key targets within a major restructuring and consolidation exercise being led by Roger Schmidt at mall//herlan.

The project is called SHAPE. “We want to be in better shape,” he says. “We will increase our business share, increase our development activities and also focus on diversification. There are so many opportunities out there where the mall//herlan knowledge and expertise could deliver valuable new markets.”

Mr Schmidt joined mall//herlan in mid 2014 with a clear brief. “The group was very successful in selling machines to customers – but the internal structuring over four different locations had become too loose. My task is to restructure the organisation and to bundle competences, to be more effective internally, and to boost innovations” he says.

“I have done this with other companies before, seeing through major restructuring, internationalisation and business development” At mall//herlan, some subsidiaries have already been swept up in consolidation changes and there has been a planned process of technology transfer, with key technologies combined and focused on specific sites.

“First successes are seen already, from January 2015 on we will deliver necking machines from Pfinztal and washers from Neuhausen and first ovens and conveyors are built in Thailand already.” he announces.

Mr Schmidt says the immediate project, with the key changes, will be completed by March 2015. “But it will always be a work in progress – there are always improvements to be made,” he says.

Production profile mall//herlan, part of the wifag/polytype group, supplies single machines, complete lines and turnkey solutions for the production of aluminium or steel monoblock packaging’s.

It supplies machines for the production of aluminium containers made by the Impact Extrusion (IE) process and aluminium or steel containers made by the Draw and Wall Ironing (DWI) process, as well as the forming of the hollow tube bodies by IE, the production lines also integrate presses, trimming, washing, printing, curing, necking and shaping. Customers have the advantage of ‘one-stop-shopping’, with all the

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machines needed for the manufacture of these products coming from mall//herlan as the general contractor.

The key markets are aerosol and beverage cans, bottles and tubes. Produced containers are used in segments like beverage, cosmetics, household and body care, pharma and technical products. IE and DWI technology enables the production of lightweight, individually shaped, colourfully decorated and recyclable bottles and other kinds of containers out of aluminium or steel. In all above mentioned segments shape, functionality, decoration and design are key in this very crowded and competitive market, for aerosol containers to collapsible aluminium tubes.

The group employs about 200 people in three factories – two in Germany and one in Italy.

“Each plant delivers its specific expertise and products into the system,” says Mr Schmidt. At the same time, the mall//herlan group has access to its parent company’s footprint . “We use the production facility in Thailand and the world wide network of the subsidiaries ” he says.

Core technologies So which technology is the main focus, IE or DWI? “Historically, IE is the basic technology at mall//herlan,” he says. “This process gives you a lot of flexibility and stability for the production of a can. With DWI, the walls are less thick, so the product is lighter.

“However, we are looking into this technology to develop more products. DWI can make significant savings in material costs, which is the major driver of the cost of one of these containers. In addition, DWI gives us the option of going into stainless steel cans or other containers.”

Cans that are currently being produced in three pieces could be replaced by a DWI monoblock can, produced in one piece on one machine, he says.

Of course, there are different solutions for different requirements.

As for what the customers are looking for, there are, says Mr Schmidt, two specific issues – cost and differentiation. “Look at any supermarket shelf and you see a lot of different sizes and looks and styles, all driven by marketing and the need to differentiate.”

Container development

Expanding globally

In parallel with the SHAPE project, mall//merlan is to concentrate its technology and R&D at its headquarters, where it is investing several million euros in a new technology/ test centre. “Here we will have the ability to produce cans, to increase our system knowledge and offer the opportunity to develop containers in partnership with customers. In parallel, we will be able to develop machines and tools for specific containers. Another successful step within our project– being in a better shape!” The first phase of the test centre has been built, and a second phase is due for completion in April 2015.

The group’s present manufacturing and subsidiary set-up is suitable for serving the global market and offering all sorts of service activities, says Mr Schmidt.

“China has improved and India and South America are on the way,” says Mr Schmidt.

“For us, the aerosol business hot spots are Asia, South America, Europe and North America – each market in itself being a little bit different. The Chinese and Indian markets are particularly promising.” n Visit: www.mall-herlan.de

Roger Schmidt, Managing director

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Improving

total efficiency From conveyor components all the way to turnkey solutions, FlexLink delivers automated production flow solutions to let clients optimise the material and information flow in their production processes. Piotr Sadowski reports.

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lexLink is a global provider of automated production flow solutions which help customers around the world enhance total efficiency in their manufacturing processes. Since January 2012, FlexLink has been a part of Coesia Group. “FlexLink constantly invests in new technologies and cutting-edge solutions, serving clients globally through a network of sales and engineering units in 30 countries, and a partner network in more than 60 countries,” explains Hans Vos, general manager at FlexLink Systems BV in the Netherlands.

“Within our FlexLink network we have very strong cooperation and work through geographic clusters of units. In Europe, the particular focus is on the western and central Europe clusters, where units work closely together and, of course, across the entire network. Recently there has been even more teamwork, which strengthens the efficiency of cooperation including major developments such as centralising the assembly plant in Poland. This has helped us to offer the best supply times, which is a critical factor for new product introductions.”

FlexLink in the Netherlands supplies a great multitude of clients, including some of the largest global companies in the FMCG segment. These include United Biscuits, Mars Unilever, D.E Master Blenders – a renowned international coffee and tea company headquartered in the Netherlands – and many others besides.

“Automated production flow solutions enhance production efficiency by minimising non-value adding operations and eliminating bottlenecks, cutting throughput time by as much as a half,” says Mr Vos. The solutions reduce the total waste and energy consumption per unit produced, thus reducing the environmental impact of operations.”

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Increasing operational efficiency There are primarily three ways to increase the profitability of a manufacturing unit: increasing the sellable throughput, reducing operational costs and reducing working capital. With the automated production flow solutions offered by FlexLink, all these issues can be addressed and improved. Increasing the sellable throughput is achieved by reducing bottlenecks through balancing the production flow; reducing process waiting time; reducing change over time, which increases the line flexibility and available production capacity; and improving quality assurance and increasing yield, which results in less waste. Operational costs are reduced by minimising non value adding operations; reducing power consumption per produced unit; reducing manual administration; achieving space efficient solutions – i.e. more capacity per factory metre square; and improving the after-sales service, which reduces the total cost of ownership (TCO). And the reduction of working capital is achieved by reducing stocks of finished goods; reducing work in process (WIP); and better utilisation of the factory floor.

FlexLink has recently introduced a brand new concept which is revolutionising the efforts towards increasing customers’ OEE on their production lines. Called ‘YOUTILIZEin-a-Box’, the solution is a mobile measurement product installed on a production line, which, over the course of three to five days, measures the product flow and the output for every machine in the production line. The results are transferred to an Excel sheet which allows the user to see where the downtimes and bottlenecks have occurred. A simulation model is created, which shows the distribution of downtimes and enables FlexLink to remove the bottlenecks by adding appropriate solutions and run the simulation again after the changes.

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We provide the customer a report stating the increase in OEE and the required investment. What makes this concept unique in the market is that ‘YOUTILIZE-in-a-Box’ is the only solution available which tells customers how to increase the OEE effectively.

Another new product is the ‘WLX System’, a wide belt conveyor for wet and dry processes. From packaged meat and dairy to bread and flour, the system ensures troublefree operation and long service life. Ready to be installed in any application area – from primary packaging to end of line – the standardised and modular design of the wide belt conveyor makes assembly and modifications easy. The system is available in 374, 526 and 678mm widths, and all sharp corners, flat surfaces, hollow bodies and crevices where pathogens and contaminants tend to get trapped have been eliminated. “The ‘WLX System’ is a much more hygienic conveyor solution; it is very easy to clean and there is a much lower risk of contamination of the entire conveyor system should packaging break,” adds Mr Vos.

High quality and responsibility FlexLink works with the most reliable suppliers, which is essential in order for the total overall quality to be maintained at the highest possible level. Suppliers are important to FlexLink through their provisions of components and materials which are crucial for

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the company in creating and delivering customer value. FlexLink has developed its own supplier handbook which is a guideline for all suppliers working with the company on a local and/or global basis. FlexLink requires all of its suppliers to develop systems based on international standards such as ISO 9001, ISO 14001 and OHSAS 18001, aiming at continuous improvement in related performances. Suppliers are also asked to actively work to comply with the UN Global Compact’s ten principles on sustainable business.

FlexLink itself has been officially supporting the UN Global Compact initiative for two years, which means it is fully committed to reducing the impact on the climate by ensuring the most efficient and responsible approach in all areas of its operations. The company also drives local community programmes aimed at changing processes and systems for the better. In fact, over the past few years its own efficiencies in energy consumption have resulted in an 83 per cent reduction in CO2 emissions, which is a tremendous achievement. “We are proud of our strategy of operating as globally responsible business,” concludes Mr Vos. “We will continue to develop through organic growth, working within the Coesia Group, always mindful of the ultimate goal to help our clients improve their efficiency and be better global corporate ‘citizens’.”

Visit: www.flexlink.com

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Innovation Leading the Market DuPont Teijin Films is the global leader in polyester films and a renowned innovator at the forefront of the flexible packaging market. Dr Keith Rollins (Chief Innovation & Marketing officer) and Steven Davies (Market Manager) told Tim Sykes how the company’s ethos is driving the development of a new generation of functional films for the food market.

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uPont Teijin Films came into existence on an appropriately historic date, 1st January 2000, as a joint venture between two industry giants. The two parent companies DuPont of the US and Teijin Limited of Japan invested all of their existing manufacturing, R&D and sales resources for polyester film into the new 50:50 entity.

Fifteen years later, DuPont Teijin Films is of course the reference point for PET films, a business employing over 2500 people, turning over around $1.5 billion annually and manufacturing around 250,000 tonnes of film each year. It is a truly global company with production facilities in the USA, Luxembourg, the United Kingdom, Japan, China and Indonesia. The European business, headquartered in Luxembourg, manufactures in Luxembourg and Scotland, as well as hosting DuPont Teijin Film’s state of the art Global R&D centre in the North East of England.

“The rationale behind the JV was to create the world’s number one polyester film business,” explained Dr Keith Rollins. “In fact the two businesses were surprisingly complementary, with little overlap in products and territories. It formed a global grouping with global reach, clearly focused on delivering to customers in every region. It also brought about the platform to realise a vision of becoming the preferred PET film development partner based on unique technical capabilities as an innovation engine, bringing novel and value-adding PET and PEN film solutions to customers through the value chain.”

Reference brands Today DuPont Teijin Films’ brands – Mylar®, Melinex®, Teijin®Tetoron® for PET films, and Teonex® for PEN films – are known throughout the global industry for their technical excellence, performance, quality and reliability.

“One of the key benefits of founding the JV was the creation of an industry leading product range,” remarked Steven Davies. “While DuPont Teijin Films itself is relatively young, the parent companies have been active in the Polyester films market for over 50 years and handed down a wealth of technology, including many industry firsts, and customer relationships to the new business.”

The company’s packaging brand Mylar® encompasses a dizzying range of specifications and applications. “Our aim is to be a one stop shop with the widest available range of films for packaging applications across all market segments,” said Dr Rollins. “Our flexibility and grade range comes from our unique range of polymer production, base film and coating assets. These allow us to develop a range of products using different polymers (white, matt, super clear), coatings (high metal adhesions, high barrier, peelable) and base film properties (shrink, thermoforming).”

Commitment to growth markets DuPont Teijin Films places particular emphasis on developing value adding products for key growth market segments, such as ovenable packaging and fresh produce in the food space.

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The company’s position as global leader in the ovenable packaging market came about with the invention of peelable lidding films for the ready meal market. Today its ambition is to establish PET films as the cooking medium of choice for all proteins, for cooking in Mylar® addresses two key themes that DuPont Teijin Films focuses on in the food segment: consumer convenience and safety.

“Our vision is to help provide restaurant quality food at home, with no need to touch the uncooked food, no fuss in preparing it and quicker cooking times,” Dr Rollins affirmed. “No touch cooking also enhances food safety with protection against harmful bacteria such as campylobacter in poultry products. These aims have driven innovation in developing functionality such as thermoformability and shrink – essentially getting close to the ease of forming that some polyolefin films have but with the high temperature capabilities of PET.” Another heavy focus in food packaging is fresh produce, such as fruits and salads, where reliable seal and peel functionality have made DuPont Teijin Films’ OL range of films first choice within the industry. Mylar® comes into its own when reliably sealing at low temperatures on rPET punnets, which are distorted by heat sealing techniques.

“Our films deliver very high clarity and anti-fogging performance,” said Mr Davies.

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learned over several years how to deal with the sharp fluctuations in demand caused by seasonal items.”

Industry leading innovation DuPont Teijin Films inherited a commitment to innovation from its parent companies, which among many other achievements invented polyester films in the 1950s.

Investing tens of millions of dollars annually and employing around 200 scientists and engineers in R&D, the business holds more than 200 patents and boasts a track record of market-leading innovation, enabling the creation of many new product categories along the way and delivering new PET film products to meet new challenges.

“For many years we have been regarded as the leader in PET films, which facilitate the delivery of novel packaging solutions,” said Dr Rollins. Our approach to innovation is based on three tenets. The first is recognising, anticipating and responding to needs of the market. This is underpinned by analysis of mega-trends – for instance in the food market we focus on food safety, food security and sustainability. Secondly, we believe that technical excellence lies at the heart of meeting the market need. The third is customer success.

We have a relentless focus on the success of our supply chain partners in innovation, and I believe this truly differentiates DuPont Teijin Films from our competitors.

Among the company’s latest cutting edge innovations is a new high water vapour transmission rate film for modified humidity packaging with water vapour transmission

rate five times higher than standard PET. “The driver behind this development is shelf life extension for produce that either creates a lot of moisture throughout the pack life and/ or are susceptible to fungal spoilage due to excessive moisture,” explained Mr Davies. “Essentially what we are doing is taking all the functionality of Mylar® products – clarity, ease of sealing, antifog properties – and adding in the ability to manage in-pack humidity.”

Meanwhile, a new skin film has been developed for the ovenable packaging segment.

“Skin packaging is clearly a major trend and is fast becoming the retailer’s favourite choice for pack presentation,” observed Mr Davies. “Mylar® SKIN combines the benefits of the shelf presentation of skin packaging with the convenience and safety of cooking in the pack, all with the peace of mind of complying with the food contact rules and legislation.”

Both of these solutions are in advanced trialling and will undergo retail launches early next year.

Defining the market DuPont Teijin Films’ task might be characterised as a combination of studying the market, as described above, and educating it. In some regions such as the UK ovenable films are becoming the standard medium, while the translation into others remains a work in progress – a similar journey to that of the ready meal, which took hold in the Anglo-Saxon world before penetrating continental European markets.

Packaging is central to DuPont Teijin Films’ portfolio and food is the key packaging market, since its characteristics fit well with the company’s innovation based strategy and competencies. The increasing demands associated with megatrends in food are met with solutions that have been developed explicitly to address these needs. For instance, the transitional arrangements for migration testing specified in the new food contact regulations will end in December 2015, leaving no grey areas on compositional and migration compliance – a significant competitive advantage for Dupont Teijin Films given the company’s commitment to product stewardship.

While there has not been space to discuss them in detail in the space of this article, it should be noted that DuPont Teijin Films has exciting developments across a range of film applications. “Our other targets for growth are typically characterised by scale, value for the functionality of PET and innovation,” commented Dr Rollins. “In addition to food packaging, other important application sectors include digital print and labels, healthcare, electrical insulation, capacitors, flexible electronics and photovoltaics.”

Across all of these markets and applications the company intends to continue with its innovation engine strategy, working with converter partners, focussing on providing solutions to their needs and working throughout the supply chain to understand the market.

“Converters expect us to bring them innovation,” concluded Dr Rollins. “Our ultimate goal is that whenever a converter needs a new application, they will call at our door first.”

Visit: www.dupontteijinfilms.com

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ILAPAK INVESTS

IN INNOVATION

ILAPAK is a leading manufacturer of packaging machines for flexible film applications. In recent years, a slew of major investments in innovation have delivered a number of new solutions to deliver hygienic design, modular construction and low cost of ownership to industrial bakers.

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LAPAK is dedicated to offering state-of-the-art packaging solutions. To this end, it makes substantial annual investments in R&D and this approach has certainly paid off.

One of its most significant recent product launches is its HFFS Carrera 6000 – the industry’s first IP65 rated fully modular flowrapper, launched at Interpack. Users of this flexible future-proofing machine will benefit from shorter lead times and lower COO as a result of the Carrera 6000’s unique modular design. Users can customise their machine by selecting only the modules they need, and can easily add modules such as film autosplicing, gusseting, and even a completely new jaw set up, at a later date.

Complete IP65 protection has been achieved through full stainless steel execution, isolating the electrical cabinet from the main machine frame and smooth, angled surfaces without recesses. This ultra-hygienic construction enables full wash down capability, even of the sealing elements.

The bakery specification Carrera 6000 is the leading technology for buns, biscuits, flat breads, morning goods, sliced bread, crackers and other typical bakery products, delivering high performance, uptime, hygiene and low maintenance costs The Carrera 6000 can also be fitted with a revolutionary new wafer feeding module.

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cross belt feeder in which indexing plates pushed groups of wafers at a 90° angle, shortside leading, into the chain. This method placed limitations on speed and any wafers whose layers were misaligned were prone to breakage.

ILAPAK’s innovation team has created an in-line solution in which wafers are delicately lifted without pressure and fed into a chain, long-side leading, without the need for a 90° movement.

Delta VACMAP® extended to pizzas and tortillas In a further HFFS development, ILAPAK’s Delta VACMAP® technology, which is equipped with Camozzi pneumatic components, enables customers to benefit from increased thermoforming shelf life and the flexibility and premium quality of a pillow pack presentation, is now available to manufacturers of tortillas and pizzas.

This unique modified atmosphere and vacuum technology can extend the shelf life of fresh pizzas and tortillas by up to 28 days – normally only achievable with a thermoforming process. At the same time manufacturers benefit from a more attractive, environmentally friendly packaging format and great production flexibility.

“Consumers prefer flowrap packs to thermoformed trays because they use less packaging material, are easy to open and close and give their products a fresh look. Retailers like

the fact that flowraps occupy less shelf space, cost less and give their product a premium look,” said Christian Ballabio, Project Manager at ILAPAK. The modular design of the Delta VACMAP® also gives users the flexibility to run frozen and fresh pizzas on the same line. They can simply disable the carousel unit via an automatic cell selection function to operate the machine at higher speed as a standard flowrapper. This system is equipped with the Dansensor gas analyser MAP Check 3 and automatic gas mixer MAP Mix Provectus.

The VACMAP® concept has been extended to ILAPAK’s vertical Vegatronic series for lengthening the shelf life of fresh, pre-baked and par-baked bread rolls – extending their shelf life to 6–8 weeks.

Extending the Delta series A second new addition to the Delta series of HFFS machines is the 3SSC, which opens up new presentation possibilities for tortillas and sandwiches. Three side-seal pillow bags can

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now be produced on a horizontal flowrapper with MAP and different types of reclosable zipper. ILAPAK has already installed a number of 3SSC machines for presenting products such as round pittas, squared tortillas and sandwiches in this eye-catching and truly innovative pack style.

The main advantage of this system lies in its flexibility. Users can switch between running packs with and/or without different reclosable zip tapes. In addition the 3SS format means both sides of the pack can be used for marketing purposes without disrupting important branding messages.

“This system, which utilises pneumatic components from one of our key suppliers Camozzi, can be a major benefit to bakers, who often run many different products and have important marketing needs. It means that, for example, 3SS packs of tortillas with a reclosable zipper can be run on the same machine as rolls or buns in standard pillow packs without reclosable zippers,” said Christian Ballabio.

“Like the Delta VACMAP® system is also equipped with the Dansensor gas analyser MAP Check 3 and the automatic Dansensor gas mixer MAP Mix Provectus. Dansensor products are reliable, flexible and can be configured for each application: for example, with the MAP Check 3 gas analyser, we can have “02 only” detection or “02+CO2” detection with the integrated GasSave function. This is a big plus for Ilapak flowrappers since it allows the end user to run the flowrapper with the lowest possible gas flow and still meet the required oxygen level in the pack. In addition, with the continuous on-line 02 detection the end user can save both time and money in comparison to off-line checks.“ “End users can also benefit from the modular nature of the Dansensor product range.

For example, these products have a single HMI to drive multiple devices (mixer and analyser). A lot of useful data can also be collected from them, including flow rate consumption data and all other significant production data. The Dansensor HMI is intuitive, simple to use and can also be integrated easily with Ilapak HMI” said Christian Ballabio, Project Manager MAP at Ilapak.

Knowledge transfer ILAPAK is active in a number of industry sectors, and one advantage of this is that its technologies can be transferred between different sectors. This knowledge transfer approach has resulted in a number of innovations over the years crossing between these industries, the latest being a reclosable label combined with inline film die-cutting for bakery products.

Reclosable label technology in which a tab pulls a label and breaks a pre-cut made in the film beneath has long been used in the bakery industry on dry products such as biscuits. Now ILAPAK is bringing this technology to bakery products requiring MAP products such as sandwiches, guaranteeing the pack tightness and shelf-life that is requisite for MAP applications.

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ILAPAK has made a breakthrough in this area with a new module for its Delta range which it is launching into the sandwich industry. ILAPAK’s solution performs the labelling and the die-cutting in-line, in the unwinding section of the film. This not only enables an extremely accurate cut, but also gives users the flexibility to change the shape, position and dimensions of the die-cut and label very easily.

Further innovations On the vertical side, ILAPAK’s Vegatronic 1600 VFFS for bulk sized bags is the newest addition to its range and, like the others, comes equipped with Camozzi pneumatic components. With a maximum bag width of 580mm and maximum film width of 1200mm, this ‘beautiful giant’ is ideal for producing catering bags of rolls. It boasts the highest seal pressure on the market and is available in vertical or up to 55° angled transfer to minimise the risk of damage to fragile IQF rolls.

Last but not least, ILAPAK has developed a revolutionary flat-bottom bag option for sandwiches, giving manufacturers a cost-effective, automated alternative to expensive pre-made bags.

Making block-bottom bags out of thick packaging substrates is a challenge for VFFS machines, as the thickness of the film makes it difficult to create the folds.

ILAPAK has overcome this challenge by equipping its Vegatronic 2000 OF with a sophisticated carousel with servo-driven mechanical cams. This unique flexible system can produce traditional looking bags with a home-made feel, at a fraction of the cost of pre-made bags.

Visit: www.ilapak.com

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Lean cooperation Complete packaging solutions provider Eson Pac is leading the way in delivering added value packaging to customers that value close cooperation. Emma-Jane Batey spoke to CEO Michael Bolin, sales and marketing director for the Nordic region Niklas Bengtsson, and European sales director Gilles Ceytte to find out how this is being achieved.

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amily-owned complete packaging solutions company Eson Pac is based in Veddige, Sweden and operates six production facilities in Europe – four in Sweden, one in Denmark and one in Switzerland. With dedicated sales offices across the whole of Europe, Eson Pac is increasingly expanding its presence throughout the continent, bringing its unique approach to packaging to a wider audience.

CEO Michael Bolin joined the company in 2006, taking the ‘First Class Packaging’ promise and further building its reputation as a reliable supplier. Mr Bolin told Packaging Europe, “We have excellent availability on cartons and labels and thoroughly deserve our market leading position in the Nordic countries. We are also increasingly leading the way in the rest of Europe too, with our sales offices in Germany, France and the UK joining those in Sweden, Denmark, Norway and Switzerland.”

An important development in the recent history of Eson Pac has helped to boost the upward trajectory of the company. As the only Nordic carton supplier in the 1960s, the major changes in globalisation and consolidation for both its customers and producers from the late 1990s onwards meant that Eson Pac identified a path for growth. Mr Bolin explained, “Around this time we identified a need to give our

customers more than just great products; we needed to offer a whole service that relied on working closely together. So we started adding leaflets to our production portfolio of cartons and labels and really understanding how a complete packaging solution is valued by our customers.”

Smart acquisition It was the acquisition of its biggest competitor on the Nordic packaging market three years ago that truly cemented Eson Pac’s position as an innovative solutions provider. Mr Bolin continued, “The acquisition helped us to establish a broader sales force across Europe as the company already has an excellence presence in markets where Eson Pac had not yet penetrated. So as well as adding multipage labels to our offer, we also quickly became the only true pan-European packaging partner.”

Eson Pac develops, produces and delivers complete packaging solutions with a focus on achieving the lowest total cost through efficiency. The company works together with its customers and suppliers to standardise processes throughout the value chain, seeking constant optimisation and implementing improvements wherever possible. Sales and marketing director Niklas Bengtsson explained how

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Sun Chemical is proud to be the ink partner of choice for Eson Pac

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ver the past 40 years Eson Pac and Sun Chemical have worked together with the aim of improving image and colour quality in packaging.

One of the main focuses has been to achieve consistency in print across all presses, and throughout all of Eson Pac’s production facilities Another goal is to print within the tolerances of ISO 12647-2 2013.

Sun Chemical’s technical consultants will work with Eson Pac to digitally save colour references to prevent variations in spot colours caused by ageing paper standards and different batches or colour guides.

Herzog-Heymann

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erzog + Heymann is a worldwide leading specialist for individual and specialist paper folding machines along with bespoke packaging solutions.

We develop technical solutions for economical and cost-effective production by utilising the creative ideas of our customers. Decisive know-how from consultation, design and construction to delivery.

Our Long term relationships to highly valued customers like the Eson Pack Group demonstrates the leading position in the market, with over 60 years of experience based in the folding and packaging industry.

We would like to be your partner for your next projects and to support you right from the start.

Please contact us or visit our website: www.herzog-heymann.com

For more information, please contact your local Sun Chemical team or visit our website www.sunchemical.com

About Sun Chemical Sun Chemical, a member of the DIC group, is the world’s largest producer of printing inks and pigments and a leading provider of materials to packaging, publication, coatings, plastics, cosmetics, and other industrial markets.

With annual sales of more than $3.5 billion, Sun Chemical has over 8,000 employees supporting customers around the world.

Sun Chemical Corporation is a subsidiary of Sun Chemical Group Coöperatief U.A., the Netherlands, and is headquartered in Parsippany, New Jersey, U.S.A. For more information, please visit our website www.sunchemical.com.

Ziegler Paper Mill Ziegler Paper Mill with its headquarters in CH-Grellingen is a world leading and independent family run manufacturer of premium quality wood-free fine papers for the printing industry. Ziegler Paper Mill, founded in 1861, counts about 150 employees. Thanks to a spirit of innovation and the constant desire to develop its products, the company has always concentrated on producing quality rather than quantity. Ziegler Paper paper products are hallmarked by their excellent standard of workmanship and first-class properties (of special importance in the field of pharmaceutical leaflets). This business approach results in long term business relations with customers (e.g. ESON Pac). Ziegler Paper supports its customers by offering complete solutions and individual advice, with a great team of experts and an aboveaverage know-how in its areas of business.

The Mill’s paper machine has a production capacity of about 72,000 tonnes per year with weight ranges from 40 to 400 gsm. Ziegler Paper Mill product line can handle nearly every challenging application. The thin printing paper produced in two shades provides special opacity, thickness and luminescence specifically tailored to the needs of the producers and packers of pharmaceutical package inserts. It also offers excellent folding properties.

Ziegler Paper Mill stands not only for products of impeccable quality but also for an innovative and sustainable environmental strategy.

Visit: www.zieglerpapier.com

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this works in practice. He said, “It’s not just about pushing prices down to be competitive; we are committed to being smart with our cost take-outs so that the total process costs less. This means that we analyse the whole process of providing our customers with a complete packaging solution and see where in the chain elements can be taken out and the cost can be further reduced.”

“It’s not just about pushing prices down to be competitive; we are committed to being smart with our cost take-outs so that the total process costs less. This means that we analyse the whole process of providing our customers with a complete packaging solution and see where in the chain elements can be taken out and the cost can be further reduced.”

This careful analysis of the complete process is key to Eson Pac’s ongoing success.

By working closely with its customers and continually assessing what it offers and how it achieves its offer, the company quickly identifies weaknesses and improves the whole process. Mr Bengtsson continued, “It’s all about lean thinking between us and our customers. We value the deep partnerships we have created and know that we really help them to be more effective. And these partnerships go two ways – we cooperate closely with our suppliers to get the best stuff for our customers.”

Continual achievement Having recently received an ECMA Pro Carton finalist award, Eson Pac is proud to show that its fresh way of thinking has been acknowledged by its peers in the industry.

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development work is to continually identify how things can be done differently; there are always ways in which we can improve our processes and pass those improvements on to our customers, without negatively impacting on the supply chain. But we’re not interested in quick results that don’t last – it’s not about next week’s figures, it’s for the next four or five years and many years after that. As a family-owned company we’re not obsessed with quick answers.”

Indeed, Eson Pac’s dedication to lasting results is illustrated by Mr Bolin’s assertion that the whole company is ‘driven by passion’. He concluded, “We’re not just a mercenary team looking for a fast buck. My family built Eson Pac for the love of packaging. Of course we want to be successful and we are very proud that we have achieved success across Europe, but we believe it is our long-term appreciation of the impact good packaging has on our customers’ business that gives us the edge over our larger competitors. We see big organic growth on the horizon and predict a n turnover of well above €130 million turnover within the next three years.”

Packaging and Marking Solutions from a European perspective Boxon is one of the leading packaging companies in the Nordic countries and Europe. From a wide range of services and products we put together unique integrated solutions that deliver our customer promise - an increased profitability for our customers. Our network of market-leading packaging specialists in Europe, NovuPak, allow us to increase our international presence within the packaging arena. With the many services NovuPak offer, we are able to provide optimum solutions for the customer, meanwhile giving local benefits from a global perspective.

Gallus Group The Gallus Group is the world market leader in the development, production and sale of narrow-web, reel-fed presses designed for label manufacturers.

Its folding carton business offers a range of wide-web, reel-fed presses and die-cutters for the cost-effective in-line production of folding cartons and cardboard products. The machine portfolio is augmented by a broad range of screen printing plates, globally decentralised service operations, and a broad offering of printing accessories and replacement parts. The comprehensive portfolio includes consulting services provided by label experts in all relevant printing and process engineering tasks. The group headquarters is in St.Gallen. www.gallus-group.com

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The bigger

picture

Lantech founded the stretch wrapper in 1972, so its credentials are clear. But as Felicity Landon reports, this innovative company doesn’t just focus on machines. It is far more interested in the bigger picture – the total, bespoke packaging solutions it can offer its clients.

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T

he big issue for Lantech’s customers, says Bob Lemmen, is their own product.

“Certainly they are not really interested in our machine – from their point of view, that is just a tool which fulfils a part of the process with which they deliver their perfect product,” he says. “Our focus, however, is on getting involved in the customer’s product, so we understand what the output of their factory should be and embed that in the solution we provide and our way of thinking.”

Lantech specialises in the development, assembly and marketing of modern packaging machines, serving a range of industry sectors including healthcare, chemicals and food & drink. It has more than 65,000 machines deployed worldwide and, with more than four decades of experience, it can justifiably claim to be very close to the market. And, as a relatively small, family-owned company, it is able to react quickly to trends and technology developments in packaging.

Bob Lemmen, marketing manager based in Lantech’s European headquarters in Cuijk in the Netherlands, says being close to the market is vital. “We believe our strength comes from the knowledge we get out of the market and the way we react to that,” he says. “We have a lot of knowledge and experience in implementing our machines in lines and companies’ production areas but we are also involved in the total ROI of our customer.”

The overall philosophy of Lantech is also refreshing. “We are an open, flat-structure organisation.” he says.

“At Lantech, we involve all our people. We want them to be personally interested and have the opportunity to pick up projects and ideas and work with each other instead of sticking to their functional area. So teamwork is really important.”

Global presence Lantech’s two locations are based on its history. Headquartered in Kentucky, it was created by the merger in 2001 of two companies – the US-based stretch-wrapping operation and a Dutch company which led the way in case handling machinery. Today the company serves all continents with a broad product line. The European operation is the centre of competence for case-driven packaging machines, including sealing trays and lids. The Kentucky operation is the centre of competence for stretch-wrapping machines.

The Dutch office is responsible for Europe and Africa, marketing the entire product range that comes from both sites.

Clearly, Lantech is well known around the world, but with the elements of its twintrack history mean there is a need to reinforce one identity. Bob Lemmen says: “We are globally present and we have sales offices in Asia, Australia and other key markets. The customers see us as one company solving their needs. Now we are starting out on a project of global identity, to reinforce that message. So that our customers around the world can define us as one company with one global identity.

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“Due to the way the company has developed itself, you might find our visible presence is slightly different in some regions, or some of the machines are named differently. We need to be sure we all use the same appearance and same quality systems, the same order confirmations, brochures and other material.

Committed to excellence The company employs about 350 people in the US and just over 100 in the Netherlands, with additional colleagues in its worldwide network. A key theme throughout the company is a commitment to Lean manufacturing principles, of which Lantech was an early adopter.

“Lean is a big driver – we have been practising it for 15 years,” says Bob Lemmen. “We are really ahead of the market in this, both inside and outside the company. The focus is constant quality. Whether we build a machine on Monday morning or Friday afternoon, the quality is always the same. It has all to do with people, processes and structure. This is particularly interesting to our multinational customers; they notice not only in the machines they get and the high standards but also in the best cooperation and relationships we have with them.

“We are not talking about our machines but about providing solutions and thinking Lean with them, helping them to achieve the same benefits.”

What are the priorities for Lantech’s customers? Bob Lemmen says it is ensuring that their products get from their factories to logistics centre to shop shelf without any damage and still looking perfect for the end consumer. “Transport damage is a huge issue.

An estimated 1% of transported products worldwide are damaged on arrival. That is money going down the drain. We focus on that by providing packaging solutions that ensure their products will be safe and not damaged. That means delivering the perfectly shaped package.”

However, Lantech’s commitment goes a great deal further than merely delivering that perfect machine. Its highly experience service engineers travel with the machines when they are delivered, to oversea commissioning and ensure all is running as it should be.

Besides that, Lantech has an extensive network of partners who are trained and certified to service and repair machines locally, and provide spare parts.

“A production line has to run – it can’t stand still. We have to act immediately if something happens. Through our network, we can ensure that an experienced and certified service engineer can be onsite the shortest possible time .”

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The importance of packaging Packaging, of course, is a rapidly moving feast of trends and new demands. There’s an increasing requirement for high-quality shelf-ready packaging, raised capacities, higher uptime, different sizes, lower costs and solutions that have less environmental impact.

Lantech is constantly monitoring market developments to anticipate and respond to these changes.

For example, PET water bottles are being produced using less and less plastic. That means the bottles are less stable and can be squashed more easily. Lantech has responded with a packing solution that secures the bottles without damaging them. Cartons are being made with thinner cardboard – Lantech has adapted its machines to work with this. Internet shopping continues to gather pace – Lantech is working with customers to deliver customised packaging of products for delivery.

As for geography, the US and Europe are the company’s biggest markets but, says Bob Lemmen, ‘there is still a lot to gain in Europe’.

“The biggest growth at the moment is outside Europe. We build our machines for the biggest multinationals – we have a really good cooperation with them, so we ship a lot of machines to Asia, Eastern Europe and Africa. The advantage for them is that if they buy a machine from us, they know it will be a global standard which can be adapted as their own production strategies develop.”

Visit: www.lantech.com

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Keeping up with the times Plastotecnica SpA is a major European manufacturer of linear low-density polyethylene packaging. It is headquartered in Bagnoli Di Sopra with a second production plant based in Pernumia. Plastotecnica also has a storage facility located in San Giuliano Milanese, concerned solely with the distribution of the company’s products. Eugenia Fiusco talks to marketing director Stefano Iazzolino to find out more.

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lastotecnica was set up in 1976 and originally focused on the production of shopping bags. At the time, it bought semi-finished products from local suppliers. In less than 40 years, the company has evolved into a leading polyethylene packaging supplier thanks to constant expansion both in terms of production plants and equipment. Today, the Italian company’s output amounts to 138,000 tonnes per year with a turnover of around 200 million euros. It employs 363 people. Plastotecnica utilises blown film extrusion and cast extrusion processes; products can be died both during the process and afterwards using flexography. Plastotecnica has a state-of-the-art flexo-printing department which, alongside the graphic design office, can meet all printing needs.

Plastotecnica has six main production lines: tubular FFS, stretch hood, technical films, green products, extensible films and heatshrink films. Heat shrink polyethylene film is a traditional packaging system that protects the products by adapting perfectly to their shape. Plastotecnica is aiming to reduce the thickness of its packaging and works continuously to develop innovative solutions to meet the evolving needs of the market in terms of both performance and sustainability.

SkinLite Line: an evolution of ProLite Plastotecnica is strongly committed to diversifying its production lines and target sectors. “We are diversifying our production to keep up with the times and market trends,” explained Mr Iazzolino. “In particular, we are developing new lines of top-of-the-range industrial packaging, products for technical applications and food and beverage packaging. In the area of the food and beverages, on the other hand, we are studying products that meet new health regulations.”

A new line dedicated to the industrial sector is an evolution of the previous ProLite and will be branded as SkinLite. According to the company, this new range of high efficiency stretch films can guarantee excellent performance and constant savings. Their key benefits include: high puncture resistance; excellent holding force; low thicknesses up to 7 MY; more metres per roll; light cores and time reduction for roll change-over. In particular, the decreased thickness makes ProLite a more environmentally friendly film than anything that has come before. SkinLite can be a substitute for standard/medium pre-stretch machine film. It is suitable for automatic or semi-automatic machines with a pre-stretch up to 300 per cent. It is also suitable for light or heavy loads, even with sharp

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edges. Furthermore, because SkinLite rolls are much longer than is normally the case, this leads to a huge reduction in change-overs which greatly improves efficiency.

The main applications for Plastotecnica’s products are the beverage industry, paper and cardboard industry, glass, brick and ceramics, building materials, fertilisers, cereals, chemicals, pasta, mattresses, furniture, insulation, silicone sealing and coating adhesives, food and canning industry, granular polymers and additives, fertilisers, soil, salt, mortar and much more besides. “Currently, our main market is the Italian industrial packaging market,” said Mr Iazzolino. “Our main clients there are food and beverage companies.”

Diversification and development “Around 40 per cent of our production is exported abroad, while the remaining 60 per cent is sold in Italy. In particular, we export to northern Europe and South Africa. We aim to achieve a 50-50 balance between import and export,” continued Mr Iazzolino. “It is likely that with the development of our future production lines we will export to new markets. However, our priority at the moment is the upgrading of our equipment and the diversification of our lines.”

Plastotecnica’s three-year business plan involves investments in human resources, new equipment and top of the range product development. “We want to upgrade outdated equipment and offer larger sizes of films. We are also looking to purchase new extruders with the goal of entering the propylene business,” said Mr Iazzolino.

Moreover, Plastotecnica’s concern for the environment can be seen in the large investments it has made over the past two years to further reduce the impact of its manufacturing equipment. It was recently awarded the ISO 14001:2004 certification for its Environmental Management System. Most of the films produced by the company are 100 per cent recyclable.

Plastotecnica is a member of COREPLA (association for the collection, recycling and reuse of plastic packaging waste), which in turn forms part of CONAI, the national association concerned with managing and monitoring the way in which plastic packaging is collected, recycled and reused in Italy.

“We have three main future goals: keeping a constant level of growth in spite of the current financial situation; diversifying our fields of application and increasing our exports to those countries where the economy is more stable,” concluded Mr Iazzolino.

Visit: www.plastotecnica.com

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Exceeding expectations

Procap is a caps and closure system producer based in Luxembourg with a European footprint. Elisabeth Skoda spoke to Benoit Henckes, the company’s CEO, to find out more about the company’s recent innovations and investments.

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rocap has been following a continuous growth strategy over the last 25 years and boasts an annual turnover of €118 million, employing 500 people in seven production units all over Europe, ensuring the ability to cater for the growing needs of an international market.

“Our customers are continuously growing themselves, and they need international companies present in different markets to be able to supply their plants in different countries, in order to avoid high transport costs. So being no more than 500 kilometres away from our customers is imperative. In order to provide our customers with new product developments, a certain size is necessary,” Mr Henckes says.

Cap innovations At the Interpack trade show in Germany, Procap presented a range of product innovations. “Because of its international significance as the biggest packaging trade fair in Europe, Interpack is the most important fair for us to exhibit at. All our major customers are attending, so we put a lot of effort into our presence there,” Mr Henckes explains.

At the trade show, Procap presented several new standard products, including its 63 PROSLIT closure, a secure TE closure for HDPE, Co-ex and PET containers with a 63mm neck finish, which has been specifically designed for larger agro chemical containers and aims to improve overall product safety for end users.

The 38 PROLINE for sensitive non-carbonised beverages which have to be packaged in clean conditions, such as juices and milk, was also presented. It was specifically developed to adhere to the stringent conditions for bottling these types of products.

“It offers extremely high-performing capping within these constraints. Highly efficient capping supports a reduction in stoppage times, saving significant time and costs. The closure is also suitable for bottled waters. 38 PROLINE can be used for any PET container featuring a 38-3SOT neck finish,” Mr Henckes adds.

Another item on show at Interpack was Procap’s unique Lab Capper system, offering more intense and comprehensive testing of caps and closures. The Lab Capper replicates conditions found at the customer site to enable assessment of how its caps and closures will perform once introduced to capping lines. Testing in such a laboratory setting enables changes and adjustments to be made to shape or design quickly and with no disruption to production lines or customers’ businesses.

“To date, Procap is the only producer of plastic caps and closures in Europe to own a system of this kind and to be able to offer such a beneficial service,” Mr Henckes reports.

Procap takes pride in being a full service provider for its customers. “Our aim is to put in place a full service module, starting with the design and development of closures to production and quality specifications, and also to help customers to use products on their filling line. We stand right next to our customers to support them in all steps of development.”

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Europe-wide coverage Procap has a total of seven production sites. The company headquarters are situated in Luxembourg, and further sites are located in Belgium, France, Spain, Ireland, Hungary and Germany.

“From the location of our sites we are able to cover the whole of Europe very well, never being more than 500 kilometres away from our major customers. Each of our plants has a historical link to customers situated close to that plant, making customer-specific products. Different plants are also increasingly manufacturing standard products in the different regions of Europe,” Mr Henckes explains.

Procap has made major investments in its production sites all over Europe.

In December 2012, it opened a manufacturing facility with state-of-the-art equipment in Wicklow in Ireland. The plant allows the company to better serve existing local customers and to expand not only its product portfolio, but also its customer base in the region, especially in Ireland and in the UK. The facilities currently serve customers in the pharmaceutical industry, specifically closures and scoops for the infant milk market, helping Procap to further consolidate its strong position in this segment.

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In 2014, Procap opened its new production and storage facility in Hoboken in Belgium. The new facility more than doubled the company’s warehouse and production space and offers an ideal way to support the group’s strategic growth ambitions.

“Brand new factories and technologies increases customer interest and leads to new projects. This is happening in Ireland and we will also see this at our sites in Belgium and Germany,” Mr Henckes points out.

In 2013, Procap acquired Schoeller Cap Systems in Schwerin in Germany, enabling it to better serve clients in the region.

“The current focus of the plant is on closures for the drinks industry, and investments are being made to turn the building into an ultra-modern site,” Mr Henckes adds.

Steady growth is important for Procap. “We have been growing for the past 25 years together with our customers, who require suppliers with a European base and the capacity to develop new products. We will continue on this road. We will be looking at new locations and increasing capacities, as we still have potential for existing and new customers,” Mr Henckes concludes.

Visit: www.procap.com

Complete Packaging Systems Supplier Radpak, a company from Wloclawek, is Poland’s leader in the production of packaging machines and complete packaging lines. Dariusz Balcerzyk reports.

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adpak was founded by Tadeusz Radzanowski in 1991 in Wloclawek, an industrial city located in the centre of Poland. Mr Radzanowski gained experience in the design of packaging machinery in Canada and the United States. The company’s own production base allows it to offer design, production, marketing, sales and additional services from a single location. At the same time Radpak has been developing its administrative and technological structures. As a result, the company has transformed into a thriving business with more than 100 employees. Since the very beginning Radpak has been focused on developing complete packaging lines including vertical FF&S baggers and dosers, cartoners, tray formers, case erectors and end of line case packers.

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Turnkey packaging systems In the domestic market, Radpak is now positioned as a leader in the production of packaging machines and complete packaging lines. Its product range has been increasing year on year. Nowadays, it offers a wide range of packaging machines, including vertical formfill-seal (VFFS) baggers; dosing (multi-head combination and linear scales, volumetric cup dosers, auger fillers); horizontal end load cartoners with semi & automatic loading (intermittent and continual); vertical top loading cartoners with semi & automatic loading (intermittent and continual); fully automatic case packers; automated loading systems (including industrial robots); custom designed packaging lines; and machines or packaging systems designed to meet individual needs.

The company’s goal is to provide complete, turnkey packaging lines and it is constantly updating its range. This strategy means that Radpak is able to offer its customers some of the highest quality machines in the automated packaging market. The company is an active user of the European Union ‘Passport to Export’ subsidies, which provide Polish companies with support to develop their export business.

Radpak’s supply chain includes some of the world’s leading companies such as Allen Bradley PLC (programmable controllers), Festo (industrial automation and process automation), SEW (drive automation solutions), Nordson (adhesive applicators) and many others. Radpak ensures that it uses only best components so that its machines are well known for their longevity and trouble-free operation.

And who are Radpak’s core customer groups? The majority of end users are from the food sector, although it also serves the chemical and pharmaceutical industries. The company’s future development will see the strengthening of its position in the Polish market and expansion into foreign markets, especially in the US market where the company sees great potential for its products.

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All Radpak’s machines are equally popular amongst its clients. Recently, the company has noticed an increased level of interest in complete packaging lines or cartoning machines for multipacks. Demand for the Radpak vertical packaging machines is also at a consistently high level.

Close cooperation with clients Radpak produces complete packaging lines which can be customised according to what the client demands. According to the company, some clients already come with a vision for their finished line but others only know what they want to be packed. Radpak works closely with its clients from the initial design phase up to the final product. At each stage the customer is free to inspect the progress of the work – both virtually and by visiting the company’s factory – in order to ensure it meets their requirements.

But Radpak does not only produce and sell packaging lines: the company also offers additional services including spare parts, shipping, inspection, after-sales services and on-site training. Its service team consists of experts with years of experience and a wealth of knowledge in the packaging industry.

Radpak is an active participant at major trade fairs, both at home and abroad.

These provide it with an excellent opportunity to make new contacts or new sales. It regularly attends shows such as PACK EXPO in Chicago; IPACK – IMA in Milan, Manchester and Birmingham; Interpack in Düsseldorf; and ProSweets and Anuga FoodTec in Cologne. Radpak will often present its prototype solutions at these shows prior to full production.

Visit: www.radpak.net

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Leading the way IMP (Imballaggi Materie Plastiche SpA) is a leading Italian contract packer and plastic packaging manufacturer.

Sales director Giampaolo Ferronato talks to Packaging Europe’s Alessandra Lacaita about his business.

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MP was founded in 1952, primarily to produce injection moulded containers for the pharmaceutical industry. Some six decades later the company’s focus is now on contract plastic packaging (jars and bottles), injection mouldings (caps and packages for detergents, cosmetics and food products) for the food and household cleaning industries, and chemical production.

Giampaolo Ferronato says: “We don’t have branded products, but instead develop products for our customers and then the launch is managed by them. We work for companies such as Reckitt Benkiser, Unilever, Bolton, Bolton Manitoba group and Johnson Wax.” | 154 | Packaging Europe

The company has two production sites: the first one, which is the central headquarters, is based in Altavilla Vicentina (Vicenza); while the second is located in Mira (Venezia) within a Reckitt Benkiser plant.

Technology IMP specialises in blow-moulding, screen printing, filling and chemical production. With regards to blow-moulding, it has 46 blowing machines with leakage control units and includes co-extrusion and in-mould labelling plants and injection-stretching blow-moulding units. For its screen printing, hot stamping

and sleeving it has one to six colour units. As for chemical capabilities, IMP operates a chemical laboratory equipped with mixing units and a testing lab that ensures its products meet the necessary requirements.

As Ferronato explains: “With regards to chemical and filling technologies, we produce household cleaning products but also wax, cream, abrasive crème, products for metal cleaning, fabric softeners, washing machine and dishwasher products based on hydrochloric acid, hydrogen peroxide, sodium hypochlorite, sodium hydroxide, ethyl alcohol and medical and surgical devices.

“IMP’s ability is characterised by a capacity to provide a full service from conception up to the logistical management. We follow our clients in all the design stages,

researching innovative and specific materials suitable for the type of application required and developing the graphic design and structure of the product. So a customer can come to us with his idea and we can develop graphic concepts and the implementation of the industrial product. We prepare the product ready for sale and are able to serve as a logistics platform receiving goods from other contractors and managing the delivery to the final client.”

With regards to plastic container production, IMP serves the automotive (with clients such as Arexon), food (with companies such as Formec Biffi), cosmetic and household detergent markets. Ferronato emphasises the extremely important role suppliers have in production and business. He says: “We are closely linked

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with our suppliers with regard to the innovations and new technologies we can propose to our customers. If a client asks us about a product with sustainable characteristics, we can move between our suppliers and look for compounds that meet those specifications.”

Future growth In addition, the role of IMP’s customers is very important as the company works to respond to their requirements. Ferronato says: “With our clients we are looking for the opportunity to create other production sites and other in-house manufacturing lines, where we can continue the business we have had in these two major areas.

Generally, our investments are focused upon important projects with customers.”

With regard to filling activities, 60 per cent of IMP’s business is in Italy and 40 per cent abroad, while in the blow-moulded product area, 85 per cent of its sales are domestic.

On the subject of future projects, Giampaolo Ferronato remarks: “We are planning an expansion on the European market. I think we will grow by organic expansion. The idea is to strengthen partnerships we have with our existing clients, and then support them in the development of other European markets, developing for them new types of blow-moulding technologies wherever they operate.”

Visit: www.imp-spa.it

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Innovation, quality and service

Product quality, a high level of service and innovation are the three crucial elements on which film manufacturer Albertazzi G. SpA’s latest strategy has been based, as Mr Albertazzi explained to Barbara Rossi. | 158 | Packaging Europe

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lbertazzi G. S.p.a. started two years ago a development program, with the aim of rationalising the company’s structure and repositioning it on the market.

This involved a special focus on European exports. From the beginning of 2015 the company will again be led by members of the founding family. Albertazzi G. SpA is based in the Reggio Emilia area of northern Italy (Correggio) and takes its name from its founder – Giuseppe Albertazzi – who set it up in nearby Carpi in 1938.

Today a representative of the second generation of the family, Alberto Albertazzi, is involved in its management. The expected turnover for the current year is €17,5 million and the company hopes to increase its number of employees in the near future. ”We saw a rationalisation in the number of employees as part of the reorganisation process. The aim has always been to reorganise the company in order to re-launch it on the market and create additional jobs, because we are indeed a family company with a strong attachment to our local area,” Mr. Albertazzi stated.

Special packaging solutions Albertazzi G. SpA offers its clients a range of packaging products and services. It is specialised in plain and printed high-barrier technical films, mainly for food packaging applications. Albertazzi distinguishes itself thanks to its special film range which, among many products including anti-fog film and Surlyn based film®, features tactile effect film.

“Tactile effect film is the latest addition to our offer. It is able to recreate the effect of other materials, including paper and wood, not just visually but also in terms of touch

and thickness. It can be employed in a wide range of applications and materials. We officially launched it in June 2014 and are in the process of obtaining a patent.”

Around 70 per cent of production is for plain laminated films flexible from 40 up to 250 micron and semirigid from 400 up to 900 micron even sterilizable, with the remainder being for printed versions. All products are real solutions, developed with clients and customised in order to fulfil their individual needs. The company offers its customers a range of services, including concept and design thanks to its internal graphic design studio. If customers require it, Albertazzi can also offer localised support and, thanks to its collaboration with external partners, can develop labels to tie in with the customer’s branding concept. Stock and logistics management services are also available.

The company operates from two sites, both based in Correggio and covering a total area of 10,000m2. It obtained the ISO 9001 certification at the end of 2013 and BRC/IoP in May 2014. It has an internal laboratory where different materials and product performance are tested. Tests are also carried out by external partners. While food packaging is its core business, Albertazzi also serves other industries, such as the pet food, drink & beverage, pharmaceutical, construction, agricultural and gadget & promo sectors.

Focusing on exports Around 20 per cent of the company’s turnover is generated by exports. “We have every intention of expanding our exports. Our main export markets are central Europe (Germany, Belgium and the Netherlands) Scandinavia and the UK, as well as France where

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we have been established for a while. We are planning to increase our sales in all of these countries rather than entering new geographical markets. This is why we are completing our distribution network here. Our core business will remain film solutions for food packaging. We are interested in these geographical markets because what we offer is a quality and innovative product. Our future expansion will be driven by innovation, as well as product and service quality, and special films will have an important role to play.”

The importance of innovation at the company is proven by the fact that Albertazzi has an R&D centre, the sole purpose of which is to continuously develop new products and solutions.

“We also offer our customers the option of delivering training courses to them on-site.

The aim of these courses is to inform them of the advantages offered by the different solutions. For instance, if we think of tactile film, we can inform our clients of the advantages that this has to offer in comparison to the traditional paper and film combination. Tactile film can reproduce also the paper effect, while also being suitable for customers who

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experiences humidity issues in their production processes and for whom paper can be problematic even in high speed.

“Our company’s approach is to integrate all the business actors (Suppliers, Customers, Agents, Distributors) in our processes, so as to gain awareness of market needs and develop suitable solutions.”

Visit: www.albertazzi.com

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Strength in design One of the UK’s most comprehensive independent corrugated board packaging companies, Devon-based Atlas Packaging Ltd offers an extensive range of bespoke design and manufacturing solutions. Emma-Jane Batey interviewed managing director Jason Sharman to find out more.

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ounded in Barnstaple, North Devon in 1983, independent packaging company Atlas Packaging Ltd has gone from strength to strength, consistently delivering its design-led solutions to customers across the South West region. Increasingly active across the whole of the UK, Atlas Packaging’s growing infrastructure is allowing it to bring its award-winning corrugated board packaging to a wider audience.

Mr Sharman said, “We celebrated our 30th anniversary last year and it’s been really exciting to see how far we’ve come. We’ve grown steadily to become a market leader in packaging. The fact that we have both our design and manufacturing capabilities inhouse enables us to stay competitive.”

It is the sophisticated design skills of the Devon-based team that truly help to set Atlas apart from the competition. Mr Sharman continued, “Our holistic service is unique in the fact that we have the expertise, equipment and industry knowledge to take care of multiple aspects of our clients’ projects in-house, saving time and money and enabling us to maintain control of the whole project. We employ a team of six dedicated designers

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who have the creative flair and technical expertise to be able to provide our clients with a bespoke design service regardless of what stage of the process they’re at.”

It is clear that Atlas Packaging’s design skills are highly appreciated: its coveted designs have been recognised by the packaging industry with a Gold Star in the prestigious Starpack Awards for excellence in packaging.

Custom solutions The Atlas Packaging portfolio is varied, thanks to its ability to create and manufacture custom-made products from corrugated board. From basic designs through to sophisticated and innovative marketing campaigns, the company can produce ‘an almost unlimited range of packaging solutions’. Its offer includes shelf-ready packaging, counter display units, floor standing display units, presentation packaging and POS packaging.

Mr Sharman said, “We have state-of-the-art production facilities that allow us to bring to life the designs our team creates, so we love to work together with our clients to come up

with really fresh ideas. We relish the challenge of coming up with an innovative packaging idea that adds value to our customers’ product and then we can utilise our facilities to make the idea a reality.”

A recent innovation from Atlas Packaging is its clever corrugated board chair, the patented Bum Box. A surprisingly sturdy, comfortable chair able to withstand weights of up to 120kg, the Bum Box was developed by an Australian company with Atlas being granted the exclusive UK and European distribution rights.

Atlas Packaging has continually invested in both the operational and manufacturing aspects of its business to ensure that it retains its competitive edge. Its latest investment in the most advanced machinery available in the packaging industry has helped the company to not only further improve the quality of its output but also become more reliable, efficient and cost-effective. The plant is accredited with a number of quality assurance certificates, including ISO 9001:2008, BRC/IOP category 2008 and FSC.

Special service Service at Atlas Packaging is closely entwined with quality and design. Mr Sharman explained, “We make sure that the service our customers receive is as exquisite as the products we create for them. Alongside our graphic design and print sit our structural design and our manufacturing capabilities. We have gained a reputation for superior customer service and I am quite sure that this is down to the excellent people we employ.

I know it is a bit of a cliché, but we really are like a big family. Everyone here is a bit quirky with a creative streak and there is no hierarchy – we love a good idea, wherever it comes from. I am pleased to say that our unique character comes across in everything we do, from the products we develop to the way we talk to out customers. We’re always open and friendly while being reliable and professional. Customers know they can trust Atlas to deliver a unique, reliable packaging solution.”

With its heavily invested & diverse plant and dedicated, unique team, the fact that Devon-based Atlas Packaging is increasingly active across the whole of the UK and potentially further afield is good news. Working with local haulier CL Transport has effectively opened up the whole country to Atlas’ packaging solutions, as well as the appointment of business development manager Liam Beades. Mr Sharman concluded, “Our continuous investment, exceptional design capabilities and strength in using social media have all combined to create a very positive future for Atlas. With our new dedicated business development manager working to highlight our offer across the UK and into Europe, we are really looking forward to the next 30 years of achievement.”

Visit: www.atlaspackaging.co.uk

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Flair for Success Afa Dispensing is a leading developer and a global supplier of technology-rich, liquid dispensing products. Abigail Saltmarsh looks at some of its cutting edge innovations.

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technology and innovation are the engines of growth at Afa Dispensing, it is not surprising the group is leading in the fast lane. With numerous ground-breaking products behind it, and with more and more of the top brands in home and garden care, food, beverage and other packaged goods turning to the dispensing specialist for solutions, the goal is to stay well ahead of the competition and to continue to push out globally, according to Ariel Gratch, CEO. “In the past five years we have doubled our sales - all organic - and in the next five years we project to do it again. Our strength has come, and will continue to come from product development which we do with special emphasis on the consumer’s needs.

We invest heavily not only on product development, but also in understanding the consumer preferences through market research and other testing, and it is the combination of our technology and the consumer insights we gain as a result of these efforts, that drive our growth.”

Flair platforms in order to develop this revolutionary propellant-free sprayer that rivals the spray performance of aerosol without using propellant gases. It is a non-pressurized package which bridges the gap between aerosol and trigger sprayers.”

Success story Indeed, Flairosol has been a success story for Afa Dispensing, with the new Flairosol ImPress 360, winning the prestigious Dispensing Innovation Award at the Paris Aerosol Dispensing Forum.

“The market for spray products is about 20 billion units a year, of which about 75 per cent are aerosol and 25 per cent trigger sprayers and pumps,” explains Mr Gratch. “The potential for Flairosol is therefore huge. Aerosol is used where a highly pressured, fine

Advanced spray solutions Headquartered in Amsterdam, Afa has one production site in Helmond (The Netherlands) and two in China. Sales, logistics and customer services centers are located in Amsterdam, St Louis and Shanghai.

Shortly after its incorporation in 1965 as a custom injection-moulder, Afa started to produce its own products, and in the early 1970s it became the first company to offer trigger sprayers in Europe. Since then, Afa has continued to focus on developing proprietary technologies that enable it to offer unique liquid dispensing products to the global markets.

“We now focus on our three technology platforms that we use in our main product groups: OnePak®, DuO1® and Flair®. OnePak is our sprayers platform, DuO1 is our platform for the new aerosol-like dispenser (Flairosol®), and Flair is our bag-in-bottle platform. We are especially enthusiastic with Flairosol where we combined the DuO1 and Packaging Europe | 165 |

mist is required, for example for air fresheners, while trigger sprays and pumps are used for basic liquids where small droplet size and fine mist are not required. Flairosol is meant to serve the high-end liquids that cannot use the basic pumps and sprayers and seek an alternative to the aerosols”.

Mr. Gratch continues: “What we attempted to do was to develop a product that offers the same benefits of an aerosol package but without the pressure or the gas, thus making the supply chain more efficient and the environment safer.”

Champion packaging Flairosol provided the performance power and creative inspiration behind the revitalization of Carr & Day & Martin (CDM) equine brand. The prolonged, fine and uniform mist spray has proved ideal for the horse grooming products and the Equimist 360 won the innovation award at the BETA International 2014 (UK) and 2014 Spoga Horse International Trade Fair (Germany).

“Flairosol’s ability to deliver a prolonged, fine and uniform mist spray from first to last drop in all directions won the jury. It also has a stylish and sleek design which is not common in the packaging industry”, said Mr. Gratch.

Carr & Day & Martin as all other customers of Afa use the unique features of the Flairosol to reposition their brands and successfully differentiate their product offerings from the competition. “Beyond its technical features and superiority, we found that the consumer actually enjoys the use of the product, and that gives the underlying brand the opportunity to offer a complete brand experience to the market”, says Mr. Gratch.

Bag-in-bottle technology Another great success has been Flair, which is Afa’s bag-in-bottle technology. “The beauty of the Flair technology is its versatility. The bottle can be as small as 100cc or as big as 20 liters, and it can dispense low viscosity liquids such as beverages, as well as, high viscosity fluids like soft food items”, says Mr. Gratch. “We chose to partner with two leading brands to demonstrate the versatility of Flair - Heineken for its home draft system (THE SUB®), and Unilever for its professional soft ice-cream dispenser (Ola®)” explains Mr. Gratch. In both cases Afa was invited to join in on the development of the new product due to its expertise in liquid dispensing and its technical platforms which make it possible to control and seal the liquid, extend its shelf life and control its dispensing.

Extending its reach Mr. Gratch, who describes Afa Dispensing as “the Apple of its industry,” said the group is looking to expand across Europe, Asia and the Americas. It currently has production on two continents and already has a strong presence in China.

“We took a risk 10 years ago when we brought our technology to China,” says Mr. Gratch. “But it paid off for us – we now dominate the shelves there with our trigger sprays. Our aim now is to expand further in Asia both with our trigger sprayers and some of the new technologies. Within the next 10 years we expect the market for sprayers in Asia to be even bigger than Europe or America.”

Afa’s ability to expand its reach into the various Asian markets is also a function of what Mr. Gratch calls “Afa’s Global Flexible Production Model”. He explains: “Our learning | 166 | Packaging Europe

from being a high volume producer in China has paved the way to the development of a production methodology that enables us to expand rapidly into the Asian market, gradually and with relatively low investment. We call our model Afa’s Global Flexible Production Model because it combines learning from manual assembly and high speed automation regimes, and allows us to place relatively small production cells in markets that are growing fast but currently their demand for our customers’ products is not sufficient enough so as to justify the investment in high cavitation molds and high speed assembly machines”.

Mr. Gratch concludes: “Due to its flexibility and modularity, the Global Flexible Production Model has sprung serious interest from several multinational brands who are seeking to enter the many smaller Asian markets around the two main ones (China and India). We are enthusiastic and confident with our ability to be at their service”.

Visit: www.afadispensing.com

GORE® PACKAGING VENTS With the growth of global distribution, your active formulations are shipped all over the world. The last thing you want is for your retailers to receive a sticky, deformed product that leaks all over their shelves.

Why does it leak? Most often it is not a quality defect in the cap or trigger sprayer — it’s usually because the container cannot manage the pressure changes it experiences during transport.

Incorporating a vent into the cap or sprayer equalizes internal pressure to compensate for environmental and formulation changes. GORE® Packaging Vents maintain continuous airflow, even after exposure to your most powerful formulations! At the same time, these durable vents prevent the formulation from leaking out through the breathable membrane. These vents improve container integrity because their design repels highly concentrated formulations that can clog other vents.

GORE® Packaging Vents are integrated into many trigger sprayers available in the market today, and our application teams can work with you to design the best solution for your new packaging.

For more information, visit www.gore.com/nozzle From your manufacturing site to your retailer’s shelf, protect your brand by maintaining container integrity — choose GORE® Packaging Vents for your container!

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Discovering Della Toffola:

know-how and style in beverage sector Della Toffola Group offers many technological solutions suitable for the entire production and packaging cycles across the whole food industry. Eight manufacturing companies within the group can supply a range of industries: wine, water, beverages, juices, milk and milk derivates, oil, sauces, liqueurs and spirits. The company competes as a leader in its sector across the globe. Not bad for a family company, able to preserve its roots and original soul.

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are a big, traditional family company,” Alberto Della Toffola – sales director of Della Toffola comments. “Starting from my grandfather up to the third generation, the company has walked down a rewarding route during its long history.”

A family story Giacomo Della Toffola established the first stainless steel vertical crushers and presses in the 1960’s. From the beginning, a distinctive dynamism and manufacturing ability allowed the company to compete with far larger industries operating in the wine-making sector. When Giacomo’s sons Vittorio, Francesco and Luciano entered the business, they brought Della Toffola to achieve international awards as one of the world leaders in the sector.

Throughout the 1990s, further development took place through the acquisition of complementary Italian companies, the diversification into new market sectors, the production of machinery with exclusive technologies, and the inauguration of branch offices abroad. At the same time, activities expanded into the waste water treatment sector and the food processing and chemical industries.

The firm grew up and the founding family still own and run the company; today, 18 members of the family are serving.

Patented innovations “Della Toffola introduced some fundamental innovations in the winemaking technology sector,” says Mr. Della Toffola. “In 1985 our internal R&D department patented the first pneumatic presses with a central membrane, a new technology aimed at obtaining a gentle separation of the must from the grape skins with a very limited disruption of the fibres and a minimal production of lees; the gentle pressing became an increasingly indispensable characteristic of quality wines.”

Della Toffola counts over 20 licenses; its latest innovation is the cross-flow filter, a filter that thanks to new ceramic membranes can offer virtually an unlimited working life.

More recently, there have been further developments in the company’s BioThermo thermal vinification systems too: these systems implement a process that involve rapidly heating and cooling of crushed grapes to achieve remarkable improvements in the extraction of colour and other noble compounds that would unavoidably be lost with conventional vinification methods.

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Complete range The group provides a complete range of winemaking products for every step in the winemaking process, from the moment the grapes leave the vineyard until bottling and labeling. The experience acquired and the acquisition of leading companies in the sector has enabled Della Toffola to expand its production and to enlarge its offer also to the food-processing and beverage industries with avant-garde solutions. The company can supply machinery for every step in the entire chain of production up to the final bottling and labeling phases. Della Toffola produces a wide range of filters developed and optimized for water treatment systems, from the most rudimentary to the most complex.

The company’s technologies are also widely applied to the dairy sector and the processing of mature and fresh cheeses, yoghurt, and other milk products as well as to the foodprocessing, beverages, and chemical/pharmaceutical industries.

International corporation The Della Toffola family has proven capable of sharing and fulfilling a dream, transforming a simple mechanical workshop into a multinational corporation where everyone works to the best of their skills and abilities. The know-how and the expertise it has gained in 50 years of activity now enable Della Toffola to provide turnkey systems. | 170 | Packaging Europe

With eight production units and branch offices, and two brands, Della Toffola Group employs over 450 employees on six continents in a total 190,000 sq m area for an average annual turnover of 110 million Euros, 70 per cent of which is derived from exports all around the world.

The manufacturing companies which make up the group are: Della Toffola; Sirio Aliberti; OMB; DT Separtech; AVE Technologies; Gimar; Priamo Food Technologies s.r.l.

(Italy); Della Toffola Iberica (Spain); DT Inox S.A. (Argentina). There are also five commercial branches: DTF in France; Z-Italia in Italy, Della Toffola USA Ltd. in California (USA); Della Toffola Sudamerica S.A. in Chile; Della Toffola Argentina S.A. in Argentina and Della Toffola Pacific in Australia.

The company is active mainly in the design and manufacture of bottling and packaging machines and systems, with capacities of up to 36,000 bottles an hour. This explains why the contribution of the company’s own team of technicians is so fundamental, and their projects have been adopted for numerous systems installed at prestigious industries.

Future growth In running the business, the brothers Vittorio, Francesco and Luciano have been supported by members of the Della Toffola family’s third generation, who share the same goals of the company’s founders.

“Our aim for the next few years,” affirms Mr. Della Toffola: “Is to further strengthen our market position and to reach those regions, like Africa, Eastern Europe and the Russian Republic, where our presence is still limited. We made significant investments in our research & development division that we consider the firm’s cornerstone. We like to think of ourselves as being much more than a mere supplier, and rather as an authentic technological partner who brings a wide range of instruments to obtaining the best possible result: an excellent product.”

Visit: www.dellatoffola.it

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Innovative plastics-based packaging PLASTICOS ROMERO of Spain, founded in 1979 by the Romero Family in Molina de Segura, Murcia, offers a diverse range of products including plastic bags, packaging films and paper for food packaging. Piotr Sadowski reports.

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2007, spurred on by the imminent EU ban on non-reused plastic bags, PLASTICOS ROMERO made the strategic decision to diversify its product range and significantly upscaled its R&D activities. In 2009 it introduced a film for automatic packaging and a new line for the production of high quality self-closing bin bags supplied to retail networks, which today are available in practically all retail chains throughout Spain.

“The year 2008 saw the first version of the norm for reusable bags, UNE53942.

PLASTICOS ROMERO participated in its drafting, together with ANAIP in AENOR, and promoted the norm both at regional and national level, as well as implementing it across the Spanish market,” says Javier González, general manager of the company. “In fact, PLASTICOS ROMERO was the first company in the country to achieve all the relevant product certifications required by the norm, which has given us a strong competitive advantage over other industry players.”

In 2009 the company received two certifications the ‘Blue Angel’ environmental certification for the manufacturing of ‘Blue Angel’ bags and the “OK Compost” biobased certification, thus opening more doors in this niche market in Germany with eco-friendly and

biodegradable products according to the standard EN 13432. In addition, the ISO 9001, ISO 14001, ISO 22000 and subsequently BRC Packaging OSHAS18000 certifications have helped PLASTICOS ROMERO to prove it is a company that is fully focused on the highest quality, food safety and customer orientation. “Since 2008 we have also been able to offer 10-colour overprinting on bags, which has significantly strengthened our export market operations,” adds Mr González.

Strong market position PLASTICOS ROMERO is the leader on the Spanish market for plastic bags and is also considered a major player across Europe. Exports over the past three years have grown by more than 60 per cent, representing more than 20 per cent of overall sales currently.

“We have recently introduced many different innovative products, such as the beforementioned ‘Blue Angel’ certified post-consumer recycled content bags, covers for car seats and for wheels, as well as paper bags with a twisted handle and film for microwave cooking,” explains Mr González.

“We also offer PE film modified to improve the quality of welding when laminating, which includes a layer of PET (developed together with AIMPLAST Technology Centre), peelable PE with PA CAST, PE for packaging liquids, including alcohol, shrink

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film, active packaging to help extend shelf life of food, high and medium barrier film and other products. In addition, our R&D department is able to develop brand new products tailored directly to the needs of our customers.”

Most recent investments The company’s 2013–2014 investment plan included the introduction of new, technologically advanced equipment, such as three-layer high efficiency extruders and a printer with a central drum machine, allowing the company to expand its sales of film for alimentary products by 300 per cent, to approximately €14 million. PLASTICS ROMERO has also increased its production capacity for food paper, including the introduction of a machine for paper bags with a twisted handle.

Next year, the company will introduce a high efficiency printing machine and two cutter machines. “We are currently in the final stages of planning our 2015–2016 investment strategy and we expect to acquire machinery for refuse bags, based on contracts with our existing customers,” adds the general manager. “We promote our innovations through attendance at trade fairs as well as through direct contact with customers via our extensive network of exclusive trade agents.”

Major customers PLASTICOS ROMERO serves all major food chains and large distributors. It is important to note that 80 per cent of the company’s sales reach more than 100 clients, while the total number of active customers exceeds 2000. “Each and every customer is important to us, because it has been through customer diversification that we have been able to grow even during times of crisis,” explains Mr González. “While the number of employees in the transforming plastics industry in Spain was reduced from 86,000 to 63,000, we have maintained the same number of employees. Our sales grew by 21 per cent in the period 2009–2013 and we expect further growth of 10 per cent in 2014.”

The most important markets apart from Spain, are Germany, the Netherlands, France, England, Algeria, Morocco and other destinations. The company is continuously developing these markets and over the past three years export sales have grown by 60 per cent. “We look forward to further growth, mainly through organic development, but we are not ruling out opportunities for acquisitions or joint-ventures,” concludes Mr González.

Visit: www.plasticosromero.com

Javier González, general manager

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ISOLAGO ISOLAGO is a company supported by an innovating, dynamic and flexible structure, focused on satisfying the needs of every customer. Our projects involve several areas of the polymer´s market.

ISOLAGO and PLASTICOS ROMERO are partners since 2008. P. ROMERO is a demanding/innovating customer that requires from its suppliers a high quality standard, reason why both R&D departments are in permanent contact.

In the end, we aim to satisfy not only our partner but also the end user. The trust of PLASTICOS ROMERO in our Quality strengthens our commitment in looking for continuous improvement.

Excellence is the main goal of all our actions and thoughts, creating a culture of awareness and effective involvement of all employees in optimizing results.

ISOLAGO’s mission is to be recognized in the market not only as a mere supplier but especially as a partner in the improvement and development of new products and solutions that can help optimize the production process of each of our clients.

Visit: www.isolago.com

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PACE: Europe’s Premier

Networking Event

The Packaging and Converting Executive Forum (PACE) celebrates is tenth edition next year with the goal of once again providing a platform for collaboration to help industry professionals respond to the ever-shifting trends and challenges of the marketplace. Tim Sykes spoke to the organisers of the packaging industry’s premier invitation-only event.

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idely regarded as the must-attend event for senior executives in the packaging industry, PACE Europe, which takes place in Brussels, 10-12 February 2015, is meticulously planned in order to bring the right people together to address the most important issues of the day facing their businesses. It is a cross-industry event where executives from brand owners such as Coca-Cola, GlaxoSmithKline, Procter & Gamble and Mars rub shoulders with converters in workshops, case study sessions, one-to-one meetings and presentations.

Delegate driven forum Since its launch in 2004, PACE has grown into a global medium with sister events in Asia and the Americas. One constant has been an ethos of providing a unique and stimulating space for converters and brand owners to come together. However, over the decade the organisers have continually innovated to perfect the format to maximise the benefits for participants. Drawing on packaging supply chain knowledge as well as the wealth of experience gained through running the event, PACE designs its programme based on a profound understanding of the needs of attendees, the key market drivers affecting their businesses, and how to create an environment which maximises touching points for networking.

“PACE is a delegate-driven forum,” said Antoine Marsden, director of PACE Forums.

“It is set apart from any other event by its research-driven agenda. We spend a great deal of time talking to our delegates and getting to understand what challenges they face today and envisage in the future. Such insights are channelled into the selection of topics to be addressed by our programme of presentations, case-studies and workshops.”

Strict qualification A core principle of PACE is to select high level attendees in order to ensure that meaningful communication takes place throughout the myriad networking opportunities. For instance, to attend as one of the 100 or so VIP delegates on the brand owner side, an individual must work for an organisation with a turnover of at least £100 million and personally have control over a budget of at least £1,000,000. This strict qualification bracket sets PACE apart from any would-be competitors.

The solution providers present, meanwhile, are also controlled both in terms of numbers, seniority and job functions. While there is an emphasis on including only top management, the PACE forum hosts a spread of heads of R&D, engineering, marketing, sustainability and other departments involved in the value chain, reflecting an understanding that the industry must overcome its habit of working in silos.

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Bespoke agenda Each attendee will come to PACE Europe with a personal agenda for the forum, comprising a tailored mix of sessions and meetings. Participants get to choose particular workshop and case study sessions based on their roles, and meetings based on their needs.

“Marketing and engineering executives have divergent interests,” remarked Antoine Marsden. “The multi-stream format of PACE, with sessions taking place in parallel, means there is something interesting going on all the time. Everyone can pick and choose in order to make the very most of their time, and their bespoke timetable matches their objectives.”

The organisers do their utmost to ensure that professionals have a platform to communicate openly while assessing the strengths and weaknesses of their supply-chains.

Although they emphatically state that ‘PACE is not a trade show’, it is a forum which fosters collaborations and business relationships.

To this end, the event programme incorporate eleven half-hour slots dedicated to one-to-one business meetings, which pair up VIP attendees with carefully selected solutions providers.

“The governing idea of one-to-one meetings is quality over quantity,” said Antoine Marsden. “Each attendee supplies us with data about their needs, enabling us to introduce them to relevant solution providers. We encourage parties to do their homework on each other and we provide passwords to allow participants to communicate in advance of the meeting. This isn’t about speed dating. The aim is to create an environment that is conducive to doing business: to have an in-depth and open discussion about their supply chains.”

the context of packaging as an investment, addressing how to deal with the fragmented nature of the packaging business.

The key trends under scrutiny include present and future areas of innovation, marrying technology with packaging, how to respond to changes in demographics and consumer behaviour, the rise of e-commerce and a multi-channel environment, as well as issues revolving around sustainability, such as food waste and water consumption.

The customer case study sessions are designed to explore challenges and opportunities within an area to which most of the brand owners can relate. Converters can sponsor a session to show an alignment of their capabilities to the technology or challenge under discussion. Meanwhile, the series of workshops, many of them running concurrently with the business meetings, are sessions tailored to specialised audiences, talking through the practicalities and specifics of a solution, technology or application. The brand owners pre-select which of these they wish to attend before the event.

Fresh perspectives

Presentations and discussions

“For the tenth anniversary of PACE Europe we will be innovative, not through radically changing the tried and tested formula but focussing on the content,” said Antoine Marsden. “The agenda is driven by the most important conversations taking place in the packaging world, which we try to frame in fresh and interesting ways.”

Attendees will hear from inspiring thought leaders, to swap ideas on crucial trends with the packaging industry, and to get an inside view of how projects such as Heineken’s light-up can or the integration of Coca-Cola’s mass-personalisation ‘Share a Coke’ initiative into the supply chain came to fruition. They will establish new contacts and initiate new business relationships. The forum can be guaranteed to provide the three most intense days of learning, sharing and networking of the year.

Around the business meetings is a packed agenda of keynote presentations, group discussions, workshops and case-study sessions. PACE Europe 2015 will frame its topics around

Visit: www.arena-international.com

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Extrusion experts Abriso specialises in the extrusion of PE foam, air bubble film and extruded polystyrene for the packaging and building industries. Since its foundation in 1985, it has gradually gained a strong position in the European packaging and insulation markets by utilising its seven production units across Europe. Libby White spoke to commercial director Chris De Mazière to find out more about the recent management buy-out and plans for the company to exhibit at the upcoming Emballage exhibition.

Packaging Europe | 183 |

F

ounded under the well-known name BFI (Bubble and Film Industries); the company originally focused exclusively on producing bubble film. Expanding into the building market, it then started to offer products such as extruded polystyrene for use as thermal insulation as well as expanding into providing protective packaging through its Abriprofile range.

Abriso’s headquarters are based in Anzegem, Belgium, and it has further facilities across Europe. For example, Abriso France, founded in 1994, is located in Saint-Rambert D’ Albon (60km from Lyon). The strategic location of this site is of vital importance for Abriso’s strong position in the South and middle of France. With 50 employees and 30,000m² of storage space Abriso France is a flexible daughter company with an evergrowing turnover.

Mr De Mazière explains Abriso’s growth across Europe: “As we became more and more oriented to offering our products in eastern Europe we expanded our facilities to cope with the demand. For example, we bought an extrusion facility in Cecejovce, Slovakia, which we have since invested into to increase its capacity. We have also acquired plants in Cluj Napoca, Romania and started up from a greenfield in Gora, Poland. We were exporting our products to the Ukraine; however, every year import prices were increasing so we decided to extrude locally and opened a plant in Brovary-Kiev in Ukraine.

In Hungary we operate a converting plant in Sarvar.”

2013 was a defining year for Abriso when it achieved a consolidated turnover of €85 million. At the end of the year, it concluded a successful management buy-out and since then has gone from strength to strength. The Abriso management team - with Jan Dejonghe

| 184 | Packaging Europe

aims as CEO – aims to uphold its belief in the future of the company and its competitive strength through service and flexibility, extensive product range, competitive prices, a customer-oriented management team and an international organisation with a focus on product innovation. Mr De Mazière comments, “Since the management buy-out we will continue to work with our partners all over Europe. The packaging division of Abriso is currently our main focus, with 65 per cent of our business dedicated to the packaging industry.”

Packaging product range With such an extensive portfolio, Abriso is set to exhibit at the upcoming Emballage exhibition in Paris this November. With its own stand in Hall six M 149, visitors can expect Abriso’s professionals and experts to be ready to answer any questions about the full range of products on show. Mr De Mazière comments, “We are ready to welcome French customers and international customers to our stand and we plan to launch at least one new product range of self-adhesive Abripads produced in-line. In preparation for the launch, Abriso is planning to install the line and carry out the first test runs before the show.”

On top of its recent innovations and product launches, Abriso offers a wide range of products to the packaging industry. Abribubble is an air cushion film consisting of bubbles formed between two or more polyethylene foils. These air bubbles ensure maximum protection and come in a range of applications from rolls, sheets, bags and covers to laminates and transformation. Abrifoam is an extruded polyethylene foam, available in different densities and dimensions. This expanded foam has a closed cell structure, giving high resistance to scratches and impacts.

Abrifoamflex is a combination of Abribubble (air cushion film) and Abrifoam (polyethylene foam). The air cushion film is laminated with polyethylene foam, which combines the advantages of both materials. This makes Abrifoamflex an ideal shock and scratch resistant packaging material.

Abriprofile comes in a wide range of different types to protect a variety of products.

Abriplank, Abripads and Abricare have also been developed to provide the best in protection for a range of materials and products.

Mr De Mazière comments, “We export our products all over Europe through our network of loyal distributors. Many have been working alongside us for 25 years. We have a very good relationship with our partners and aim for long-term relationships with them.”

Objectives and growth strategy Based on steady growth and the recent management buy-out, Abriso looks to grow its turnover further through a number of objectives. Mr De Mazière comments, “We aim to optimise efficiency and productivity and reduce our costs through the recycling of materials and reduction of internal waste in our facilities. Research and development is also a key focus – we are always looking to develop new markets and new products.

“Our advantages include our extensive portfolio which we can produce from one site, and our focus on establishing partnerships with our customers. I would also like to emphasis our service and flexibility which is important to our geographical growth. As we can produce in seven different countries, we have the strength of being able to transfer and exchange know-how between our facilities.”

Abriso is a company built on strong values, as Mr De Mazière explains: “The values of the company are humble leadership, respect and ambition, teamwork, passion for our products and service, commitment, motivation and self-discipline, responsibility and accountability and R&D as a technical accelerator – these are all very important cornerstones for our company.”

Flexibility and specialist solutions Abriso prides itself on offering flexibility. “As a company, we have no rotation in personnel so our customers will always speak to the same professionals. Flexibility is also a very important offering from us as we provide a whole range of products from one site and we are very customer-orientated.”

Mr De Mazière continues, “80 per cent of the customers we built relationships with 25 years ago are still our customers today and we have grown together with them over the years.”

Abriso is optimistic about the future thanks to its solid background. Mr De Mazière concludes, “We are looking to continue investing in the quality of our products. We are always investing in our research and development to expand the special grades, densities, thicknesses and laminations of our products. We are well-known as experts in finding specialist solutions.”

For more information, visit www.abriso.com

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Innovative print and specialised laminating company Parkside Flexibles has undergone a ‘total evolution’ in the past nine years.

Emma-Jane Batey spoke to managing director Nick Smith, development director Chris Kozlik and director of speciality packaging Steve McCormick, to learn how this has been achieved.

Evolve and solve B

ased in Normanton, West Yorkshire, UK, Parkside Flexibles has over 40 years’ experience in bespoke packaging, offering high quality flexographic printing and specialised laminating products and services. Since 2005, Parkside has undergone a ‘total evolution’ and now, while it is still a globally-recognised leader in tobacco packaging, it has grown to be a valued player in a broad range of industries.

Managing director Nick Smith told Packaging Europe how this evolution has proved positive for both Parkside Flexibles and its customers worldwide. He said, “As a company that has long been known for our innovation, our quality and our reliability, we were determined to maintain our market-leading position by staying fresh and relevant. Our real transition started nine years ago when we were bought by our current owner, which prompted a total transformation of our offer. But the really exciting thing is whilst we’ve | 186 | Packaging Europe

kept our core business as a printer, the creation of our innovations centre of excellence has allowed a much more focused and targeted expansion of our business.”

By extending its offer from traditional print, laminates, coatings, pouches and sleeves, Parkside Flexibles has gone beyond its proud history as a pure printer to that of a total packaging solutions provider. Steve McCormick, director of speciality packaging, explained to Packaging Europe how this expansion has utilised the company’s longestablished expertise. He commented, “Our innovations centre of excellence is the perfect partner to our existing business portfolio as it allows us to harness what we’ve learned about packaging over the past 40 years and maximise our potential in a complementary field. Our long standing history in packaging is a real advantage as it gives us a good foundation from which to deliver a total packaging solution that includes and under-

Chris Kozlik, development director

Nick Smith, managing director

stands print. As well as our established offering we now offer added value elements that meet the challenges of today’s end user. Innovation is at the very core of our business and our ability to think differently has allowed us introduce some interesting and practical packaging solutions into the market place.”

Driven by adding value The added value elements that Parkside Flexibles is committed to integrating into its whole product range are chosen through careful communication with its customers and smart trend analysis. Chris Kozlik, development director, explained, “We’re always adding new products to our portfolio and adding value to our existing products. This has been a key driver in our evolution, which has been a gradual upward trajectory over the past

nine years and shows no sign of slowing down! We look at every stage of the supply chain in which we operate and think how we can add value for the customer and their end user; our recent investment in a laserscribe machine, has allowed us to develop easy opening solutions and resealable packaging which are new additions to our portfolio and have been created in collaboration with our customers.”

The very exacting standards maintained by the company have contributed significantly to its recent growth. Its background in print has also proven to be a strong advantage, with knowledge of different substrates and finishes translating into more decorative and tactile options for brand owners. MD Nick Smith added, “We’re not limited to print, but we know that our deep understanding of print is a valuable asset. We now offer a whole range of high-tech solutions including security systems and laser scribing. We don’t Packaging Europe | 187 |

blinker ourselves; by listening to our customers and taking the time to truly understand what their consumers want, we can deliver products and services that maximise our investment in technology and our extensive expertise.”

Strong supplier relationships One of the keys to Parkside Flexibles’s success, as with any business, is its ability to maintain long-term partnerships with its key suppliers. One of these is the company Windmoller & Holscher. Parkside’s association with Windmoller and Holscher goes back many decades, during which time a strong relationship has been formed.

“Windmoller understand the needs, requirements and pressures a business like Parkside face every day and has a proven history of technical support and excellent customer service.

“Exceptional print quality, speed and reliability were key drivers when choosing our print presses, all of which are supplied by Windmoller. This gives us the flexibility to interchange machinery as and when required in order to meet our customers’ demands, which is essential in today’s market.”

Growing and investing With the global tobacco industry enjoying a growth surge in Asia, South America and Africa, Parkside Flexibles’s purpose-built facility in Malaysia is helping it to boost its production capabilities for these regions, as well as a number of commercial partnerships established in Mexico, eastern Europe and Africa. The company has been supplying print

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and laminate products and services worldwide for some time. Its ongoing investment programme will bring further international locations into the Parkside Flexibles global footprint as part of its successful strategy of following the customer.

Mr Smith concluded, “We continue to make significant investment in our future, our people and our facilities. We’ve also got some really exciting new additions to our portfolio later this year too. Going forward, we’re really putting our money where our confidence is. We have a fantastic calibre of people here and we encourage our workforce to be creative and take ownership of their ideas; it’s this atmosphere of achievement that really helps give Parkside Flexibles the advantage.”

Visit: www.parksideflex.com

Leaders in IML labelling The Italian company Viappiani Printing S.L. specialises in labelling and In-Mould-Label (IML) technology. Matjaž Gorjup, the company’s managing director, talks to Vanja Švačko about the market opportunities for IML solutions and explains the importance of technical support and extended communication between producer and end-user.

All photos copyright of Viappiani

Packaging Europe | 189 |

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stablished more than 80 years ago, Viappiani has grown from a small family print shop to a modern printing supplier with a global reach. In the beginning its modest portfolio consisted of labels produced using wet-glue technology. Today it has its own patents on labelling and printing technologies. Its main focus is on the production of various kinds of IML for the food, dairy, chemical, construction and cosmetic industries.

With its head office in Segrate near Milan, Viappiani operates one state-of-the-art manufacturing facility with 115 employees. The company is logistically very well placed to reach customers all over Europe within 48 hours.

In 2009 the company seized the opportunity to become a part of the CTI Holding AG, an international printing group with seven factories worldwide. Through this, Viappiani has gained access to the latest technologies and global markets. Mr Gorjup explains, “Besides western Europe, the CTI Holding has facilities mostly in South America and that is a natural expansion area for Viappiani. We already have direct sales there, as well as the sales of our technologies through our affiliates in the Latin American markets.” The group benefits from close cooperation with some of the leading label printers all over the world.

Multilingual support Mr Gorjup believes that direct communication with its customers is what gives Viappiani an edge over its competitors. “What distinguishes us is the level of service we offer in a multitude of European languages (Italian, German, English, French, Spanish, Slovenian, Croatian and Czech),” says Mr Gorjup. “Our ability to communicate with | 190 | Packaging Europe

customers in their own languages enables us to offer them a quicker response and more comprehensive support.”

This multilingual service also helps customers to solve the many technical challenges associated with IML applications and therefore to increase their productivity. This support is particularly important when it comes to developing new projects.

Mr Gorjup continues, “Some of our customers enter the IML markets having used very different technologies so we know how important it is to help them start with IML in the most productive fashion.

“Customers are often facing pressure in terms of productivity and we help them in reducing cycle times, scrap rates or in reaching their cost and environmental targets by downgauging.

Innovation driven A significant share of the company’s portfolio covers durable and semi-durable products in the food and chemical (paint) industries.

“We have developed products that offer high scratch and water resistance, which are particularly important for durable and semi-durable products. Some of these products are also very suitable if a customer is seeking to downgauge. We can produce a very resistant label on relatively thin substrates,” explains Mr Gorjup.

The resistance and durability of labels are also of the utmost importance for particular applications in the food industry. In certain cases the packaging has to be pasteurised, All photos copyright of Viappiani

which puts a great strain on the IML label. Viappiani has developed an advanced IML pasteurisation solution.

The company is currently investing in new solutions for speeding up productivity in the finishing area. As for future investments, Viappiani is looking into expanding its capacities, but more importantly it wants to improve flexibility.

Evaluation of new technologies Faced with the rapid evolution of this market, Viappiani has started exploring digital technology that would be particularly suited to IML as a possible solution to short runs.

Mr Gorjup adds, “Apart from that, we are currently evaluating a couple of new technologies, introduced by equipment suppliers, that combine conventional and upcoming technologies. They are going to offer additional productivity and flexibility. Soon we will make our decision about one of these technologies in order to achieve greater flexibility and speed.”

The company spares no efforts to meet the requirements of its clients. In one upcoming trade show it is set to exhibit two installations with labels that can achieve cycle times very close to the productivity levels of thermoformed labels.

“Thermoforming and injection moulding are two competing segments and the productivity of Viappiani IML labels facilitates both technologies to converge for the benefit of the customer.. At Viappiani we are strong believers in maintaining focus. For us, good work leads to more work and provides us with an excellent opportunity to grow organically. With a high level of productivity, the high quality packaging will become accessible to bigger markets. So this is where, I believe, the growth will come from,” concludes Mr Gorjup.

Visit: www.viappiani.it

All photos copyright of Viappiani

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Passion for Innovation Windmöller & Hölscher have many shared goals with Parkside Flexibles none more important than the need for innovation and to serve their markets worldwide with the highest quality equipment for the production of innovative packaging such as that developed and manufactured by Parkside. This of course can be said for all of W&H customers. ‘W&H and Parkside have been working together for at least the last two decades and it has been very interesting to witness the metamorphosis of Parkside as it has happened’ comments Tom Wiltshire of Wantzen the UK agent for Windmöller & Hölscher.

W

indmöller & Hölscher is a German-based manufacturer of technologically advanced machines and work with Parkside for their Flexographic printing requirements. In addition to this offer highly technical solutions for Blown and Cast film equipment, gravure printing presses as well as converting machines for industrial sacks made of paper, PE-films, PP-woven’s and composites. In addition, W&H supplies high-performance industrial bagging machines (FFS) for free and non-free flowing bulk materials. By implementation of its “Greenovation” strategy, W&H committed themselves to creating sustainable and energy-efficient technical solutions.

Founded in Lengerich/Westfalia in 1869 by sales man Gottfried Windmöller and technician Hermann Hölscher and still a family owned business, W&H has become number one supplier globally within its market segment. With sales in the vicinity of EUR 600 million in 2013, the W&H-group employs a staff of about 2.300 at 17 locations worldwide.

Flexible packaging is the central point of W&H’s entrepreneurial thinking and acting. There is no getting around packaging. It protects valuable goods against loss

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and spoilage and is an indispensable requirement to the modern distribution of goods. The fact that W&H have made flexible packaging the focus of their business is attributable to the ecological and economical advantages provided by this packaging genre which requires less resources than packages made of rigid materials.

With their commitment to flexible packaging W&H want to make a contribution to the sustainable use of natural resources as well as energy saving and waste reduction.

Living up to these maxims, W&H want to grow with their tasks and work towards their company goals, that is to constantly improve their customers’ production processes and aim at global leadership in the manufacture of machinery and equipment for flexible packaging. W&H’s technological superiority and their thinking in holistic correlations are important elements that will help them achieve their goals.

“Passion for Innovation” is the company maxim and expression of its philosophy which not only exists on paper, but is the guiding principle of everything they do.

Among the customers convinced of the advantages of Flexo presses such as the MIRAFLEX is the company Parkside Flexibles Ltd. with which W&H has been maintain-

With their commitment to flexible packaging W&H want to make a contribution to the sustainable use of natural resources as well as energy saving and waste reduction. ing a long term and faithful cooperation. ‘Apart from the Flexo presses already supplied

by W&H to Parkside we are very happy and optimistic about our relationship going forward with Parkside’s already successful venture in Malaysia and will strive to support them however we can’, said Stefan Honke area sales manager for W&H. Like Parkside, W&H have been quick to notice the need to be truly world Focused and have opened a subsidiary organisation based in Asia to serve the Asia Pacific Markets. They have a strong service and sales support structure headed by MD Michael Fischer.

Contact: Elisabeth Braumann, M.A. Tel.: +49 5481 14-2929 · Fax: +49 5481 14-3355 elisabeth.braumann@wuh-group.com Dipl.-Ing. Ulrich Stienecker Tel.: +49 5481 14-2412 · Fax: +49 5481 14-2680 ulrich.stienecker@wuh-group.com Visit: www.wuh-group.com

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A pioneering Tank-Free Hot Melt Delivery System

For over 80 years, Graco has been a world leader in fluid handling equipment. Its ongoing investment in product development continues to provide innovative solutions to a diverse global market.

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he latest innovation within Graco’s range of adhesive applicators is the new Invisipac Tank-Free Hot Melt Delivery System for case and carton sealing applications.

This pioneering concept is completely different to the traditional hot melt systems. The main difference is its tank-free design, which allows the system to work on a melt-on-demand principle, instead of using a large capacity Hot Melt Tank.

Tank-free design While traditional hot melt systems use large tanks to heat adhesives to a liquid form, the InvisiPac system is tank-free and its compact melting chamber processes pellets in small batches. Because the adhesive only spends a short amount of time at high temperatures, there is significantly less char formation than in traditional tank systems. Having less char eliminates plugged nozzles and greatly reduces overall system maintenance.

Operators no longer need to go through the time-consuming process of tank scraping and cleaning as there is simply no tank involved. The end result is enhanced production line efficiency and less down-time, which means significant savings in both time and money for customers. | 194 | Packaging Europe

In addition, start-up times on an Invisipac production line are approximately 10 minutes, compared to a 35-minute start-up for traditional hot-melt systems that use a tank to heat adhesives.

Automatic feeding system By using an automatic feeding system, the Invisipac system eliminates thermal shocks, reduces contamination and provides an automated and safe supply of hot melt to the melting unit. Its integrated vacuum system is used to feed adhesive to an in-line melter. An ultrasonic sensor monitors adhesive in the chamber, and additional adhesive is automatically added based on application demand.

The InvisiPac’s efficient heat transfer design provides an equivalent or better adhesive flow than many hot melt tank systems. The result? A continuous flow of adhesive during production that significantly reduces the time adhesive sits at temperature. Less time at high temperature means less char, less maintenance and more uptime. It is a highly innovative hot-melt solution for the packaging industry.

Production line operators can also learn to use the system very quickly thanks to its clear graphic display and embedded diagnostics, which also saves Graco’s customers significant service time. Greatly improved heat-up time is achieved through the product’s intuitive power management system and multi-zone heat controls. These minimise power consumption, whilst maximising production line performance.

Visionary Award Graco InvisiPac™ Tank-Free Hot Melt System received the Gold Visionary Award from UBM Canon’s Packaging Group in a ceremony held at the EastPack 2013 packaging industry trade show in Philadelphia, USA. The award recognised Graco for its design of the InvisiPac.

Graco sells in North and South America, EMEA and Asia Pacific through approximately 30,000 distributors worldwide.

Graco is here, every day, around the world. From an airplane in the US, to a wind farm in Brussels, a railroad in Shanghai, a sports arena in Brazil, Graco paints, finishes, powder coats, fills, glues and seals components in these and many more.

Graco equipment pumps tomato paste into tins, fillings into cookies, oil into cars and ink onto bank notes. It also dispenses glue onto the soles of shoes, sprays coatings onto pills, paint onto houses and furniture, and plaster on walls. Graco products were even used to paint the US White House and to stripe the UK Wembley Stadium sports field.

Graco strives for continuous improvement and excellence in production, and its ‘comprehensive system approach’ is an example of its dedicated commitment to customer service and efficiency.

Graco Europe headquarters are situated in Maasmechelen, Belgium. From this location about 120 employees serve Graco´s external and internal customers throughout Europe, the Middle East, Russia and Africa. The dedicated sales teams and application specialists cover all these markets and are available to support the specialised local distributors at all times.

Multi-lingual InvisiPac classes Graco also has an online Graco University where multilingual InvisiPac classes are available. This allows customers to learn about products in their preferred language.

For more information on the Graco InvisiPac System, visit graco.invisipac.eu

About Graco It all began in Minnesota in 1926. Graco started small in Minneaopolis – the vision of two brothers who needed a better way to lubricate cars. Since then, Leil and Russell Gray’s dream has grown into a $1 billion company.

Today, as a leading fluid handling company, Graco markets products in more than 100 countries on six continents for diverse industries such as agriculture, aerospace, electronics, energy, oil and gas, manufacturing, transportation and automotive manufacturing, repair and maintenance.

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Guido Aufdemkamp, director of communications

Focus on Flexibles Flexibles have enjoyed the biggest growth of any packaging material over the last decade, as they have increasingly innovated to add value while capturing a share of new end use segments. Guido Aufdemkamp, director of communications at Flexible Packaging Europe, the association representing the European speciality films and laminates industry, spoke to Tim Sykes about the conditions in the market today.

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key narrative in the industry over the last decade has been growth in the turnover and market share of flexible packaging – a trend that has continued in the face of poor growth in the general economy. A recent report by MarketsandMarkets forecasts annual growth of 3.9 per cent for the speciality flexible packaging industry in Europe up until 2018. Another, by PCI Films, projects two to three per cent annual growth over the same period, predicting the market will reach around 14 billion euros in value in 2018.

“Speaking of added value and high converted flexible packaging films, the market outlook is good,” said Mr Aufdemkamp. “As everybody knows, eastern Europe is performing better than western Europe, as it is a less mature market. However, it is a significantly smaller market overall, so absolute growth of around two per cent in western Europe will account for a greater proportion of total growth in the market than four or five per cent growth in the east.” | 196 | Packaging Europe

In terms of its international dynamics, there is not a major global trade in speciality flexibles, with the continents and major regional markets relatively insulated from one another and limited exports between Europe and China or Europe and North America. However, Europe as a whole is a very open marketplace, and Mr Aufdemkamp notes that he cannot think of a single member company of FPE which only serves its domestic market.

Growth during downturn How food and beverage consumption might be affected by an economic downturn is always hard to predict. However, the post-2008 recession has not been unkind to flexibles.

“We have seen that an economic crisis can benefit the packaging industry,” Mr Aufdemkamp remarked. “One reason is that people visit restaurants and bars less frequently, and therefore consume more at home. In these cases, visits to restaurants

are often substituted by buying premium level ready meals from supermarkets – such formats tend to gain from an economic crisis. In addition, Unilever for example has reported that people have been spending less money on individual shopping trips. When you spend just €30 or €40 per shopping trip, you cannot afford to buy larger packs.

This leads to an increase in the purchase of smaller units, which of course means more primary packaging.”

The converse, according to Mr Aufdemkamp, is that when economic times are good, packaging can also benefit because there is higher demand for premium packaging with features which add value.

Migration from rigids Another factor underpinning healthy growth rates in flexibles has been the continuing encroachment on markets until recently dominated by rigid containers, in areas such as sauces, pet food and baby food. This is a phenomenon which Mr Aufdemkamp expect to continue: “In theory the only products that cannot be packaged by flexibles are carbonated beverages,” he said. “Otherwise there are almost no limitations. There is always a potential flexible solution for just about any product you can think of. However, whether there is really latent demand in a particular market depends on many factors. Consumers in different countries act differently and have their favourite packaging formats for different products. Often the market requires a choice between different packaging materials: in certain consumption contexts rigid packaging is more suitable, in others people might prefer flexible.”

Similarly, from a marketing point of view, brand owners seek differentiation on the shelf. Therefore, if all of the products are in pouches, one means to achieve this would be to switch to a different packaging solution. Sometimes a marketing department will choose to spend its budget on more expensive packaging rather than on advertising. Thus while in theory the possibilities are endless, in practice market conditions dictate where

the opportunities are and often impose a natural limit to penetration of a particular market by any particular packaging material.

“Brand owners will always look for a balance between the benefits of the packaging and cost considerations,” observes Mr Aufdemkamp. “Generally, take up of flexible packaging in a particular market is a case of evolution, rather than revolution as brand owners assess the merits from all angles. The move away from tin cans in the pet food segment was, for instance, a gradual process. Growth in speciality films is driven not so much by whole market segments as by tailor made solutions which meet the needs of a particular brand owner. The market is looking less for standard formats and more for the speciality attributes that can help deliver differentiation or better functionality. It can often be that when a product is moving from a rigid container to a flexible solution, a speciality film is required to deal with particular properties and requirements (whether shelf-life or migration issues) of the contents.”

Often the migration towards flexibles in a particular market takes on added velocity where, in addition to the cost benefits and the novelty factor, flexibles can add new functionality. For example, in Germany there has been a shift in the market for Frankfurter sausages, which used to be usually packed in glass jars, towards using a plastic container with a flexible lid and without the liquid inside. This has facilitated a wider range of consumption situations. Now consumers can conveniently take this product on a hike or a picnic, which would rarely have taken place when it was in a glass jar filled with liquid.”

Shifting supply chains A significant change in retail which is affecting the entire packaging supply chain in many ways not yet codified is the rise of e-commerce and home delivery. What this means for the flexibles industry is equally an open question.

“I’m not sure how it is impacting on flexibles,” said Mr Aufdemkamp. “We don’t know whether food packaging will fundamentally change due to e-commerce. Personally, I doubt that it will. There are people saying that we will have a future of plain packaging, Packaging Europe | 197 |

because when people shop online they usually see a picture of the product without packaging. However, if brands want to engage with their customers, packaging remains an ideal medium through which to do this, when they open their cupboard at home. Therefore, I don’t foresee many changes or threats to packaging with regard to printing, etc.”

Perhaps a more intriguing questions is whether there are opportunities for flexibles to develop a serious presence in the market for secondary packaging in home deliveries.

“This remains to be seen,” said Mr Aufdemkamp. “It will probably depend on the levels of automisation as e-commerce grows bigger. If you look at the pharmaceutical segment, for instance, packers have a high level of automisation, with everything done by robots. In a world where a robot can grab a biscuit without crushing it, I don’t think it is a problem to develop one that can handle a flexible pack.”

New properties Inevitably, as films move into markets traditionally dominated by rigid containers, flexible packaging formats must innovate to replicate the functionalities of the containers it displaces.

“Tailor-made packs are now offering a huge range of capabilities,” remarked Mr Aufdemkamp. “In terms of shelf-life, with flexibles everything is possible from zero barrier to absolute barrier. There are lots of innovations around the area of easy opening and reclosing packs, from zip locks to spouts. In addition, there is a huge variety of pouch formats these days, not just rectangular but all kinds of wavy shapes and appearing in multipack formats.”

Representing the industry The core roles of Flexible Packaging Europe are to facilitate communication within the industry on important issues that affect all of its members and to represent the common views of the industry to the regulatory community.

The FPE’s Technical Committee is the focus of much of the activity dealing with regulatory affairs such as food contact legislation. Experts from member companies sit on the committee to discuss industry-wide issues and act as counterparts to other stakeholders in the discussion: suppliers, customers, other packaging manufacturers and regulators.

“We are a well known partner to the Commission because we speak for our industry as a whole. When you take into account all the various materials involved flexible packaging, FPE acts as a consolidator of their views, meaning a third party such as the Commission doesn’t always need to contact each material segment individually. They know that when FPE states an opinion it has already extensively discussed the matter with the stakeholders.”

In addition, the Technical Committee, run by John Dixon, supplies FPE members several times a week with information emerging from its activities. Such information feeds into a members’ library listing all of the regulations with which members have to comply – a particularly valuable resource to FPE’s small and medium sized members. | 198 | Packaging Europe

“An important asset for FPE is that our membership consists not only of manufacturers but also national flexibles associations,” said Mr Aufdemkamp. “They are able to feed us information about what is going on at the national level, enabling us to understand what is going on and engage not only on a European basis. This is particularly useful since, as I said, our members are supplying into multiple markets throughout Europe. For such manufacturers, one of the biggest challenges is when new national regulations, such as the Swiss ink ordinance, differ from others.”

Environmental case Discussions about the environmental credentials of flexible packaging usually revolve around the reductions in weight and material usage offered by films on one hand, and their low recycling rates on the other.

“I’d like to reinforce the fact that in the Packaging and Packaging Waste Directive the stated first target is prevention of waste, something that flexibles contributes to by reducing packaging volume,” Mr Aufdemkamp pointed out. “This in turn leads to resource efficiency, and one of the overriding targets of the EU Commission is a resource-efficient Europe. It therefore concerns us that recycling always seems to be the focus of discussion, rather than prevention, which is actually higher up in the hierarchy of priorities.

Even though recycling rates are comparatively low for flexibles, compared with some rigid materials, the use of flexible packaging leads to greater resource efficiency. Part of our industry’s task is to increase the amount of Life Cycle Analysis carried out in order to better demonstrate the factual basis of this case.”

However, Mr Aufdemkamp detects a welcome shift in approach to sustainability: “It is no longer an isolated topic, but included in the everyday thinking as part of the business,” he said. “In such a climate people become more realistic and educated about what is possible and what is important, which is a good thing for us.”

Ampac – E-Z SnackPakTM Ampac is the world’s leader in creative packaging solutions. We passionately create and bring to market packaging designed to advance our customers brand and value globally. The E-Z SnackPak™ by Ampac is a new packaging format for the single-serve snack food market. This tetrahedron shaped pouch transforms into a serving tray upon opening – providing a unique consumer experience – and also adds package support which provides product protection during shipping and handling. The geometric design can be packed into a corrugated shipper with an efficient interlocking pattern or displayed in a shelf-ready carton at point-of-sale making your product stand out on the shelf.

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A passion for

sustainable

innovation P

etainer’s corporate head office is situated in London, United Kingdom, they also have manufacturing plants in Aš, Czech Republic and in Lidköping, Sweden.

The sites are supported by an R&D centre in Aš and sales offices in Germany, the United Kingdom and the USA. Petainer also recently opened a new manufacturing site in Russia, producing recyclable PET beer kegs and water cooler bottles for the local market in Klin, 40 miles from Moscow, it is equipped with state-of-the-art SIDE blowing machine capable of manufacturing 700 kegs per hour, up to a maximum keg size of 50kg.

As a global company, in addition to its own production sites Petainer works with a range of distributor and has created close partnerships with equipment providers such as KHS. Petainer’s packaging offering is divided into two segments – small containers, which includes petainerJar™; and large containers, including PetainerKeg™ and cooler products with a capacity of up to 15, 20 or 30 litres.

Manufacturing the products takes place in two stages – first the resin is mixed and injection moulded, the preform then gets shipped to the customer locations or blowing hubs in bulk where Petainer is able to blow according to standard and customer specifications.

“This allows us to ship many more products in an unblown/preform format to blow on site. It’s important that we don’t transport air. For example, we can ship 30,000 preform kegs in a truck, but only 2000 blown kegs. Thereby we help to take freight off the road.”

As a specialist engineering and technology business, Petainer is an industry leader in the development, design and manufacture of PET plastic containers. Elisabeth Skoda spoke to Annemieke Hartman-Jemmett, Petainer’s Group Commercial Strategy Director, to find out more about the company’s strengths and its recent rebranding.

Maximising performance Petainer is continuously developing new products staying ahead of the competition across all segments. . At this year’s Brau Beviale from 11–13 November they will be presenting a new keg called PetainerKeg™ Linestar, based on the company’s classic PetainerKeg™, which also can be used on pre-existing filling lines.

“The PetainerKeg™ Linestar is based on the PetainerKeg™ classic blown, oneway, recyclable PET keg, and features a significantly redesigned outer shell which enables it to fit specifically on existing steel-keg filling lines; it reduces logistics costs up to 30 per cent and maintains taste quality equal to that of steel,” Annemieke explains.

“At the recent WE 2014 (Watercoolers Europe) conference in Budapest, Petainer presented a new water cooler with a handle; a similar water cooler without a handle was introduced last year, following customer requests,” she adds.

The recently introduced PetainerJar™ range is made from a PET blend and is available in varies sizes, colours and moulds in two formats –fully blown jar for short lead times and a wide mouth preform, ready to be blown by manufacturers at their own premises as and when required.

“It is available in sizes ranging from 63mm up to 120mm. With the 120mm opening, jar sizes of up to 7.6 litres can be achieved,” Annemieke adds.

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Rebranding In an effort to communicate Petainer’s core competences even more effectively to customers and the supplier base, the company underwent a comprehensive rebranding earlier this year.

“We recognised that we needed a tool to effectively communicate the essence of our business. The new logo features three triangles in blue, purple and orange – each shows clearly how we structure our processes with customers,” Annemieke explains..

“Blue stands for our understanding of customer needs and what they want to achieve with their packaging solutions. This leads onto orange, which stands for innovation, covering our materials mix, highly designed and engineered preforms, technical blowing, and all ongoing new product development activities. We focus on the outcome, and ultimately the value for the customer, which is represented by the colour purple. Our sales team is consultative in its approach, focusing on understanding what the customer is looking to achieve so we can provide them with the best packaging solution.”

In order to showcase the rebranding, Petainer is in the process of developing a new web presence at petainer.com, this presents a company overview and outlines core competences. In addition, there are a number of micro sites: Petainer Small Containers, Petainer Keg, Petainer Cooler and Petainer Jar, allowing current and future customers to find the product range they are interested in more quickly and easily.

Economics Petainer puts a high value on sustainability, highlighted by the Economics principle which incorporates working with sustainable elements and reusing bottles. Petainer’s products are generally made of up to 50 per cent virgin material and 50 per cent postconsumer recyclates.

“It is important to us not to just offer competitive pricing, but be commercially viable, with improved packaging performance offering longer shelf life. Petainer operates on a ‘zero waste’ premise, referring to materials, production processes and also to the customers’ time and efforts,” says Annemieke | 202 | Packaging Europe

Petainer is proud to be a reliable partner to its customer’s, she explains. “We share a close relationship with our customers. We don’t just provide products but also services, such as technical support on-site, and rental systems for customers to enable them to go to market much more quickly with our keg products, saving them expenditure. Customers can enter the market on a small scale, and as demand grows we can accompany them with appropriate equipment.”

With a strong position in the market place, Petainer is ready for the future. “Petainer is the number one provider in European refillables, a strong market particularly in Germany and also leading in the field of one way packaging in Scandinavia. With a proactive sales strategy, Petainer is very much in the market to continue growing,” Annemieke concludes.

Visit: www.petainer.com

INVISTA INVISTA’s PolyShield® resin is a reliable and proven technology for cost-efficient, transparent, monolayer PET bottles for high-barrier packaging applications such as beer, juice, wine, and others. PolyShield® resin can be processed on standard PET preform and bottle manufacturing equipment with only minor changes and minimal additional investment. This technology provides oxygen scavenging and passive carbonation barrier when combined with Nylon-MXD6 and provides outstanding clarity for tinted bottles. One-way kegs made from PolyShield® resin blends with Nylon-MXD6 enable brewers to package draught beer cost effectively and can expand their markets and extend their distribution reach. Imagine no more handling, storage and cleaning of returned kegs as well as kegs not lost in transit. One-way kegs are available on demand to fill during peak season or for seasonal brews. With the one-way kegs, there is no need to keep an inventory of kegs and bind your capital during the low season.

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The complete solution to shape the business Arti Grafiche Network stands out from its competitors on the European packaging and cardboard display market thanks to its ability to offer entire solutions rather than single packaging products. Barbara Rossi spoke to Mirko Arioli, Arti Grafiche Reggiane & Lai SpA general manager, to find out how it has reached its current leading position.

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A

rti Grafiche & Lai SpA SpA was set up in 1959 by Luigi Cantagalli. The company has always been based in Cavriago (Reggio Emilia), in the north area of Italy and is still run by the founding family. It specialises in the development and manufacturing of flat cardboard boxes for packaging using offset printing technology. Over the past 15 years it has focused increasingly on acquisitions in order to expand the range of products on offer and to broaden its skills and synergies.

Thanks to constant development, Arti Grafiche has grown into a strong network of companies based in northern Italy. Today it is recognised on the European market as a leader in the area of solid board and laminated board boxes both for secondary packaging solutions, including rigid boxes, both for point-of-sale (PoS) display and multimedia solutions. In fact, through its complete supply chain, Arti Grafiche Network is able to serve the market interacting with different departments of multinational companies from Industrial Packaging to Brand communication and In store Marketing promotions.

Mr Arioli explained, “Our current target is the FMCG (fast moving consumer goods) industry throughout Europe, serving multinationals and international clients, including their co-packers. Most of our clients, either in the food and chocolate industry, or in personal care or wine and spirits industry, are based in western Europe and we provide them with complete customised solutions, including innovative design and materials, so as to fulfil their requirements. Our solutions start at the pre-design phase. In fact, for us participating in the artwork agency briefing is fundamental because we contribute in terms of advice on technological feasibility and possible solutions. Then we take care of manufacturing, from prototyping to pre-serial and serial (industrial) production. This is important because not many companies offer such a complete, comprehensive solution.

We also offer an entire range of services and technologies which, as well as pre-printing, includes offset printing, hot and cold foil, UV processing and printing on APET, lamination, die-cutting, window patching and folding and gluing.�

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Mirko Arioli, general manager

| 206 | Packaging Europe

Innovation is key “Research and development is very important for us, as we are committed to pioneering new designs and manufacturing customised solutions in order to offer an added value service to our customers. Today over 40 per cent of our projects are new developments, for which we are providing integrated solutions combining state-of-the-art technology with Italian craftsmanship. We make continuous focused investments in modern technology and, thanks to that (over €15 million in the past two years), our production capacity has grown significantly. Our modern equipment also allows us to offer our clients extremely high performance solutions. For instance, thanks to the acquisition of new cold foil machinery we have been able to introduce more complex products in terms of graphics, especially with regard to high level technical decorations both in chocolate, personal care and spirits industry.

“Our R&D efforts are channelled into anticipating market trends, but also into the fulfilment of our customers’ developing needs. In fact, being able to respond to the actual future requirements of our clients is the main focus of our R&D department. Overall AGR network has over 50 people working in the technical areaworking towards researching new materials and processes and developing new graphic effects and technologies.”

Flexibility, reliability and quality The companies belonging to the Arti Grafiche Network (apart from Arti Grafiche & Lai SpA SpA itself) are F.A.G. SpA, Espo & Cartotec SpA and Litografica Can-

netese. Even though each division is focused on different product, having all these companies in the network brings some clear advantages in terms of flexibility and reliability of supply when required. In fact, if there is an increase in demand at one particular site or a problem occurs, one of the other production facilities is able to step in and offer back-up, thus maintaining the excellent service levels.

The company’s true distinguishing feature, however, is its ability to offer a complete solution. This makes it a one-stop shop for its customers and allows it to deal with several of their departments all at once, at both regional and global level. As mentioned above, it is able to take care of the entire process, from the concept and design phase to industrial production for secondary packaging or limited scale production for display products.

“Over the past five years we have been implementing the process of internationalisation and today our exports generate 50 per cent of turnover. The main export market is Western Europe, especially France and Germany, although sometimes our clients ask us to deliver our products to their non-EU based facilities.

“Our management is determined to grasp every opportunity for growth offered by the demand for a new generation of products consistent with the current economic, social and regulatory developments. AGR expectations are that export share can increase, also in eastern Europe, where we have already supplied some clients. We are certainly going to follow an organic growth path, but we could also consider possible acquisitions if they would allow us to be closer to our clients. It is hard to predict how the footprint of our multinational and international clients is going to develop, but we are ready to follow it.”

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A perfect combination Turkey’s Duran Dogan is a market leader in the cardboard packaging sector and a supplier to many leading companies, including the Scottish giant Diageo. Partially listed on the Istanbul stock exchange, the company brings together some of the most experienced players in the industry and focuses particularly on developing innovative and environmentally friendly products. We spoke to the company’s international sales manager, Nancy Teminyan.

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D

uran Dogan specialises in manufacturing both standard and value-added luxury packaging, including offset printed folding cartons, litho-laminated microfluted cartons and POS displays, with 60 per cent of these products being used in the food and drink industries. The company uses the latest finishing techniques, such as printing on metalised board, hot foil stamping, window patching and hi-tech embossing and gluing solutions. It has 250 employees and is one of the most established yet modern and environmentally friendly packaging companies in the country.

bers are still involved in their management even after the merger, which transformed Duran Dogan into the biggest producer of cardboard packaging in Turkey.

In 2013 the French packaging group LGR Emballages also become a significant shareholder, having bought a stake previously held by Ulker, Turkey’s largest food company.

Nancy Teminyan, the company’s international sales manager, believes that the combination of a strong corporate structure and family ethos will continue to be the core strengths of Duran Dogan in the years to come.

A perfect Union

Secure domestic and overseas growth

Duran Dogan was formed in 2005 from the merger of Turkey’s two most experienced packaging companies, Duran Ofset and Dogan Printing. Duran Ofset was founded in 1953 and was the most recognised and highly respected brand in the country, having been listed on the Istanbul stock exchange from 1991 onwards. The equally well-respected Dogan Printing was established in 1934 and was particularly known for its luxury chocolate packaging. Both companies began life as family firms and several family mem-

According to Ms Teminyan, in 2013 the company generated sales in excess of €40 million and has experienced growth of 5–10 per cent each year. Teminyan also explained that the company has a strategy of balancing domestic sales with exports in a 50-50 ratio. 70 per cent of such exports go to Europe, particularly the UK, Ireland, France, Belgium and Holland, although 10 per cent also go to the US. The remaining 20 per cent is divided between the Middle East and African countries.

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Nancy Teminyan, sales manager

The company’s target is to continue growing at an average rate of 10 per cent per year, which it hopes to achieve by improving its position in all its existing markets. Teminyan singles out Diageo, the multinational producer of alcoholic beverages, as one of the clients from which it has learnt the most, having benefitted from growing alongside the Scottish giant and thus fully understanding its requirements.

2013: A year of transformation Teminyan explains that the company began several investment projects in 2013, opening a new production facility in the Omerli district of Istanbul to add to its existing factory in the Hadimkoy district. Another key investment project was the purchase of new inline litho-laminated and microflute machinery, allowing the company produce its own corrugated cardboard, where previously it had relied on domestic suppliers and handled only the lamination process. With this investment, worth €5 million, Duran Dogan will be able to offer better quality at more competitive prices. It plans to use the Hadimkoy factory to produce normal cardboard packaging and the Omerli factory for corrugated cardboard packaging. The new factory has increased the company’s production area to 24,000 square metres, and its capacity has gone up to 25,000 tonnes per annum.

Environmentally conscious Teminyan highlights the company’s focus on environmental protection. The management team regularly monitors its carbon emissions, supports a number of recycling projects and ensures that the latest technologies are used to minimise environmental impact.

Three years ago the company replaced all its dyes with environmentally friendly alternatives, and Teminyan is also excited about Duran Dogan’s latest product, designed to replace metallic products which cannot generally be recycled. The company has invested a lot of time in finding this solution and has managed to design a new machine capable of producing a metallic look without a film layer. Since the film layer was the only obstacle

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to recycling, it can now offer luxurious metallic packaging that is fully recyclable and greatly superior to the cold foil alternative.

Teminyan is proud that, even after becoming the Turkish market leader, Duran Dogan has continued to search for innovation and to invest heavily in research and development.

The company already stands out for its quality and value but she believes that new investments have helped bring an even sharper competitive edge by enabling the company to be more flexible than its competitors in meeting delivery schedules and product requirements. She believes that this comes from the Turkish cultural attitude that ‘customers are our bread and butter’ and the fact that companies rooted in family tradition tend to offer excellent customer relations.

Visit: www.ddpack.com.tr

Leaders in pallet wrapping Atlanta Stretch SpA is a leading European manufacturer of pallet wrapping systems. In particular, it produces automatic and semi-automatic machines to wrap pallets with stretch film. The company was founded in 2005 by Mr Angelo Forni – a man with extensive experience in the industry. Eugenia Fiusco reports.

W

ith an annual output of around 2500 machines and a turnover forecast of €20 million for the current financial year, Atlanta Stretch is today among the leading players in the European packaging industry. It is able to offer the entire range of automatic and semi-automatic stretch film wrapping machines.

The latter can easily be introduced as part of the production chain thanks to their high flexibility. “We work both with international distributors and end customers,” explained Mr Forni. “Today we are one of the three main producers of these types of machines in Europe, in terms of the number of items produced.”

Over the past few years, the company has never stopped researching and developing new products. Among the latest models are the Mytho and Lybra station machines. The Mytho Automatic is a standalone wrapping turntable with clamp and cutting system, whereas the Lybra station is equipped with a rotating arm. They are both fully automatic.

“Our 30-year experience has enabled us to produce a complete range of machines, from our MYTHO turntable pallet stretch wrappers to our REVOLUTION rotary arm pallet stretch wrappers and our OMEGA rotating ring pallet stretch wrappers with jumbo reel facility,” explained Mr Forni.

The new MYTHO-A turntable is a unique, compact, double reel automatic stretch wrapping machine with a much higher level of performance than previous models.

It’s exceptionally good value for money and fits into small spaces. This double reel machine can wrap faster so more wraps can be added to make heavier and more secure products. They can also rotate unstable products more slowly if needed. “We patented the double reel feature mounted on the same axis,” continued Mr Forni. “This translates into cost cutting and time saving operations. We are the only producer in Europe to provide this product.”

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Increasing production capacity The significant growth in the number of items produced has created the need for new facilities. Atlanta Stretch now runs three plants in the Italian region of Emilia Romagna.

The main plant is in Poggio Berni, in the Province of Rimini, where the design and production operations are carried out. “Starting from next year, the production of the two main product families will be kept separate and our third site of Pietracuta will be solely dedicated to the production of the REVOLUTION models,” added Mr Forni.

“The company has kept its old name, Comarme, as this is a very important name in the Italian industry. It would have celebrated 100 years of business if it hadn’t gone bankrupt,” said Mr Forni. “It is now fully owned by Atlanta Stretch. We are more competitive than ever.”

Geographical markets and investments

Future goals

Atlanta Stretch mainly operates on the international markets. “Our main geographical markets, aside from Europe, are South Africa and South America, the Middle East – especially Turkey – and some of the former Soviet Union countries,” said Mr Forni.

Last year, the company made an important investment in its future when it took over another Italian company. The importance of this acquisition lies in the fact that it can now add taping machines and box machines to its product offering.

“Our main goal is to expand our presence in the developing markets through new investments. The markets we are looking to move into are China, India, South America and the USA,” explained Mr Forni. “We plan to set up production plants there. In the next three years, we aim to have our machines produced in these three strategic geographical areas.”

Visit: www.atlantastretchspa.com

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Mitsubishi Electric’s MELSERVO MR-J4 used in the PACKAGING DEL SUR packaging machines.

Innovation in Packaging

applications with Mitsubishi Electric’s

Motion Control technology

M

itsubishi Electric is a world leader in the three principal application areas for servo drives in industrial automation: robotics, CNC and general motion control (GMC). Mitsubishi manufactures its own technologies in all of these fields, something which very few other manufacturers can match. Combining this capability with unmatched service results in control solutions enabling the construction of the highest quality machines and systems.

All these technologies can be seamlessly integrated onto one single controller platform, the MELSEC iQ Platform, combining a PLC CPU with a robot CPU and a motion CPU, along with an MES IT module to provide direct connection to higher level business sys| 216 | Packaging Europe

tems such as SAP - an integrated solution that is unique throughout the industry. What were once simply individual control components become fully integrated systems with synchronised scanning cycles.

Recently introduced products include the new MR-J4 series of servo-drives and matched servomotors, with features such as a 22-bit absolute encoder, a frequency response of 2.5kHz, and the inclusion of a double vibration suppression filter.

These features help machinery manufacturers to develop machines with reduced positioning times and reduced cycle times, meeting the production requirements of customers.

Greater production flexibility is a further requirement, which translates into an increased number of axes to be controlled. To meet this need, Mitsubishi Electric uses a full duplex 150Mbps fibre optic bus, which simplifies connection and commissioning and permits multi-axis co-ordination in synchronous machines, allowing the control of up to 96 axes with the Q173DS controllers.

Mitsubishi Electric contributes to innovation in packaging solutions For example packaging machine manufacturer PKS develops end-of-line solutions that meet the latest market requirements. In the ten years since its formation, PKS has built its reputation on constant innovation, meeting customer requirements for production lines that meet the needs of ever changing markets, where companies face an ongoing challenge to develop new products and styles of packaging. This is true not only in primary packaging, but also and perhaps more importantly in secondary packaging and palletisation.

PKS offers turnkey systems including packing and pack/box conveyors, underside distributors with and without pressure, balers, tray fillers, wrap around box fillers, mosaic formers, palletisers, pallet conveyor shuttles and pallet conveyors and elevators. Antonio Corpas, General Manager of Packaging Del Sur S.L. comments, “One of the keys our success is the integration of advanced drive control systems from Mitsubishi Electric, which enable our machines to provide reliability, flexibility and speed.”

Extended reliability When considering the issue of reliability, PKS places special emphasis on extending the useful life of the machine, and this can be easily appreciated in the dimensioning and choice of the components. For example: • Chains with rollers in the links for robust anchorage of power elements (folding fingers in box fillers, box, tray, pack conveyors, palletizer shutter rollers, etc.).

• A Mitsubishi Electric servomotor for each axis, with grease-free stainless steel planetary gearboxes and pressure couplings. The mechanical components are simplified and the use of pneumatics is confined to secondary or safety functions.

• The basic construction of the machines is in stainless steel.

• Simple maintenance, with all the components being standard and easy to source market. Programming of the drives is carried out from the central Mitsubishi Electric QMotion controller, enabling the operator to replace one damaged servo drive with a new one, just by setting a switch in the front panel display.

Backward Compatibility The backward compatibility of Mitsubishi Electric products and their worldwide presence supports the key demands of PKS. For example, the new MR-J4 series servos can be configured in exactly the same way as the current MR-J3 series.

Flexibility at every level

“cover” and “wrap around” box. A heat shrink film and tunnel module can also be included in order to configure a “COMBI” version. Staggered grouping on open trays with high production is also possible.

Speed and productivity When we talk about the speed of a machine, what we are looking at is its production capacity. Of course this means a high production speed, but also a minimum changeover time from one product to another. PKS has developed both qualities to high levels, and is keen to stress that the true cost of the machine is a relation between price and productivity. The use of motor control technologies has a very large effect on the denominator, whilst it does not have as high a relative impact on the numerator, so that in practice the cost of a 30 boxes/minute box filler does not differ greatly from one offering 60 boxes/minute.

The PKS ALCO PAL F Palletiser System consists of a mosaics grouper with eight Mitsubishi Electric servomotors and a handling capacity of 90 packs per minute. The grouper has the capacity to move and to rotate each pack as a function of the layer mosaic, while it accompanies the product with an electronic synchronous coupling system. This is followed by the palletizer which has seven Mitsubishi Electric servomotors and can handle up to eight layers per minute. The line production rate can be estimated with these details, but what about the impact of the changeover time for different formats? On many machines, that could be considerable downtime, which impacts on overall productivity.

By contrast, on the PKS machines, the change is simply made by the operator from the HMI screen.

About PACKAGING DEL SUR PACKAGING DEL SUR is a Spanish company founded in 2004 by a team of electronics and mechanicals packaging experts with more than 20 years experience in the sector. We are committed to provide the best service, efficiency and knowledge for achieving the highest quality because we understand the importance of customer´s business.

Our highly trained and experienced professionals will meet the customer´s needs and requirements.

PKS has been selected by leading companies in beverages, chemicals and food industry.

The high degree of satisfaction and brand loyalty is a constant because Customer´s success is our future!

Further information: www.pksur.com

One of the keys to its success is the integration of advanced drive control systems from Mitsubishi Electric, which helps to ensure machines that deliver reliability, flexibility and speed.

From an innovation point of view, flexibility is of the greatest importance, impacting on the design of every aspect of the machine, both in hardware and especially in software.

As an example, the PKS IBER60C wrap around box filler has 16 absolute Mitsubishi Electric servomotors with angular planetary gearboxes, which control the process from the separation of entry lines and gathering of products into groups to the filling of the box, folding or the optional fitting of a cover. Thanks to a form type interface on the integrated 10.4” touch screen, the user can control the different machine formats. Adjustment in operation is also possible, for example by de-phasing the corresponding axis and memorising the change, without needing to stop or to empty the machine.

In the development of the machine, PKS addressed the requirements of a wide range of packaging formats, ranging from 3x2 groups of 1 litre cartons to ½ pallet trays (800x600mm) with 185mm flaps. PKS can even look at repurposing existing machines at a customer’s plant, for example by converting a “tray filler” (tray only) into a “wrap around” so as to be able to pack with it a low tray, high tray, open box, open box with Packaging Europe | 217 |

Packaging machine manufacturer PKS develops end-of-line solutions that meet the latest market requirements.

About Mitsubishi Electric With over 90 years of experience in providing reliable, high-quality products to both corporate clients and general consumers all over the world, Mitsubishi Electric Corporation is a recognized world leader in the manufacture, marketing and sales of electrical and electronic equipment used in information processing and communications, space development and satellite communications, consumer electronics, industrial technology, as well as in products for the energy sector, water and waste water, transportation and building equipment.

With around 124.000 employees the company recorded consolidated group sales of 39,3 billion US Dollar* in the fiscal year ended March 31, 2014.

Our sales offices, research & development centres and manufacturing plants are located in over 30 countries.

Mitsubishi Electric Europe B.V., Factory Automation European Business Group (FA-EBG) has its European headquarters in Ratingen near Dusseldorf, Germany. It is a part of Mitsubishi Electric Europe B.V., a wholly owned subsidiary of Mitsubishi Electric Corporation, Japan. | 218 | Packaging Europe

The role of FA-EBG is to manage sales, service and support across its network of local branches and distributors throughout the EMEA region. *Exchange rate 103 Yen = 1 US Dollar, Stand 31.3.2014 (Source: Tokyo Foreign Exchange Market).

Further Information: Website: eu3a.mitsubishielectric.com/fa Website: www.mitsubishielectric.com YouTube: http://www.youtube.com/user/MitsubishiFAEU Twitter: https://twitter.com/MitsubishiFAEU

SPS IPC Drives The 25th edition of SPS IPC Drives, which takes place in Nürnberg on 25-27 November 2014, is the exhibition for electric automation technology. It covers all components down to complete systems and integrated automation solutions.

T

he trade fair and its adjoining conference are the ideal platform for comprehensive information on products, innovations and current trends within the electric automation industry. Hence it gives an overview of the entire market.

The exhibitors - manufacturers of electric automation technology - present products and services from the following sectors: • Control technology • IPCs • Drive systems and components • Human-machine-interface devices • Industrial communication • Industrial software • Interface technology • Mechanical infrastructure • Sensor technology In 2013 the exhibition attracted 1622 exhibitors – 1137 exhibitors (70.1 %) from Germany and 485 exhibitors (29.9 %) from other countries. In the same year 60,027 visitors came to the show - 46,248 of them (77 %) from Germany and 13,779 visitors (23 %) from abroad.

A diverse, professional supporting program with panel discussions, product and company presentations, awaits you at the exhibition forum. Join the discussions, gain practical insights and use this ideal platform for an exchange of experiences.

Interesting and exciting panel discussions on up-to-date automation issues take place at the forums, directed by publishing houses and associations. Furthermore this is where exhibitors provide special presentation on their newest products and solutions for your individual automation task.

Parallel to the exhibition, the SPS IPC Drives conference offers you Germany’s most important user-oriented conference on automation and drive technology (in German language). The conference offers product managers and design & development engineers from the supply and user industries as well as academics from applied research an excellent platform in order to discuss new technologies and innovative applications and find answers to concrete questions.

The key to use modern automation products both successfully and profitably is knowing what the best available technology is and its applications in practice.

The dialogue between research, product development and application is of central importance in this process. The SPS IPC Drives conference represents an ideal platform for this. New products, system solutions and concepts are being presented and evaluated on a neutral basis.

Arrange your personal further education program in the frame of SPS IPC Drives from various elements of the Conference individually.

Visit: www.mesago.de/en/SPS

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Board

but never

bored Cardboard packaging specialist Corex is continuing its upward trajectory with an expanded product range, greater geographical reach and further utilisation of its parent company’s vertically-integrated network. Emma-Jane Batey spoke to Managing Director Geert De Meyer and Finance Director Nico Nimmegeers to learn more.

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stablished in 1973 and now a key part of the vertically-integrated VPK Packaging Group, Corex is dedicated to developing and manufacturing cores, tubes and edge protectors from high quality cardboard. Under the banner of ‘closed circle, open mind’, Corex has succeeded in creating a locally-focused, internationally-active packaging company that sits apart from the competition.

Both spoke to Packaging Europe to explain how Corex has a competitive advantage.

They said, “Corex is based on a local, entrepreneurial spirit. We are always ready to serve our customers and we are proud to be a viable, reliable alternative to any other supplier.”

In the past ten years in particular, Corex has enjoyed rapid growth through both acquisitions and organic expansion, with the VPK Packaging Group also adding a considerable number of companies to its roster. With nearly 3500 staff, subsidiaries, companies and 37 plants in 11 European countries, VPK Packaging Group has a solid presence. Corex itself has 12 companies across 11 countries employing 400 staff, all working together to produce around 120,000 tonnes of cardboard tubes and edge protectors.

Innovative packaging The cardboard tubes, cores and edge protectors produced by Corex are used for winding a wide range of products including paper, film and various packaging materials but also floor coverings, metals, photography and textiles. Mr De Meyer explained, “We produce both spiral and parallel wound tubes for winding lots of different packaging materials and edge protectors. We are always adding innovative new products to our portfolio to ensure that we are meeting the markets’ changing demands; our locally-focused approach of really listening to our customers means that we have to adapt as their needs change.” Two of Corex’s most recent additions are its AC80 and AC90 tubes, which have been developed

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EOC Group EOC Belgium, member of the EOC Group, is a supplier of industrial adhesives.

One type of glue is never enough to guarantee the perfect fit.

So, EOC Belgium, Adhesive Division has moved into three types of glue: water based Adhesives, hot melts and powder adhesives.

EOC’s industrial adhesives are tailor-made and used for a wide variety of applications.

The water-based cold glues are used mostly in the paper and card-board industry: production of cardboard tubes, corner profiles, lamination of corrugated and solid board, litho-laminating, box and tray erection, honeycomb cardboard, building and wood applications.

Hot melts are used, among others, in the following industries: packaging, hygiene, printing and graphics, construction, textiles, labelling and tapes.

Powder glues are based on natural or synthetic polymers, ready-to-use adhesives can be prepared by dissolving the powder adhesives in cold or boiling water.

EOC is environmentally conscious. The entire range of cold glues is waterbased. The hot melts and powder adhesives are also made of environmentally friendly products.

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“Service and sustainability are both very important issues to Corex and across the whole VPK Packaging Group. Our track record in these areas is second-to-none – and not just because we know it is popular at the moment but because it is the right thing to do.”

to ‘counter the advancing technology of the printing industries’. Mr De Meyer said, “Our industry is like many others in that it is always moving forward, always needing to be as innovative as possible. In order to maintain our impressive market position we have to ensure that we are moving one step ahead of the competition and are giving customers want they want – and what they will want soon! So our latest AC80 and AC90 tubes, together with other recent developments in textile tubes, RFID technology, polished cores etc. are a good illustration of that. They’ve been developed using our extensive state-ofthe-art facilities and have both standard and special options, including special finishes, so that they exceed our customers’ specifications.”

Thanks to the vertically-integrated set up within the VPK Packaging Group, Corex is able to utilise the benefits of being part of a well-known group. A rapidly-growing industrial group, VPK Packaging Group is based in Belgium and active across Europe. As the market leader in the cardboard tubes, cores and edge protectors sector, Corex can call on the support and resources of VPK to deliver its reliable, flexible service.

Service and sustainability Mr De Meyer added, “Service and sustainability are both very important issues to Corex and across the whole VPK Packaging Group. Our track record in these areas is secondto-none – and not just because we know it is popular at the moment but because it is the right thing to do. Service means that customer service at every stage must be excellent and it also means that our products must give perfect service. Sustainability is of course very important for a packaging group. We make maximum use of recycled fibres | 224 | Packaging Europe

and we constantly optimize our activities through lean management. We also produce the vast majority of the paper we use ourselves within the group and this helps us to maintain both quality control and strict environmental standards.”

Part of Corex’s plans for continued success reflects Mr Nimmegeers appreciation that service and sustainability is key. The company expects to further boost its focus in these two areas through continuous optimisation of processes in both manufacturing and sales functions. Its ‘made to measure’ solutions will also play a role in its predicted growth, with its philosophy of working closely with customers to create ‘positive closed circles’ already a proven success. Mr Nimmegeers said, “Our local entrepreneurship and our strong position within the VPK Packaging Group will continue to deliver long-term value for our customers, our staff and our shareholders. We’ve been working to reach a higher segment of the market with our ongoing investment and more customisable solutions so this will also influence our growth strategy as we move into new markets with new products and support our existing markets too.” Some of our sites already have a food safety certification (ISO 22000) others are looking into this matter, which will mean we can expand into this exciting market.

Visit: www.corexgroup.com and www.vpkgroup.com

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Tony Smurfit, chief operations officer

Smurfit Kappa opening the future Tony Smurfit, chief operations officer at Smurfit Kappa Group, talks to Packaging Europe about the driving trends in the transit packaging segment, the position of corrugated packaging in the market, and his own company’s drive to spread the word about its all-round excellence.

PE TS

From your observations what are the big market drivers in secondary and tertiary packaging?

The biggest driver today is undoubtedly the move towards more display-ready packaging. This means more print and more colour so that private label or branded products in the supermarket catch the eye of impulse buying consumers. I’ve heard of research which indicates that only 20-25 per cent of purchases on the retail floor are pre-planned, which leaves a great deal of purchase decisions that can be influenced by packaging.

The rise of display-ready packaging is therefore a huge trend, reflected in the exponential growth in both coated and regular recycled and Kraftliner white papers. It has been broadly recognised that it’s no good having nice looking primary packaging if the secondary packaging undermines the visual appeal. On the other hand, in some cases it is possible to downgrade primary packaging if the secondary packaging has been upgraded.

The opportunity to put secondary packaging on the shelf allows you to be very innovative. There are plenty of examples of this in Smurfit Kappa, from our 3D Store Visualiser to the way we perforate boxes to optimise the visual impact of the product inside.

Clearly, this trend is ultimately driven by the need to eliminate costs in the store and the supply chain. Opening up a box and putting it on a shelf takes about a third of the time of store filling. In this context, this transition to shelf-ready packaging has been accelerated by the recession. Since the start of the crisis people have been more careful about their purchases. Slightly smaller quantities are being sold, individual shopping trips are downsized. A consequence of this is that discount retailers such as Lidl and Aldi have experienced growth.

It was the low cost retailers which pioneered shelf-ready packaging as they sought to cut costs by eliminating the step of filling up displays on the shop floor. These retailers subsequently led the push for higher quality packaging, recognising that putting an unattractive box on the shelf was counterproductive, a false economy. So these kinds of discount retailers were at the forefront of the trend, which gained momentum as other retailers got behind it.

Today a lot of the new machinery installed across the industry has printers behind it.

PE TS

How is the industry responding to the growth of e-commerce?

Whereas books and magazines are seeing displacement as a result of the internet, e-commerce is a good news story for packaging companies. Mirroring the trend in physical retail spaces, we are beginning to see a shift from lower specification packaging, e.g. a scruffy looking brown box, to branding the products that arrive at your door. At the moment the high quality internet retailers are doing this. I think we’ll gradually see more and more mid-level e-commerce adopting high quality packaging. | 226 | Packaging Europe

PE TS

Where are the key points of competition between corrugated and competing materials in secondary/tertiary packaging and how is it faring?

Corrugated is an incredibly versatile material in terms of size, thickness, grades of fluting. You can play with corrugated endlessly to fit any purpose. In addition, there is great flexibility with regard to colour and appearance.

From a sustainability point of view, its renewable feedstock can be monitored through Chain of Custody and at the end of life it is 100 per cent recyclable. Even if it ends up in the ground it will decompose. We contend that return trip plastic containers have a greater environmental impact in terms of energy use, as well as being more expensive.

They are also associated with water wastage, since, unlike corrugated, plastic crates need to be washed after usage. Obviously, this is an argument which goes to and fro and it is one that the corrugated industry hopes to win.

The world is looking for ever lower costs and decreased environmental impact. In response, corrugated is moving to lighter weight packaging which is still fit to use: we are using ever thinner papers, a trend that has accelerated as newer paper machines have come into the market.

PE

Smurfit Kappa recently unveiled its ‘Open the future’ brand strategy, the result of a year- long global research programme to establish what brand owners really from the packaging industry. What is ‘Open the future about and what does it reflect in terms of the placement of the business?

TS

One of the things we have been doing since the merger with Kappa Packaging in 2005 is harnessing the combined capabilities of the organisation by implementing the best systems and ideas. Smurfit Kappa now has over 41,000 employees, including 700 designers, who can generate an enormous amount of innovation. ‘Open the future’ is another step in this process of harnessing the potential of the company. We want to explain to our customers how we can give them insights as to how they can sell more. We have a great deal of intelligence about the marketplace that we can share with them, tests that we do for our customers, and tools such as the Store Visualiser.

We are opening an experience centre in Amsterdam’s Schiphol airport so that lots of our customers can easily visit in one day and we can open their eyes to our capabilities and the future possibilities of what Smurfit Kappa can bring them.

I’ll give you a recent example of how we can work with a customer. We spent a year helping a partner develop standardisation across their corrugated packaging throughout European, standardising the colours, making sure they have the right stock, fine tuning their supply chain. At the end of the process the customer was astounded by the results

and the savings, and we won a tremendous amount of business as a consequence. This was down to the insights into their business that we were able to share with them.

This is very much the way we are looking to work with all of our forward thinking customers today.

We operate in every country in Europe and we are nearly the number one or number two in every one of them. In addition to the major experience centre in Amsterdam we have local centres at the headquarters/manufacturing plant in each country. These are on a smaller scale but offering a great deal of local expertise.

When people visit one of our plants they see the same cleanliness, together with efficiency and significant investment, when they visit our experience centre they are amazed by the level of innovation, when they visit our paper mills they see the amount of investment that goes in. They know we are good on costs, ethics, environment and service. All of this also comes down to the quality of the people who work for us. Part of our mission is to let the public know how important we are to their lives. The more that people understand the role that packaging plays, the more we will attract people and skills into the industry. Part of the role of the experience centres is to sum up all of these things and show the world what kind of company we are.

PE

The last point you made chimes with the comments of a previous Big Interviewee, Erik Bouts of O-I Europe, who told us that he wants to reposition glass as a business to consumer industry. Is your approach analogous to this?

TS

At the end of the day we all have to feel we are relevant to the markets we serve. If you are a pure commodity, you are not going to add any value to your supply chain. Anyone can make a brown box and sell it cheaply but eventually they will not make enough return for their shareholders and go out of business. The

only sustainable solution is to find a way to add value to the supply chain. At the same time, you won’t get enough business if you are being innovative and charging too much.

You need to find the balance between being the perfect service provider, making yourself relevant, and achieving a return for your owners.

At Smurfit Kappa we are particularly proud of the fact that we are investing 420 million Euros this year across many different businesses: investing in bag-in-box, in completing a large plant in Spain, upgrading mills in our paper business, numerous machines for corrugated lines across Europe and Latin America, in MG papers – the list goes on.

Such investment is what underpins our ability to stay relevant and innovative while manufacturing on a competitive basis.

PE TS

Which markets do you identify as key to Smurfit Kappa’s next phase of growth?

We have a large business in Latin America, where we have been investing heavily. We recently made an acquisition in the northern Mexico area. That region is growing very strongly again as growth lost to China starts to come back due to logistics costs and complications. We are also looking seriously at the USA, where we currently have a small presence in Texas and California. When we look at the macro trends towards onshoring and the general state of the US economy, which is more dynamic than the European economy at the moment, together with our skill set, we see that as an area of opportunity for us.

As for Europe, there are particular segments and even countries that are performing strongly and we are investing behind these, whether it is bag-in-box, MG or sack paper. In other markets it is difficult because there is very little growth. In these we are investing in cost reduction measures so we remain competitive and survive whatever storm is out there.

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Swiss precision A true partner for automation solutions in production processes, Swiss customised machinery company Zaugg Maschinenbau AG is active worldwide in a broad range of sectors. Emma-Jane Batey spoke to sales director Calogero Imperia to find out more.

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augg Maschinenbau AG is celebrating 20 years in the field of automation solutions in 2015. Based in Schonenwerd in Switzerland and still owned and managed by the founding Zaugg family, Zaugg Maschinenbau offers the development and manufacture of production lines, machinery and controls from concept to completion.

With an interesting balance of broad and specific, Zaugg Maschinenbau provides its custom-built automation solutions to various global sectors including pharmaceutical, medical technology, textiles, food, construction and logistics. Sales director Calogero Imperia told Packaging Europe how this varied client base has helped the company grow successfully over the past 20 years. He said, “As a family-owned Swiss engineering company that builds custom-made machinery from start to finish, we are successfully present in various sectors and this has been an important part of our on-going leadership in our field. We’ve been able to capture our advantages and pass them on to our customers – one in four of which are new clients.”

Everything the customer needs One of the core advantages offered by Zaugg Maschinenbau is that everything is done in-house. With a talented team of mechanical engineers based at its Schonenwerd head office working alongside machine-building experts, project managers and constructing engineers, the company provides a full service. Mr Imperia continued, “Our project man-

agers accompany our customers right from the first contact and stay with them every step of the way. They are supported by our highly experienced team and maintain that ‘one pivotal point of contact’ throughout. We work with three or four key suppliers for some specific components, but we don’t rely on anyone else to complete our projects; Zaugg is really focused on delivering a complete automation solution from start to finish that is perfectly devised and manufactured according to each customer’s specific requirements.”

Mr Imperia noted that the ‘concept to completion’ promise from Zaugg Maschinenbau includes after sales too. He explained, “Effective, customer-focused after sales is a very important aspect of our business. Relatively recently we’ve increased our offer in this area by adding maintenance agreements to customers so that they can choose exactly the level and type of after sales they need. All customers get our expert after sales as standard, but they can also add on service agreements like fixing machines within 24 hours or including every spare part. We appreciate that customers need to be able to rely on not having expensive downtime so we ensure that they can bank on our flexible, responsive after sales service at a level that meets their needs.”

Automation at its core Zaugg Maschinenbau’s core competence lies in the automation of processes in manufacturing companies. Building tailor-made machines in accordance with the demands of each customer is what enables the company to stand out from the competition: it

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is dedicated to realising an optimal automation solution in each project. Mr Imperia added, “The common thread throughout all our projects is our complete understanding that an optimal solution must be reached for the customer. So whether we are creating a robust machine for making stacking units for the plastic industry or denesters that are operated pneumatically, mechanically or by servo-drives, we are always in tune with our customers.”

Already active worldwide, Zaugg Maschinenbau is not looking to expand in the near future but rather to focus on its current successful business. Mr Imperia explained that, with a 50-strong workforce based in the high labour-cost country of Switzerland, it is the company’s strategy to stay at its current size and maintain its exceptional quality

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focus rather than expand. He said, “If we grow more, we would have to enter certain markets, industries or types of machinery.”

The company’s future plan for success is also tied to its strong relationships with existing customers. With a big portfolio of long-term customers who bought Zaugg Maschinenbau machines 10 or 15 years ago now coming back to replace or buy additional machines, the fact that it saves all the customer-specific drawings and development details for each project means that they are already a good match.

BUT NEW CUSTOMERS ARE ALWAYS WELCOME…..

Visit: www.zmb.ch

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Rise and shine

As the pioneer of transfer metallising, Amsterdam Metallized Products BV has been right at the heart of adding shelf appeal to packaging for more than 40 years. Emma-Jane Batey spoke to managing director Pim Honig to learn more.

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ased in the heart of The Netherlands, Amsterdam Metallized Products BV has been responsibly creating metallised packaging since it was founded in 1966.

With its forward-thinking, entrepreneurial team inventing the process of transfer metallising in the early 1980s, the company has continued to be a pioneer in the European packaging field, particularly as it continues to add to its ‘dedicated to shelf appeal’ promise with the recent strategic acquisition of a printing company.

Managing director Pim Honig spoke to Packaging Europe about how Amsterdam Metallized Products BV’s past, present and future is all ‘dedicated to shelf appeal’. He said, “The technically-advanced process of transfer metallising that we developed in the early 1980s has been a defining characteristic of our market-leading position in the packaging for shelf appeal arena. Our core business has long been the ability to deliver packaging that attracts the consumer; whether it’s for wine and spirits, health and beauty, personal care, tobacco or any other product that needs to stand out on the shelves.”

Its acquisition by a long-established packaging company in the 1970s has certainly helped set Amsterdam Metallized Products BV on its successful path. Furthermore, a recent acquisition has enabled the company to offer a truly ‘one-stop shop’ for shelf appeal. The company it bought was considered ‘an eye-catching proposition that fit perfectly with our way of thinking’: its understanding of print finishing is a strong match with the Amsterdam Metallized understanding of technical and raw materials. Mr Honig

explained, “We had been dancing around each other for a few years, so when we had the opportunity to buy the company, including its machines and highly experienced staff, we knew it was a great chance to expand our offer.”

Understanding metallising The transfer metallising process allows for a metallised layer from a film to be transferred to any kind of substrate that can be supplied on a reel. First a thin layer of aluminium is applied to a coated carrier film. This is then laminated to paper, board or film. The carrier film is then removed leaving a glossy layer behind on the base material. Primarily sold directly to self-adhesive converters and printers, this process is ideally suited to bottles (such as shampoo, wine, beer or spirit bottles) and cans. Mr Honig added, “Many of our customers are brand owners too, as they value the higher shelf appeal of metallised packaging. Ideally, we like to all work together – to team up with the converter and the brand owner to create and manufacture an innovative packaging solution that utilises our capabilities. We are aware that the technical advantages and cost savings of transfer metallising can be tricky to explain to marketers, but by quantifying the advantages in terms of enhanced shelf appeal it’s clear that we’re a strong packaging partner. That’s why we say ‘where the eyes don’t stop the feet move on’ – it’s all about making sure the consumer sees your product on the shelf.”

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Amsterdam Metallized Products BV’s development team is highly experienced in working together with customers to create bespoke packaging solutions and, with the addition of the capability to add eye-catching details such as lenses on packaging following the acquisition, this is now a complete solution. Mr Honig said, “We are heavily involved in the label business but we can be a bit far away in the chain, so by ensuring we can offer bespoke solutions as well as some volume business, we can truly present ourselves as a one stop shop for shelf appeal.”

translates to their sales. With our strong environmental responsibility, our ability to communicate with our customers and our technical capabilities all perfectly aligned, we have an excellent future ahead. For anyone looking for a solution in packaging to help their product stand out on the shelf, they need to be talking to Amsterdam Metallized!”

Visit: www.metallized.nl

High performance The functionality of Amsterdam Metallized’s portfolio is guaranteed. With high performing barrier properties ensuring that its broad range meets all the requirements of its customers and end users, the company uses the term ‘special projects’ to describe its ability to further add properties as the customer demands. All its products are created in the most environmentally-responsible manner too, in line with its long-held view that operating sustainably is simply the right thing to do.

As a company that prides itself on its core values of involvement, reliability, versatility of product range and innovation, Amsterdam Metallized Products BV is keen to distinguish itself by its specialities. Mr Honig concluded, “We are a highly capable partner to printers, converters and brand owners, offering a complete one-stop shop for shelf appeal.

We work with our customers to integrate our extensive experience in transfer metallised packaging solutions into their products, so that our dedication to shelf appeal perfectly

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A new generation Hagmaier Etiketten & Druck has a slogan: ‘We Live Labels’. Felicity Landon reports on a family company with nearly 70 years’ experience and a new generation on board.

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agmaier Etiketten & Druck is a company with a strong sense of history and tradition. It was founded by Adolf Hagmaier, the father of the current managing director and owner, Thomas Hagmaier. Its headquarters and main production site are still where they started, in a village between Ulm and Stuttgart. Many of its workers have been with the company for 20 or 30 years. And the company’s expertise remains the same – labels.

But at the same time, this is a company that has seen almost a ‘fresh start’ over the past two years, with a new generation joining and some major reorganisation, modernisation of production and a renewed attention to environmental issues.

A strong tradition For more than 30 years, Thomas Hagmaier managed the company jointly with his brother, Werner. Then, two years ago, Werner stepped out of the business, leaving Thomas as the sole owner, and Thomas’s three children – Rodolfo, Max and Veronika – joined the company.

“Our slogan is ‘We Live Labels’ and that is the message to our customers and employees,” says Thomas Hagmaier. “We now have a third generation in the company, who are just as enthusiastic. When my brother stepped out of the business, we first took over the company – and then this year we took over the buildings. We have spent the past two years reorganising a lot of things, investing in software and modernising the production. We have looked for ways to work more efficiently, introducing systems like 5S – that is very important for the future, because time and money must not be wasted. It is worth focusing on new ideas, programmes

and processes in order to reduce costs and keep a clean and comfortable working environment for everyone.”

Environmental issues are also to the fore. In 2000, the entire air conditioning and exhaust air system was updated when the building was expanded, to provide hotair heating with integrated air humidification, heat recovery, air conditioning and insulation and insulating glazing.

Today, 1100 square metres of photovoltaic panels cover the company’s medium power consumption. There’s a UV drying facility with LED UV, and LED lighting is installed throughout the production area and offices. The company also focuses on buying raw materials locally to reduce carbon, and has some very sophisticated recycling processes in place.

Range of labels Broadly speaking, Hagmaier produces three categories of labels. First, blank labels, in which it offers all of the die-cutting versions, including laser, rotary, semi-rotary and flatbed. Second, industrial labels, including fairly standard colours, materials and foils. And third, non-adhesive labels, which encompasses a very wide range of speciality materials, processes and knowledge. These labels can be of composite structure with a thermal layer inside, or feature very special foil components and layout.

“In this category of products, we do a lot of ticketing for theatres and other special applications,” says Mr Hagmaier.

In fact, the Hagmaier range is enormous – including blank, laser, thermal/ thermal transfer, industrial, adhesive, paper/cardboard, logistics, pricing, barcode, Packaging Europe | 237 |

UPM Raflatac UPM Raflatac is one of the world’s leading producers of self-adhesive label materials. We supply high-quality film and paper label stock for consumer product and industrial labelling. Our label materials are designed to combine economy, ecology and optimized performance throughout the label lifecycle, from conversion and end-use right up to eventual reuse or recycling. We strive to provide our customers the best total experience with profound expertise and the most attentive service in the business.

composite/plastic, sheet, fanfolded, sandwich and special labels, as well as tags and tickets.

What’s unusual about Hagmaier’s production is that 90 per cent or more of its labels are not actually ‘ready’. Rather, they go through printing machines in the customers’ premises or warehouse, because information has to be added at a later stage.

“This is quite unusual because many companies – in the food or cosmetics industry, for example – need a million labels to go directly on to the products, with no printing to be done by themselves. With most of our labels, the customer may not know the final use or details, so we might print a basic label with the name, logo, and so on, and they will need to add information later. This makes our labels very special – it isn’t just information, but also the functionality of the label that is so important. These people are not specialist printers and they need to be able to put our labels into a printer without experiencing any problems – for example, with boarding passes.”

Widespread customer base About 50 people are employed in Hagmaier’s 4000m2 factory and offices in Münsingen, a village that is out in the countryside but also within easy reach of the nearby cities. The company has a wide range of customers, although geographically they are mainly limited to Germany, Switzerland and Austria.

“Most of our customers are in Germany, from north to south – and we are doing a lot of business in Switzerland and Austria because they are close to us,” says Mr Hagmaier. “I believe that labels are a product you will always buy in your own country or from a neighbouring country, because most countries have a lot of label companies. So our focus was never on the French, UK or Spanish markets.”

Hagmaier has a careful policy of not becoming too reliant on one customer; a few years ago, the company unexpectedly and suddenly lost a customer on which a high percentage of its turnover was based. “We lost a large quantity of work and this was very hard. So our vision now is not to do more than 10–15 per cent with one customer,” he says. “In any case, we are focusing on the very specialist products – of | 238 | Packaging Europe

course we could print millions of standard labels for a company, but we want to be known for our expertise in specialist labels.

“If there is something which the other label companies can’t do, maybe people should ask us. If they want a special material or special die-cutting, we will find a solution.”

Growth in RFID The company stepped out in front by combining laser die-cutting machines and inkjet printing, and this combination is in demand. A market it is looking at afresh is RFID. “We actually started with RFID in 2008 but after the crisis nobody was interested in RFID products,” he says. “So the RFID market is very quiet at the moment – but we are thinking about doing this again.”

Hagmaier’s flexibility and range of technologies are key to its competitive edge.

Indeed, until recently the company had no official sales team at all, doing any marketing via third party agents. “That worked for a long time but now we are changing and are setting up our own team of sales people,” says Mr Hagmaier. “Because our product is so special, we need dedicated people to explain our flexibility and our very high-quality results.”

Visit: www.hagmaier-etiketten.de

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