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EXPO SPECIAL – SEPT 2016

FACHPACK

EXTENDED SHOW PREVIEW K 2016 GUIDE PLASTICS TRENDS FINDING EFFICIENCIES


Contents

3

4 6 8 10

Editorial Tim Sykes News and Reports Design How to bring a packaging idea to life Personalisation HAVI on the trend everyone is talking about Dow The changing face of innovation Sumitomo interview Plastics in the age of industry 4.0

EXPO SPECIAL – SEPT 2016

110 113 116 119 120 121

Joma Joma presents compelling innovations at FachPack in Nürnberg Faubel German quality labels Scanware A one-stop shop for inspection systems Robatech Innovations for an efficient gluing process Gamma-Wopla Customer-centred reusable packaging Fefco Why corrugated packaging keeps your product fresh K Show 2016 Comments & Reports K 2016 essentials K overview Cautious optimism Kuka at K 2016 Reade-to-use solutions for the plastics industry K 2016 news NRG World premieres, innovations and highlights from NRG, Britas and Collin at K2016 K Show Industry Features Inpak The customer is King at Inpak Makina iPB Printing Taking in-mould labelling further Total Total, Pioneering sustainable polymer technology Breyer ThermoFlex system The modular Breyer concept European Bioplastics The evolution of the bioplastics industry in Europe D.R. Joseph The film family Intravis Preform quality inspection Kiefel High-performance pressure forming SiTOR The world’s leading press manufacturer Nanocyl Nanocyl’s multiwall carbon nanotube technology Jomar Corporation Injection innovation Sabic Innovations by sabic to minimize food wastage, reduce weight, and lower carbon footprint of packaging materials Reifenhäuser Group Setting the standard iMould: The next big thing IML Solutions Sukano Master in masterbatch innovation Dr. Collin Innovative, automatic pilots FKuR Plastics in tune with nature AGR International Maximising quality and performance Commodore Smarter thermoforming and extrusion processes Soltex Creating masterpieces

12 14 16 22

FachPack Comments & Reports FachPack essentials Floor plan FachPack interview FachPack news

124 126 130 140 142 162

50 53 56 58 61 62 65 68 71 74 77 80 82 85 88 90 91 94 96 99 102 104 107

FachPack Industry Features Alpma Alpenland Maschinenbau High-precision portioning and flexible packaging Herrmann Ultraschalltechnik First time right GEA Availability is everything Micro Laser Technology Precision and flexibility Ferag Ultraflexible SkySorter conveyor technology for fashion logistics Jindal Films Pioneering bi-axially orientated film solutions Persson Innovation Carrying packaging technology further Bühnen Complete hot melt adhesives solutions Orbis Corporation Reusable packaging driving supply chain efficiency Model Group The packaging family Bizerba Complete solutions Treffpack One-stop shop Pilous Packaging Packed with care Optel Vision Serialisation one-stop: Is it possible? Alois Kober Thermoforming the future Cognex Quality and traceability with vision based systems KTP Kunststoff Palettentechnik Innovative solutions for transport and storage Özerden Custome-made thermal insulation solutions PackSynergy Competence in shipping, packaging and logistics Domino Cracking the code Sonoco Innovation at its core Delta ModTech Creating modular masterpieces Simco-Ion Moving static control forward

164 167 170 173 174 180 183 186 187 188 190 193 196 198 201 202 205 208 211 212


Advertisers Index A Agr International

G 143

O

Gamma-Wopla

36

Optel Vision

35

Özerden

15

AL-KO

27

GEA Food Solutions

17

Alpma

52

GlobalVision

29

AmbaFlex

19

Ampac Flexibles

21

P H Herrmann Ultraschall

B

High Grade Industries (India) Pvt. Ltd

Pack Synergy 24 215

Palsgaard

39

Perstorp

177

44

Bericap

49

I

Bizerba Busch

23

Illig Maschinenbau

Bostik

45

iml Solutions

150

Branson

33

Inpak Makina San ve Tic A.S

133

R

Breyer

125

Intravis

147

Robatech

BST eltromat International

127

iPB Printing

139

Bühnen

Pilous Packaging

J Cognex

24

Colines

137

Commodore

127

Sabic

153

37

145

Jindal Films

41

Scanware

20

Joma

17

Simco-Ion Netherlands

28

151

SiTOR stiskalnice d.o.o.

149

Jomar Corp

Sonoco Alcore

K D

Preco

43

S

19

C

153

Persson

Bak Ambalaj

48

35

Kiefel Technologies

Sukano

ii 144

155

DeltaModTech

36

Kornelis

31

T

Domino

19

KTP Kunststoff Palettentechnik

31

thyssenkrupp Industrial Solutions

179

Total Petrochemical

128

Dow Europe

131

Dr Collin

139

D.R. Joseph

149

Kuka

141

L LeanLogistics

Emerson European Bioplastics

27

Trinseo

147

216

E Elba

Treffpack

U 159 33 161

F

M

Uhde Inventa-Fischer

MLT Micro Laster Tech

30

Model

46

N

Faubel

33

Nanocyl

133

Fefco

25

Netstal

135

Ferag

23

Next Generation Recycling

154

FKuR

39

NürnbergMesse

Flux-Geräte

47

13

179


Editor Tim Sykes

Art Editor Paul Abbott

Deputy Editor Victoria Hattersley

Designers Rob Czerwinski Leon Esterhuizen

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

Tim Sykes

EDITOR

IT Support James D’More Web Development Neil Robertson Production Manager Tania Balderson Administration Amber Dawson Kayleigh Harvey Senior Account Managers Kevin Gambrill Jesse Roberts Features Managers Mauro Berini Clayton Green Matthew Howe Dominic Kurkowski

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

M

ajor trade shows have traditionally featured heavily in the September edition of Packaging Europe magazine. This year we have a particular abundance of events to cover, starting with FachPack – Europe’s most important general packaging exhibition of 2016. As part of our collaboration with the show, which takes place in Nürnberg on 27-29 September, we present a dedicated guide to the fair, featuring all the practical information you require about the exhibition and its programme of events, an exclusive interview with the organisers on the packaging trends and contexts that will be reflected at FachPack, and in-depth profiles of many of the most exciting exhibitors. We also preview K 2016 – the world’s most important expo for plastics, which comes to Düsseldorf in October. In addition to our comprehensive guide to the event, we take the chance to delve into market trends and what is new in the world of polymers. Libby White reports on Dow’s pursuit of innovation through collaboration, which has brought about product developments that will be showcased at K. Meanwhile, Nigel Flowers of Sumitomo (SHI) Demag talks about the way plastics converters and processors are responding to the demands and opportunities of Industry 4.0. Stepping out of the whirlwind of fairs and conferences, HAVI explores the increasingly significant issue of personalisation. Meanwhile, Gillian Garside-Wight of Sun Branding Solutions discusses how to bring a packaging idea to life, while bringing life to packaging ideas. It’s about mastering the interplay between two crucial forces of creativity and function. And you can read about it on the next page. We wish you a successful and stimulating events season, and hope to encounter many of you in person in a Messe, convention centre or conference venue over the next couple of months. Tim Sykes ts@packagingeurope.com @PackEuropeTim

© Packaging Europe 2016 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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Packaging Europe | 3 |


How to bring a packaging idea to life (and life to your ideas) The clearest, most intuitive and understandable ideas are usually the simplest ones. Apple is a classic example. Its packaging mirrors the simplicity and minimalizing of the branding through a clean, intuitive structure that’s not only functional, but beautiful. The products inside are revealed bit by bit, adding to the whole experience of unwrapping the device – writes Gillian Garside-Wight, packaging technology director at Sun Branding Solutions.

W

hen it comes to packaging, it’s best to avoid the temptation to overcomplicate. Sticking with the basics, recognising the value in being straightforward and direct, can make it far easier to take that idea out of your head and bring it to life. So how does this process work? How do you find the right ideas and make them work practically and effectively in the real world? It comes down to the interplay between two crucial forces: creativity and function.

Turning the creative into something real Creativity is a hugely important part of the packaging design process. It’s what gives you an edge, allows you to create something new and exciting that will stand out on the shelves. But where does it come from and how can it be brought to life? We traditionally think of creativity as the “light bulb moment”. People imagine the flash of inspiration that strikes your mind, where an idea with all its intricacies comes together in an instant. Sadly it’s not that simple. | 4 | Packaging Europe

While a design may sound ingenious in your mind, when you put it together you will encounter practical constraints and challenges. Ideas can work brilliantly in the abstract, but developing them into tangible products can be a long and difficult process, especially if the idea is difficult to implement. Once you settle on an idea, you need to identify the right combination of materials and finishes that won’t break the bank. Then you must ensure that it will be fit for purpose and easy for consumers to use. The design must be aligned aesthetically with the brand, or it will confuse customers. And you have to meet your sustainability goals – a common mistake is to dream up a shiny white design that will be made entirely from recycled materials, only to find that most recycled materials tend to come in darker shades. Your idea won’t survive without experts in packaging function, who can anticipate and help you to navigate these logistical challenges. That doesn’t mean that the creatives come up with the ideas and the technical experts implement them. Both disciplines have to work together throughout the


Design

process, bringing creative vision and technical wisdom to each stage of the development process. If a technical challenge arises, you can use creative thinking to overcome it. And if you’re suffering from a creative block, use insights into the technical process to establish your options and set your creative boundaries. Packaging design is not just about dreaming up a fantastic idea. It’s about how you implement it and making sure that it consumers will ultimately buy and love it.

where the ingredients came from, opportunities that couldn’t be realised before are now available to inspire us. While not yet mainstream, smart packaging is certainly one to watch for ideas. Life can inspire our creative processes, while logistical challenges can lead us to innovative solutions. It’s just a question of staying observant and staying open to the possibilities that the world offers.

Using the real world to inspire creativity

Keeping sustainability at the heart of the design process

Creativity doesn’t happen in a vacuum. Our lives and the world around us inspire us every day by shaping our perceptions and expectations. The Apple logo only makes sense to us when we know what an apple is. But once we do, we can access the infinite range of ideas and possibilities for using the apple in a design. Observing and fully appreciating the world around you is a core part of finding the best ideas. Consider this simple observation: olive oil does not dissolve sugar, but water does. It’s an easy concept to test and most school children will discover this in their Chemistry classes. With this knowledge, there are a range of possibilities that are open to us. A Swedish design firm called Tomorrow Machines used this fact to package an olive oil brand. It opted to use a sugar-based shell to store the olive oil, knowing that the oil wouldn’t degrade or dissolve the sugar. To open it, you crack the shell and pour the oil out. And thanks to the sugar’s solubility, to dispose of the packaging you simply drop it in a sink filled with water and it dissolves. It’s easy to use and no waste is left behind. One of the world’s best designers is Nature. Take the egg for example. The form of an egg is an almost perfect solution for packaging. It is incredibly strong when subjected to vertical pressure, making it easy to stack, but can be easily cracked from the sides making it easy for the consumer to access. Designing packaging in this way solves a host of logistical challenges, simply by creatively reflecting about the world around us. Digital technology can extend our imagination even beyond nature. Smart packaging can create new uses and new functions for packaging that weren’t possible before. Whether it’s a box that can automatically cool the product to the right temperature, or an innovation like TouchcodeTM that allows you to scan it and see

As creativity and logistics work together to make innovative new packaging solutions possible, we must remember our responsibility to be sustainable. Getting better at recycling should be priority, but just using recyclable materials isn’t enough anymore. Despite our best efforts, many consumers just don’t recycle at all. And when the materials that can and cannot be recycled varies by each local authority, educating consumers becomes an even greater challenge. This mixture of inspiration and technical knowledge is key to finding new ways of creating packaging that isn’t just recyclable, but reduces our environmental impact more broadly. Much like the dissolvable olive oil shell, or edible packaging like KFC’s edible bowls, imaginative solutions can have a significantly better environmental benefit. And this is an area that is filled with opportunities. Water bottles are long overdue a rethink, with British people throwing away 7.7 billion empty bottles a year. Is there a way we can redesign the bottle that will take off, like the Ooho edible water capsule that is made from seaweed. Sustainability should be a part of every aspect of the design process, not a last minute consideration. Creative ideas and logistical implementations need to be assessed against their environmental impact from the beginning, otherwise it risks falling off the priority list. If there are three things that make an effective, sustainable packaging solution, it’s these: carefully observing the world around you and using its wisdom; respecting the interplay between creativity and function; and appreciating the art of keeping it simple. Forget about light bulb moments and overthinking your designs. Embrace the wisdom of the world around you. When it comes down to it, this is the simplest way n of bringing the best ideas to life. Packaging Europe | 5 |


Packaging Gets Personal If there is one trend today which the packaging industry is able to capitalise on, personalisation is undoubtedly it. No longer satisfied generic, non-customised goods, consumers are opting in their masses for products which – at least a first glance – speak directly to them. Perhaps more significant, at least for sales executives, is the extent to which customers are willing to pay more for this premium. A standard jar of Nutella will set a consumer back around £2.50 in the supermarket. Offer consumers the opportunity to stamp their name on the side of the product, and the price increases by as much as 50 per cent. By Richard Bunch, packaging director Europe at HAVI.

AS

companies wake up to this new phenomenon, it is important to assess the various challenges at play, in addition to the new opportunities which lie ahead for company’s packaging strategies. Uncertain as its exact future may be, for an industry which is valued at $111bn – equivalent to 15 per cent market share – its significance must not be underestimated. Widely lauded by industry professionals and consumers alike, Coca-Cola’s “Share a Coke” campaign undoubtedly marked a turning point for digital printing and personalised packaging. Initiated in 2011, the seemingly straightforward process of putting people’s names on millions of bottles and cans took the industry by storm, and helped to revive the somewhat stagnant sales for Coca-Cola in Europe. Despite having been in existence since the 1990s, digital printing was, at the time, thought of as a largely new and form of technology. It was also regarded as largely inferior, following an historic struggle to compete with analogue presses in terms of its quality and price. However, as the campaign demonstrated, the technology has come a long way since and is now regarded as mainstream in the printing industry. | 6 | Packaging Europe

That is not to say that it is without its challenges. While digital printing is thought of as the most efficient method, this is only true for jobs of less than 3,000 metres. For mass runs, analogue printing remains the cheaper of the two. In addition, digital offers a slower print speed, making it crucial it focus on shorter runs. Thankfully, the majority of companies nowadays are looking for more short label runs than long runs. Nevertheless, the difference in capabilities between the two technologies accentuates the need for constant communication with sales officials to ensure the business stream is allocated appropriately. An additional key challenge for digital printing is the ever-present challenge of having a skilled workforce. Sophisticated technology such as digital printing machines requires in-depth knowledge and skills. While processes can seem straightforward to begin with, the picture can become less rosy when things go wrong. From uneven colouring to inconsistent toner levels, the variety of issues which can arise during the digital printing process are wide and varied. As a result, the need for contingency planning, such as additional IT support or standby machines, is all the more crucial.


Personalisation

A final challenge for a personalised packaging strategy is the integration of digital printing into an already existing system. If companies continue to use the same systems as had been used with more traditional approaches such as flexo press, there is the strong likelihood the resources will be wasted. Given digital printing is the more streamlined approach, if processes still take over a week to process, there is clearly an imbalance between the capacity of the systems and the waste being produced. While the challenges which digital printing brings are significant, so too is the window of opportunity it presents to companies, namely, the chance to grab the attention of the most influential consumer groups; millennials. Part of the reason why the “Share a Coke” campaign was so successful was that it had a social media strategy at its very heart. Having identified its core demographic, Coca-Cola targeted them, rewarding consumers who shared a selfie with the hashtags #ShareACoke and #SelfieSweeps with access to popular music events. The approach not only boosted sales significantly, but increased CocaCola’s visibility across multiple social media channels. With the number millennials willing to pay significantly more for personalisation at an all-time high, a strategy which incorporates a social media is not only crucial, but extremely powerful. The question left on people’s lips is now, what next for customisation and digital printing? For now at least, the demand for it does not seem to be fading. The queues across department stores for personalised Nutella are testimony to this fact. While such personalised gifts remain a novelty to consumers, they are likely to move increasingly into the mainstream as time goes on. However, as with all economic predictions, there are no guarantees. The fact that customers are willing to spend twice as much money on customised products today is no affirmation

that this will still be the case in ten years’ time. For many companies, personalised packaging strategies are short term manoeuvres that do not form part of a wider business blueprint. In addition, the more frequently such campaigns are used, the more likely it is that the novelty factor may wear off. As ever, the importance is authenticity. Personalisation does not necessarily mean printing people’s names on products. As demonstrated by Heinz, it can also include a common messages such as ‘Get Well Soon’. And once again, the consumer is willing to pay for such a premium, with the customised can costing more than twice as much as the standard one. For the time being at least, it’s still very much personal in the packaging world.

Packaging Europe | 7 |


Dow: The Changing Face of Innovation Ambitiously developing innovations through collaboration, Dow is at the forefront of the plastics industry, drawing on expertise in the EMEA region. At K 2016 Dow’s booth (Hall 8a, stand K48) will attract the attention of attendees to its theme ‘the face of innovation’. Focused on the three pillars of growth, sustainability and innovation, the stand will share stories of collaboration for sustainable solutions, and demonstrate how Dow helps smaller and medium sized companies grow alongside it.

“O

ur focus will be on the key faces that bring solutions alive and to the marketplace, whether that means our value chain partners, customers, researchers, world-class scientists or marketing experts,” comments Judith Hicks, senior business communications manager, EvvMEA. Dow’s stand will include an interactive collaboration zone, bringing to life stories of how the company has worked with partners to overcome challenges and technical problems to develop groundbreaking packaging solutions. Visitors can also learn about Dow’s innovations such as Pouchug™ and PacXpert™ through an application touch table and sample room. “Our experts will be discussing their solutions and collaboration successes in our auditorium, and for the first time ever, we have invited our partners to give talks with us,” Judith Hicks adds. “This reflects the whole ethos of our Pack Studios concept- bringing people together to collaborate and find the right solution, regardless of who they are in the value chain.” Launched in 2015, the Pack Studios concept represents a new model for collaboration. | 8 | Packaging Europe

It offers Dow customers a distinctive and advantageous position to leverage Dow’s expertise, broad product portfolio, and application testing capabilities as well as the ability to access a global network of additional industry experts and resources to help accelerate the development of packaging solutions. At K Dow will be showcasing new innovations for markets ranging from food packaging, transportation, infrastructure and appliances to consumer durables, utilities, healthcare, medical and more. There will be live demonstrations of the latest processing and performance advantages of Dow’s next generation products, from its packaging & specialty plastics, elastomers, and electrical & telecommunications businesses.

A flexible alternative to rigid containers Since the PacXpert™ solution won the Packaging Europe Sustainability Award in 2015 for weight reduction, there has been further development and success, as Fabrice


Innovation

Digonnet (NBD leader, EMEA) reveals. “We have effectively introduced PacXpert™ on the shelf in Europe, with more than 15 packs active today on the marketplace - a massive achievement over the course of a single year which we are very proud of,” he says. “We want to take the opportunity to showcase some of these packs at K 2016, and to highlight the collaborative stories with our partners in order to reach this feat.” PacXpert™ Packaging Technology is an innovative technology that enables the transition from larger traditional rigid containers to flexible packaging options. The distinctive flexible stand-up pouch is durable, lightweight, and cost effective. While flexible, the cube-shaped package is shelf stable and can stand equally well upright or on its side. Suitable for a wide range of applications, from loose food products and bulk beverage containers to windscreen fluid, PacXpert™ Technology’s flexible, lightweight design delivers 50 to 80 per cent weight savings over traditional rigid packaging alternatives. It is also lightweight for transportation purposes, weighing ten times less when empty, and for disposal, meaning emptied containers take up less receptacle space when discarded. Mr Diggonet highlights two successful collaborations which will be shared with attendees at K. The first came about when Swiss brand owner FRIPOO required packaging for a year-round windshield cleaner for vehicles. The result is a five litre lightweight flexible packaging based on an innovative solution brought by O. Kleiner AG, converters who are licensees of the PacXpert™ packaging technology. Dow worked closely with leading Swiss food service provider, Hugo Reitzel, in order to understand the current trends and challenges within their industry. As innovation and problem solving is in both companies’ DNA, Philippe Michiels, CEO of Hugo Reitzel, immediately could see the opportunities that this partnership could create. Thanks to close collaboration, and PacXpert, a new and more efficient flexible packaging solution was introduced to the market with great success.

On-the-shelf differentiation The second is PoucHug™, a technology designed to elevate consumer perception by communicating a natural look, authenticity, a soft feel, and premium message. It was developed after Dow identified a specific need for a natural and soft-to-touch packaging

solution, which would enhance product branding and address the market trend for natural and high quality products. Using Dow’s Pack Studios capabilities, PoucHug™ combines Dow’s expertise in packaging and non-woven materials for the hygiene industry, as well as its packaging and lamination adhesives offerings, including: AFFINITY™ Polyolefin Plastomer Sealants, ELITE™ Polyethylene Resins for Optimized Flexible Packaging, and MOR-FREE™ Solventless Laminating Adhesives. With PoucHug™, the external layer of the laminate is replaced with a non-woven substrate which changes two main aspects of packaging: the look and feel. The nonwoven surfaces are textured and opaque in comparison to incumbent BOPP and PET surfaces which are normally flat and glossy and can be perceived as cold and hard. Additionally as the non-woven laminate is soft, PoucHug™ feels like fabric instead of plastic. Giuliano Butti, value chain manager, EMEA, comments: “More and more, we are seeing a trend for bio and natural products, especially within the food segment. We aim to address the needs of our customers, converters, and brand owners with PoucHug™ by offering a pack that can communicate their values through the packaging. Often, you see glossy, shiny, stiff packaging which does not address the market needs, and we aim to differentiate.” Target applications for this technology are rice, coffee and tea packaging. “PoucHug™ recalls the traditional packaging that was used for these products in the past. It can also be applied to other premium market segments such as for pet food. Outside of the food segment, there are many other applications that can benefit from the features of this technology. Giuliano Butti gives the example of wet wipes: “This product is soft, with a natural look, and our technology can reflect the lightness and softness of the product it packs.” The concept has been promoted for a year, and is currently a work in progress. “We are working with converters in Europe to fully develop this technology,” continues Mr Butti. “We are also focused on discussions with brand owners to drive this product to the shelf on a global level and are looking forward to how the concept will be received at the K fair.” For more information, visit www.faceofinnovation.com

Packaging Europe | 9 |


Plastics in the Age of Industry 4.0 Nigel Flowers, managing director of Sumitomo (SHI) Demag UK, talks to Packaging Europe’s Tim Sykes as we look ahead to K 2016.

Tim Sykes

As the world of plastics gears up to K 2016, what would you say are the biggest trends and talking points across the

industry this year?

Nigel Flowers

Without doubt, it is Industry 4.0 and, most importantly, how moulders can leverage technology to their future advantage. This is true across all sectors as customers try to increase output and reduce costs. In general there seems to be a lack of clarity among the plastic moulding community about what Industry 4:0 means and where it is heading. It’s a bit of an unknown technology with no clear end game, and this is holding manufacturers back in terms of defining their Industry 4:0 strategies. At K 2016, we aim to clarify this under the banner Electrified 4:0. Our exhibits at K 2016 will help put Industry 4:0 into context for injection moulders and illustrate how upgradable technologies, including automation and robust process optimisation programmes, are already adding value to businesses.

TS NF

Are there any packaging-specific trends and challenges that are impacting on the way that injection moulders approach the marketplace?

Packaging customers operate in one of the most demanding manufacturing sectors and as such output, equipment reliability and energy efficiency, continue to be the main drivers. Two El-Exis SP machines, with a clamping force of 2,000 and 4,200 kN will appear on the stand at K 2016. Both will showcase packaging applications. The El-Exis SP 200 will be producing four high quality decorated cups in less than two seconds, and is anticipated to be the most rapid IML exhibit during the show. Demonstrating the production of thin-walled packaging is the El-Exis SP 420, producing four polypropylene trays in a 2+2 stack mould, featuring a high-speed Sepro side-extraction robot. 
 With packaging formats constantly changing, it makes economic sense to build a complete moulding system that anticipates future applications, with robotic capabilities integrated for speed, repeatability, multi-tasking and long-term cost saving. Our packaging customers are increasingly asking for complete IM applications, which, once set up, require little modifications or engineering intervention. By 2020 the flexible and rigid plastics packaging market expected to have expanded significantly. Sustainability is an ongoing concern with a strong commercial incentive to do more with less. As a result thinner, lighter and easier to handle packaging is one of the fastest emerging trends and thin walling and weight reduction has been a focus area for innovation at Sumitomo (SHI) Demag. From a cost and sustainability perspective, shaving off two grams in polymer weight per packaging item can save mass manufacturers thousands of tonnes in raw material a year. However, producing thinner wall sections requires higher pressures and speeds, faster cooling times, and modifications to part-ejection and gating arrangements. All of which must be factored into the mould, machinery, and part design. The use of bioplastics is also poised to play a greater role in packaging going forward. Caps and closures is a market driven by costs, which filters down the supply chain. For injection moulders, this means deriving more value, with a focus on lean manufacturing and optimising production processes. Beverage caps remains the most dominant market, accounting for approximately 60 per cent of all units, while the toiletries and cosmetic sector and homecare markets remain the largest user of polymer caps and closures. There is a definite trend emerging towards more sophisticated tamper evident closures. In the pharmaceutical sector, this trend is mirrored with child-resistant and senior-friendly dispensing closures, with a greater emphasis on product security.

TS

Across the industry automation is a topic on the lips of many at the moment. To what degree would you say European injection moulding has responded to technological opportunities? Are some countries further ahead than others in this respect?

Nigel Flowers, Managing Director of Sumitomo (SHI Demag UK helps put Industry 4:0 into context for injection moulders | 10 | Packaging Europe

NF

In my opinion, Europe and Germany in particular are leading the way globally, both through the setting of interoperability standards via EUROMAP and by bringing products to market which will create real value to moulders.


Plastics Interview

Where high precision is required, the integration of robots into moulding cells is increasing

EUROMAP figures also reveal a marked rise in robotic integration within injection moulding applications over recent years. The number of IM machines sold equipped with robots rose from just 18 per cent in 2010 to almost a third (32 per cent) in 2015. Due to faster ROI, sterile conditions and safer production processes robotic automation in the IM process is no longer the preserve of pharmaceutical manufacturers with cleanroom environments. Applying robotics to precision moulding tends to be about minimising damage to parts and reducing quality costs and defects. There are also safety benefits. Robots can also be used to strip sprues and waste from around the mould and placing them in a granulator for recycling.

TS NF

What are the push and pull factors and the barriers associated with continued adoption?

The main pull factor is cost reduction. A connected factory can significantly reduce the costs of WIP, inventory and scheduling, with quality control data being shared in real time across the organisation. In terms of pull, the introduction of cheaper and smart IoT sensors will allow the direct collection of data from production equipment.

TS

How about the dimension of the Internet of Things? In what ways does smart, connected machinery possess the scope to extend the benefits of automation machinery?

NF

The issue with the Internet of Things, Industry 4.0 etc. is that it covers a multitude of technologies. Ultimately, it is about increasing productivity and profitability, reducing costs and waste, personalisation and traceability, factory connectivity and optimising energy usage.

TS NF

Like the entire Sumitomo (SHI) Demag range, the interface of the Systec Servo 280 has been upgraded to OPC/UA making the machine Industry 4:0 and Euromap 77 compatible

advanced than they might perceive. Instead of adding to the hype, at K 2016 we’re providing practical examples on how Sumitomo (SHI) Demag is already assisting moulders to optimise future production processes in the context of Industry 4:0.

TS NF

Is IoT now central to your product development? How has Sumitomo incorporated Industry 4.0 into its technologies?

Yes, but as our strategic vision illustrates, Industry 4:0 is not a paradigm shift. We have been working on the technology for some time now. Consequently, moulders are already optimising production processes and benefiting from our smart machines, smart service support and fully-connected smart production solutions. Our machines can be equipped with an OPC Unified Architecture (OPC/UA) interface, offering broader scope for connectivity and enabling moulders to use data to optimise production, make operation decisions quickly, and generate reports. The OPC/UA interface is also Euromap 77 compliant.

TS NF

What will be the focus of your exhibit at K 2016?

Electrified 4:0 at K 2016 is probably the most comprehensive exhibit we have staged to-date, covering the entire key moulding applications. Five machines will be actively running on the stand, demonstrating the speed and precision already being deployed to produce quality packaging, caps & closures, pharmaceutical, automotive and in-mould decorated (IMD) plastic components. In addition, K 2016 will be the world premiere of a new IntElect platform. We are also showcasing three injection moulding partnership installations developed in collaboration with Sepro, Yushin and ONI.

Visit Sumitomo (SHI) Demag at K 2016, Stand D22, Hall 15.

How far down the Industry 4.0 path have the supply chains in which Sumitomo is involved travelled?

Three key elements underpin Sumitomo (SHI) Demag’s ‘Smart Factory’ vision: • Smart Machines equipped with an intelligent and future proof user interface, fully synchronized to external ERP systems, robots and the supply chain; • Smart Service, integrating quality assurance and featuring remote diagnostics and maintenance to increase machine availability; and • Smart Production, with fully connected systems and a host manufacturing execution system (MES) tracking real time production information. In many respects, moulders that have invested in Sumitomo (SHI) Demag machines in the past five years, particularly all-electric machines, are probably more Industry 4:0

The most rapid IML exhibit at K 2016 the El-Exis SP 200 will produce 4 decorated cups in less than 2 seconds. Packaging Europe | 11 |


FachPack Essentials Where and when? Exhibition Centre Nuremberg, Germany 27-29 September

Opening times 27 September 2016: 09:00 - 18:00 28 September 2016: 09:00 - 18:00 29 September 2016: 09:00 - 17:00

Profile International trade fair for packaging, technology, processing and logistics.

Tickets One-day ticket: EUR 42 Permanent ticket: EUR 47 Advance tickets: https://www.fachpack.de/en/visitors/tickets/ticketshop

Contact NĂźrnbergMesse GmbH Messezentrum, 90471 NĂźrnberg, Germany Phone: +49 9 11 86 06-49 79 www.fachpack.de | 12 | Packaging Europe


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General plan

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FachPack Interview FachPack answers Tim Sykes’s questions on Germany’s biggest annual packaging fair.

Tim Sykes

How will FachPack 2016 compare with last year’s event in terms of the number of expected visitors and exhibitors? How does this reflect the overall levels of confidence in the German packaging industry at the moment?

FachPack

From 27 to 29 September it will be presenting products and services covering all aspects of packaging, technology, processing and logistics – for industry and consumer goods in equal measure. At the last event, around 44,000 trade visitors obtained inspiration and concrete solutions from the total of 1,565 exhibitors. We expect that the eleven exhibition halls will again be fully booked and are looking forward to offering the sector its innovation platform again this year. The positive mood of the market was also reflected last year by the number of visitors: 44,022 industry and trade visitors, willing to invest, seized the opportunity to experience the European packaging industry under one roof.

TS

What will be the highlights of this year’s show? What are the special focuses and themes of the exhibition and the parallel conference events?

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FP

At the heart of FachPack is the large number of trends and innovations waiting to be discovered – and not only on the stands, but also in the support program. And once again this year, themes and topics from the sector will be covered: in cooperation with renowned sector partners, the PackBox Forum dedicates itself in the usual way to the triple combination of innovation, inspiration and information. Outstanding and innovative solutions from the entire packaging value-added chain are recognized by the German Packaging Award, the most renowned European competition covering all aspects of packaging, to be held once again this year at FachPack. A new feature however is the award presentation held directly on the first day of the fair. Other proven highlights in the support program include the: • Corrugated Cardboard Forum • “Labels & More” Pavilion • Packaging Design Special Show • German Packaging Award Special Show • “Packaging in Medical Technology and Pharmaceuticals” Theme Park • “Process & Materials@FachPack” Market Place • Tracking & Tracing Theatre • “Human Being - Machine – Future” Theme Park


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TS FP

Will you be introducing any innovations to the format of FachPack 2016?

Over 500 new products, processes and services will be presented at FachPack 2016. Our exhibitor and product search new feature offers various selection options. Products and industries that involve the application of current trend themes can be accessed quickly. As a result, exactly the right innovative packaging solutions can be found among all the new items in a very short space of time: https://www.fachpack.de/en/ events/1/trends-and-innovations-/18593

TS FP

What do you think are the most important market conditions and trends to which German packaging manufacturers are currently responding?

Sustainability is a key theme in the packaging sector. Smart product developments enable resources savings in the value-added chain. There are already numerous examples of this in the market, others are in the development pipeline. Innovations – be it in products, processes or services – are an elementary component of FachPack, the European trade fair for the packaging industry. “Even if the term sustainability is today already somewhat overworked, we must not forget what it basically means – and it is indeed much more than just a current trend” says Director Exhibitions Heike Slotta. “This extremely important theme has reached the heart of society. The packaging sector is also making its contribution here: it is developing and offering solutions and alternatives. We will find them all at FachPack in autumn.” The measures apply to the entire value-added chain: packaging is being designed in a recycling-friendly approach in order to save resources and once again free up recyclable materials. In the mechanical engineering sector digitization is providing the basis for saving energy and reducing material consumption. And in logistics, products are being designed according to the “Cradle-to-Cradle” recycling management

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concept, for example pallets and boxes in recycled plastic or corrugated cardboard. In packaging printing in turn, LED-UV technology is saving energy in comparison to conventional UV lamps.

TS FP

How do exhibitors feel about the broad outlook for packaging in the context of economic and political instability, which has increased as a result of the UK’s Brexit vote?

For FachPack we do not expect consequences. Of course free trade is a decisive prerequisite for flourishing trade fairs and exhibitions. Whether and how the planned exit of the United Kingdom from the European Union will affect NürnbergMesse, mainly depends on how the British economy itself will further develop.

TS FP

Are there any areas of new technology in which you expect to see a lot of product launches at FachPack?

Over 500 new products, processes and services will be presented at FachPack 2016, which can be clustered in several trend themes: • Attractive short runs • Controlling and networking in the logistics process • Handle with care! • Labelling equipment: peripheral devices with a key role • Networking in production (Industry 4.0) • Packaging machines – adaptable modules • Signals at points of sale

A description of each trend theme and new products within these themes you can find in our exhibitor and product search: www.fachpack.de/en/events/1/trends-and-innovations-/18593


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BERICAP Presents Innovations B

ERICAP will be presenting groundbreaking technologies, integrated solutions and innovations tailored to individual packaging requirements. The global manufacturer of plastic closures, will be showcasing new packaging solutions, such as the e-smoCapTM for e-liquids, alongside advances in its tried-and-tested closure solutions for canisters, metal packages, pesticides, lubricants, sauces & dressings, edible oil, food and beverages. Innovative ideas are born of the increasingly high requirements made of packaging and, more particularly, the closure. Depending on the area of use, the latter must not only ensure that the container is closed and tightly sealed, but also protect its contents against product piracy whilst complying with high official technical safety standards. In order to guarantee product safety and quality, the assembly of all BERICAP closures is fully automated and process-controlled on state-of-the-art machines. Product piracy and the accompanying product counterfeiting are a sensitive problem with serious consequences when it comes to chemicals, especially in the agricultural sector. In order to protect refills from being adulterated or tampered with, all closures have a folded and cut guarantee strip which is extremely difficult to manipulate and shows clear evidence of tearing when the closure is opened. Other safety options are customer-specific closure designs, possibly complemented by an additional security label connecting the guarantee strip to the closure, or the use of laser technology enabling, for example, the company name to be lasered across the security strip and closure, including on uneven surfaces.

BERICAP has developed a special counterfeit protection system for one engine oil manufacturer. The bottler’s logo is affixed to the side of the closure across the security strip. As soon as the closure is opened, the security strip breaks and the logo is “destroyed”, making it obvious that the bottle has already been opened. Visit: www.packagingeurope.com/News/68963

Hall 6, stand 418

Hugo Beck and mopack Showcase End-to-end Film Solutions H

ugo Beck, a leading manufacturer of flowpack, film packaging, and post-print processing systems will team up with mopack and at this year’s FachPack trade fair. As a leading supplier of polyolefin, polyethylene and polypropylene packaging film and shrink film, mopack complements Hugo Beck’s range of horizontal film packaging solutions perfectly. Visitors can explore applications for various mopack films and Hugo Beck packaging machines first-hand on Stand 307 in Hall 4A. Hugo Beck is also represented in the ‘Packaging in Medical Technology and Pharmacy’ theme park on Stand 360 in Hall 9.

Flowpack seal-tight packaging The flowpack X-e is the entry-level model of Hugo Beck’s film packaging machines for flowpack applications in many sectors, including the food and confectionery industry. It offers all the features of larger machines, such as a rotary transverse sealing unit, a servo axis control system, and an adjustable forming shoulder for a high degree of flexibility. Its typical fin seals produce exceptionally airtight packs suitable for modified atmosphere applications and enhancing presentation at the point of sale. The spectrum of films that can be used ranges from hot or cold-sealable across metallic or paper coated films through to laminated films. Flowpacking using biaxially oriented polypropylene (BOPP) film from mopack will be demonstrated at FachPack. The flowpack machine line’s X-D version is designed especially for use in the pharmaceutical and medical technology sectors, where Hugo Beck specialises mainly in customised solutions. Fully hermetic packaging seams, full traceability, and reproducibility from the first product packaging are guaranteed. Examples of packaged items are infusion tubes, drug and alcohol tests, plaster, diagnostic equipment, etc. Stringent cleanroom requirements are easily maintained when petri dishes are seal-tight packaged. Visitors to the ‘Packaging in Medical Technology and Pharmacy’ theme park in Hall 9 are invited to obtain further information from Hugo Beck at the venue. | 22 | Packaging Europe

Bagged and shrink-wrapped packaging Using mopack’s polyethylene and polyolefin films, Hugo Beck and mopack are also presenting bagging and shrink packaging applications for many different areas. Hard or soft materials, bulky or compact designs: the film packaging solutions of each partner allow for the reliable, high-quality packaging of countless products. By way of example, visitors will be able to see the entry-level flexo X – a true all-rounder when it comes to tubular bag machines – and Hugo Beck’s servo X side sealer combined with a four-axial parallel robot and shrink tunnel. The company showcased its high-speed robot technology for various automation options in a live demonstration for the first time at the drupa 2016 trade fair.

Centre of Excellence for Film Packaging After many years of working together, Hugo Beck and mopack established the Centre of Excellence for Film Packaging in 2015. The packaging process in its entirety is the focus of the co-operation between the two companies, enabling customers to further benefit from single source solutions. Hugo Beck machines have been fine-tuned for mopack films to the greatest extent possible – as will be demonstrated at FachPack. Visit: www.packagingeurope.com/News/68899

Stand 4A, Stand 307


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Bischof + Klein: FFS on the Advance B

ischof + Klein will be presenting flexible packaging solutions manufactured from plastic and laminates for the industrial and consumer sectors. The packaging and film specialist is seeing a clear trend towards form, fill & seal in the industrial sector. “FFS solutions are not only a particularly economical alternative, but also offer additional advantages in terms of hygiene, barrier protection and printing”, explains André Altevogt, head of industrial packaging sales for foodstuffs at B+K. Industry is increasingly making use of FFS films made of plastic rather than paper packaging. Bischof + Klein is accompanying a number of customers in switching to this fully automatic packaging solution, and is regarded as the European pioneer in the field of form, fill & seal. In consumer packaging, focus is placed on individual forms, convenience and high-quality printing. One current example is the round stand up pouch for SONAX

window cleaning solution from Bischof + Klein. This offers all of the advantages of a stand up pouch: it saves space and material, and has little impact on disposal. One additional advantage is the small spout, which enables the solution to be poured precisely into even small openings without spluttering, because the pouch simply contracts. This stable, flexible packaging is very well received at the point of sale. The B+K Twister Plus® makes a convincing contribution to the sparing use of resources. This newly designed wicketed bag for tissue products from Bischof + Klein requires around seven percent less material. An increasing number of customers are switching to reverse-printed hygiene packaging with a handle and easy opening function. Visit: vwww.packagingeurope.com/ News/68892

Hall 7, stand 220

New service portal for labellers H

ow can operators quickly set up different sensors for their labellers or for their specific labels? How can customers reliably identify the exact spare part you need? How can they adjust the drive roller on many different label tapes? Answers to these and many more practical questions about labellers are now just a mouse click away: HERMA is launching a large-scale offensive for Industry 4.0 with the go-live of a new Internet-based service portal at Fachpack 2016. “This service portal at www.herma-service.com will enable our customers to carry out processes, settings and maintenance on HERMA labellers more efficiently, safely and comprehensively”, explains HERMA Service Manager Mark Bulling. The time-consuming search for the corresponding information in actual folders and manuals or in electronic directories will largely be unnecessary. “The essence of Industry 4.0 is to interlink production and state-of-the-art communication and information technology”, states Mark Bulling. “The service portal gives our customers access to all the knowledge relevant to them on a tablet or laptop with just a few clicks of the mouse, directly on the respective labeller.” Different search and filter functions as well as drop-down menus make it easier for users to find the desired information immediately. Self-explanatory videos that guide users step-by-step through specific setting processes - even without sound – are integrated for many recurring questions. Visit: www.packagingeurope.com/News/68979

Hall 3A, stand 236 | 26 | Packaging Europe


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ALPMA: High-precision Portioning and Flexible Packaging C

utting-edge technology, fully automated and flexible in configuration – these are the attributes of the systems manufactured by ALPMA Alpenland Maschinenbau GmbH – which thus meet all requirements for efficient cheese production. At this year’s FachPack trade fair, the global market leader for Process, Cheese-Making, Cutting and Packaging Technology is presenting its latest developments for highprecision portioning and fully automated packaging of a wide range of cheeses. The focus will lie on systems that ensure both precise and flexible portioning and packaging of cheese. The SC 60 segment cutter, for example, cuts both soft and semi-hard cheese loaves into fixed-weight portions – and reduces losses in the cut portions to a minimum, while the MultiSAN fold wrapping machine packs cheeses of virtually any shape, format and consistency in next to no time. The MultiSE is a newly developed system for boxing cheeses of widely ranging formats, at the same time setting new standards in terms of hygiene and maintenance. At this year’s FachPack, for the first time, ALPMA will be presenting a key member of its segment-cutter family, the SC 60. It is equipped with state-of-the-art servo technology for optimum monitoring and control of the cutting process. Users can choose flexibly, based

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on the specific requirements, whether to cut their cheese loaves according to the number of portions (in the case of price-labelled portions) or by weight (in the case of weightoptimised portions). Whichever option they choose, measurement and segmentation of the cheese is performed fully automatically – as is the forward transport of the finished cheese pieces via a discharge belt. In contrast to other cutting machines, with the SC 60 it is possible to cut cheese loaves of widely varying consistencies in one and the same plant: this segment cutter can portion soft cheese loaves just as precisely as firmer semi-hard cheese loaves. This is achieved by the use of different quick-change knife systems: while semi-hard cheeses such as Edam are cut with classic precision blades, the SC 60 portions soft cheeses such as blue cheese with ultrasound knives specially developed by ALPMA. These ultrasound knives cut the fragile and pressure-sensitive loaves by means of their high vibration alone, which at the same time ensures that no cutting residue accumulates on the knives. Visit: www.packagingeurope.com/News/68929

Hall 1, Stand 321


Fachpack NEws

Products and Technologies from PrintCity Alliance F

ollowing their successful participation last year, the members of the PrintCity Alliance will again be exhibiting on a joint stand at FachPack. The Alliance will be presenting both its own work and the latest technologies – not only on the exhibition stand, but also at a seminar in the PackBox. The exhibits at the last FachPack already included MÜESLOVE, the comprehensive system solution for cereals, which shows just what is possible and permissible against the backdrop of the increasingly strict statutory regulations in the food industry. The lifestyle product in an elegant design has now been supplemented by a highly attractive POS display. Produced by digital printing, it expands the Alliance’s portfolio to include liner-board and solidboard products. The highly finished outer packaging of the Real Life Sample series have also been the subject of further development work:

To complement the packaging for “El Drago” luxury drinks, there are now also labels featuring virtually identical optical and haptic effects. A new edition of the carton itself is being produced by flexo printing. Also being produced again are the high-quality folding cartons for cosmetics, which are suitable for the mass market. In addition, visitors can find out about more of the latest capabilities and products, and get an insight into new technologies that are currently still in the development phase: Absolutely scratch-resistant, deep-matt coating (Diamond Matt), personalisation by innovative digital foil finishing (Digital Metal), virtual 3D with hot foil (Spatial FX), lens effect with hot foil (Deep Lens) and virgin-fibre board now also coated (a new extrusion coating system). Visit: www.packagingeurope.com/News/68866

Hall 7A, stands 235 & 236

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Sappi to present innovative, sustainable packaging solutions S

appi Packaging and Speciality Papers is set to exhibit once again in Nürnberg. FachPack a key platform for the manufacturer of speciality papers and carton for presenting its innovative and sustainable packaging solutions to a broad European expert audience. Well-known brands, agencies, packaging manufacturers, printers and print finishers will be showcasing their latest products and solutions. Sappi will be presenting its environmentally sustainable carton and paper-based packaging solutions for Containerboard, Rigid Packaging, Flexible Packaging, Label Papers and Functional Papers. Sappi has recently restructured its containerboard product range in order to provide both new and improved solutions for the corrugated cardboard market. This includes the bright white Fusion® topliner as well as corrugating liner & fluting Ultraflute™. Fusion topliner is unique in the containerboard market. Compared with other topliners available on the market, it has an outstanding surface finish. This is reflected in its exceptional colour brilliance with high shelf impact for excellent brand differentiation. Fusion topliner also enables significant cost savings when it comes to finishing. Sappi will also present its multi-award-winning bright white coated cartonboard Algro Design at FachPack. Algro Design is typically used for folding cartons containing highquality products such as cosmetics, perfume, premium chocolate and confectionery. The bleached cellulose carton helps convey the value of the end-product to the consumer. Sappi will showcase its comprehensive portfolio of coated and uncoated papers for the flexible packaging and labels market, including papers for food and non-food applications such as sachets, pouches and wrappers as well as a range of self-adhesive and wet-glue labels. The speciality papers that are coated on one side are ideal for outer packaging of consumer products requiring high-quality printing and high shelf impact. Uncoated varieties lend themselves to inner packaging and pouches. The versatile Sappi product portfolio offers brand owners and converters the best packaging solution for every individual requirement.

Functional papers from Sappi provide paper-based packaging solutions with integrated functionality. Algro® Guard OHG, an innovative paper-based packaging solution with high barrier functionality and heat seal characteristics, will make its trade debut at FachPack. It has been developed for flexible packaging applications and features integrated barriers against oxygen, grease, water vapours and mineral oil mixtures. Visit: www.packagingeurope.com/News/68594

Hall 9, stand 122

Design tool for spectacular plastic bottles E

xtravagant and striking color designs for plastic bottles: Kreativbox 1.0 demonstrates the wide variety of special effect colorings offered by Finke. With its Kreativbox 1.0 Finke puts an indispensable drafting tool for PET-, PEand PP-bottles in the hands of designers as well as packaging manufacturers. A variety of appealing bottles made from those three materials demonstrates the whole range of aesthetic effects that can be achieved with FIBAPLAST, FIBAFFEKT or FIBACOMP masterbatches. The Kreativbox gives examples of transparent, translucent as well as covering employment of a coloring and illustrates the impression of metallic gleam, pearly shine, rainbow or color flop effects. It also demonstrates, how lustrous, lacqueredlike finishes, soft-grip surfaces or incorporated fragrances can show to advantage. The Kreativbox 1.0 provides valuable ideas and suggestions and vouches for their technical feasibility. It summarizes Finke’s renowned expertise in the development of plastics colorings enabling the quick and economic translation of design ideas into production stage coloring and additive systems, and will be showcased at Fachpack 2016. Visit: www.packagingeurope.com/News/68471

Stand 9 - 234

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DS Smith Presents Solutions Virtually D

S Smith is showcasing the impressive range of possibilities that virtual reality offers brand presentation and promotion at the point of sale. The display and packaging strategists carry trade fair visitors off on a virtual tour of discovery. By using VR, visitors experience interactively the added value, which the full-service-packaging- provider offers to his customers with its innovative display and packaging solutions throughout the entire supply cycle. How can displays and packaging build up brand awareness faster? How can modular solutions for secondary placements become more versatile and this way more efficient? How can membrane packaging significantly reduce the number of required packaging variants? How can clever shelf-ready packaging solutions bring products into the pole position and effectively prevent out-of-stock situations? These are just some of the questions, which the display and packaging strategists of DS Smith ask themselves every day. In DS Smith’s virtual showroom, visitors to the FachPack can play around with and reproduce the solutions to these questions themselves and experience multisensory shopping worlds in an authentic setting. As a pioneer of innovative brand presentation, DS Smith is heavily involved in point of sale digitisation and in investigating how this digitisation can be implemented profitably for brands and retailers. “Emotionalisation is an important competitive factor particularly for retailers,” says Michael Lamprecht, Sales Director at DS Smith in the Germany & Switzerland region. “Only then can retailers keep up with competition from the web and position themselves in the omnichannel of the future in a way that is sustainable.” Combined with state-of-the-art technologies such as multi-sensor technology, Quick Response Codes, Augmented and Virtual Reality, displays and packaging have huge potential in terms of staging unique worlds of experience on the sales floor, interacting with customers and increasing brand awareness and sales. In addition to displays and consumer packaging, at FachPack DS Smith presents impressive solutions for transport, protective, industrial and hazardous goods packaging. Visit: www.packagingeurope.comNews/68912

Hall 5, stand 239

Mosca’sNew EVOLUTION SoniXs MS-6 Heads Widelyvaried Product Range

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osca GmbH is presenting its unique EVOLUTION SoniXs MS-6 at this year’s FachPack. Visitors can see the first side seal machine with SoniXs ultrasonic technology at its booth. The latest model from the strapping experts at Mosca features full network functionality, variable frame sizes, and many more advantages for optimizing production. Along with other strapping machines from the EVOLUTION series, the Mosca display includes everything from entry-level machines to high-end models and pallet strapping systems. The focus of the Mosca display at FachPack 2016 is on the EVOLUTION series. This line features modular construction with standardized components for quicker assembly and easy disassembly without tools for maintenance, etc. At the heart of the series is the Standard-6 sealing unit that can be equipped with either heat-welding or the patented SoniXs ultrasonic technology to seal the straps – using the same mechanical system. The Standard-6 strap path can be used in all machine classes and points to the future direction of Mosca strapping technology. Mosca has created the latest development in the EVOLUTION series: SoniXs MS-6 – the world’s first side seal machine with SoniXs technology. This machine is available in Base and Pro versions in combination with the matching feeding mechanisms and will be presented for the first time at FachPack 2016. The sealing unit is positioned on the side of the machine body for easier strapping of heavy products or items transported close to the ground, such as furniture or household appliances. The Pro version is fully networkcompatible, bringing side-seal strapping machines into the Industry 4.0 era. “This means, for example, that we can run a diagnosis via online remote maintenance. We gladly offer this service because it is uncomplicated and convenient for our customers,” explains Christian Zwieb, who is in charge of product management at Mosca. With upstream and downstream feeding mechanisms, the SoniXs MS-6 is fully automatic and can be easily integrated into existing production lines. It processes machine-compatible PP, PET and PLA straps with a width of 5, 6, 8, 9, 10 and 12 mm. Other advantages, including a frame with flaps, ergonomic strap threading, and an optional fully-automated double strap dispenser, make the EVOLUTION SoniXs MS-6 a versatile premium product. Visit: www.packagingeurope.com/News/68876

Hall 4A, stand 513 | 34 | Packaging Europe


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Cardboard Packaging Equipped with Self-adhesive

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ame-day delivery and delivery within one hour: The challenges of meeting deadlines that businesses face are constantly increasing. - Every step must fit like clockwork. At Fachpack 2016, BÜHNEN Adhesive Systems will present its product solutions for the packaging industry: The packaging step can go faster by using pre-assembled cardboard packaging. The maker of this packaging equips it with adhesive strips in advance. Just one pull on the silicone paper and the packages are ready for shipping. And the right adhesive can also reliably seal the returns – even after weeks, if necessary.

At the stand the BÜHNEN team will be able to tell visitors all they need to know about self-adhesive finishing with the new D1628.1 hot-melt adhesive. Here is an overview of the product in advance: The product is permanently sticky, offers strong adhesion, is flexible at cold temperatures. There is no need for adhesive tape, and there are no changes in the package appearance. Further benefits for stand visitors: At the same stand the matching applicator tools will also be exhibited. Melt-on devices for low and high speeds, together with application heads and accessories. Visit: www.packagingeurope.com/ News/68568

Hall 2, stand 306

TSCs Prominent Improvements in Displays and Firmware

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SC Auto ID will demonstrate how thermal label printers with a full-colour touch display can facilitate the barcode printing process. The Taiwanese manufacturer, well known as very innovative of its branch, has equipped within the desktop segment the models of the TC series and TX series as well as the industrial printers of the 4“, 6“ and 8“ series and the MX240 series with such Touch Panels. The well-arranged and user-friendly display directly shows the user what to do. The Full-Colour Touch LCD includes as standard a graphic interface allowing stand-alone print solutions without an additional PC. Thus installation and operation are very facilitated. Variable data may be directly entered at the display of the MT or MX. Additionally, simplified data input is possible by use of external keyboards and scanners. For the same purpose the compact models of the TC and TX series use an USB host interface. Moreover, resellers have the possibility to install the company logo, a service-hotline, the order number of consumable materials as well as the device identification for internal support. This ensures not only a better service but also a stronger presence with sustainable effects on the customers. The powerful TSC firmware TSPL2 secures the full programmability of the touch display, allowing the implementation of individual applications and functions by resellers. An optimized and highly efficient printing process is assured. And last, but not least it allows the preview of the label on the display as a verification before the label is printed. The high performance printer MX240 will be an absolute highlight at the stand. TSC has tuned the firmware and offers as an option a turbo for its bestseller in this range. The “tuned” model enables thermal direct printing with maximum precision barcodes, texts and signs on a label at an unbelievable printing speed of 24 ips (= 588 mm per second). Visit: www.packagingeurope.com/News/68492

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Rovema solutions from standard to premium

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ovema manufacturer of packaging machines, headquartered in Fernwald near Giessen, will be presenting a compact edge sealed packaging system for flat bottom bags with clip and the BVK vertical form-, fill and seal machine for standard bag styles. High-grade confectionery and candies, premium pasta and selected legumes are increasingly packaged in flat bottom bags with a clip for reclosing. Typically the clip applicator is connected to the vertical bagger as a separate component, whereby the set performance is considerably limited. The company will also be exhibiting our SBS 250 packaging system including a vertical BVC continuously working form-, fill and seal machine and the integrated clip applicator. The operation of both components is done by the machine control Rovema P@ckControl. The filled bags are transferred by cycle chain, which holds the bags and transfers them safely to the closing clipper. Due to the direct infeed, a set performance of up to 80 bags/ minute is possible, depending on bag style and weight. The vertical form-, fill and seal machine as well as the clip aggregate are very accessible so that size changes, cleaning and maintenance work can be shortened tremendously. The packaging system allows the handling of nearly all mono and laminated films of various thickness and is also prepared for different sealing procedures such as heat sealing and impulse welding. The SBS packaging system offers high flexibility in the choice of film material as well as bag style. As the clipper is height adjustable, it is also possible to produce long fin seals, which cannot be produced with clippers customary in the market. Needing a space requirement of approx. 9 m² the SBS packaging system with integrated clipper is a compact solution for attractive packaging styles with clip closure. Rovema will also be presenting the BVK 260 vertical continuous form-, fill and seal machine for standard bag styles like pillow bags and flat bottom bags. At a competitive price the machine offers extremely high production safety by proven and robust machine technology. Visit: www.packagingeurope.com/news/68484

Hall 4a, stand 411 | 40 | Packaging Europe


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MULTIVAC: Everything from one source T

he focus on the MULTIVAC stand will once again be on innovative and needs-based solutions for packaging food, medical products and consumer items. The highlights on the exhibition stand will be the R 105 MF and R 245 thermoforming packaging machines as well as the T 250 and T 600 traysealers. Among other exhibits, MULTIVAC Marking & Inspection will be presenting a conveyor belt labeller and an inline labeller as a stand-alone solution, and the company will also be showing its entire range of inspection systems. With its R 105 MF thermoforming packaging machine, MULTIVAC will be showing an entry-level model for producing high-quality MultiFresh™ vacuum skin packs. The R 245, which is equipped with a die changing system and a film quick-change system, offers maximum flexibility at high output and quick conversion to other pack formats. MULTIVAC will be showing the semi-automatic T 250 from its traysealer range, and this machine is ideal for packing small batches efficiently and flexibly. The compact machine is

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suitable for producing MAP and EMAP packs as well as vacuum skin packs. Representing the high-output machine sector, the fully automatic MULTIVAC T 600 traysealer can be seen in action within a complete line. The line to be shown at FachPack consists of a MTD 751 denester, a MDC 255 infeed, a MCS 270 transport conveyor with turning pin for aligning the trays, a L 301 direct web printer with TTO 10 thermal transfer printer, and a MRT 100 rotating table for the finished packs. In addition to the P 600 and C 300 TI chamber machines, MULTIVAC will also be presenting on the exhibition stand the compact R 081 thermoforming packaging machine and the T 260 traysealer. Visit: www.packagingeurope.com/News/68573

Hall 1, stand 221


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Fachpack NEws Tuning for Packaging: Innovative Adhesives from Jowat SE

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owat SE is attending FachPack 2016 under the headline “Tuning for Packaging”, introducing several innovative adhesives for the complete value chain in the packaging industry – from the manufacture of packaging materials and applications during the packaging process to securing goods for transport. Tailored adhesive solutions from Jowat facilitate state-of-the-art packaging processes, especially for current issues, such as energy-efficient End-of-Line processes and food safe packaging.

Tuning for Packaging Jowat is attending this year’s trade show under the headline “Tuning for Packaging”, and is going to introduce innovative adhesive solutions which ensure the perfect packaging and facilitate reliable manufacturing and packaging processes. Jowat delivers a wide range of tailor-made adhesives plus competent and extensive assistance in all bonding-related issues from a network of experts. At the trade fair, Jowat is also going to present a powerful all-rounder from the Jowacoll® product group for the manufacture of packaging materials. The dispersion adhesive is especially suitable for laminating packaging with a high degree of finishing and embossed surfaces. Another highlight of this product group are the special adhesives for laminating cut-out windows. Adhesives from the Jowatherm® und Jowat-Toptherm® product groups facilitate reliable processes for erecting and closing sales packaging, outer packaging and transport packaging (e.g. trays or special shelf-ready packaging). A coating with

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special adhesives gives the packaging anti-slip properties and helps secure the goods during transport. With professional and comprehensive assistance, Jowat supports the industry and facilitates a constant improvement of packaging materials and processes. Visit: www.packagingeurope.com/News/68878

Hall 2, stand 320


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Packaging Europe | 47 |


Hapa to Present CMYK Pack-Printing Solutions H

apa will be exhibiting two of its latest CMYK pack-printing solutions will be exhibited. The Hapa 862 will be printing labels and aluminum foil, and the 800 BlisterJet CMYK will be printing multiple colours on blisters. The Hapa 862 is an in-house, CMYK / four-spot-color printing solution for any foil or label-printing application. The UV DOD piezo inkjet printing system complies with the stringent requirements of the pharmaceutical segment and meets the challenges of serialization with high-resolution results. The BlisterJet CMYK is a fully digital piezo inkjet system. It prints pre-printed or blank blisters, blister-packaging cards, and small, flat and glued cartons. The solvent-free, UV-curable inks print sharp graphics and text in single or multi-colour spot process applications. A sales team will be present to discuss Hapa’s various printing solutions for any primary and secondary packaging, solids and liquids. Visit: www.packagingeurope.com/News/68887

Hall 3, stand 323

Marbach: Packaging Performance T

he Heilbronn based cutting die manufacturer Marbach once again will be exhibiting at FachPack. Presenting its innovations, especially for corrugated board, but also for paperboard and labels. New technologies for best performance and convinced customers. Marketing manager Tina Dost: “Round. And round. That’s how it goes on the product side with marbapeed|r. The rotary tool for corrugated board. pure edge provides clean visible edges in flat die-cutting. And the nick changing system helps replacing nick rules fast. To adapt the tool to changing material properties. Our customer save make-ready time with mpower|+. And even more with digital zone patching.” Marbach not only shows its new products at FachPack, but also presents a new trade fair stand concept. Visit: www.packagingeurope.com/News/68840

Hall 7, stand 616

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Fachpack NEws DUO PLAST as Solution Provider for Load Unit Security T

he film specialist DUO PLAST will present its solution concept comprising the three business units stretch film, packaging machines, and technology centre for load unit security. Distribution process managers are faced with questions such as: How can I reduce packaging costs and consumption? How can I improve the safety and secure my products? Last but not least how can I protect simultaneously the environment? Granted, it’s hard to meet all requirements at the same time. Even so DUO PLAST is going to present how the right combination of stretch film, packaging machines and technology centre creates an efficient packaging concept at optimal costs. DUO PLAST’s this year’s fair presentation is based on the requirements of safety, cost savings and sustainability. The relations in the packaging process will be shown practically at numerous stretch film samples, various packaging machines and the possibilities of the Technology Centre DUO LAB. The combination of three DUO PLAST business units offer its customers a full-service concept from a single source. A unique concept occurs, which is characterized by comprehensive expertise and maximum safety in the range of load unit security. Sustainability and cost efficiency are getting a whole new meaning. DUO PLAST presents for the first time also a further highlight: the new DUO XS. The stretch film producer has developed an 8 micron thick stretch film. DUO XS stands for minimum film consumption and is well suited for the internal transport safety as well as for dust protection and the transportation of light goods. Visit: www.packagingeurope.com/News/68683

Hall 5, stand 111

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High-precision portioning and flexible packaging Cutting-edge technology, fully automated and flexible in configuration – these are the attributes of the systems manufactured by ALPMA Alpenland Maschinenbau GmbH – which thus meet all requirements for efficient cheese production. At this year’s FachPack trade fair in Nuremberg, the global market leader for Process, Cheese-Making, Cutting and Packaging Technology is presenting its latest developments for high-precision portioning and fully automated packaging of a wide range of cheeses.

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the FachPack, ALPMA, specialists in the production, processing and packaging of cheese and based in Rott am Inn in Bavaria, are presenting machines and systems which bring cheese into perfect shape. The focus will lie on systems that ensure both precise and flexible portioning and packaging of cheese. The SC 60 segment cutter, for example, cuts both soft and semi-hard cheese loaves into fixed-weight portions and reduces losses in the cut portions to a minimum. Meanwhile the MultiSAN fold wrapping machine packs cheeses of virtually any shape, format and consistency in next to no time. The MultiSE is a newly developed system for boxing cheeses of widely ranging formats, at the same time setting new standards in terms of hygiene and maintenance. “We have made considerable progress over the past few years, particularly in the field of cutting and packaging technology, and are very proud to present the results of our development work to a broad specialist audience,” says Gisbert Strohn, managing director of ALPMA. “Our company stands for solutions which ensure flexible and efficient cheese production coupled with simple handling of the systems and high production reliability. And this is what we intend to demonstrate at the FachPack.”

ALPMA SC 60: high-precision portioning with minimum ‘give-away’ Once again, the ALPMA segment cutters, which ensure precise and economical cutting of cheese pieces, are at the centre of the company’s fair presence in Hall 1, Booth 321: “As cheese is a matured natural product, no two loaves are ever the same. | 50 | Packaging Europe

This makes portioning a challenge,” explains Robert Zosseder, regional sales director for Cutting and Packaging Technology at ALPMA. “Thanks to their integrated measuring technology, our segment cutters are able to process even widely varying loaves, with a high degree of precision and producing fixed-weight portions. This optimises the yield and at the same time reduces the amount of ‘give-away‘.” At this year’s FachPack, for the first time, ALPMA will be presenting a key member of its segment-cutter family, the SC 60. It is equipped with state-of-the-art servo technology for optimum monitoring and control of the cutting process. Users can choose flexibly, based on the specific requirements, whether to cut their cheese loaves according to the number of portions (in the case of price-labelled portions) or by weight (in the case of weight-optimised portions). Whichever option they choose, measurement and segmentation of the cheese is performed fully automatically – as is the forward transport of the finished cheese pieces via a discharge belt. In contrast to other cutting machines, with the SC 60 it is possible to cut cheese loaves of widely varying consistencies in one and the same plant: this segment cutter can portion soft cheese loaves just as precisely as firmer semi-hard cheese loaves. This is achieved by the use of different quick-change knife systems: while semi-hard cheeses such as Edam are cut with classic precision blades, the SC 60 portions soft cheeses such as blue cheese with ultrasound knives specially developed by ALPMA. These ultrasound knives cut the fragile and pressure-sensitive loaves by means of their high vibration alone, which at the same time ensures that no cutting residue accumulates on the knives.


ALPMA MultiSAN: the all-rounder for flexible packaging As with Cutting Technology, the success of ALPMA’s Packaging Technology division is based on fully automated systems which guarantee maximum flexibility and highspeed packaging of the portioned cheeses. At the FachPack, one of the flagships of the division, the MultiSAN fold wrapping machine, will demonstrate its capability. As a true all-rounder, the MultiSAN can process cheese of virtually any shape, format or consistency. And there is free choice of packaging material, too: the system operates with plastic or aluminium films.

The MultiSAN is operated via a state-of-the-art touch panel which ensures full control of the entire packaging process at all times. The user can quickly and easily select from a wide range of requirements in the integrated product type memory, which can store up to 80 applications. And a display on the MultiSAN itself shows which machine parts need to be replaced for a format changeover. “The MultiSAN shows just how far our capabilities at ALPMA extend in the field of packaging: as an intelligent machine, it makes an important contribution to ensuring simple, problem-free handling and to meeting hygiene and maintenance

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requirements,� says Zosseder. And the results of this fully automated packaging process are also a visual highlight: products packaged on the MultiSAN have a traditional look.

ALPMA MultiSE: the boxing machine of the future Boxes made from wood, cardboard and plastic have many advantages as packaging for cheese: they keep the product fresh, protect its aroma and are eye-catching at the point of sale. And the requirements placed on boxing plants are correspondingly high. The wide variety of shapes presents a particular challenge in practice. At the FachPack, ALPMA is also presenting its new boxing machine, the MultiSE. Compared with its predecessor, the SE 80 boxing machine, the MultiSE represents a new development from the ground up by the ALPMA experts, with a state-of-theart servo control system that will allow cheese-making factories to switch flexibly between cheeses of different shapes. The MultiSE reliably boxes round, oval and rectangular cheeses.

Minimised format changeover times At the same time, the machine helps to keep the time required for format changeover to a minimum: all format parts and parts that require cleaning can be replaced very quickly without the use of tools. Among other things, this reduces the time needed for necessary cleaning measures. The lean, compact design of the MultiSE is also an advantage here: the new boxing machine operates as a line, which means that all parts of the machine n are readily accessible at all times and are correspondingly easy to clean.

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First Time Right

For minimum reject rates ultrasonic sealing is the first CHoice Herrmann Ultraschalltechnik GmbH & Co. KG is a technology leader and specialist in ultrasonic welding for applications in sectors such as automotive, food, hygiene, medical and electronics. Libby White spoke with Alexander Boppert, regional sales manager for PACKAGING, about the company’s expertise in manufacturing modules and components for ultrasonic sealing systems for the packaging industry, and its plans to exhibit at FachPack 2016. Packaging Europe | 53 |


errmann Ultraschall draws from over 50 years of experience and has established an innovative portfolio of solutions such as its ultrasonic digital generators. Alongside a focus on providing components, the company prides itself on being a solution provider. It consists of three divisions: NONWOVENS, PLASTICS and PACKAGING. The PLASTICS business unit makes up around 50 per cent of the business, and PACKAGING and NONWOVENS make up around 25 per cent each. There is continuous growth across all three sectors, supported by 350 employees worldwide. Global headquarters are located in Karlsbad, Germany, and there are a further three sites in the USA, China and Japan. Through ongoing organic growth, the company has impressively doubled its revenue in the last seven years. Mr Boppert comments, “Today, we are now servicing more markets and industries than ever before, and are present with 25 locations in 19 countries worldwide. Our growth is both regional and in applications and we have a strong focus on expanding our reach.”

“As the requirements and needs of our customers have become increasingly demanding, we have continued to develop and provide ongoing changes to our salad bagging solutions. This application has become one of our success stories within our packaging division, especially in regions such as the UK,” Mr Boppert shares. The main benefit of the salad-bagging application is the significant cuts to reject rates. “With heat-sealing, the average reject rate is six per cent or more. With ultrasonic welding, we can drastically reduce this figure to 0.5 per cent. Our technology increases efficiency and ensures the process is completed right the first time which saves on time, waste, and reject rates. The process is more effective, produces tight seals and has the extra optical advantage of producing thin, fine lines, whereas heat sealing can produce a wrinkled effect.” Herrmann Ultraschall works in triangular relationships when it comes to solving ultrasonic sealing applications, cooperating on individual projects alongside the machinery manufacturer and the end customer, such as the salad bagging company. Mr Boppert explains, “This relationship model is worthwhile although a lot of communication is needed for it be effective. We can bring the ultrasonic technology experience to the table, while the machine manufacture brings their expertise in the machinery and process. Overall there is coordination in the technical and commercial aspects. We have invested a lot of time and effort into delivering a robust plugand-play portfolio geared towards the requirements of different packaging machine manufacturers and are proud of the hard work we have put in to garner success.”

Developing solutions

Customer relationships

Ultrasonic welding is a sealing method which has established itself as an alternative to heat sealing for certain applications such as wet pet food, salad, coffee, chocolate and pharmaceuticals. A clear advantage is the ability to seal through contaminations in the sealing zone and produce a higher percentage of tight bags when compared to heat sealing. Herrmann Ultraschall has focused on developing its solutions for salad bagging applications.

Herrmann Ultraschall offers a range of service packages such as technical partner management, tool management, and ultrasonic engineering services to give strong support to its customers. Tool management is an option for customers whereby at fixed intervals tools will be reworked (rather than exchanged) to ensure optimum tool quality and tool life. The technical partner management service provides support with integration for

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the machine manufacturer. Mr Boppert explains, “Perhaps the machine manufacturer has limited experience of ultrasonic welding. We can support them, giving consultations and recommendations based on our experience.” For ultrasonic welding, the company has developed a ‘kit’ of standardised engineering services which can be tailored to each individual application, covering every step of a project from the first feasibility tests, to the end of commissioning and operator training. “Of course each application and customer is different but the general steps of ultrasonic engineering are more or less the same,” Mr Boppert adds. Customers can also benefit from Herrmann Ultraschall’s own laboratories. Mr Boppert points out, “We frequently use our laboratories to solve welding issues. This gives our customers the advantage of our knowledge and expertise, meaning we can quickly and efficiently provide them with solutions.”

lot of potential for us, especially in the packaging sector. With regards to regional expansion, we are currently looking for local representations to grow our packaging applications on the UK and Ireland markets in particular. Visit us on our website www.herrmannultraschall.com or join us at • FachPack tradeshow, 27. – 29.09.2016, Nuremberg, booth 107, hall 1 • PPMA Total Show, 27. – 29.09.2016, NEC Birmingham, booth G32 • K2016 tradeshow, 19. - 26. 10. 2016, Düsseldorf, booth E26, hall 11

Continuous success Reflecting the ongoing development of Herrmann Ultraschall, the company will be showcasing a number of recent solutions on its stand at FachPack 2016. “We regularly attend FachPack, as it is one of our most important shows, however this year will be of particular value as we will be showcasing our new ultrasonic generator ULTRAPACK AMG, especially developed for fast running multi-track packaging lines and the requirements for industry 4.0 such as data driven manufacturing and interfaces. The stand will also concentrate on our core and standard applicationssalad bagging and stand-up pouch solutions will be a highlight. We will also be attending PPMA later this year in the UK,” says Mr Boppert. “We look forward to meeting with existing clients and potential new customers, whilst also discovering new applications and areas of interest.” Herrmann Ultraschall is set on a successful path and looks set to continue in the same direction. Mr Boppert concludes, “As a company we have high expectations, especially for global growth into specific markets and core applications. There is a Packaging Europe | 55 |


GEA thermoforming machines have been used for many years for the packing of the Rostbratwurst product range. (Picture: HoWe)

Availability is everything For over 30 years, German sausage makers HoWe Wurstwaren KG have relied on GEA thermoforming machines for packaging their traditional grilling sausage, the Nuremberg Rostbratwurst. Because the product range of sausages is constantly expanding and the demands from discount and grocery retailers are subject to never-ending change, the medium-sized company has decided to invest in the latest packaging machine technology from the tried and tested machine manufacturer. This guarantees product reliability, transparency and consumer safety.

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ince our company was founded in 1985, we’ve specialised in the production of Rostbratwurst which from the very beginning has met the very highest quality standards,” explains Florian Hoeneß, managing director of HoWe Wurstwaren KG at the company’s headquarters in Nuremberg, Germany. “Our bratwursts are delivered straight onto the market in conventional vacuum packaging or delivered in bulk for the food service industry.” In the year 2015, the medium-sized company decided to replace three of its vacuum thermoforming machines. There were a number of reasons for doing so. Among these was the increasing variety in HoWe’s packaging forms due to their expanded product range. For consumers, changing demands, such as traceability, have become increasingly prevalent. “Consequently, we have completely revised our internal logistics, overhauled our packaging and invested in the very latest generation of machines,” says Hoeneß.

Decades of trust The bratwursts are produced on a production floor of around 8,000m2 by up to 300 employees. Since day one, the sausage producer has relied on technology from the machine manufacturer GEA. Alongside preparation machines for mixing and grinding, thermoformers have proven their reliability and flexibility in the vacuum packaging of fresh products. “Meanwhile, we have started using the third generation of GEA packaging machines. They have always fulfilled our requirements,” explains the managing director. “Because of this long and trusting partnership, it was clear to us this time as well, from the very beginning, that changing machine suppliers would be out of the question.” For packaging the Rostbratwurst product range, modular GEA PowerPak thermoformers are used. These rely on a form-fill-seal concept which meets the highest | 56 | Packaging Europe

packaging demands. The product series offers countless configuration possibilities and is well suited to production lines with high output or frequent product changes. Thanks to their low downtime, their excellent performance is combined with significant potential for savings. Customers are on the safe side: the ever-expanding spectrum of packages on supermarket shelves can be safely and efficiently realised using these thermoformers.

Standardised processes At the factory in Nuremberg, original Nuremberg Rostbratwurst, along with the light version with 30 per cent less fat, and a diverse range of other grill bratwursts are prepared five days a week, working in two shifts in the summertime and one shift in the wintertime. The products have repeatedly been awarded with the German agriculture industry’s prestigious DLG Golden Prize. Each year, more than 10,000 tonnes of meat are processed here; during the peak periods in the summertime, the number reaches up to 80 tonnes a day. “Despite the relatively limited number of applications, what matters to us is that all processes can be fundamentally standardised,” says Hoeneß. “The availability and operating times of the individual machines are extremely important in that regard,” adds plant manager Dieter Maier. Where just a few years ago there were only two package sizes: 200 or 300g. Today the packages range in size from 160g up to 1kg, which means the packaging machines must support frequent format changes. The necessary reconfigurations must take place quickly, safely and reliably. From a technical standpoint, swivel-mounted top tools make it simple to change tools. Formsets can be quickly dismounted from the packaging machine and replaced with new formats. “For our technicians, this makes the changes much easier and more ergonomic,” says Hoeneß.


Standardized processes are relevant for packaging.

The thermoforming machine sets standards in terms of process and

Machine availability plays an essential role for this. (Picture: HoWe)

investment safety as well as cost-efficiency and flexibility. (Picture: GEA)

Significantly reduced downtimes

Focus on line compatibility

To further minimise downtimes during bratwurst production, the issue of film and label changes was a crucial factor in the company’s decision to invest in the machines. First of all, the thermoforming machines use jumbo film rolls in standardised widths with corresponding lengths, which guarantee long runtimes. Secondly, the thermoforming machine’s two labelling systems with large label rolls prove their excellent performance. Among other things, the machines can print bar codes and variable dates, which ensure traceability from a consumer protection point of view. “Where we used to have to change labels every 15 minutes, now the window period has been increased to 40 minutes,” explains the plant manager. This significantly increases the machines’ continual runtime. It can reduce downtime by up to 40 per cent. Labelling systems and packaging machines are perfectly coordinated with one another via operational and software technology. “This is a full system solution, which is user-friendly in everyday operation,” says Horst Waldner, Head of Food Processing & Packaging Sales for GEA in Germany. “Plus, it’s designed for evergrowing capacities.” An added benefit is that the labeller takes up less space. Because it is installed within the frame width of the packaging machine, there’s no bothersome overhang, even on production floors where space is limited. Soft film is used as the packaging material for vacuum-packing the bratwursts. The thermoforming machine is also equipped with a print mark control for creating printed upper-layer film. This ensures that the printed image is perfectly aligned.

All three of the PowerPak machines are custom-made and finely tuned to meet the needs of the bratwurst producer. “Despite the wide variety of package sizes, the runtimes have been significantly increased,” says Hoeneß, pointing to one of the major advantages of the machines. Quick format changes, as well as jumbo films and sophisticated labelling technology, ensure high availability. On top of that, there’s the modular construction, which can be retroactively adapted to meet everchanging packaging requirements. “This ensures sustainable production for the future,” explains Waldner. A fundamental added benefit of the thermoforming machine design is the line’s compatibility with all other GEA machines in the areas of preparation, packaging, printing and labelling. This ensures high product reliability on location. “This concept scores extremely well in the food industry. The consistent control and operation designs are perfectly in tune with one another,” emphasises the GEA manager. In total, there are four GEA thermoformers in operation at HoWe. They have all worked perfectly from the very beginning. Detailed planning, starting in the initial proposal stage, is the reason why the entire project falls into place without a hitch. Equally important are the close personal contacts between everyone involved in the project, which are built up over years of cooperation. “We have been working alongside the company for so long that we know their packaging requirements for fresh products like the back of our hand,” says Waldner. “The mutual trust is what guarantees our long-lasting partnership.” Florian Hoeneß fully agrees: “We are so satisfied with the technology, service and personal advice that we ordered the packaging machines with a handshake and without any hesitation.”

Hygiene-friendly design The sausage producer also places very high demands on hygienic design. Its circle of customers includes discount retailers, grocery stores, restaurants as well as processing companies in Germany, Europe and the USA. “We have to work hard every day to maintain our success,” says Hoeneß. “Safety and hygiene are extremely important factors in that regard.” The hygienic construction of the thermoforming machine ensures the strict requirements of the company’s global customers are adhered to. Stainless steel and the high protection class of all components allow complete wet cleaning of the entire line. No dismantling is required. The open frame construction makes cleaning quick and efficient. Lubricant-free bearings in the lifting system guarantee freedom from grease, which means that no foreign objects wind up on or inside the machine, which could in turn have implications for the hygienic design. Top quality components ensure a long life cycle. The special sealing membrane and the vacuum system guarantee long-lasting product safety. The control box is integrated into the frame and the construction is open from all sides so that the packaging machine is highly accessible, not only for cleaning, but also for operation and switching formats.

Visit: www.gea.com

From left to right: Dieter Maier (plant manager, HoWe), Horst Waldner (GEA), Florian Hoeneß (managing director, HoWe) (Picture: GEA)

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Precision

and Flexibility Micro Laser Technology GmbH is one of the market leaders in the field of laser machine design and manufacturing. Founded in 2000, MLT is situated in Kirchheim, east of Munich. Libby White spoke with Walter Herrmann, product manager and application consultant, about the latest solutions from the company and its plans to exhibit at the upcoming FachPack exhibition.

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ith 16 years of knowledge and expertise, MLT started developing laser systems for perforation for tipping paper in the tobacco industry. Shortly after, it applied its expertise and technology to modified atmosphere packaging for products such as fresh cut lettuce and vegetables. Mr Herrmann comments, “Today, we are very well known as a system integrator- our aim is to supply turnkey systems for our customers. We are present in the tobacco and food packaging markets across four continents (excluding Australia). Over the years we have benefited from a steady growth.” MLT’s machines are used in a wide range of sectors, such as the tobacco, paper and packaging industries. “Our customer are mainly converters. Of course, we also have installations with end customers, and in some cases we supply our machines to large multinational customers for their R&D departments,” says Mr Herrmann. The company prides itself on having a deep knowledge of rewind web material and the ability to provide precision laser technology in this moving environment. “For the packaging industry, we provide applications such as easy-opening and perforation, and it is quite a specialty to achieve precision during the movement of the web,” Mr Herrmann explains. On top of this, MLT owns some patents on its perforation equipment which makes its machines highly competitive with regard to throughput, with perforation speeds of up to 750 m/min and quantities of more than 1,000,000 perforations per second achieved on web material.

Advantages of laser technology

technology. Mr Herrmann explains, “On a CAD system you can create and import easily to the laser control different and individual shapes, scoring, cutting and marking abilities. The changeover requires less down time than a mechanical punching system. It also gives packaging designers more freedom and possibilities in creating packaging solutions.” MLT can explain its success on offering customised solutions, which sets the company apart and has ensured its reputation has flourished on the market. “We have a demo system at our facility and can develop and find the best combination of laser technology and optic modules for specific enquires. We also ensure that the solutions we provide are stable and when integrated, give high precision as standard,” says Mr Herrmann. He continues, “The first systems we sold 16 years ago are still running today, and our yearly maintenance offering ensures the smooth running of daily operations. This can be explained by the fact we do not use the cheapest modules for our machines. Instead, we provide quality and long term stability. My experience is that ‘made in Germany’ is still renowned on the market.”

Market presence With a global presence, MLT firstly supports its customers with a service team based at its headquarters in Munich. Additionally, it has technicians based in Brazil, China and Thailand to ensure a quick and efficient response to customers. Mr Herrmann adds, “We have remote access to our machines, enabling us to check reported problems. MLT also has a telephone hotline 24/7 to ensure a technician is always on hand to answer our customer’s questions.”

As a non-contact tool, laser remains sharp compared to a mechanical punching system which becomes worn over time. A second plus point of laser is the flexibility of the

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In order to share ideas, and meet new and existing customers, MLT is present at major exhibitions internationally. For example it has plans to attend the upcoming ICE in Munich, interpack in Düsseldorf, as well as shows in Thailand, India, and the US. Of particular note, the company will be present at FachPack 2016. Mr Herrmann shares, “We have attended this show for several years now. We will be showcasing a laser module designed for integration with a horizontal packaging machine, and will be presenting our new quality control system. These will be our two highlights on our stand. “We look forward to the exchange of ideas and meeting new contacts: every week I receive new enquiries that I hadn’t even thought of and it’s unbelievable some of the ideas attendees bring along to the shows. Of course, we also use FachPack to meet with our existing customers to talk about their existing machines and future planning. It is a great platform for face-to-face communication.”

Flexibility and new developments Within the last year MLT has established a new machine concept to the market which offers flexibility. Mr Herrmann explains, “Our customers can start with a basic system, and we can give them the ability to upgrade easily with laser technology and optical modules. The idea is to provide ease and flexibility for our customers, so as they can upgrade when they become more established on the market themselves.” Standard applications for food packaging include easy-opening, perforation, and scoring straight lines for stand-up pouches, however MLT also provides some more specialty solutions. For example, it has integrated a laser system with a horizontal flow-wrapper in order to score the film, giving a sleek bend on the pack and sharp edges where the material is bent. This can be seen in the Mondelez Cadbury Glow luxury packs. MLT has also realised another solution for coffee capsules: an innovative coffee company has launched a complete PLA solution whereby the lidding and the capsules are both 100 per cent PLA. Conventionally, the lidding film is made with aluminium. With its innovative laser technology, MLT can weaken the lidding film so it breaks exactly in the coffee machine under the high water pressure and temperature. With an increase in packaging for the convenience food market, MLT can provide an innovative solution for packaging suitable for microwave use. “We can locally weaken the pack or the film, so whilst cooking in the microwave the over-pressure is exact and the pack cracks and opens whilst maintaining an inner-pressure to ensure the cooking time is short. We see requests for this especially coming from Asia,” Mr Herrmann explains. | 60 | Packaging Europe

As of this year, MLT is introducing its new quality control system, which is based on camera systems. This solution evolved from the needs and requests of MLT’s customers, who wanted to inspect the quality of laser applications inside the reel, an important requirement when working from reel to reel.

Laser evolution MLT has an ongoing commitment to invest in new technologies. Mr Herrmann explains that laser is a substitution for existing technologies in the markets that they serve, and it is a continuing transformation. He comments, “If you go into a supermarket today, you can see that there are a lot more packs to be realised and improved upon, there is a lot of opportunity on the packaging market.” He points to a combination of laser technology and digital printing as an interesting development for the market: “In the past few years, we have seen some exemplary combinations of laser technology and digital printing on the market. They both provide the advantage of fast changeovers. An ongoing trend for smaller batches means turnaround times need to reflect and react much faster to the market requirements. These two technologies go hand in hand and I think in the next ten years we will see this as a growing trend on the market.” Visit: www.microlasertech.de


Ultraflexible SkySorter conveyor technology for fashion logistics Skyfall overhead conveyors from Swiss systems supplier Ferag AG are gaining a foothold in more and more application areas. The latest project comprises a complete SkySorter line for the transport, sorting, intermediate buffering and order-picking of garments, shoes and jewellery.

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group SDI Systems is primarily a specialist in Multi Channel solutions for the distribution industry and is integrating the Ferag innovation into an existing distribution centre owned by speciality retail chain Stage Stores, based in Houston, Texas. Equipped with 5,000 Skyfall hangers, the installation is expected to become operational in the autumn of 2016. The installation is specifically aimed at improving the efficiency & speed of picking for the fast growing Ecommerce Channel that Stage Stores operates. “We are very pleased to have been able to convince SDI Systems about the advantages of our Skyfall technology,” explained Jürg Möckli, CEO of Swiss company Ferag AG. “The company SDI Systems was meticulous in its all-round evaluation of our conveyor technology’s potential, and examined a number of alternatives before finally deciding in favour of our system.” According to the CEO of SDI Systems Krish Nathan, it was not only exceptionally high flexibility and ease of servicing (the system is almost zero maintenance) that spoke for Skyfall, but also the high energy efficiency that comes with the drive technology, which is largely gravity-based. Also, the Swiss were able to deliver the system extremely quickly. Ferag is very proud that, in collaboration with SDI Systems, the first Skyfall line in North America is to be installed at Texan fashion chain Stage Stores. Amongst the items distributed by this famous store chain are shoe and clothing labels like Calvin Klein, Clarks, Dockers, Jockey, Lee, Levis or Ralph Lauren. The goods distribution centre that will accommodate the new SkySorter conveyor technology is located in Jacksonville, Texas. There, Stage Stores transfers goods to stock that arrive directly from overseas via Houston. The Stage Stores head office is also in Houston. This metropolitan area on the Gulf of Mexico is not only the fourth largest city in the USA, but also has one of the country’s busiest ports. After a brief period in intermediate storage, the products are sent out from Jacksonville to the fashion group’s stores, which currently number 850. After commissioning in the autumn of 2016, the Swiss system, which is integrated into the existing logistics centre, will be one of the biggest Skyfall lines so far delivered by Ferag. It incorporates ten loading stations, one

intermediate storage buffer, one sorting buffer and 24 packaging lines. The SkyTrain interconnects all these areas and has more than 5,000 hangers, each configured for loads up to six kilograms. Ferag’s partner SDI Systems sees itself as the preferred supplier of logistics solutions for clothing manufacturers, fashion chains and fashion houses. Founded in 1977, the Californian company has realized a major share of the goods distribution centres for this sector in the USA, and optimized their supply chains.

About Ferag AG Ferag AG, with its headquarters in Hinwil in Switzerland’s Zürcher Oberland, is a specialist in innovative conveyor and processing technology. It is seen as the global market leader in the development, manufacture and marketing of postpress processing systems. At the same time, this traditional, family-owned company is stepping up its activities in the intralogistics and packaging industries. Like its associate companies Denipro AG, WRH Marketing AG with 20 WRH Global subsidiaries, and PMC Print Media Corporation, Ferag is part of the Walter Reist Holding AG corporate group, which employs a staff of more than 1000 worldwide. Visit: www.ferag.com

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Jindal Films is a global leader in the development and manufacture of bi-axially oriented speciality films for the packaging industry. The company continues to lead the field with its ability to develop innovative new products for the flexible packaging and labeling markets. Philip Yorke reports.

Pioneering bi-axially orientated film solutions

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indal Films, previously known as Mobil Plastics and ExxonMobil Films, has been a global technology leader in the development and manufacture of speciality bi-oriented films since the early 1970s. The company also has the largest product portfolio of BOPP (biaxially oriented polypropylene) films in the industry. Jindal has affiliated manufacturing plants at Virton in Belgium, Kerkrade in the Netherlands, and Brindisi in Italy. It also has North American production facilities at La Grange in Georgia and Shawnee in Oklahoma. With a network of sales offices and distributors in North America, Europe and Asia, the company is well placed to meet the needs of its customers worldwide.

Unrivalled technology Placing a high priority on R&D, Jindal Films has developed leading building-block technologies through the formulation of proprietary water-based coatings that exhibit superior aspect, barrier and printing properties. In addition, the company has developed a unique cavitation technology which offers an exceptionally white aspect and a higher yield. Jindal Films has also created a purpose-built in-house metallisation capability that delivers outstanding barrier properties and a high-quality finish. | 62 | Packaging Europe

Recognised as the technological innovation leader in the industry, it can now offer even more advanced innovation capabilities with a brand new in-house pilot orienter line and pilot coating line. Additionally, Jindal Films can perform extensive in-house film testing with state-ofthe-art packaging machines including HFFS, VFFS and Pouch, as well as having in-house converting test capabilities including UV Flexo and gravure printing.

Hybrid polymers launched At the Fachpack Trade Fair later this year, Jindal Films will highlight their superior technology and innovative capabilities with a range of new product innovations. SealTOUGH™ film is a unique coextruded packaging film designed to replace blown PE (polyethylene) films. SealTOUGH provides unmatched puncture resistance, enhanced clarity, improved modulus and seal strength that can exceed 5,000g/2.54cm. This latest breakthrough technology provides downgauging potential of 30-40% or more, compared to traditional sealant films. With a three-fold improvement in tensile strength, two-fold improvement in modulus, puncture resistance, and impact resistance, SealTOUGH surpasses the current


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performance of blown PE in applications including confectionary, snacks, dry fruit and nuts, pasta, rice, bakery items, produce, and dry products. Utilizing the property enhancements of SealTOUGH in FFS bags, freezer bags, lamination and hygiene bags enables thinner films, weight reduction and cost savings. Another new product to be showcased is the company’s Label-Lyte ™ LLC films. These are hybrid polymers that bridge the gap between two traditional plastic films, polyethylene (PE) and polypropylene (PP) used for pressure sensitive labels. . This new platform combines the best characteristics of PE, such as conformability, squeezability and flexibility with the inherent properties of OPP, which includes stiffness, no elongation and excellent transparency characteristics. Due to its improved mechanical properties offered by the bi-orientation production process, brand owners can downgauge from an 85micron PE film to a 52 micron LLC film for less waste and fewer trucks required for transportation. “Our strategy is to help customers grow by creating added value for targeted segments through the launch of a series of innovative new technology platforms,” commented Nathalie Lesieu, market development team manager, Jindal Films Europe.

Exceptional product range Jindal films offers the most comprehensive range of oriented films for flexible packaging and labelling markets. The company has a unique portfolio of water-based coated films in transparent, white or metallised finishes that provide robust barrier properties, secure sealing and faultless printing and machine performances. Due to their unique cavitation technology, OPPalyte™ films enable the production of a very broad range of white, opaque films from high to low density to address a variety of packaging and labelling challenges. Ultra-transparent Bicor™ films can be coated or uncoated, glossy or matt for use as monoweb or for lamination. Metallyte™ films come in a wide variety of configurations and encompass white, coated and ultra-high barrier film types. Label-Lyte™ films are tailored to meet the specific requirements of the reel-fed, cutand-stack, and pressure sensitive label markets. As mentioned earlier, SealTOUGH™ is the latest innovative addition to Jindal Films’ brands, offering exceptional sealing characteristics and significant downgauging opportunities, compared to blown PE films. Discover how these technologies can support your business growth by visiting Jindal n Films Europe at FachPack, Nuremberg, September 27 to 29, Hall A7 – 123. For further details of Jindal Films latest innovative products and services visit: www.jindalfilms.com | 64 | Packaging Europe

Label-LyteTM 52LLC film


Carrying packaging technology further Persson Innovation is a global market leader in the design and manufacture of handles for the packaging industry. Philip Yorke reports on a company that continues to excel and innovate with packaging solutions that enhance brands and consumer convenience.

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ersson Innovation was founded in Kumla, Sweden in 1982 following a visit to the US by the directors of a leading Swedish converting company who realised that there was a growing demand for carrying solutions in the packaging industry. One of the key entrepreneurial staff at the company, Olof Persson, came up with a unique carrying solution and the best way to produce it. Persson began work in his basement in the late 1970s and the company Olof Persson Innovation was born. The current brand name Persson Innovation (PI) was first registered in 1982 and new manufacturing facilities were established in 1984. Persson’s innovative idea quickly became an international success and the unique carrying device is still being exported to the company’s main markets, which include North America, South America, Europe and the Far East. Today the company is a global leader in its niche market and retains its culture of being a family run company despite the fact that it was acquired in 2012 by Connecting Capital, a private equity company. Persson Innovation has decades of experience providing high quality services and products to the packaging industry. Even before Persson Innovation started to produce its first handles, the company already had more than 20 years experience in the packaging industry producing paperboard cartons and other packaging products. It is this wealth of experience that the company’s success is built upon and for which it is recognised worldwide.

Increasing global reach For many years the company has worked in close partnership with a machine manufacturing company called Nordgren Konsult (NK), that designed, built, installed and serviced the automated application machinery PI’s customers have used to enable them to optimise the company’s range of products. In 2012 the new owners of PI decided to merge the two companies and during the same year increased its presence in North America. Since then the company has continued to expand its

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global reach with a growing network of agents and distributors and the opening of a new office in Belgium. “We continue to see steady growth in our diverse global markets and business segments. We offer a high level of quality at a competitive price, however, it is our service that sets us apart from our competitors. Since we come from a family background we maintain that mentality as for us business is not just business but something that we live and breathe every day. “Add to this our unique range of products, which can be customised to suit a customer’s specific needs, and strong products which can carry up to 30kg, we can


offer a complete solution. We provide the optimal solution for our customers from the design of the handle to the machine applying it in line at our client’s manufacturing facility. We are willing to work from the concept stage of a project to the final product solution thereby adding value throughout the packaging supply chain,” said Kristian Nordgren, plant manager at Persson Innovation.

Innovation driving sales As the company’s name implies, it is innovation that is behind its on-going success. Persson Innovation sells carrying solutions and its customers come to it for answers to complex packaging challenges. The company will be exhibiting its unique product range at FachPack this year, as Nordgren explained: “Historically we have seldom been at any trade shows, but with the change of owners in 2012 we decided that it was time to get our name into the general packaging market, not just with the converters that we normally target and where we are already well known. “FachPack last year was only the third trade show we have exhibited at and then we focused on getting people to recognise our brand. However, this year we will focus on the complete carrying solutions we offer. We will also exhibit at PackExpo in Chicago later

this year. We have some new innovations to launch and some important improvement projects that we plan to market and implement this year so there is plenty of exciting new product news to follow in the months ahead.”

Committed to sustainability Persson Innovation is committed to work for a sustainable environment and has set management guidelines to support its environmental care programme. This includes minimising its use of raw materials, commodities and energy, and to work preventively for continuous improvement in the environmental field. In addition Persson strives to meet or exceed the requirements of the laws, regulations and ordinances concerning the protection of the environment. Persson also continues to decrease the use of resources and when it comes to paper, all the company’s handles are produced using only paper that meets the EU regulation number 1935/2004. For further details of person Innovation’s range of unique carrying solutions visit: www.perssoninnovation.com

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Complete hot melt adhesives solutions Bühnen GmbH & Co. KG is a family-owned European market leader for hotmelt systems and offers a unique combination of adhesives and application systems. Elisabeth Skoda spoke to Valentino Di Candido, Bühnen’s director of marketing and international sales, to find out more about what makes the company stand apart from the competition.

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ounder Heinrich Bühnen established the business in 1922 in Bremen in the North of Germany as a machine repair workshop, originally focusing on repairing machines for roasting coffee. “This was a much requested service, as Bremen has a long tradition of importing and processing coffee, being the home of major coffee brands such as Kaffee Hag and Jacobs,” Mr. Di Candido explains. From the mid-1930s onwards, the focus shifted to the manufacture and repair of upholstering machines. The company continued to grow over the years, and in the mid1970s, Bühnen started to move towards the use of hotmelt adhesives and the development of corresponding applicators. This segment expanded to become the core business area, serving the automotive, construction, floristry, electronics, furniture, filter and packaging industries. In 2006 it was decided to make hotmelt adhesives systems the sole focus of company activities. “This was the right strategical move at the right time, and growth really took off from this time,” Mr Di Candido points out.

Vast product range Bühnen offers solutions for a wide range of applications, including displays and packaging, polymer foams and textiles.

The company provides a wide range of adhesives and application systems, from simple EVA grades in stick shape to granules, polyolefine and polyamide based glues, reactive glues and PSA. With more than 500 different types of hot melt adhesives, the company’s application laboratory is equipped for a wide range of tasks, with custom-made bonds also possible. Complementing the adhesives is a diversified range of applicator systems, starting with simple glue stick guns for handicrafts and bigger guns for industrial applications, to more powerful applicator systems. “The devices are characterised by perfect handling, reliability, and outstanding melting performance. Applicators on offer include mechanical glue guns, pneumatic hot melt hand applicators, bulk tank systems, drum - and bag melters,” Mr Di Candido is happy to report. Bühnen’s is proud to be the only manufacturer in Germany offering matching applicators for its hot melt adhesive range, not just for its own product range, but also for adhesives from competitors. “Bühnen’s range is also compatible with our competitor’s products. Our one4all-range offers compatible replacement parts, including application heads, modules, nozzles, filters and screens and solenoid valves, produced by Bühnen for applicator units manufactured by Nordson, Robatech and ITW-Dynatec,” Mr Di Candido explains.

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Flexibility and innovation counts Bühnen currently employs some more than 80 people, and this small size results in more flexibility compared to big corporations. “Bigger competitors are often only willing to deliver big amounts of adhesives, however we are able to serve our broad customer base of around 7000 active customers even if they only need small amounts of adhesives. Many of them are small or medium sized companies or major companies with low adhesive consumption, such as automotive suppliers, who use our hotmelt glues e.g. for car seat parts. They appreciate our flexibility, our fast delivery times and our service,” Mr Di Candido points out. “Bühnen subscribes to a full service principle, from on-site consulting and tests in an on-site application laboratory through to a 24-hour delivery service. We offer high quality spare parts made in Germany, compatible to units of other applicator systems producers with a very reasonable price tag. Our customers are keen to receive both adhesives and applicators from one source. We offer speed and flexibility, as well as a personal service.” At Fachpack 2015, Bühnen relaunched its updated HB 6000 Series - a bulk tank system for melting EVA, PO adhesives and PSA. “The new award-winning HB 6000 Series is based on years of experience and continuous development by our long-standing partner Meler Glueing Solutions, a Spain-based company that focuses on producing tank units for hotmelt applicator systems,” Mr Di Candido explains.

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The company showcases its products at numerous exhibitions in Europe together with its distribution partners, such as Stuttgart’s Bondexpo and Eurasia Packaging in Turkey, and it will be returning to FachPack 2016.

European presence In addition to its headquarters in Bremen and the domestic market, Bühnen has several subsidiaries and sales offices. “In 2008, Bühnen Polska was founded in Wroclaw in the south-west of Poland in order to be closer to the eastern European markets. In 2009, Bühnen Benelux was created. The company also has sales representatives in several European countries, and recently purchased established hotmelt businesses in Austria, Poland, Hungary, Slovenia and in Czech and Slovak Republic,” Mr Di Candido adds. The company sees the biggest potential for growth in Europe. “Our focus lies predominantly with the European markets. The domestic market and the countries surrounding Germany provide us with good business opportunities. We have distribution partners in the UK, where we have seen a very good development as well as in Scandinavia, Turkey, Romania, France and the Eastern European countries. Beyond that, we are also active in the Northern American markets,” Mr Di Candido explains. He sees the secret of continued success in sustainable growth. “We want to look out for new possibilities, and grow not only organically, offering the best service for our customers, and establish ourselves in different markets in order to be even closer to our customers.” Visit: www.buehnen.de


Reusable packaging

driving supply

chain efficiency

As a subsidiary of Menasha Corporation, which has more than 40 locations across the globe, Orbis has a rich history in packaging. For more than 150 years, Menasha Corporation has been dedicated to a customer-focused approach, providing a diversified offering of high quality material handling and packaging products and services for a wide variety of industries. Libby White spoke with David Heer, senior commercial director, to find out about the company’s success and plans to exhibit at FachPack 2016. Packaging Europe | 71 |


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oday, Orbis Corp. uses proven expertise, industry-leading knowledge and superior products (containers, pallets and dunnage) to create and implement reusable packaging systems. As companies continue to optimise their supply chains, the future promises a growing need for cost-efficient reusable packaging products, worldwide. “Orbis supports world-class companies to handle their products faster, safer and more cost effectively around the globe,” Mr Heer is proud to say. “With our reusable containers and pallets, we support industries from automotive, consumer goods, and the food and beverage sectors.” With Orbis’ proven customer solution approach, its experts analyse customers’ operations and design for them a dedicated solution with a strong focus on sustainability and long-term cost savings.

Comprehensive service Orbis focuses on delivering value through a combination of innovation, engineered solutions, and improving its customers’ supply chain. Enhanced profitability, a positive environmental impact and streamlined operations are the main benefits for customers.

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Mr Heer comments, “Our goal is to support our customers through reducing costs, and helping them reduce CO2 emissions. We have a great team of experts who are inspired by working together with our partners and customers – driven to innovate and dedicated to delivering solutions that will lead our customers to success. We are experts in injection moulding, thermoforming and compression moulding, and offer one of the most comprehensive portfolios on the market.”

European focus “Year on year, the European market is evolving towards reusable solutions. There is a strong focus on sourcing solutions with environmental benefits, reduced total cost of ownership, and optimisation of the supply chain,” says Mr Heer. With local sales and customer solution experts and manufacturing facilities based in Europe, Orbis is focused on supporting its European partners to improve their supply chains and benefit from reusable packaging. Mr Heer says, “Leveraging on our success and experience, with a leading position in the automotive market in north America, we will build our presence in Europe.”


“We aim to meet with our existing customers for discussions and listen to their challenges and current needs, and to meet potential new customers. The possibility to present our solutions to customers allows us to exemplify how we can improve their supply chains and operations,”

Orbis will be present at FachPack 2016 in Nuremberg, Germany where it will be sharing a range of its solutions. “One of the highlights of our stand will be our HDB1012 BulkPak® collapsible container system. The 1000x1200 container can hold up to 900 kilos, enabling it to support a large portfolio of customers in Europe,” shares Mr Heer. The customisable solution offers key features and benefits such as multiple heights, access door and bottom configurations as well as enhanced repairability features for easy, on-site repair. Designed to optimise supply chains, it can lower the total cost of ownership due to its reusability. “We aim to meet with our existing customers for discussions and listen to their challenges and current needs, and to meet potential new customers. The possibility to present our solutions to customers allows us to exemplify how we can improve their supply chains and operations,” says Mr Heer. “Our European experts will be on hand to offer their knowledge.”

dressed the growing need for hygienically designed packaging which is suitable for use in clean room environments. Mr Heer concludes, “We aim to support our customers by reducing their impact on the environment through analysing the output of their current supply chains and showing them the benefits of using our solutions, especially concerning greenhouse gas emissions, solid waste, energy usage, and the impact of reusable packaging. We can help them meet their strong environmental targets in Europe, and are proud of our status as a steward of sustainability.” Visit: www.orbiscorporation.com

Progressive outlook Orbis as a company has a significant focus on developing new products for leading applications. Mr Heer explains, “We have an advanced approach to product design, understanding the needs and trends of the market, resulting in a comprehensive portfolio of reusable products we can offer to our customers.” The corporation has a very strong presence in its key markets, and is experiencing continuous growth, especially within the automotive industry. Mr Heer credits this to the fact that OEMs are expanding on a global scale, meaning they need optimised packaging to support their operations such as intercontinental shipments – a service Orbis is in a prime position to supply. Focusing on a key trend, Mr Heer adds that with the development of Smart cars, the packaging has also needed to develop in order to adapt and suit the needs of new technology, which needs more protection during transit. In terms of the food and beverage sectors, Orbis has ad-

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The packaging family Family-owned cardboard and corrugated packaging specialist Model Group is leading the way when it comes to creating solutions that marry effective packaging with digital printing. Emma-Jane Batey spoke to Model’s head of marketing Iris Brugger to learn more.

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ounded in Switzerland in 1882 as a hand pulping factory by Louis Model, the Model Group today is still a proudly family-owned packaging company. The Model family still owns 100 per cent of the shares of Model Holding AG and is led by Dr Daniel Model and Elisabeth Model. Dedicated to providing ‘intelligent and efficiently manufactured packaging made of cardboard and corrugated board, together with a comprehensive package of services’, Model is a widely-respected solutions provider. Model Group develops, produces and delivers a wide range of high value packaging solutions using cardboard and corrugated board. The group is made up of 10 subsidiaries | 74 | Packaging Europe

in nine countries and employs over 4000 people. Primarily focused in Europe but active worldwide, its current main markets include its domestic Swiss territory as well as Germany, Austria, France, Czech Republik and Poland. Head of marketing Iris Brugger told Packaging Europe, “With our head office located in Weinfelden in Canton Thurgau, we are perfectly positioned to meet the demands of our customers across Europe. We have enjoyed a number of European acquisitions in recent years, including our third factory which is located in Poland and includes a state-of-the-art production and storage facility of over 20,000m2.”


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Another acquisition recently took place in Germany, where Model Holding took over 100 per cent of the P-WELL Group, a specialist in the production and sale of corrugated board formats and packaging. P-WELL GmbH has branches in Berka Werra (Thuringia), Bad Bentheim (Lower Saxony), Altenberge (North Rhine-Westphalia), Ochtendung (Rhineland-Palatinate) and Elterlein (Saxony). It employs 880 staff and in 2015 achieved annual sales of almost €200 million. For the Model Group, the acquisition of this company is an ideal geographic addition to its existing corrugated board plants in Poland, Czech Republic, Croatia and Switzerland. With its plants in Weinfelden (Switzerland), Nymburk (Czech Republic) and the recently announced new plant in Nowa Sól (Poland), Model already has three plants close to the German border. This takeover now makes it possible to comprehensively supply existing major customers throughout Germany and the Benelux countries. In addition, through its own in-house preprint method P-WELL gives Model access to new printing processes, including specialities such as heavy-duty and fanfold corrugated board, thus offering interesting additions to the product portfolio. A significant move has been the merging of the subsidiaries CE-PE-Wellkisten GmbH + Co. KG, CE-PE-Logistik GmbH + Co. KG and P-Print GmbH + Co. KG with Model GmbH as the holding company (the reformation was entered into the Commercial Register hold by the District Court of Steinfurt). According to Dr Daniel Model, the company’s CEO, “We are now able to increase the performance and quality of our service even further, on the basis of this leaner and optimised organisational structure.”

Effective and innovative Achieving a consolidated sales turnover of CHF 614 million in 2015, Model Group has invested nearly ten per cent of that figure – as it does every year – in ensuring it maintains its market leading position. Ms Brugger continued, “We believe there is no future without a past. Our firm’s history stretches back over 130 years, always with the Model family at the helm. But we also strongly believe that we must continue to prove ourselves with the most effective, innovative products on the market if we are to continue to see our successful path unrolling before us.” As a leading packaging partner, Model Group’s extensive portfolio is all centred on the creation of high quality cardboard and corrugated board packaging, which is available for the transport, display and container board sectors as well as special packaging. Ms Brugger added, “Our teams always work very closely with our customers to make sure the packaging we are creating perfectly matches with their needs and expectations. We work with a number of very recognised global brands, such as Jaguar and Clarins, and we are proud that our reputation is built on our many years of achievement as a packaging partner.” For Clarins, Model has created high quality packaging for its Double Serum antiageing product. Ms Brugger explained, “Like the Clarins product itself, our folding box derives its quality from a combination of exquisite components. The smooth, velvety-soft | 76 | Packaging Europe

varnished surface in pure white is reminiscent of flawless skin. The integrated insert offers optimum protection for the unique dispenser and its valuable contents. We have used two fine hot foil-stamped stripes in different tones of glossy gold and it also has a shimmery gold lid and brand name which has been accentuated by high-relief embossing and finally a glossy varnish. It’s a beautiful product and we’re very pleased with the high-end packaging we’ve created for Clarins.”

Reflecting brands For Jaguar, Model Group has been responsible for creating the packaging for the famous car brand’s men’s aftershave. As the product needs to reflect the brand’s quality standing in the automotive sector, Jaguar asked Model to develop and manufacture a packaging solution that befits its ‘vigour and unbridled power’. Ms Brugger continued, “We utilised our technical capabilities with this project as we used a combination of finishing techniques with different laminating films to make a design that fulfilled the Jaguar brief. We took perspective lines in metallic grey and silver tones to play cleverly with the associations of gleaming chrome and rapid accelerations, as well as a realistic soft-touch effect to depict the soft leather interior and an embossed solver brand name.” Also well known for its leading role in the digital printing sector, Model has recently been working alongside European cleaning equipment specialist Kärcher. Model has created packaging for Kärcher’s pressure washer and vacuum cleaner ranges, with the print quality taking centre stage. Ms Brugger noted, “Kärcher has been able to capitalise on the many advantages of digital printing on corrugated board, including considerable design flexibility, quick layout changes, outstanding print quality and short delivery times. We have also been able to implement contactless printing to allow the use of cheaper linerboard and corrugated cardboard while retaining the impressive Model quality we’re famous for. Kärcher described working with us as ‘constructive and goal-orientated right from the start’, which is exactly what we are always aiming for!” Visit: www.modelgroup.com


Famous worldwide for its industrial weighing, slicing and labelling technologies, Bizerba has made the strategic move to add filling systems to its portfolio thanks to the acquisition of Busch Filling Systems. Emma-Jane Batey spoke to Richard Schick, Industry Sales Director, Market Organization Germany, to learn more about how this development benefits the Bizerba family and its customers.

Complete solutions Packaging Europe | 77 |


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izerba SE & Co. KG was founded in Germany in 1866 by Andreas Bizer and continues to be the world’s leading name in weighing technologies. Well known for its weighing, slicing and labelling technologies, Bizerba has over 3700 employees worldwide and a global sales force that covers 120 countries. Its headquarters are still located in its founding city of Balingen, where it also operates one of its three German production facilities as well as 41 subsidiaries. With what Richard Schick calls ‘the Bizerba family’ clearly a long-established, successful operation, its almost-continual strategic development has seen a number of smart acquisitions to keep the family growing. Mr Schick said, “Bizerba has been characterised by a number of pioneering decisions over the century and a half that we have been in business! From patenting the world’s first pendulum scale in 1924 to developing the innovative KscalePad that is both a weighing surface and hygienic cutting surface in 2012, we have been driving forward.” Bizerba’s recent acquisition of the respected Busch Filling Systems means the Bizerba family now includes high quality filling systems for liquid goods, under the divisional

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name Bizerba Busch Filling Systems. Mr Schick continued, “While we have made many acquisitions over the years, this is one of the only times we have retained the acquired company’s name and integrated it with our own; Busch’s fantastic experience in filling systems fits perfectly with our own dedication to weighing solutions, so we’ve created a terrific opportunity. After all, at the heart of every filling system is a scale, so with Bizerba as the world’s leading scale manufacturer and Busch as the leading filling systems manufacturer, it’s truly a win-win situation!”

FachPack first To highlight this development, Bizerba will be presenting its latest weighing and filling solutions at the upcoming FachPack exhibition. Mr Schick added, “Exhibiting at FachPack is a great way for us to tell everyone that Bizerba now offers filling systems as part of our portfolio. And they’re among the best available filling systems in the world as Busch has excellent expertise which has now been integrated into our offer.”


Indeed, the Bizerba offer is second-to-none. Its unique portfolio means it is the only company that offers complete weighing, filling and slicing systems from one source. All of the components of the systems are developed and manufactured by Bizerba across its global network of experts and production facilities – from the software to the scale to the control – making it a very attractive prospect to customers and potential customers. Mr Schick continued, “All your weighing and filling needs from one source is unique in our industry. After all, many companies use Bizerba scales as a component in their systems, but we are Bizerba! We have the best components for our weighing, filling and slicing systems because we have developed them specifically for our solutions. It makes for a very reliable product.” The Bizerba portfolio includes industrial scales and systems for all industries, including even explosion-proof scales for the chemical industry. It also includes checkweighers for the food and non-food industries for both packaged and unpackaged goods, semiautomatic and fully-automatic filling systems for liquid products and various inspection systems. Conveyor systems, software solutions and a number of different labelling solutions are also on offer. Mr Schick added, “As a company operating worldwide, providing high quality devices and systems that integrate optimum solutions by marrying tradition, expertise and innovation, Bizerba is very much a solution provider and technology leader.”

portunity for us to present our current solutions for the logistics and packaging industry in particular. We believe that the market is ready to invest when there is a proven strong ROI advantage, which is exactly where Bizerba excels.” Bizerba’s growth strategy for the coming years will continue to see its upward trajectory over the last 150 years achieved through investment, innovation and continual development. Mr Schick concluded, “We will continue our steady growth with a special focus on solutions tailored to the requirements of Industry 4.0. This includes integration of new service models like predictive service and machine-to-machine communications in order to provide better response and restore times. This will result in increased overall equipment availability, quality and performance.” Visit: www..bizerba.com

All weighed up With FachPack offering Bizerba a great opportunity to present its new generation solutions and highlight its ‘all from one source’ capabilities, Mr Schick is very much looking forward to meeting existing and potential customers at the event. He said, “FachPack will attract visitors from all the industries that Bizerba is focusing on so it is a great opPackaging Europe | 79 |


One-Stop Shop

Treffpack is a leading independent supplier of primary packaging in Europe. As an expert in global sourcing the company provides local markets with tailor-made solutions. Libby White spoke with Peter Börner and Harold Lienau, managing partners and owners, and Dorothee Lienau, marketing and sales manager, about the company’s advantageous position in providing complete solutions across a variety of markets, and its plans to exhibit at the FachPack exhibition.

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he brand Treffpack is the grouping of two German companies (F. Dau & Sohn and C.E. Gätcke’s Glas Gesellschaft), both with a rich heritage dating back to the 1870s. Since World War Two, the two companies operated in parallel with a focus on primary packaging across the glass, aluminium and plastic sectors. It stands today as one of the major players in Germany on the primary packaging market. The headquarters remain in Hamburg, a logistically ideal and strategic location. In order to cover the entirety of Germany and other German speaking markets, Treffpack also has sales offices in the south and mid-west of Germany. It can provide the means for its clients to bridge the cultural gap in its national market for international manufacturers. However, aside from Germany the company has clients all over Europe, the US and the Middle East. It has a small production of specialty closures in the United States as well as well-established cooperations in China and South Korea for sourcing in Asia. It also has well-established cooperations in China and South Korea for sourcing in Asia. | 80 | Packaging Europe

Treffpack has its own warehouse with a large capacity, and use of additional warehouses all over Germany in order to provide a punctual and efficient service to its clients. Alongside its sourcing abilities and warehouse and logistics offerings, Treffpack provides services such as technical design consultancy, and project management related to complete packaging solutions, especially for new launches. This ability to offer complete packaging solutions is a result of the company’s ability to offer a comprehensive range of products, from dispensing solutions and caps to containers.

Across the board Treffpack is active in the food and beverage, cosmetics, pharmaceuticals, and the household and cleaning industries. Harold Lienau explains the depth and breadth of the company’s offerings: “These sectors all have different requirements but they all use glass,


metal and plastic packaging. We are a one-stop shop with a comprehensive knowledge across a wide range of packaging materials, industries and markets.” Dorothee Lienau adds, “We are not constricted to offering just the container or dispensing system. We can provide the complete packaging solution, even down to the carton wrapping or outer boxes. For example, if a client needs a packaging solution for perfume which usually has a unique design we can offer the glass container, the spray pump and closure, the outer box, together with the design process which is all monitored through the whole process until the packaging runs on the filling line.” Whilst being independent, the company prides itself on its strong links with a variety of manufacturers, meaning it can offer its clients a wide range without restrictions. Peter Börner explains, “If there really is nothing suitable for our client’s needs in the portfolio, then we will initiate a project where we can find packaging which suits their requirements. As we are independent and in the centre of discussions, we can build bridges – for example between buyers, marketing and designers – and hence manage the project to succeed, building long-term relationships along the way.” Furthermore Treffpack has a clear advantage in its expertise and knowledge across the industries. Harold Lienau says, “Working across the industries brings a competitive advantage as instead of having a specific focus, we can draw on knowledge across the board. For example, we are already aware that regulations and quality standards in the food industry are increasingly getting tighter. So we can use our knowledge from the pharmaceutical market and bring this to our clients in the food sector.”

Building relationships Harold Lienau explains that Treffpack builds new relationships through sourcing innovative solutions, alongside recommendations from existing clients: “We continue to maintain long term relationships through the services we offer and the success of our projects.”

A strong ethos is placed on building up a reliable and knowledgeable sourcing team who are active not only in Germany and Europe, but worldwide. Peter Börner explains, “We take every step possible to ensure we keep up to date with the latest innovations and best solutions from manufacturers around the world.” The company continuously invests in employees, and has at present expanded to a total of 32. Treffpack is anticipating the upcoming FachPack 2016 exhibition, which it has been attending for decades. This trade fair is well suited to the company as it is not limited and covers a wide cross-section of industries. It will be exhibiting its new portfolio of products and designs developed across the markets and industries it serves. Dorothee Lienau says, “We are expecting to connect with current clients and business partners, as well as of course build links with new potential clients and manufacturers. We will use the exhibition to discover what is new on the market and to exchange ideas.”

Future growth Peter Börner explains that Treffpack has always prided itself on its key strengths of offering variety and flexibility. Along these lines, it has been working with a reliable partner in China for many years to help meet these requirements whilst also maintaining its reputation for providing quality and reliability. This effectively means the company can serve both larger clients and smaller clients alike. Harold Lienau concludes, “We are on a good path for continuously developing our business and fortunately we have the next generation already on board so there is no question about the company’s successor. We have a strong advantage as an independent company with partners all over the world and our focus is to develop the business organically. We have all the abilities to grow further, and keep up with the growing market players.” Visit: www.treffpack.de

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Packed with Care Pilous Packaging is a major producer of one-way non-returnable wood and fibrewood packaging for the engineering industries, particularly for the automotive sector. In 2016, the company won the top prize in the Packaging of the Year Award for its special packaging designed for the transportation of partially dismantled vehicles. Romana Moares reports.

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riginally set up as a garden wood furniture manufacturer in the early 1990s, the company changed its focus shortly after its establishment as a result of a failure to capitalise the business idea and, also, emerging demand for wooden packaging from the German as well as Czech engineering sector. The milestone came around 2000 when, encouraged by rising sales, the company decided to target major players operating in the European automotive market. This has lifted Pilous Packaging to a global level. “One of our key strengths, which has significantly contributed to our success with international customers, is our excellent value:price ratio. This is, to a high degree, the result of our young and hard working product development team who are able to consider and combine materials in a innovative manner so that we remain in the lead,” says Mr Jiří Klimeš, the company owner. He adds that the company has also

capitalised on the trend of space saving, opening opportunities for integrating logistics into the product solutions, not only in terms of supplying packaging products but also outsourcing the whole area of packaging management.

Comprehensive range The company currently has over 300 active customers who can avail themselves of a wide range of products and services. Its current offering includes standardised, one-way, atypical pallets, transport crates and panelling made of wood, OSB boards and plywood. “The products may be divided by materials – wood, cardboard, various types of foams and foils and any combinations of these, or by sectors to which they are supplied, from automotive, engineering, electrical to food, representing an almost limitless combination od products and services that we can deliver,” claims Mr Klimeš.

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He explains that Pilous Packaging has developed into a supplier of a comprehensive range of packaging services, which includes the development of tailor-made packaging, storing, associated services, JIT and JIS deliveries.

New directions Pilous Packaging is now preparing for FachPack 2016. The objective will be, as Mr Klimeš explains, to present the company as a dynamic central European business (currently operating in Germany, Austria, Hungary and Slovakia) seeking to grow and expand its services to new markets, with an expanding portfolio reflecting the latest trends and technologies. “We will of course present new products which we have developed in-house or in partnership with customers. The focus will be naturally on the product that won the top prize in the Czech Packaging of the Year Award. I believe customers will be impressed,“ he says. Next year the company is planning to introduce several new projects and to focus efforts on penetrating new European markets. “We are aware that growth driven merely by our own efforts has its limits so we are considering potential acquisitions which would fit our line of business,” reveals Mr Klimeš. “To be completely honest, my personal objective has always been to achieve the full satisfaction not only of our customers but also of our employees and their families,” he concludes. Visit: www.pilous-packaging.com

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Serialisation One-Stop

Shop: Is It Possible?

Implementing serialisation to meet upcoming legislation deadlines can be daunting as the process can be quite complex. With different lines, different packaging, different departments and sometimes different countries involved, it is no wonder that simplification is a key factor in the supplier-selection decision.

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this article, our aim is to help you better orient your choice according to your needs by describing the most popular scenarios and their main pros and cons. We will also provide a brief comparative overview of the solutions currently available on the market and what they cover, as well as giving examples of potential impacts to consider, based on our experience.

The scenarios We all know that time is of the essence for serialisation, so the ability to integrate everything quickly becomes an additional factor. As for aggregation, since the legislation timeline is still uncertain, many pharmaceutical companies have, for the time being, chosen to focus on serialisation only. The first school of thought on implementing serialisation is to look for a module or supplier that does everything on the line – tamper evidence, vignettes, printing, and serialisation. For example, for boxed tamper-evident products, one-machine serialisation is certainly a possibility. The all-in-one option presents clear advantages in that it simplifies the overall procedure and communication because there is only one provider who will be aware of and address every line challenge. A second viewpoint is that serialisation should be about adding the best and most suited solutions to every single line. Those who hold this perspective feel they will get the best of both worlds if they entrust serialisation to a serialisation expert and leave all options open with machines so that everything is perfectly adapted to each line. Any way you look at it, the machines account for a large part of the cost, and because of this, a recent trend has been to turn to machine manufacturers for seri-

alisation. Other reasons behind this choice are that you can rely on key players that are already known, reliable, sustainable and so on. Regardless of the specific point of view, most would agree that finding a supplier or a machine that can handle all aspects of the serialisation project would be very practical: but is this feasible? In order to help determine this, we researched six of the main machine solutions and compared them in terms of key parameters.

Available solutions: How do they compare to each other? When looking at machines, there are several variables to consider to determine if they are appropriate for your line, namely: available space, speed, carton sizes, artwork, accessibility, print location and, of course, budget. According to our research, key parameters vary from one machine to the other, which results in some being more appropriate in certain contexts than others. The table below provides a quick comparative overview of the most prominent solutions.

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As you know, there is a high variability of products in every single pharma company, as well as high variability in terms of serialisation compliance requirements. For example, suppose you handle cartons that are more than 100mm in height – your choices would be machines B and E. However, if you also have cartons that are less than 25mm in width, then your choices would be either D or F for that product. And if physical space is a consideration, your choices may be even more restricted. Assuming that most lines run more than two products and carton sizes, the choices can be limited as, for some dimensions, there is only one possible machine. In addition, there is also a need for carton sizes outside the ranges shown in the table. Also, we must keep in mind that, based on the six variables mentioned above, designing a machine for tamper evidence and serial numbers could lead to up to 250 possible combinations! This usually results in having to purchase more than one type of – or even several different – machines, as it would be extremely difficult for a single machine manufacturer to possibly meet all line configurations and requirements. Although the idea of entrusting serialisation to machine manufacturers is good in theory and seems to make perfect sense, in practice it can be next to impossible for a single machine manufacturer to adapt its solution to all the design variables required by your lines. Even though the concept can work for a few lines, chances are that if you operate more than five lines (be it now or later), the one-stop machine solution will need considerable adjustments.

Potential impacts of high variability No matter how similar lines may seem at the beginning of the process, when you dig deeper, it is usually not the case. Most reputable suppliers will conduct site surveys on all lines prior to the first pilot to determine if it is a good fit. If this stage is passed, the next step is a pilot project. As these are usually carried out on simpler lines, the first trial runs and even early deployments can work well. So far so good. Now on to full-on deployment: This is where it gets tricky and where most people discover that their lines are not as similar as they first appeared. Even minor differences – such as print location – can cause major issues. As more and more lines are deployed, more and more complications arise, until eventually it no longer works and you find yourself either having to change your line design significantly or look at other machine manufacturers for specific lines. Once you decide on those additional machines, you will have competing machines running on your lines, which can affect overall productivity. But, more importantly, the bigger problem is that since you already started serialisation with your current machine manufacturer, you won’t be able to use it to serialise your other lines – at least not right away, or efficiently. Software compatibility and data exchange between systems could become a major obstacle at this point.

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This interoperability aspect is a key variable that is often neglected. As each system and/or machine communicates differently, the more machines or systems you have, the more connection types will be required. This not only results in additional initial expenses, but will also make your process longer and a lot more tedious, which means an increased workload for your staff and higher indirect costs in the long run. Since there are currently no set standards on Level 1, 2, 3, and 4 communications in our industry, integration requires significant modifications and debugging so that systems can work together, as machine serialisation solutions are usually only compatible with their own machines, and retrofitting is rarely an option. So the questions now, are: How do you avoid being stuck with a serialisation solution that works with only one vendor? And how do you integrate competing machines on your lines without having to start the whole serialisation process all over again with a generic solution?

The new way forward: Light at the end of the tunnel The all-too-common scenario described above can cause significant delays, additional costs and a lot of headaches, but it doesn’t have to be that way. What if you can take the one-stop shop idea and apply it to serialisation instead of machines? By applying the concept at the serialisation level, it is possible to get the best of both worlds and benefit from the simplicity of a one-stop supplier. That is exactly what Optel Vision aims to provide: expert serialisation solutions that are tailored to each of your lines and that can be integrated with any machine, covering your entire plant, under one serialisation umbrella. In fact, we regularly integrate serialisation systems in plants with various machines from different manufacturers. Our hardware is adaptable and our software architecture is specially designed with an open scripting component that can be personalised to accommodate differences. Therefore, you can choose whatever machine suits your needs best, and we make it fit. Our solutions can easily interface with different machines at Level 1 and enterprise systems at Level 4, such as ERP. What’s more, this feature makes our solutions so open you also get the source code to create any additional connections to communicate with any other system you may have or need in the future. Ultimately, this personalised approach to serialisation means faster integration, less training, more efficiency and lower costs. It also helps ensure that you meet your deadlines effectively and lets you go back to concentrating on production, so that you can tackle new business opportunities and recuperate your investment faster. So go ahead, choose any machine you feel is best to support each of your lines’ particular requirements, regardless of what they are – without worrying about serialisation integration. For more information on Optel Vision’s cutting-edge serialisation solutions and personalised process, visit www.optelvision.com.


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Thermoforming

the future The Alois Kober Thermoforming Division is a global market leader in the development and manufacture of complex thermoformed products for the automotive and ventilation industries. Philip Yorke talked to Lothar Grimm about the industry’s move into plastic resins and how AL-KO’s robotics are enhancing the quality of its products.

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L-KO was founded in 1931 by Alois Kober and began life as a small metalworking shop in the Bavarian-Swabian town of Grosskoetz, near Guenzburg. The company has seen consistent growth since then and today employs more than 4000 people at 45 locations across the globe. It is one of the world’s leading providers in the fields of thermoforming for the packaging industry, vehicle technology, lawn technology and air technology. Alois Kober Thermoforming Division is also leading the field in thermoforming technology for both thin and heavy gauge parts, and offers value-added services such as CNC trimming, assembling, gluing and welding. Over 90 per cent of the company’s products are tailor-made in order to meet its customer’s individual requirements. Main applications include the automotive industry, which includes supplying OEM’s, Tier 1 and Tier 3 contractors as well as a wide range of manufacturing industries. In addition the company offers automation and process optimisation where the focus is on packaging and trays for companies involved in the beverage, furniture, lighting and electronics industries.

Unique, innovative resins Currently the market is demanding more durable, cleaner and safer packaging, which includes electrical conductivity, anti-slip properties and anti-abrasion surfaces. According to Alois Kober Thermoforming Division there is a switch from wood, paper, cardboard and metal bin boxes to more sophisticated, technical packaging made from sustainable plastic resins, which also offer a weight advantage. Grimm said, “We are leading the field thanks to our unique blend of highly skilled technicians and overall flexibility, which means that we can bring products to market faster and with greater reliability and Guaranteed quality. We can create bespoke packaging in very short time-lines and complex components do not present a problem because we have our own extensive inhouse design and development division that makes it possible for us to offer a one-stopshop service. We also work with leading institutions such as the SKZ plastics centre and use VDZ in Dortmund for our transportation and logistics needs.” Grimm added, “At the FachPack fair this year we will be showcasing a number of new plastic resins with outstanding properties that we are bringing to market and you can find us in Hall 6 at booth number 6-333. These will open up a lot of new opportunities for us and for our customers and we will be driving the market forward with our innovative new materials. Our latest packaging materials are designed to protect sensitive electrical products in a safe and hygienic manner. “As a result of our growth forecasts we are looking to appoint a number of new sales reps in these markets, which will be based throughout Europe. Despite the company’s thermoforming division being relatively small we are now able to leverage the business opportunities provided by our close partnership with our group companies that we are involved with in the automotive and lawn business sectors. We are also looking to contract partners with local manufacturing facilities throughout the EU.”

Hi-tech production Alois Kober Thermoforming Division continues to invest in new technology and to upgrade its facilities at every opportunity and has a wide variety of machines that range from small and medium sized machines to very large format equipment. The maximum size at the present time is 3000mm X 1500mm and the company has installed the latest state-of-the-art twin-sheet machine with a form plate that measures 2600mm X 1400mm. In addition, AL-KO has the most modern CNC-routers as well as specially designed robotic trimming cells that enhance its ability to produce the highest quality products in a consistent and reliable way. “More recently we became the R&D partner for our customers thereby providing design, development, prototyping and serial production of the latest packaging techniques as a one-stop shop operation. In addition, our new 3D printer is enabling us to react faster than ever to increasing demands with high quality prototypes produced to meet our customer’s exacting specifications. Furthermore, in order to promote the benefits of thermoformed packaging we also contribute to the knowledge of certain leading councils like the VDA, GKV and SKZ who are also our network partners,” commented Grimm.

Expanding global reach AL-KO’s main market is Germany but the company is seeing growing demand in central Europe, the US and its Asian markets. AL-KO sees its future growth coming from continuing organic expansion, acquisitions and joint ventures as they present themselves. The company will continue to manufacture its products from its state-of-the-art, 7,500 square metre facility that is located between Munich and Stuttgart. Currently the Alois Kober Thermoforming Division employs over 80 people and last year recorded sales of more than €16 million. The company’s long-term experience and highly motivated team that work with state-of-the-art equipment and processes supported by SAP project management systems, is looking to achieve substantial growth in all its key markets. For further details of AL-KO’s innovative thermoformed products and services visit: www.al-ko.de

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Quality and

Cognex DataMan 260

traceability

with vision

based systems

At FachPack 2016, Cognex is presenting its latest vision solutions and ID systems for production, packaging and logistics – including the vision sensors In-Sight® 2000 vision sensors and the DataMan 150/260 vision based fixed mount barcode readers. Like all products from Cognex, they help to ensure high quality production and allow for efficient product tracking throughout the supply chain.

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ognex In-Sight vision systems combine a library of advanced vision tools with high-speed image acquisition and processing and are employed in all industries for inspecting, identifying and guiding parts. Available in a wide choice of models, In-Sight systems can be found, for example, in chocolate manufacturing facilities to inspect synthetic moulds which might be subject to wear and tear, or at packaging plants for ‘zero defects’ in product seals while using Cognex’s PatMax pattern recognition technology.

The In-Sight 2000 The new In-Sight 2000 series combines the power of its industry-leading In-Sight vision systems with the simplicity and affordability of a vision sensor. Ideal for solving simple error-proofing applications, these vision sensors set new standards for value, ease of use and flexibility thanks to the powerful combination of proven In-Sight vision tools, a simple setup, and a modular design with interchangeable lighting and optics. The In-Sight 2000 series includes an integrated, high-performance image formation system consisting of field interchangeable lenses and a patent-pending LED ring light that produces even, diffuse illumination across the entire image, eliminating the need for costly external lighting. Customers can easily swap out the lens and change the colour of the integrated ring light as needed for their application. Together with the In-Sight Explorer™ EasyBuilder® interface, which provides a fast, step-by-step application setup, the In-Sight 2000 series allows even novice users to achieve extremely reliable inspection performance in nearly any production environment.

traceability. As each product can be tracked until it reaches the end customers, food & beverage as well as pharmaceutical companies can not only ensure quality according to high industry standards and avoid mislabeled products with allergens, but also allow for efficient recalls. The flexible ID DataMan 150/260 systems deliver the highest reading rates, especially in harsh environments such as automotive, consumer products, document handling, food and beverage and logistics in general. These vision based fixedmount barcode readers achieve the highest possible read rates thanks to a highspeed, dual core processing engine that runs the latest Cognex algorithms. 1DMax™ with Hotbars II™ and 2DMax® with patent-pending PowerGrid™ technology decode damaged or poorly printed 1-D and 2-D codes, despite code quality, printing method or the surface the codes are marked on, and can even read sophisticated 2-D codes without visible perimeters or quiet zones. Visit Cognex at FachPack 2016, Hall 3 / Stand 3-408 www.cognex.com

Cognex In-Sight 2000

Showcasing DataMan DataMan is a series of high performance handheld and fix-mount readers from Cognex designed for 1-D barcode and 2-D code reading. Manufacturers are implementing DataMan readers to establish robust one up/one back databases for | 90 | Packaging Europe


Innovative solutions

for transport and storage

As a specialist and pioneer in plastic reusable transport packaging, KTP Kunststoff Palettentechnik GmbH has been a leading container manufacturer since 1988. Elisabeth Skoda spoke to Andreas Wintrich, the company’s managing director, to find out more about its role at the forefront of developing reusable transport packaging.

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TP develops, produces and markets foldable, reusable transport containers made of plastic for large-volume and sensitive goods as well as plastic pallets and containers in all common European, US and sea container dimensions for overseas shipping. Mr. Wintrich is proud of the fact that KTP with its 200 employees is still family run.“When KTP was founded by my father, the aim already was to manufacture reusable transport packaging out of secondary raw materials. At the time, this kind of packaging did not exist, so KTP was at the forefront of developments. An innovative press process with open moulds was used to develop a reusable carrier.” The company faced challenging times to convince companies that reusable carriers were the way forward, but with the advent of the new millennium, focus on the supply chain increased, with the automotive industry as a major driver. “In 2000, we gained the interest of Volkswagen. The company transported their goods on single use steel carriers, and their logistics manager was excited about our lower weight options. Previously, a packed item maybe weighed 50 kilograms, but the carrier weighed 250 kg. Our carriers offer a much better balance.” Together with VW, KTP went on to develop a wide product portfolio of containers in different sizes,catering for the trend of moving away from heavy steel containers to load carriers that make more ergonomical sense. Business has grown considerably over the years, as Mr Wintrich is happy to report. “At the beginning, we manufactured 3000 containers a month, today we manufacture almost 3000 containers a day.”

Business with Volkswagen still makes up around 15 per cent to 20 per cent of turnover, but KTP has been keen to spread its wings and widen its customer base. “Apart from other automotive companies, we also work with white good suppliers,” Mr Wintrich adds.

Solution provider KTP does not just manufacture plastic load carriers and pallets, but also offers consulting services. “We see ourselves as a solution provider - our aim is to offer the expertise to package parts and send them from A to B over long distances. We gathered valuable experience by working with the automotive industry, not just in the field of containers, but also of interior packaging. We advise our customers on when reusable containers make sense and calculate economic efficiency. KTP gives customers advice, develops solutions, optimises them and does so in a sustainable way,“ Mr Wintrich says.

Innovation KTP keeps developing and moving forward. “We have continuously been growing and developing new containers. We were hit quite hard by the financial crisis in 2008, but we made use of its challenges by increasing efficiency and expanding our portfolio. One of the resulting innovations is our SmartFix® container,” Mr Wintrich points out. The SmartFix® is a returnable plastic transport container with an innovative sandwich folding technology, with components that are tightly connected Packaging Europe | 91 |


with each other. Thanks to our special sandwich folding technology, a volume reduction by up to 80 per cent can be achieved when the containers are empty. The SmartFix® folding technology guarantees fast setting up and folding, as all components are linked up to each other. Following the financial crisis, KTP was able to increase capacity by 15 to 20 per cent every year, thanks to expanding production and flexibility in supplying the European market. KTP regularly exhibits at trade fairs, showcasing its latest solutions. Major trade fairs coming up include Fachpack in Nuremberg in Germany and All4Pack in Paris in France. “Customers include major OEMs such as BMW, Audi, Fiat, Ford, Peugeot, Porsche and VW as well as Miele and Bosch-Siemens domestic appliances,” Mr Wintrich says.

International reach In order to be closer to customers expanding in the Far East, in 2013 the decision was made to open a distribution and logistics site in China, in Taicang, which is situated around 50km east of Shanghai, in order to be closer to customers who are expanding in the Far East. Taicang already boasts 200 representations of German companies. Together with another German company, KTP rented a storage hall in order to make transport boxes made in Germany directly on site, which serves as a point of contact for Chinese customers. Other interesting markets for KTP include South America. “We deliver to Fiat in Italy, and this automatically leads us to South America, just as we arrived in China

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via Volkswagen. North and South America are definitely expandable markets, and depending on business volume and market sustainability we will decide whether to open a storage facility with a distribution office there, and whether to start production in a second step,” Mr Wintrich says. He sees great growth potential for KTP, especially in the automotive industry, because of the high volume of products being transported. “There are still many steel load carriers and single use carriers out there that can be replaced by our products. For example, KTP’s Super Quad Box, which is suitable for high-rack warehouses, is not only compatible with wire-mesh boxes, but is the perfect alternative to them. The Super Quad Box can be used in conjunction with already available inner packaging. According to estimates, there are 24 million wire-mesh boxes out in circulation in Europe, giving us ample potential for replacement.”

Room for growth Mr Wintrich sees growth potential in various regions in an increasingly globalised world. “As a medium sized company, we pick out the markets with the biggest promise of potential. We see great potential for volume in China, and North/ South America. We also believe in Europe as a market with potential in the substitution business.” He looks towards the future with confidence. “We have many exciting products in the pipeline and are always working on smaller innovations. We will keep working on expanding our product portfolio of solutions around logistics, and are confident that logistics solutions will continue to keep playing a big part in the future,” he concludes. Visit: www.ktp-online.de


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coolpack.ozerden.com coolpack@ozerden.com

Custome-made Thermal Insulation Solutions Irfan Esgun, Product Manager

Özerden has been manufacturing a wide range of packaging solutions in its facility in Turkey since 1958. Elisabeth Skoda spoke to CoolPACK Product Manager Irfan Esgun to find out more about the company’s customised thermal insulation packaging solutions, its CoolPACK range and its upcoming appearance at the FachPack trade fair in Nuremberg between 27th and 29th September.

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zerden is a producer of protective packaging and thermal insulation materials with a focus on custom-made packaging solutions. The company is best known in Turkey and beyond for the production of its bubble film products as it is the first manufacturer to introduce the product to the market. The company is known for other market-first innovations, such as Bizofol – bubble film lined reflective insulation materials, chocolate pads and inflatable protective bags. | 94 | Packaging Europe


Mr Esgun describes the key features of the CoolPACK line: “Our products in this range are manufactured for thermal insulation, offering cold and heat protection, and are designed to be thin and flexible, yet durable, offering puncture resistance and leakage prevention. They are foldable and nestable, which has the added benefit of low storage costs.”

Cold Chain Packaging Solutions of Özerden CoolMAILER

Integrated Production Facility Mr Esgun is proud to point out the company’s customer focus. “All our products are highly customisable,” he says. “We are able to offer our customers products which are tailor-made towards their unique needs, offering high quality at a competitive price. We produce our products in an integrated production facility and processing the raw material all the way towards the finished product. Besides, all of our thermal insulation materials produced by fully automated customised machines thus, products with special forms such as 3D bags and covers, are provided by the machines directly with minimised labour contribution. This makes our production time very short, offsetting longer transport times to other European countries.” A key technical feature of CoolPACK thermal insulation bags, liners and pallet covers is that they are all heat sealed by fully automated machines, which improves their insulation performance, in contrast to products formed by sewing. “We also get the end product directly from the machine on site and it makes us avoid having extra labour cost,” observes Mr Esgun. “This is something many European manufacturers cannot offer and therefore makes us competitive on the market.”

2 Dimensional Envelopes with adhesive flap and closure

CoolBAG

3 Dimensional bags gusseted bags with handle and zipper or adhesive closure

CoolLINER

FachPack Focus on CoolPACK At the FachPack trade show, the company will showcase its portfolio of CoolPACK thermal insulation packaging solutions and protective packaging materials including mini bubble film rolls, bubble envelopes, bubble pouches, courier bags and bubble lined courier bags. In the CoolPACK product group, Özerden offers thermal protection packagings in different forms and shapes, CoolCOVER includes pallet covers and blankets, CoolMAILER provides thermal envelopes and CoolBAG includes functional thermal bags and CoolBOX CoolTAINER provides thermal protection liners inside seaway containers and land transportation vehicles.

Box liner solutions

CoolCOVER

Thermal Insulation Performance Test Facilities “We are also performing thermal insulation test in our climatisation cabin in order to test the insulation performance of our products under the ambient conditions specified by our customers” Mr Esgun points out. “Customers showed great interest in the range at FachPack last year, and therefore we expanded on it further this year to cater for increased demand both for the Coolpack range and our standard product range,” he adds. “We are aiming to reach the pharmaceutical, logistics, food, and chemical companies and packaging wholesaler companies serves to these markets at FachPack 2016 (in Hall 4, Stand 213).”

European Expansion Özerden is well established in Turkey and has been doing business further afield for several years. Now the company is keen to further expand its reach in Europe. “We have been present in the German market for around seven years, working with wholesalers, and we are planning to open up a branch in Germany in the near future,” Mr Esgun concludes. “We are also planning on making distribution agreements with German packaging distributors. Furthermore, in the mid-term, we would also expand our branches to France, Belgium and the UK and increase the number of our distributors throughout Europe.”

CoolTAINER

Container liner applications

CoolPACK products are; • Water and Puncture Resistant • Flexible and light • Cost saving in terms of storage and transportation • Highly customisable • Suitable for printing

Visit: coolpack.ozerden.com Packaging Europe | 95 |


Competence in Shipping, Packaging and Logistics PackSynergy is Europe’s most successful association of entrepreneurial packaging wholesalers and logistics experts. Our writer Marco Siebel spoke with its CEO Thomas A. Baur who has been at the helm of the packaging network organisation since early 2014.

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stablished in 1998, PackSynergy is a network of European medium sized family run companies working in the packaging, shipping and logistics industries. Its 12 partner companies provide customers with packaging materials, supplies, equipment and machinery. The portfolio also includes bespoke services which help reduce costs, increase efficiency and optimise processes in all areas of shipping, logistics and transport. This way customers can reduce costs, increase efficiency and optimise processes in all areas of shipping, logistics and transport. PackSynergy’s comprehensive range of packaging materials and technology is distinguished by consistently high quality. In addition to proven standard solutions from leading manufacturers, PackSynergy clients also profit from the latest product innovations and a premium own brand (TigerProducts).

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The association’s strong position when it comes to buying and research & development means PackSynergy can offer its customers extremely attractive conditions. With its unique, pan-European reach, the network simultaneously guarantees 100 per cent reliable delivery to clients operating at multiple locations, often just-in-time.

Saving warehouse space, saving money PackSynergy customers optimise and decrease their material inventories, save time and money, reduce their warehouse space, improve their flows of goods and information, offload some of the burden of their daily business and navigate successfully through the myriad of suppliers.


Thomas A. Baur, CEO

Thomas A. Baur: “We offer solutions that cash in for our customers. Just recently a leading supplier for the automotive industry who had been struggling with the corrosion of its metal sleeve during transport switched to our network partner Horna. Horna introduced a simple but clever packaging solution that is saving €1 million for our customer by eliminating the risk of corrosion.” In another recent business case, PackSynergy’s Czech network partner Servisbal developed a tailored PackStation for an international producer of steering systems. As a result the customer now saves up to 90 per cent of the space originally dedicated to the packaging process, and up to four full-time employees. Both space and employees can now be used for other production tasks.

Communicate in your own language When customers work with one of the PackSynergy partners, they get local expertise, short communication lines and optimal supply chains. Partner companies rely on each other’s competency, local contacts, and product and service offerings.

Thomas A. Baur: “Customers that operate in different European countries love it when they can handle all their deliveries through one single business contact, with whom they can communicate in their own language. As an example: Wepa, one of our German partner companies, had to face the switch of a production site by one of its customers from Germany to the Czech Republic. With the assistance of our Czech partner Servisbal, Wepa was able to guarantee a smooth and effective continuation of its services to the new construction site.”

How partners cash in Thomas A. Baur: “Companies that are part of the network create huge synergies by buying collectively, sharing information on best practices, benefiting from regular bonus and shared marketing, for example on fairs. A further advantage comes from our central store and our so called ‘virtual store’, which allows all partners to look into and work with the stock of the combined network.” The group’s business culture, which is transparent and open minded, stimulates intelligent ways of exchanging knowledge. “We put a lot of emphasis on this non-hardware

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aspect of our network: if you want to be able to compete with the bigger players in the field, you have play the game cleverly. All these factors mean that companies want to join our network. All of our partner companies are family run businesses. To some this may be just a detail, to others this matters.” PackSynergy AG is headquartered in Ravensburg, near the beautiful Bodensee that borders Germany, Switzerland and Austria. The companies that are member of the PackSynergy network organisation are all market leaders in the regions from which they operate. PackSynergy’s 25 sites are operated by 12 partner companies, spread out over seven countries: Austria, the Czech Republic, Finland, Germany, the Netherlands, Slovenia and Sweden. The companies that have joined the PackSynergy network have their own say when it comes down to strategy, products, invoicing, sales and after-sales. Thomas A. Baur: “Turnover varies according to the size of each partner company. The network’s total turnover in 2015 was around €150 million. We expect a 5–10 per cent annual growth every year during the next 3–5 years. We expanded our network in 2016 with new partners in Finland and Austria and we aim to continue enlarging the network. As you can see on our map we are currently looking at companies in the Baltic States, Denmark, Germany, Hungary, Norway, Poland, Switzerland and the UK.”

FachPack 2016 FachPack is the European trade fair for packaging, technology, processing and logistics. The packaging industry meets from 27–29 September 2016 in the Exhibition Centre Nuremberg, Germany. Secure load and save costs: As a complimentary service to its customers that use stretch wrap, PackSynergy uses a measuring system to determine the exact amount of stretch wrap needed to secure loads. Thomas A. Baur: “With our measuring system we are able to get an objective review of the stretch process. Very often customers add too many layers to secure load. This is not sustainable and it burns money. With the help of our measuring system many customers are being able to save up to 50 per cent stretch wrap. In combination with using stretch wrap from our own line of Tiger products, customers can save up to 10–30 per cent on their wrapping costs.” Another focus at the PackSynergy stand at FachPack will be solutions for e-commerce. This includes not only different types of packaging for a great variety of senders and purposes, delivering great consumer experience, but also space saving pack stations that

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can be set up in just 30 minutes. Taking advantage of its excellent range of suppliers, PackSynergy is able to offer first class solutions as the protective cushion wrap pack stations from Sealed Air. Furthermore, PackSynergy partners can offer their customers a money-saving way of shipping by taking advantage of PackSynergy’s ParcelPool. “ParcelPool bundles large volumes, saving hard cash to our customers with no additional effort while retaining full control over their shipping process,” states Thomas A. Baur. Aside from e-commerce, PackSynergy will show a wide range of pallets and solutions for transport and logistics such as the MoistGuard pouches for moisture control in container shipping. Last but not least, PackSynergy will renew its SkillsDesk at FachPack 2016. Thomas A. Baur and the managing directors of the various member companies will be at hand to provide information on career opportunities and prospects in the wholesale packaging industry.

FachPack’s best coffee One rather unusual aim – to offer ‘FachPack’s best coffee’ – will be realised with the help of external expertise. Viva Barista’s coffee artists will welcome visitors to the PackSynergy booth with espresso, cappuccino, latte macchiato and other delicious beverages made to their own recipes. Thomas A. Baur: “Our quality pledge and our just-in-time policy apply in everything n we do – even making coffee.” Contact: info@packsynergy.com or visit: www.packsynergy.com

Visit PackSynergy at FachPack: Hall 6, Stand 209-211


Cracking the code Innovative printing technology company Domino has been leading the way in the coding, marking and printing technology industry for nearly 40 years. With a passion for fresh thinking and a team of experts that love the challenge of developing new solutions, Domino is looking forward to presenting its latest offers at this year’s FachPack, in Hall 3A, Stand 3A-216. Emma-Jane Batey reports.

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ounded by Graeme Minto nearly 40 years ago, Cambridge-based Domino Printing Services has always been focused on harnessing the commercial potential of printing technology. Domino has established a successful global reputation for the development and manufacture of coding, marking and printing technologies, as well as the complementary aftermarket products and customer services. Domino’s Marketing Manager for Germany Jürgen Pflieger spoke to Packaging Europe in advance of the 2016 FachPack show to explain how the company’s latest products and solutions continue with its four-decade-long

dedication to printing progress. Mr Pflieger said, “Today, Domino offers one of the most comprehensive portfolios of complete end-to-end coding solutions spanning primary, secondary and tertiary applications designed to satisfy the compliance and productivity requirements of manufacturers. These include innovative ink jet, laser, print and the application of labelling and thermal transfer over printing technologies.” The overprinting technologies from Domino are generally used for the application of variable and authentication data, bar codes and unique traceability codes

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onto product and packaging across many industrial sectors including food, beverage and pharmaceuticals. Mr Pflieger continued, “Our digital printing technology ranges are designed to print across a number of sectors including packaging converting, plastic cards, labelling and direct mail.”

Impressive TCO Mr Pflieger explained how Domino’s USP is the impressive Total Cost of Ownership (TCO) across its range. Furthermore, thanks to the ease of use and total integration of Domino’s products, customers regularly comment that working with the company and its products is commercially rewarding. Mr Pflieger added, “The true difference is in our people and our overall service offering: Together, it’s a winning combination! Domino is committed to providing excellent sales and aftercare to our customers, and our sales and service teams are dedicated to creating long term solutions to our customers’ packaging needs. Domino is very much a total solutions provider for diverse labelling requirements.”

“The true difference is in our people and our overall service offering: Together, it’s a winning combination! Domino is committed to providing excellent sales and aftercare to our customers, and our sales and service teams are dedicated to creating long term solutions to our customers’ packaging needs. Domino is very much a total solutions provider for diverse labelling requirements.”

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Domino’s product portfolio is continually being developed and enhanced thanks to its ongoing focus on innovation. In addition to its well-known coding and marking portfolio, the company’s new range of textured labels will be presented at FachPack. These textured labels have been produced with the N610i digital label press and will feature in the FachPack Pavilion (Hall 9, Stand 9-328), alongside further information related to digital foiling technologies. Mr Pflieger explained, “This is our rather exciting ‘Textures by Domino’. This new ink jet capability allows label printers to print an endless scope of digitally textured labels just by using the high opacity white ink on the N610i digital colour label press, without the need to invest in expensive textured substrates. This technique enables printers to create visually striking, tactile labels that not only give products strong shelf presence but also help to increase customer engagement across a wide variety of sectors, particularly luxury sectors such as wine, cosmetics and beauty products.”

ethylene and polypropylene, normally without the need to prime. Key applications include industrial, security, health and safety, automotive, chemical, personal care and pharmaceutical labels.” Domino coding and marking solutions will also be presented at FachPack, with the dedicated coding and marking team at Hall 3A, Stand 3A-216. The Domino team will also be more than prepared to discuss the whole of the product range. The i-Tech Module prides itself as being ‘reliability made simple’ with its impressive TCO as a CIJ printer for all types of applications and industries. The i-Tech Module ink system removes the need for conventional servicing and reduces makeup usage. The F220i fibre laser system will also be presented; its ability to produce unlimited lines of texts and graphics making it ideal for 2D matrix codes. This machine is able to permanently mark a wide range of materials including metal, plastics and flexible n packaging with the utmost precision.

Ready for FachPack The N610i offers an industry standard 333mm (13”) print width, up to seven colours including opaque white, 600dpi ‘native’ print resolution and operating speeds of up to 75m/min (246ft/min). Mr Pflieger added, “The Domino N610i is the only press that combines the productivity of flexo printing with the flexibility offered by rapid job change digital technology. It utilises vibrant UV curable inks designed for a range of industry standard self-adhesive label stocks including coated paper, poly-

“The Domino N610i is the only press that combines the productivity of flexo printing with the flexibility offered by rapid job change digital technology.”

Jürgen Pflieger, Head of Marketing, Domino Germany

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Innovation at its core Dedicated to developing and manufacturing innovative paper cores for the packaging film industry, Sonoco Alcore is proudly leading the way with its latest offer. Emma-Jane Batey spoke to the commercial and technical segment managers, Gary Morgan and David Van Hove, to learn more.

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onoco Alcore creates a broad range of tube and core solutions for its customers across the paper, film, man-made fibre yarn, metal and construction industries. It is part of the global Sonoco family, one of the world’s leading providers of consumer packaging, industrial products, protective packaging and supply chain services. Acknowledged as the leader in ‘high-quality, innovative, value-creating tubes and core solutions’, Sonoco Alcore’s production of tube and core solutions for such a wide variety of markets means it is divided into different product-focused segments. Packaging Europe spoke to commercial segment manager Gary Morgan and technical segment manager David Van Hove, the two driving forces behind the dedicated film segment of Sonoco Alcore, who have been integral in the division’s impressive growth in recent years. Gary Morgan began: “We are very excited about the continued potential of the film industry in terms of our expertise in paper core solutions, which is why David and I have | 102 | Packaging Europe

been highly active in establishing ourselves as a dedicated division for Sonoco Alcore. Back in 2012, David and I realised that Sonoco Alcore did not have a team specifically focused on the plastic film sector and we saw great potential in the market. We therefore created a solid strategy to maximise the opportunities we identified across Europe and, by marrying Sonoco Alcore’s traditional strengths and expertise along with our innovative product development capabilities, we have successfully captured much of Europe’s growing film market.”

Positive strategy This positive strategy has proved successful for Sonoco Alcore’s film division in the four years it has been active. Mr Morgan also attributes this partly to the strong foundations he and Mr Van Hove had to build on. He continued, “Sonoco Alcore is very much the


market’s technical leader in the production of tubes and cores for the various different segments we serve. We have a unique approach: our technical team works with our engineering, production, quality and sales teams. Working together like this ensures we create the best solution for our customers. Our position as the technical leader in our field is certainly what drives our constant innovation.” This constant innovation is what has led to the development of Sonoco Alcore’s film division’s unique Radial Crush testing technology – one of the most essential tools to fully optimise many of the paper cores used in the film industry. David Van Hove explained, “Radial Crush Technology allows us to predict and measure the relevant strength properties of paper cores for applications where elastic materials are being wound on them (which is the case for many products from both the film and textile segments). This method, contrary to the historic flat crush measurement, is often much more important and allows us to optimise cores for cost/performance.” He went on: “It has far more relevant measurement parameters and it’s patented too, as it specifically replicates the kinds of forces and deformations a paper core is undergoing when the film is being wound onto the core. Sonoco in the US manufactures the testing equipment and sells it both internally and externally (worldwide).” With the patent of this particular core technology expiring a couple of years ago, Mr Van Hove noted that Sonoco now also supplies the measuring equipment to the market. He continued: “We don’t really want to share our design expertise; in fact this is something we maintain internally; however, we want to share this testing method, as it will benefit the industry by providing a much more relevant state-of-the-art technology, which we hope will become the industry standard. “Testing is so integral to what we do. We regularly visit our customers so we know how they’re using our products and we conduct many tests on the strength properties of the core, both in the lab and in real life conditions. Historically, our industry used flat crush testing but the issue with that is it measures different kinds of deformations to those generally occurring in these applications (winding of elastic materials on paper cores). Our innovative Radial Crush technology helps us to further optimise our cores for our customers. “One of the biggest issues for the film industry is core crushing, which can cause machine downtime and add waste and cost for customers. Our dedicated film division provides innovative cores that use the latest testing technologies to deliver excellent core crushing resistance to meet the challenges of this issue.”

Impressive portfolio Radial Crush testing is part of Sonoco Alcore’s film division portfolio, alongside a number of film cores that have been specifically designed to manage the stresses and pressures experienced during winding, handling, storage and unwinding of various film types. The film varieties addressed include polyethylene, polypropylene, bi-oriented polypropylene, polyester and polyvinyl chloride, giving the company a broad yet focused portfolio. Alongside the Radial Crush approach, Sonoco Alcore also offers the Dricore NG, a rain resistant paper core which has been extremely successful in the agricultural/silage film market where all of the main producers of these films have converted from plastic cores to the Dricore NG bringing them significant savings as a result; and the Intellicore RFID, which helps companies to optimise inventories thanks to its imbedded RFID technology. High performance cores are also offered for expensive and/or sensitive films as they demand very smooth surface, excellent straightness and superior dimensional stability; even though these cores are still paper, they are so completely smooth they look almost like plastic. Mr Morgan and Mr Van Hove’s clear dedication to providing a market-leading solution for core technology across the global film industry mean the outlook for the next few years looks just as positive for the film division. Mr Morgan concluded, “Our ongoing commitment to the plastic film industry is just as strong as when we were establishing our special division in 2012. We have a clear understanding of the needs of the market and are continually talking honestly to our customers to make sure we know exactly what they need and how we can utilise our experience and capabilities to address their needs.” Should you wish to contact Mr Morgan directly to find out how Sonoco Alcore can help your film business to optimise its paper core needs please contact gary.morgan@sonoco.com Visit: www.sonocoalcore.com

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Creating modular masterpieces Delta ModTech is a global market leader in the development and manufacture of web converting machinery and packaging lines. Philip Yorke talked to Dave Grenwis, the company’s marketing manager, about its latest turn-key systems and a strategic acquisition.

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converter. Through software development and digital control systems, these innovations set a new bar where digital control is the future. Delta has been building upon this platform ever since.

Inspiration driving innovation Delta ModTech delivers web converting and packaging systems for the most complex and demanding jobs in the medical, pharmaceutical, label, RFID and cosmetic industries. The company’s systems are designed to meet diverse applications and to improve its clients’ profitability and reduce risk. Delta systems feature a variety of processes including rotary and semi-rotary die cuts, tight tolerance registration, printing, laminating, heatseal packaging, precise placement and laser technology. Based on its unique technology and extensive process knowledge, Delta’s systems provide an adaptable platform for web converting, packaging and finishing. The company’s machines offer the tightest tolerances in the industry and its systems help customers to minimise material waste and improve their OEE ratings. Delta’s culture of creative innovation and inspirational problem solving is underscored by a strong ‘can-do’ spirit that can be witnessed in every challenge that is presented. At Delta ModTech customisation is business as usual where high performance is expected and innovation comes as standard.

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elta ModTech was founded in Minneapolis Minnesota, USA, in 1978 by Dave Schiebout as a service provider for servo systems and motion controls in the machine tool industry. Today the company is a global technology leader in specialised web converting and packaging systems. Schiebout knew that computer controls and servo drives would provide more flexibility, speed and tighter tolerances than any comparable line shafted machine. Despite the critics that said it could never be done, the company prevailed with its first Delta

New laser technology Delta’s latest Flex Edge® laser technology with its new on-the-fly changeover offers a flexible platform that can be used online or offline with various configurations to allow production and R&D use in both roll-to-roll and sheet fed systems. The equipment is completely portable and can use its telescopic arm to connect to an open station on an existing converting line or as a standalone unit. The Flex Edge® is the perfect solution for markets that demand flexibility as new job set-up is quick and the ability to recall saved products speeds up changeovers. In addition to installation, the company will train customers’ operators to ensure they get the most out of their investment. Packaging Europe | 105 |


Grenwis said, “All our machines are built to the highest specifications and offer the latest innovative technology. Customer service is another thing that we are well known for and this has been supporting our privately owned brand in Europe for over 25 years. Our modular system is unique – we can add modules to any of our ModTech lines and our laser cutting systems and Edge® Laser technology lead the field. Grenwis added, “The medical area is a big growth sector for us and is also a flagship industry where we have a lot of experience. We help our clients with product development and we also help them to achieve manufacturing solutions by developing specific equipment in close cooperation with them. Furthermore, we are able to perform software upgrades online and provide troubleshooting without the outlay associated with expensive service costs.”

Combined strengths On January 2016 Delta ModTech acquired Frontier Industrial Technology, a manufacturer of custom configured coating and drying machinery that is headquartered in Towanda, Pennsylvania. This unique combination of Delta ModTech and Frontier provides complete turnkey solutions for existing and future customers. This partnership offers more process solutions for customers across the diagnostics, transdermal and electrode, wound care security, label and consumer industries. “We take a threefold approach to machine design and engineering that eliminates risk on behalf of the customer,” says President Dave Schiebout. Furthermore, Frontier’s world class Coating Technology Lab paves the way for production equipment by researching, developing and troubleshooting methods for coating and drying new or existing products.

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FachPack firsts Delta ModTech in Europe will be showcasing a variety of state-of-the-art modules developed in-house at FachPack this year. Their demo system will feature tight tolerance cutting, multi-layer lamination, precise part placement and inline pouching. Advanced heat-seal packaging, cold seal packaging, reciprocating sealing, RF sealing and ultrasonic options are also showcased as both standalone machines and quick-change modules. When it comes to web converting, the company’s machines meet the tightest tolerances in the medical and pharmaceutical industries, as well as meeting the on-going challenges from other vertical industries. Delta will have on display its 13” wide Crusader® converter, which is a modular web converting and packaging machine, as well as its patented Island Placement module, a shingling conveyer and an Intelli-Mod® control system. This system will convert and package a wound care dressing example product. Demonstrations of this machine will run throughout the exposition in booth 3-405. The company will be attending other international trade shows this year, including includes CPhI Worldwide in Barcelona, Spain on 4–6 October (Booth 2B78) and PackExpo International to be held in Chicago IL USA on 6–9 November (Booth S-3971) and in addition at Compamed to be staged in Dusseldorf, Germany on 14–17th November 2016 (Booth 8aM34). For further details of Delta ModTech’s innovative products and services visit: www.deltamodtech.com


Manager IQ Easy

Moving static control forward Simco-Ion is a global market leader in the development and manufacture of products for the control of static electricity. Philip Yorke talked to Erwin van ’t Hul, the company’s marketing director, about its latest innovative products, its unique IQ Easy platform and what it plans to showcase at FachPack this year.

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IQ Easy platform

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imco-Ion Netherlands is a member of the worldwide ITW Group and it has been operational in Europe since 1966. Initially the company focused on products designed for plastics in the textile industry. Today it offers a comprehensive range of products to control electricity in packaging, converting and the printing industries. Simco-Ion’s products are sold through an extensive network of highly trained agents worldwide. The company has a broad portfolio of products that vary from those neutralising static electricity to those using static electricity for electrostatic charging, and for bonding two materials together in order to assist in a production process. Simco-Ion provides a broad range of industrial products, such as static neutralisation products that include neutralising systems and bars, communication components, ionising blowers as well as vacuum cleaning systems for narrow web machines. In addition, the company portfolio includes specialised instrumentation and metering products. Simco-Ion offers solutions for plastics packaging, converting, printing, and the medical industry sectors, as well as for electronic assembly, material processing and other related industries and applications. The company was founded in 1936 and its global headquarters are located in Hatfield Pennsylvania with its key offices based in the Netherlands, Japan and China.

range covers the full spectrum of anti-static bars and static charging equipment, including special products for IML (In Mould Labelling). By combining all products into a system that can be controlled by the Manager IQ Easy from one central location, static control is a valuable tool for process optimisation and quality control. More importantly, it ensures that no material leaves the factory with a static charge that can cause problems in further process steps and prevents costly customer complaints and rejects. Furthermore, built-in warning and alarm systems give the operator an instant insight into the status of all devices. The equipment can also be connected to a fieldbus interface for integration into the machine process control system. Van ’t Hul said, “As the European headquarters of Simco-Ion we are responsible for covering the entire EMEA region. Our IQ Easy platform is changing our business sector at a rapid pace with all functions connected and data-locked as

Unique concept

The IQ Easy platform from Simco-Ion is capable of connecting up to 32 static devices into a network via the Manager IQ Easy at any one time. This is a unique concept that makes it possible to fully control all machinery parameters and let devices interact with each other to optimise efficiency. The new products that belong to this series all share the unique feature of a 24V DC supply voltage. The latest product

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CM Tiny charging generator


A) Charging electrode B) Charging generator CMME

one. As the clear global leader, we are committed to maintaining our considerable technological lead and our unrivalled after sales service. In addition, we offer by far the biggest global coverage with highly qualified representatives and agents located strategically throughout the world. “This year at the Fachpack trade show we will be showcasing our complete product range and we will place special emphasis on our latest IQ Easy platform which can connect complex devices for static control, such as small footprint charging generators, and we can perform tasks that would have been impossible just a few years ago. We also have a unique measuring device, which is designed to control the static discharge bar.” Van ’t Hul added, “We serve a broad range of markets – in fact our products are at work wherever static electricity is involved. In packaging it starts with the extrusion of film all the way to using film to produce packaged items. The same applies to all other packaging materials, like those produced by blow-moulding, injection moulding and vacuum forming. Today packaging markets are still growing owing to expanding world economies and a growing population.”

systems. Furthermore it can easily withstand the high G-forces that occur during the IML process. In another first, Simco-Ion’s vertical form, fill and seal machine is seeing strong growth thanks to its easy installation and optimal operating efficiency. For further details of Simco-Ion’s innovative products and services visit: www.simco-ion.nl

Adding value Simco-Ion customers are continuing to save money by utilising the company’s CMME charging generator that has been specially designed for IML applications. The CMME adds value by offering a small profile footprint charging generator which has fully integrated high-voltage parts and only requires a 24V DC supply. In addition, the housing is compact and only weighs 340 grams, which in turn makes it perfect for end-of-arm mounting in IML pick-and-place handling

CMME charging generator

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JOMA presents compelling innovations at Fachpack in NĂźrnberg

Headquartered in Brunn am Gebirge just outside Vienna in Austria, JOMA has been providing high quality plastic packaging products since 1947. Elisabeth Skoda spoke to marketing and sales director Martin Riegler to find out more about the company’s innovative plastics packaging solutions which will be showcased at the upcoming Fachpack trade fair in Nuremberg, Hall 5, booth 5-235.

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oma was founded in 1947. The company started out with one injection moulding machine, producing closures for beverage bottles. The company grew and developed over the years, and today runs 35 injection moulding machines.

JOMA Solutions that offer more The company exclusively uses injection moulding to manufacture its products, and over the years moved its focus to specialised closures with added value. “This is our key USP – our products always offer added value to processors, fillers and of course to consumers. We closely observe the market and check what products are on the market and how they could be adopted to today’s and future requirements,” Mr Riegler says. One example for this is JOMA’s spice mill portfolio. “We started with the manufacture of our single use spice mills in 1993, and were amongst the first to manufacture these mills. At the moment we have around eight different mill variations as well as customer specific, exclusive solutions that are created in close cooperation with our customers. We put a lot of work into the grinding geometry, with is key for quality, offering different solutions for soft or hard spices,” Mr Riegler explains.

JOMA is proud to use only the highest quality raw materials. “Compared to products from Asia, we have much stricter controls and guidelines to follow with regards to food contact. We take the responsibility towards our customers very seriously,” Mr Riegler says. Another key product he is keen to point out is the company’s Securibox, an innovative and tight plastic container system suited for a wide variety of applications in the pharmaceutical, chemical and food industries. “It is a trademarked brand, and the name is descriptive – it is an absolutely secure pack, originally designed for the pharmaceutical industry, where rigorous demands are made in hygiene. Therefore, it has been easy for us to adapt the Securibox for the food market, and customers appreciate the quality of our products. Of course Joma has all the relevant certifications, including GMP, ISO 15378:2006, ISO 9001:2008 and HACCP. JOMA’s Securibox is available in 21 different sizes from 17ml to 1.8l and offers a unified look. It can be expanded with different JOMA accessories and is totally leak proof. Desiccants can be incorporated into the lid, as well as space fillers for tablets or capsules. Another product that caters for the food industry is the JOMA DuoFlapperCap, expanding the company’s range of spice shakers. It combines ease of use with high aroma

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and flavour protection. The ingenious arrangement of seals in the lid ensures longlasting aroma protection even after the first opening. It is manufactured in one piece, with integrated tamper protection and no need for any other sleeves or films. This saves material and eliminates extra work steps and costs.

Fachpack highlights At the upcoming Fachpack trade fair in Nuremberg in Hall 5, at stand 5/236, Joma will present its new JOMA Creme Dispenser, which is available for three different dosing volumes 3, 5 and 7.5 ml which is a novelty and unique on the dispenser market. It benefits from Joma’s vacuum pump system, which is placed directly on top of the content. A follower plate prevents unwanted air intake and transports fluids and highly viscous substances. It fits against the container walls and prevents the content from drying out in a hygienic way “Customers can be sure that all the content can be emptied out of the pack, something which is very important to consumers, as it can be frustrating if contents are stuck within the packaging,” Mr Riegler is keen to point out. Apart from the JOMA Creme Dispenser, the company will also present its JOMA DuoFlapper Cap, and a new JOMA Ceramics Spice Mill. The company will also showcase its sustainable product offerings: “Another big topic we will focus on at Fachpack is that a large portion of our products are available from renewable biopolymer from renewable sources, and partly also from biodegradable plastics. For example, our Securibox will be available in materials from renewable resources. For this product, biodegradability is not an option, as products in the Securibox will be stored for a longer time period. But it is fully recyclable and CO2- neutral. The same holds for our spice mills which are additionally degradable. We have a nice big stand at Fachpack and will present ourselves in the best light,” Mr Riegler is proud to point out. He has high hopes for the show: “Of course we hope to meet many new potential customers. Our aim is to show a broad specialised range of visitors our new products and to give them an overview of what JOMA is capable of, so it will be a presentation of our strengths. Fachpack has also grown from a regional to an international trade fair, so we are showcasing a wide programme there.” The company will also exhibit at CPhI in Barcelona in hall 2 at stand 2M10, and at Interpack 2017.

International presence Joma’s products come in direct contact with products people consume, so products have to be of a particularly high quality. Functionality and differentiation are also important, and therefore the company has had positive receptions in markets in over 40 countries. | 112 | Packaging Europe

“We are active in from East to West from Russia to Europe and the US,” Mr Riegler adds. He sees the company’s future very positively. “We had our best year in company history last year with substantial increases in turnover, and this year is also shaping up very well. We want to consolidate this year, and make another big leap forward next year, and we are well on our way to achieving that.” Visit: www.webpackaging.com


German quality

labels

Germany based family-owned label solutions provider Faubel is a company with a history dating back to 1855, which over the years has grown into an internationally operating player in the print, paper and foil-processing industries. With a total of 190 employees, the company, with its headquarters in Melsungen, achieved sales of ₏24 million in 2015. Elisabeth Skoda spoke with Frank Jäger, Faubel’s managing director, to find out about its expertise in the pharmaceutical labelling industry and beyond. Packaging Europe | 113 |


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oday Faubel specialises in providing booklet labels, multi-layer labels, singlelayer labels, mini-brochures and packaging inserts. The company has a main focus area on the pharmaceutical industry making up 94% per cent of sales, 60 per cent of sales are to the clinical trial labelling industry and the remaining 6 per cent to the chemicals industry and other sectors. Mr Jäger comments: “For CTL, we provide our services to major pharmaceutical companies who invent new drugs, which typically undergo different phases of development and regulatory requirements. One of these requirements is that the product needs to be labelled correctly with instructions and information in local languages. Instead of having one label for each language, Faubel offers the booklet label concept which provides logistical and cost saving advantages. The booklet labels we offer can go up to 113 pages and we also produce multi-layer labels.” Faubel is also able to offer its customers new custom-made solutions such as a multipage compact label with coloured index and a thumb index making it easier for users to instantly access important information inside the booklet. Also of note is the CRSF Label from Faubel which offers an effective way of making standard blister packs childproof during downstream processing, yet still guarantees packaging that is senior-friendly. The safety element is suitable for machine processing, and is certified to DIN EN 134375 and US 16 CFR § 1700.20 (F1) standards. Mr Jäger points out key points in the company’s development: “In 1994 we achieved the DIN EN ISO certification 90001, DQS. In addition to our headquarters in Germany, we also have a sales office in North America which opened in 2009, and another sales office in Shanghai, China, to cater for the Asian market. We have a strong team of business development managers throughout Europe with five additional sales offices and production sites to cater for our strong market presence here.”

From strength to strength 2015 was a good year for the company, with a 26 per cent turnover increase compared to 2014 and hiring more employees. Since it was opened, Faubel’s US sales office has gone from strength to strength. “We started out with a sales office, but now we also offer machinery equipment and warehousing possibilities, which meant employing more people,” Mr Jäger adds.

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Faubel enjoyed expansion and success in the USA. The company’s sales office in Bordentown, New Jersey, doubled business last year, and the target for 2016/17 is to double it again. “The success shows our unique way of producing and handling labels, which is a niche market in the USA we are able to fill,” Mr Jäger says. The company’s sales office in Shanghai in China covers the whole of Asia, and the company now has customers in Korea, Singapore, India, China and Taiwan, as Mr Jäger is pleased to report. “We are still at the beginning, but we are entering the Asian markets step by step, and we see good possibilities there with our special solutions.” Also in 2015, Faubel invested in new machines worth roughly three million euros in order to further increase capacity and productivity. “We also have plans to build a new facility at our headquarters next year, investing 14 million euros in the facility and machinery. It will be close to our current building, where we have some free space that we can use. This will offer the capacity for 250 people,” Mr Jäger explains.

Creative solutions Customisation is becoming a major industry trend, and Faubel is well equipped for it with its recently set up business unit ‘Creative Solutions’. This focuses on developing custom labelling solutions for clients in a range of different industries. Mr Jäger talks about two examples where Creative Solutions contributed to customers’ success: “For its 10th anniversary, Museumslandschaft Hessen Kassel designed a custom post seed®, with a colourful mix of flowers. The MHK selected an image from a painting from the Old Masters Picture Gallery at Wilhelmshöhe Palace in Kassel to go on the pack. The image is a perfect combination of art and landscaping and therefore representative of the MHK with its art treasures, collections and historical garden grounds. Inside the card, Faubel positioned basic planting instructions together with a seed tape which is easy to peel off and plant. Another application was for a public transportation company which had suffered some problems and delays. With the help of Faubel, they developed an original way to apologise to customers. As it was around Easter, the information about the reason for the delays and the apology was printed in the design of an Easter egg.”


Standing out

Future plans

Mr Jäger observes a trend of customers not just putting information on a label, but also concentrating on the end user experience, i.e. the differentiation at the point of sale through packaging. “There is more focus on things like easy opening and senior friendliness. Faubel developed a senior friendly label, which is easy to peel away and to put back and has an extra large finger lift. This becomes more and more relevant with an increasing aging population.” Faubel also puts an increased focus on the final end user. “We supply special pharma labels for the hospital sector. There is one label explaining how to use the syringe, and on top of it there is another label explaining what kind of drugs are in the syringe. In the past, this information was written down manually, now the sticker can be put on top, where the information is needed, avoiding mix-ups and making the process more safe and secure for patients, doctors and nurse,” Mr Jäger explains.

The managing director sees a bright future ahead for Faubel. “We want to expand even further in the US and Asia, in our existing markets, especially pharma. For our Creative Solutions division we are trying to expand our presence in new industries, and increase our reputation there.” Faubel has also started work in the areas of Industry 4.0 and digitalisation. “We have new R&D development for smart labels, where we are able to change information on a label electronically. We do not only supply the label, but also the software to make changes on the label, and the hardware related to it – which means that we will develop from a label provider to a complete system provider,” Mr Jäger concludes. Visit: www.faubel.de

Fachpack Faubel will exhibit its latest solutions at the Fachpack trade fair in Nuremberg in hall 9 at stand 9-320. “We want to explore the possibilities for both our business units, Pharma Services and Creative Solutions, showcasing some of the special solutions mentioned above. Our target is to convince our audience that we are not just a label producer, but a development partner. We are seeking partnerships with companies, combining our know how of packaging and labelling, and their know how of the market. Therefore our business development managers will be on stand to explain the benefits of mutual partnerships,” Mr Jäger points out.

Reliable partner Faubel is proud to be a reliable partner to its customers, and is able to offer renowned German quality, working efficiently, providing high quality labels and reliable services, and always supplying on time. “In the pharma industry especially we are seen as an innovation leader. We combine a global footprint with a local presence. Most of our customers are big global companies, but we are still relatively small, which allows us to react quickly and flexibly,” Mr Jäger adds. Packaging Europe | 115 |


Harald Mätzig, managing director

A one-stop shop for inspection systems Germany based scanware electronics is a manufacturer of high-end inspection systems, providing customers with innovative, easy-to-use, customised solutions for every step in the packaging line. Elisabeth Skoda spoke to scanware electronics’ managing director Harald Mätzig to find out more about the company’s product range and appearance at the upcoming FachPack trade fair in Nuremberg.

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canware, with its headquarters in Bickenbach in Germany, was founded in 1989 by four engineers who already had a lot of experience in the field. “Thanks to having been founded by experts, the philosophy to concentrate in-house development and service was established early on as a pillar of the company’s foundation,” Mr Mätzig points out. The company started out with the development of blister and tablet inspection systems, initially in black and white, and, in 1993 with the first colour detection for blister packs. Over the years, different camera systems for packaging lines were added for the pharma, cosmetics and food industries. “We started with a blister machine, then moved into cartoners code reading, foil inspection, code and print inspection on films, print inspection on cartons and date code inspection. In recent years we also developed end of line equipment with track and trace components on the line level,” Mr Mätzig adds. scanware is the only company in the pharmaceutical market supplying 3D inspection solutions, a growing technology, offering 3D inspection of tablets on the blister

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machine to identify the volume of a product, to find capped or chipped tablets or special double fillings. Since its foundation, the company has enjoyed steady growth. “The only way for us is to the top. We have achieved robust growth in turnover, thanks to our philosophy. Our company know-how must grow step by step,” Mr Mätzig says.

One-stop shop The company’s full in-house development capabilities consolidate its status as a technology leader. “We get a lot of technological requests from the market. Many of these are specialist, tricky tasks since we are known for our extensive in house and often customised development whereas many of our competitors buy components such as cameras or mechanical modules externally from various suppliers and put hardware and software packages together. But that was never scanware’s approach. Solving these special tasks together with our robust systems builds the foundation of our success and good reputation.”


scanware’s approach is different from other companies, as Mr Mätzig is keen to point out. “We are a real technical company, focused on our own and thorough development. We do not flood the market with half developed products but take a look at what is needed and then develop a solution thoroughly. In the past, as we started with track & trace, we have worked with other companies looking for hardware suppliers who could deliver the transport components necessary for our machines since until then our expertise lay on vision inspection and camera systems. But we eventually decided that having a third party caused delays in communications, development and improvements. So we expanded our know-how and started building our own transport systems for our track & trace solutions. We do not want to risk our excellent reputation by slowing down the full process of service. This approach also guarantees that all our products from simple code reader to high end 3D systems are developed in-house, and have the same look and feel and offer the same user interface.” Mr Mätzig also highlights the user friendliness of the company’s solutions. Simplicity is key. “There is a lot of technology on a full packaging line, and it is our job to make life easier for operators, so they do not have to work on too many user interfaces. We offer products that are easy to operate and to handle. We have built our reputation for 27 years and are proud of it.”

Standalone Solution LYNX-CAPA MV for Mark & Verify

FachPack showcase At the FachPack trade fair in Nuremberg at the end of September, among a wide portfolio of solutions, the company will showcase a new version of its tamper evidence station with a new module that will have its premiere at the trade show. “This new module is a mark and verify part that can be attached to the tamper evidence machine. Depending on which markets they supply, customers may need a tamper evidence function or serialisation on the mark and verify station. Our solution offers flexibility to the customer. It also helps to save space as it can be put on the floor plan at 90 degrees. Companies don’t always have room for bigger modules, and it is suitable for retrofitting,” Mr Mätzig says. He has high expectations for the show: “In Germany, FachPack is one of the major trade shows for us. We already get a lot of interest from the market, and expect a lot of traffic. Customers will be able to see for themselves why we are a good choice for their track and trace needs.”

Investing in the future Mr Mätzig underlines that continuous investment is key in order to keep being able to cater for growing demand from the market. “Everybody in this business has need to expand production, so we need to invest and be prepared. Our modular system is key. All our vision systems, from blister

Standalone Solution LYNX-CAPA TE for Tamper Evidence

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Combined Solution LYNX-CAPA MV+TE for Mark & Verify and Tamper Evidence

inspection, to case inspection and track and trace are all based on the same hardware. Of course there are different cameras with different resolutions connected, but the main hardware for all vision systems is identical. This gives us the chance to provide very fast service in terms of spare parts. Customers are able to upgrade the systems very easily – our products can grow with our customers. This, combined with our identical user interface make our systems easy in handling, offer fast reaction times, in combination with true in house development. In our view that is a very special package that others cannot provide.” The company has increased its sales team in Germany and forged international partnerships in Asia, including South Korea and China, as Mr Mätzig points out. “We expanded our business from our centre in Germany all over Europe, and enjoyed a presence in the US. Our next step now is the Asian market.”

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He looks to solid organic growth as the way forward. “We need to grow step by step, in an organic way. We have done this in the last 27 years and it worked well for us. Thanks to the quality and reliability of our products we look at the future with optimism. Our focus is increasingly moving towards track and trace and 3D inspection. We made the decision not to provide all levels of track and trace, our expertise lies on line managing a packaging line, and that is the level we are working on. We have developed from a company known for blister inspection to a company that offers a wide range of quality control solutions for packaging lines such as product inspection of far more products then pills in blisters, code inspection and track & trace,” he concludes. Visit: www.scanware.de


Innovations for an

efficient gluing process Under the motto ‘Gluing in Perfection’, Robatech presents powerful innovations for an efficient adhesive application in the packaging industry at the FachPack from September 27 to September 29, 2016, in Nuremberg.

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he hotmelt application heads of the Diamond series are one of the highlights at Robatech’s booth 2-323. All application heads of the Diamond series feature a modular design. This modularity enables Robatech to match the Diamond application heads exactly to the customer-specific production needs. The CoolTouch insulation of the Diamond application heads additionally increases operator protection. The heat-resistant insulation also contributes to energy savings and ensures efficient production.

Highest performance during adhesive application The new Concept Stream melter for more efficiency in the gluing process is presented for the first time to the technical audience. The innovative melting process and short heating time enable gentle but fast processing of thermoplastic hot melt adhesives. Thanks to continuous adhesive flow and circulation in the system, fewer burns occur, residues in the tank are significantly reduced, and nozzle blockage is prevented to a large extent. Furthermore, the proven CoolTouch insulation greatly reduces the risk of burns for the operator and reduces energy consumption, following the motto: Gluing in Perfection. The electrically driven cold glue application heads of the ECX Platinum series combine the highest switching frequency with maximum service life – also at high machine speed. The direct adhesive delivery from inlet to outlet reduces the mechanical stress on the adhesive within the application head. This prevents deposits and ensures gentle cold glue processing. The ECX Platinum series is optimally designed for processing of low- to medium-viscosity dispersion adhesives without solvent content. With contact-free adhesive application in dot, bead and continuous patterns, the application heads are ideal for efficient use in the packaging industry.

Efficiency and safety RobaVis Host is Robatech’s software specially developed for machinery manufacturers that offers the user the advantages of visualised operation of Robatech equipment via the main panel of the production plant. This makes gluing an integral part of the packaging plant. At the Robatech booth, RobaVis Host is presented to the audience using the central touch panel of machinery manufacturer Transnova Ruf as an example. Operation is realised via the production plant and not separately via the hot melt adhesive device. The software assumes the communication between the application system and the packaging plant. This minimises the operating effort and supports efficient production. Robatech offers the Granulate Container for clean and fault-free delivery of thermoplastic hot melt adhesives in granular form. As a functional extension to the proven RobaFeed programme, this container protects the adhesive from environmental influences and ensures efficient adhesive delivery. Robatech offers more than mere adhesive application solutions: Present worldwide in more than 60, the company is always close to their customers. A comprehensive, individually customised service offering covering all questions and issues of adhesive application is offered. Preventive measures reduce production downtime to a minimum, lower operating costs, and increase system efficiency. The comprehensive offering supports and protects the investments of Robatech’s customers – from planning to maintenance and modernisation. Robatech GmbH at FachPack 2016 / booth 2-323. More information at www.robatech.com/us

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Customer-centred reusable packaging

Gamma-Wopla’s main areas of activity are the design, manufacture and marketing of rigid and folding containers, and the design of material handling products. Packaging Europe asked CEO Jan Vandewiele about the company’s product offering and its upcoming appearance at the Fachpack trade fair in Nuremberg.

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fter having worked for more than 30 years in the development and expansion of ‘NV Michel Van de Wiele’, a family textile machinery company, Jan Vandewiele started a new industrial activity – the manufacturing of plastic logistics material handling products – by creating two companies: Gamma-Wopla is specialising in the development and production of industrial crates while SmartFlow Europe is focusing on plastic pallets. Thanks to their central location in Europe in Mouscron in Belgium, 95 per cent of the production is being exported all over Europe, from Finland to Spain, the UK and Turkey. Mr Vandewiele highlights the company’s main USPs in order to win business – innovation, competitiveness, customer focus and work environment. “Our companies have a continuous programme of new product development in order to expand their range and respond to customers’ requirements, which guarantees innovation. Thanks to working with high quality moulds and investment in modern robotised machines which are replaced every seven years, our company can guarantee competitiveness. Gamma-Wopla also maintains an open communication with its customers to understand and quickly respond to their wishes, and be able to provide them with quality products and a good delivery time and service. Last but not least, the company makes a conscious effort to create a family environment with an emphasis on trust and values, creating a positive work environment.”

pallets. Thanks to our wide experience in dealing with a large number of customers coming from a variety of industrial sectors, we are able to help them find solutions to their logistic-related problems,” Mr Vandewiele adds. At the fair, the company will present its new range of nestable and foldable crates and pallets which allows customers to reduce their freight costs. “We hope to broaden our customer network in Germany and to reach new industrial sectors within the German market. We have already shown in other countries that we were a reliable partner. Our growth strategy is to expand our business network within the German market by reaching new industrial sectors. Freight cost is a common problem shared by all countries, and our nestable and foldable products address this important issue by helping our customers to reduce freight cost,” Mr Vandewiele says. He has observed an important demand for nestable and foldable products, and has identified several reasons for this: “Nowadays, an increasing number of countries adopt policies which favour sustainable goods and products. In the packaging field, these policies require the use of reusable crates and pallets, which is exactly the type of product our companies offer. In addition to that, more and more companies are looking for customised packaging in order to differentiate themselves from others. Our companies are able to provide them with such products.”

Product range

Looking ahead

As a major European manufacturer of reusable packaging products, Gamma-Wopla’s product range covers many industrial sectors including automotive, pharmaceutical, food – such as meat, vegetables and fruit – DIY, distribution, retail and poultry. Each sector serves a large range of products which require important investments in moulds. The range includes folding containers, European stacking containers, stacking and nesting containers.

In order to respond to the increasing demand, Gamma-Wopla intends to double its production capacity within the next two years. “As we have already been doing since our creation, we will continue to invest in our research and development department in order to be able to propose new products at each main exhibition,” Mr Vandewiele points out. Furthermore, he is keen to maintain manufacturing in Europe. “We are not afraid of competition from the Far East. As long as we keep being innovative, as long as we keep investing in modern equipment, as long as we maintain our flexibility towards our customers, we know for sure that we will always be one step ahead of competitors from the Far East.”

Fachpack attendance Gamma-Wopla will exhibit its solutions at the Fachpack trade show in Nuremberg in September, at stand 9 / 9-253. “We want our potential customers to see for themselves that we can propose a solution to most of their problems, which goes beyond the mere selling of crates and | 120 | Packaging Europe

Visit: www..gammawopla.com


Why corrugated

packaging keeps your

produce fresher Packaging Europe | 121 |


(*) Decrease is shown as log cfu/ cm2 - number of colony forming units per cm2 versus T (time.)

Keeping fruit and vegetables fresh and appealing is important – but can be challenging – for retailers and their suppliers. Recent studies showed corrugated packaging can keep fruit fresh up to three days longer than returnable plastic crates (RPCs), and now new scientific work has revealed how.

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his new research is the second study by the team from the University of Bologna’s Department of Agricultural Food Sciences in Cesena, Italy. The first study investigated the exchange of microorganisms between packaging and fruit, and proved that this cross-contamination is more extensive in RPCs than in corrugated packaging. The research involved packing fruit in both materials and then tracking the cell loads of the target microorganisms in various circumstances. The new, second study built upon the results of the previous study, investigating the reasons for the difference in cross-contamination levels between RPCs and corrugated packaging. To investigate this, the Bologna scientists inoculated samples of corrugated and plastic materials with different types of bacteria, yeast and mould and then studied their survival capabilities. The team observed how microorganisms survived longer on plastic surfaces than on corrugated. The longer microbes survive, the bigger the risk of them contaminating the packed produce.

Methodology The Italian researchers introduced both spoilage microorganisms (which affect shelf life and the quality of fruit) and pathogenic microorganisms (which can cause foodborne disease) onto corrugated and plastic surfaces and took samples at regular intervals. While the level of microorganisms decreased over time on both packaging materials, the fall was significantly faster on corrugated compared to the plastic crate samples.

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The study then explored why microorganisms perished more rapidly on corrugated surfaces than on plastic ones. Their work revealed how microorganisms get absorbed and trapped in the corrugated fibres, then die there from lack of nutrients and water. The RPC samples, however, showed an impenetrable surface incapable of entrapping. This allowed microorganisms to remain longer on the surface, increasing their potential to contaminate packed fresh produce. To understand the fate of the microorganisms, the microbiologists used an electron microscope to study the contaminated corrugated surfaces. They saw microorganisms – from the 0.7 micron Listeria monocytogenes to the 10 micron Saccharomyces cerevisiae – trapped inside the corrugated fibres and unable to reach the surface. With a lower level of superficial contamination on corrugated packaging, the ability of microorganisms to cross-contaminate packed fresh produce would be severely reduced. The team also used the electron microscope to examine the contaminated plastic surfaces. They found that the smooth, continuous plastic surfaces could not be penetrated and therefore trap microorganisms. On top of that, they found tiny cuts and scratches that would be difficult to clean using industrial processes and could easily fill with organic matter – particularly in worn RPCs. In combination with humidity and suitable environmental conditions, this organic matter would allow microorganisms to multiply.


Professor Lanciotti

These tests were carried out under the same environmental conditions for both packaging materials, with the corrugated stored correctly prior to testing.

Conclusion Clean packaging minimises cross-contamination and, ultimately, slows fresh produce deterioration rates. Since microorganisms survive longer on plastic surfaces than on corrugated, this means superficial contamination and therefore the risk of contamination is lower for the latter, making paper based packaging cleaner and safer than RPCs. Through this research, Professor Lanciotti and her team (primarily Dr Francesca Patrignani and Dr Lorenzo Siroli) have strengthened the results of the previous study, which concluded cross-contamination is less likely to occur in corrugated than in RPCs. It shows that corrugated, by entrapping microbial cells, has only a

Jan Gramsma, Market and Environment Director - FEFCO

very minor role compared to plastic material in the cross-contamination of fresh produce with spoilage and pathogenic microorganisms. Jan Gramsma, FEFCO’s Market and Environment Director, said the findings added to the growing weight of scientific research showing how corrugated keeps fruits and vegetables fresher for longer. “Corrugated’s unique capability to trap microorganisms gives it a clear edge when it comes to ensuring foods keep their quality,” he said. This latest research from the University of Bologna confirms that corrugated packaging is the better choice. It has revealed exactly how corrugated reduces spoilage bacteria levels, which then minimises cross-contamination, preserves the quality and extends the shelf life of fresh produce. Visit: www.corrugated-ofcourse.eu

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K 2016 Essentials Where and when? Messe Düsseldorf - north, east & south entrances 19-26 October 2016 10:00 to 18:30 daily

Profile The World’s No. 1 trade fair for plastics and rubber

Tickets Day ticket: advance purchase: EUR 49.00 / on site: EUR 65.00 Three-day ticket: advance purchase EUR 108.00 / on site: EUR 135.00 Advance online purchase: https://eshop.messe-duesseldorf.de

Contact Messe Düsseldorf GmbH Stockumer Kirchstraße 61 D-40474 Düsseldorf, Germany Phone: +49 211 4560 7611 www.k-online.com | 124 | Packaging Europe


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K show 2016 overview

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Cautious Optimism Despite a host of issues to tackle that range from marine waste to multiple forces majeures at materials suppliers, the European plastics industry approaches K 2016 in a good state of health and with cautious optimism. It could even be that something good could come out of the ongoing migrant crisis, as thousands of well-qualified people arrive in Europe in search of new lives and new jobs. But there are still many hills to climb.

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he plastics industry consultancy Applied Market Information (AMI) said recently that the European plastics industry “finds itself in another period of upheaval and change as it struggles to pull out of the stagnation caused first by the Great Recession in 2008-2009 and the subsequent Eurozone crisis in 2012-2013.” The volume of polymers consumed in 2014 was still some 10 per cent below that used in 2007. Growth is coming back, albeit slowly. AMI reckons that, given the cautious outlook for most European economies, polymer demand over the longer term is expected to average a rate of just over 1 per cent per year up to 2019. As has been the trend for several years, recent demand has been stronger in central and eastern Europe compared with western Europe. Most of the countries in the East now have a polymer demand well ahead of where they were in 2007, AMI noted. “The countries of Central and Eastern Europe continue to offer the best prospects for growth in the European plastics industry, although the smaller economies remain vulnerable to external shocks,” it said.

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Supply side is content Overall, polymer producers in Europe appear to be upbeat. At Borealis, for example, which made record profits last year, CEO Mark Garrett says integrated polyolefin industry margins were at historic highs. “Despite lower feedstock costs, polyolefin prices did not retreat to the same extent driven by a tight market as a result of solid demand combined with a supply shortfall, in particular resulting from unplanned production stops,” he says. “In addition, imports of polyolefins into Europe have been uncompetitive following the weakening of the Euro. We expect this situation to ease in 2016, but we believe the integrated polyolefin industry margin will be solid.” At BASF, senior VP for Performance Materials Europe Melanie Maas-Brunner says: “Overall, we look positively at the current state of the European plastics industry. We have seen pleasing business growth in all our segments in 2015 and we are optimistic that those who have the right technologies, people and facilities globally will stay successful. We expect more demand from industries such as medical,


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transportation as well as from consumer industries such as footwear, sports and leisure. The main trends driving those needs are resource efficiency, lightweighting, comfort and energy efficiency.”

Processors are busier Prospects for the plastics processing industry across Europe appear to be improving, with trade associations in several countries reporting growth. In Germany, for example, the sector posted a moderate growth last year, on the back of a record 2014. Even in Italy, where consumption has been flat at best for some time, equipment association Assocomaplast reports a strong upward trend in orders. German plastics processing sector association GKV says sales rose by 1.3 per cent to just below € 60 billion. Packaging and technical products fared best, building & construction less so. Manufacturers were helped in particular by the good state of the German automobile industry, and also of some European auto sectors returning to growth. Presenting sectorial results in March, GKV president Dirk Westerheide took some swipes at material suppliers, however. Some major hiccups in supply and very volatile price development of raw materials, particularly polyethylene and polypropylene, affected business development, Westerheide said.

Too much force majeure Plastics processors across the continent last year found difficulties in obtaining raw materials. Major polyolefin plants in Europe stood still for extended periods. Across Europe, there were over 40 declarations of force majeure during a period of just four months at one stage of 2015, putting significant strains on relationships between suppliers and processors. Some processors had to shut down production lines. | 132 | Packaging Europe

Global economic and trade framework conditions made it difficult for plastics processors to obtain materials on international markets. These factors included the relative weak euro against the US dollar, and continued strong demand for plastics in Asia and the US. The GKV has for some time been calling for an abolition of customs duties on imported raw materials, to provide its members with improved sourcing choices. And the European Plastics Converters (EuPC) trade association has said that it will conduct a search for more material to be imported from outside the EU (where more modern production sites exist) “as well as the potential setting up of group purchasing platforms (in compliance with EU competition law).” Plastics packaging industry associations in Germany, France and the UK were also strong in their criticism of suppliers, hinting that some shutdowns may have been due less to production problems and more to polymer producers’ desire to improve their margins. Indications are that price volatility should be lower this year, however. The situation last year led to EuPC establishing the Alliance for Polymers for Europe in order, as EuPC president Michael Kundel put it, to “bring all forces together to fight this unjustified situation.” The aim of the Alliance for Polymers for Europe is to “provide detailed information on the current polymer market and help assist raw material users through its network of national plastics associations, as well as assist companies in requesting suspension of certain EU import duties to relieve shortages on polymer markets.” The alliance is also initiating a study on the aging of polymer sites in Europe, together with industry and independent experts, “so as to provide more transparency on the future development of the polymer production sites in Europe.” In February, The Polymers for Europe Alliance launched its online Europe­wide customers’ satisfaction survey to award the best polymer producers for Europe. “We decided to start the Best Polymer Producers Awards for Europe in order to re-establish a good


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communication between users of polymers and their suppliers, which has obviously suffered lately. We simply want to award those producers who support their European customer base,” says Ron Marsh, chairman of the Polymers for Europe Alliance. “Therefore, we chose what we believe are the five most important criteria for users of polymers when it comes to their suppliers: polymer quality, regulatory compliance, material delivery, performance, communication and innovation.” Energy costs are also very important for the whole of the plastics industry, and especially in Germany: electricity costs there are among the highest in Europe, due in part to levies designed to support the development of energy from renewable resources. The GKV says continuing increases in surcharges on electricity bills place an unacceptable burden on medium and smaller sized companies. It has called for measures to reduce the burden, noting that under current conditions, many products may not continue to be made competitively in Germany. Companies across German industry have been particularly vocal in their complaints about high energy prices, and the German chemical industry is also concerned about its falling competitiveness on the international stage, especially versus North American companies who have the advantage of shale oil and gas. This advantage is not as great as it was, with oil prices currently as low as they are, but there is a general consensus that oil prices will creep back up again in the coming years.

Could European shale gas provide a solution? Many eyes are now on Ineos, whose activities stretch all the way from oil & gas exploration through feedstocks to numerous plastics and chemicals. The company recently chartered eight ships to bring ethane from the Marcellus shale field of western Pennsylvania across the Atlantic. The first delivery landed in Norway in late March, and | 134 | Packaging Europe

shipments to the company’s refinery at Grangemouth, Scotland, are scheduled to start later this year. Europe’s first shale-based polyethylene should come onto the market very soon after. Ineos chairman Jim Ratcliffe says that shale gas economics revitalised US manufacturing “and for the first time ever Europe can access this essential energy and raw material source too.” He says the US shale will complement the dwindling supplies of gas from the North Sea. The move to import shale gas is intended to be a stop-gap measure while Ineos sets about tapping reserves under the UK, whose government is among the most pro-fracking in the region. It is set to drill numerous test cores this year alone, although it does not plan any fracking in 2016.

The circular economy On top of concerns about materials and energy supply, there is also growing awareness in Europe that more needs to be done about use, re-use, and preservation of precious plastics. Late last year, the European Commission adopted what it says is an ambitious new “Circular Economy Package” (CEP) to boost competitiveness, create jobs and generate sustainable growth. Implications for the European plastics industry are significant. The Commission says the CEP will “contribute to closing the loop of product lifecycles through greater recycling and re-use, and bring benefits for both the environment and the economy.” Key actions adopted today or to be carried out under the current Commission’s mandate include a strategy on plastics in the circular economy, addressing issues of recyclability, biodegradability, the presence of hazardous substances in plastics, and the Sustainable Development Goals target for significantly reducing marine litter.


Netstal sets a new standard for thin-wall packaging with the ELIOS 7500 At K 2016 in Dßsseldorf, Netstal will present the ELIOS, a new high performance injection molding machine with a clamping force of 7500 kN. In combination with proven technologies on the injection side, users get an extremely high-performance, robust and highly precise machine that is optimally tailored to meet the high demands of the competitive thin-wall packaging market. High performance injection molding, newly driven Through its Elion series, Netstal is renowned for high-precision and extremely fast injection molding machines with an electrical clamping unit up to a size of 420 tons. With the ELIOS, Netstal’s engineers have succeeded in transferring the high speed and typical Netstal precision to a 750 ton clamping unit with electrical movement. With the currently fastest dry cycle in its size class, the ELIOS 7500 is a true high performer. The secret lies in the newly developed and especially energy-efficient electrical clamping unit. The centrally aligned 5-point dual toggle lever ensures optimum introduction of force into the center of the mold installation space, and hence uniform distribution of the clamping force. The extremely robust design effectively prevents any deformation of the mold plates. The very large pillar distance and the extremely ample opening stroke facilitates the installation of stack molds or simple molds with large cavities. Modular design for maximum flexibility The ELIOS 7500 represents the beginning of a new machine series that will be supplemented shortly by further variants with lower clamping forces. In combination with a selection of proven high-performance injection units and the latest adaptive drive technologies, an extremely productive and high-precision overall system has been developed that can be optimally adapted to the planned application. The ELIOS 7500 can be equipped with hybrid injection units in the 2900, 4200 or 6000 sizes. Two screw diameters can be selected. As result of its characteristics, the ELIOS is a highly efficient and very fast solution that has been optimally matched to the needs of users in the competitive market of thin-wall packaging. Live at K 2016: Production of 43,000 round lids per hour The new machine can be admired live in action during K 2016 in Dßsseldorf. To demonstrate its enormous performance capacity, more than 43,000 round lids with a part weight of 2,8 grams will be produced per hour in a 24+24 stack mold. This corresponds to an impressive cycle time of 4 seconds. Netstal at K 2016, Hall 15, Booth B27/C24/C27/D24 Visit: www.nestal.com/elios

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The Commission has also proposed revisions to legislation on waste. Key elements include a common EU target for recycling 75 per cent of packaging waste by 2030 and a ban on landfilling of separately collected waste. “The efficiency of recycling is lagging [growth in consumption] – less than 25 per cent of plastic waste collected is recycled, and about 50 per cent goes to landfill,” says the Commission. The PlasticsEurope trade association for plastics manufacturers has welcomed the CEP “as a step closer to resource efficiency,” but it has expressed concerns. “The European plastics industry has been calling for a legally binding landfill restriction on all recyclable as well as other recoverable post-consumer waste by 2025,” it says. “Although a 10 per cent target constitutes a step in the right direction, it remains a timid attempt to put an end to the landfilling of all waste which can be used a resource.” PlasticsEurope considers the new 2025 recycling and preparation for re-use target of 55 per cent for plastic packaging waste as “an extremely ambitious objective;” the average plastics packaging recycling rate in Europe was under 40 per cent in 2014. It says the optimum level for plastic packaging recycling lies between 35 per cent and 50 per cent, depending on the country’s collection, sorting and recycling capacities. European Bioplastics (EUBP), the trade association for suppliers of bio-based plastics, says that “forward looking sectors with strong environmental credentials and growth potential, such as bioplastics, need to be promoted. Materials used for industrial and commercial purposes should safely enter re-use, mechanical or biological recycling systems by design or intention.” Europe is home to many innovations in biopolymers, most famous of which is probably Novamont’s Mater-Bi, now used for the vast majority of carrier bags in Italy (and for a growing number of other applications in packaging, agriculture, and the food service industry). | 136 | Packaging Europe

“With the right framework conditions in place, the European bioplastics industry could realise its immense employment growth potential while helping to lower the impact on the environment within the EU,” says EUBP. It predicts that by 2025 production capacities of bioplastics within the EU will have grown twentyfold to 5.7 million tonnes, equivalent to around 10 per cent of general plastics production. Up to 160,000 high skilled jobs will have been created in the process.

Swimming in plastics Meanwhile, the Ellen MacArthur Foundation, the UK-based charity set up in 2010 with the aim of accelerating the transition to a circular economy, has paired with the World Economic Forum to launch the report “The New Plastics Economy: Rethinking the future of plastics.” The report “provides for the first time a vision of a global economy in which plastics never become waste,” and outlines concrete steps towards achieving the systemic shift needed. According to the report, with most plastics packaging beings used only once, 95 per cent of its value is lost to the economy. It also predicts that, “given projected growth in consumption, in a business-as-usual scenario, by 2050 oceans are expected to contain more plastics than fish (by weight), and the entire plastics industry will consume 20 per cent of total oil production, and 15 per cent of the annual carbon budget. PlasticsEurope is not ducking the issue. In March, its annual PolyTalk conference in Brussels was entitled “Zero Plastics Waste to the Oceans.” In focusing on the problem of marine litter, the industry has taken the initiative in finding new ideas and solutions to preventing all plastics from entering the ocean, PlasticsEurope president Patrick Thomas (also CEO of Covestro, previously Bayer MaterialScience) says, noting that the association will provide leadership in preventing marine litter and share best practices.


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Machinery makers move on A report on the European plastics industry would be incomplete without at least some reference to the state of the processing equipment sector, which remains a global powerhouse despite strong competition from China. In 2014 (2015 data are not yet available), Euromap members accounted for € 13 billion of the global total of € 32.5 billion in plastics and rubber core machinery; that is 40 per cent. In 2013 the percentage was 41.5. China meanwhile moved up from 30 per cent to 33.5 per cent. As far as exports are concerned, Euromap members continue to export around four times as much core equipment as Chinese companies, in value terms. Deliveries to Europe and the US have both been rising, while those to BRIC countries have been slowing down. Euromap members account for 40 per cent of core machinery production and half of exports (of which almost half are from Germany, over 18 per cent from Italy, and almost 15 per cent from Austria). Around 43 per cent of Euromap member exports are within Europe.

A new industrial revolution? Many European machinery companies are likely to have the number 4.0 highly visible on their stands at K 2016, as they push their solutions for “smart” factories that operate within the Industrial Internet of Things (IIoT). The 4.0 refers to Industry 4.0, a term invented in Germany back in 2011 in reference to what was perceived as the fourth industrial revolution – and the German government’s plan to make sure German industry is at its forefront. Proponents of Industry 4.0 say it represents a paradigm shift from centralized to decentralized production – made possible by technological advances which constitute a reversal of conventional production process logic. This means that industrial production machinery | 138 | Packaging Europe

no longer simply “processes” the product, but that the product communicates with the machinery to tell it exactly what to do. Some observers may wonder whatever happened to the third industrial revolution— which signalled the rise in the use of digital electronics and IT to further automate production, and which appears to have begun around the same time as the fourth, depending on who you listen to. It will be the job of future historians to delineate the various epochs; maybe they will decide that in fact we are living in an age of permanent revolution (which would be ironic, since the term was coined by Marx and Engels). “Industry 4.0 is above all one thing: a tremendous opportunity that we want to take advantage of together with our customers,” says Dr Stefan Engleder, CTO of injection technology specialist Engel, which has adopted the term “inject 4.0” to describe its approach to meeting the challenges of productivity, quality and flexibility. Despite this, Engleder says he does not consider the word “revolution” to be very appropriate. “The changes that we are currently experiencing are more like an evolution,” he says. “For us, Industry 4.0 is not a new idea, but is already long-established daily practice in many areas.” Others in the sector will doubtless agree, but if the slogan helps drive the plastics industry forward towards increased efficiency and sustainability, it will have done its job. “For plastics processors too, new digital technologies offer new perspectives that are of interest, increasingly also in the corporate sector,” says the GKV’s Westerheide. A GKV survey recently showed that only eight per cent of responding plastics processors were putting significant effort into Industry 4.0, with the vast majority following the trend from the sidelines. Westerheide concludes: “K 2016 will provide an excellent opportunity to explore the advantages offered by the digitization of our industry.”


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KUKA at K 2016:

ready-to-use solutions for the plastics industry KUKA Robotics focuses on application-oriented automation solutions at the plastics exhibition K 2016 from 19 to 26 October 2016 in Düsseldorf. In cooperation with system partners, the robot specialist from Augsburg has developed ready-to-use solutions that it will be presenting at its 250-square-metre booth C49 in Hall 12. The showcase includes a robot-based Pick & Place solution for cell phone production.

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ardly any other industry is characterised by such short product life cycles as the plastics industry. Products and model series are modified even after just a few months. Automation solutions for production must pay for themselves quickly or be designed so they can be used for the next model series. At the same time, the complexity of the plastic components and the degree of functional integration is constantly increasing. Manufacturers cover an increasing variety of models and efficiently compensate for fluctuations in production batch size. This requires a high degree of flexibility. The increasing demands for flexibility and efficiency are the main drivers of Industrie 4.0. Here, becoming more flexible means being able to react more quickly, individually and adaptively – ideally with automatic and IT-based processes.

Development in close cooperation with system partners As a consequence, the plastics industry demands solutions and applications that are designed for immediate use and which are simple to operate and integrate. This is why KUKA, along with several system partners, has developed so-called ready-

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to-use solutions, which are to be on display at K 2016. The system partners play a central role in the strategic orientation and definition of solution packages. “We can only define and achieve the added value in collaboration with our customers – with the ready-to-use solutions tailored to the plastics industry,” emphasises Philipp Kremer, Market Segment Manager for Plastics at KUKA Roboter GmbH.

Ready-to-use: with simple operator control and integration The ready-to-use solutions on display at the trade fair booth of KUKA and its system partners represent an intelligent combination of KUKA robots, supplementary KUKA products such as KUKA application software and additional, essential thirdparty com-ponents. With offerings ranging from just a robot and software option to a combina-tion of a robot with a tool and software through to a fully equipped robot with a tool, cabling, process controller and technology software – no matter your automation experience, KUKA and its system partners can put together the right package for you. The ready-to-use solutions are specifically tailored to applican tions in the plastics indus-try and can therefore be used ‘out of the box’.


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Sumitomo (SHI) Demag to Put Industry 4:0 into Clearer Context W

ith so much talk about Industry 4:0 across the injection moulding supply chain, this October Sumitomo (SHI) Demag will illustrate how they are already assisting manufacturers confidently embrace and plan for this sea of change at K 2016. Under the banner Electrified 4:0, five machines will be actively running on the stand, demonstrating the speed and precision already being deployed to produce quality packaging, caps & closures, pharmaceutical, automotive and in-mould decorated (IMD) plastic components. In addition, K-2016 will be the world premier of a new IntElect platform, plus three injection moulding partnership installations developed in collaboration with Sepro, Yushin and ONI. “There seems to be a general lack of clarity among the plastic moulding community about what Industry 4:0 means and where it is heading,” notes UK managing director Nigel Flowers. “It’s a bit of an unknown science with no clear end game, and this is holding manufacturers back in terms of defining their Industry 4:0 strategy, we aim to help clarify this.” Three key elements underpin the company’s ‘Smart Factory’ vision; Smart Machines equipped with an intelligent and future proof user interface, fully synchronized to external ERP systems, robots and the supply chain; Smart Service, integrating quality assurance and featuring remote diagnostics and maintenance to

increase machine availability; and Smart Production, with fully connected systems and a host manufacturing execution system (MES) tracking real time production information. Putting it into simple terms, Nigel explains: “Industry 4:0 is about increasing productivity and profitability, reducing costs and waste, personalisation and traceability, factory connectivity and optimising energy usage. So, in many respects, moulders that have invested in Sumitomo (SHI) Demag machines in the past five years, particularly all-electric machines, are probably more Industry 4:0 advanced than they might perceive.” Rather than a paradigm shift, the Sumitomo (SHI) Demag exhibits at K-2016 will illustrate how upgradable technologies, including automation, and robust process optimisation programmes are already adding value to businesses and putting customers ahead of the Industry 4:0 game. Two El-Exis SP machines with a clamping force of 2,000 and 4,200 kN will appear on the stand, along with a Systec Servo (2,800 kN) and two all-electric IntElect machines (500kN and 4,500 kN.) The machines are all equipped with an OPC Unified Architecture (OPC/UA) interface, offering broader scope for connectivity and enabling moulders to use data to optimise production, make operation decisions quickly, and generate reports. Both El-Exis SP machines on show will demonstrate packaging applications. The El-Exis SP 200 is being plugged as the most rapid IML exhibit at K, producing four high quality decorated cups in less than two seconds. Visit: www.packagingeurope.com/News/68776

Hall 15, Stand D22

Systech Illinois Introduces New DualPerm, Oxygen & Water Vapour Permeation Station

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t this year’s K show Systech Illinois will be introducing of its new combined oxygen and water vapour station, the DualPerm, this combination package offers substantial savings to the initial purchase cost of two separate permeation analysers; shared computer interface; shared nitrogen supply and reduced installation costs. | 142 | Packaging Europe

Systech has been designing and manufacturing oxygen permeation and water vapour permeation analysers for many years offering reliable and versatile testing of all films, packages and bottles. With precise control, these analysers offer a wide sample temperature range of 5° to 50°C and a measured and controlled relative humidity range of 20 to 90% RH. All Systech analysers are certified traceable to NIST. Systech’s water vapour permeation analysers utilise our long-life Proprietary Coulometric P2O5 sensor, the primary method for absolute moisture measurement, which is more sensitive and stable than infra-red and does not require calibration. Its leading permeation instruments deliver: the fastest permeation results; extremely fast purge down time; accurate readings at the lowest levels and the highest quality sensor on the market. Visit: www.packagingeurope.com/News/68857

Hall 10, Stand G13


K SHOW News

New Blends Allow for Thickness Reduction T

he Bioplastic specialist FKuR has developed a new technology for the production of compounds which can be processed into flexible packaging films with particularly low thickness and, at the same time, high puncture resistance. With Bio-Flex® FX 1120 and Bio-Flex® FX 1130, FKuR will be presenting the first two products based on this new technology at the K 2016. Films made from these materials are suitable for food contact and compostable according to EN 13432. Depending upon the type, the proportion of renewable raw materials is more than 50%. The processing of both FX types of Bio-Flex® corresponds largely to standard PE processing. For especially thin films Bio-Flex ® FX 1130 is designed to complement the previous standard compound Bio-Flex® F 1130. Whilst films made of conventional F 1130 have a paperlike touch the FX quality offers a silky surface. Films produced with this blend are further characterized by an increased tensile strength, puncture and tear resistance. This enables converters to use less material without compromising the performance characteristics of the film. In practice, it has been proven that film thicknesses of 8 microns are possible. In addition, film manufac-

turers benefit from high throughputs in extrusion, as well as excellent sealing properties of the material. For 50% biobased bags Bio-Flex® FX 1120 is a new development for film production, especially for very thin bags, such as bio-waste bags. The increased water resistance, when compared to starch blends, permits a high retention of moisture which is originated during the decomposition of organic products in bio-bags. With a high proportion of renewable raw materials of more than 50%, the Bio-Flex® FX 1120 compound fulfills the requirements of the German Bio-waste Ordinance. Julian Schmeling, head of development at FKuR says: “Aside from the use of renewable resources, material reduction is an essential pillar on the road to achieving greater sustainability. This applies to conventional plastics as well as to bioplastics. In conventional polyolefin films, the trend to produce thinner films without the loss of strength and toughness is already known for quite some time. Films made from biodegradable resins have reached sufficient performance values with thicknesses of about 15 microns. In practice, the film thicknesses today are between 18 and 26 microns. Thanks to

the use of novel polymeric additive systems and an adapted compounding process, FKuR now provides converters with the possibility to follow the trend using bioplastics and combine significant material savings along with compostability.“ Visit: www.packagingeurope.com/News/68828

Hall 6, Stand E48

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PSG Presents Hot Runner Control 4.0 PSG

Plastic Service will exhibit at K in Düsseldorf the new Hot Runner Controller profiTEMP+. The key advantages are a small footprint, extended range of functions and convenient touch screen operation. profiTEMP+ offers innovative functions such as Smart Power Limitation, superfast and non-reactive current measurement as well as plurality of data interfaces. This is the basis for linking temperature control 4.0. In the division of Hot Runner PSG offers new solutions to improve part quality. Because you cannot drill a melt channel around a corner, we separate the new distributor according to length and mill out the melt channel halfway. The two halves are then hard soldered together. The result: A melt channel with perfect rounding. Dead corners are a thing of the past. Furthermore PSG presents many more innovative solutions such as the new reflector nozzle for narrowest cut outs or the new VCON. It supplements the previous cascade control varioFILL and offers two advantages as well: First, variable opening speed of needles for better process control and secondly, a sensor. Visit: www.packagingeurope.com/News/68813

Hall 1, Stand A11

IKV Focus on Industry 4.0 and Additive Manufacturing T

he Institute of Plastics Processing (IKV) in Industry and the Skilled Crafts at RWTH Aachen University will again be represented in Düsseldorf with its own stand. Since the beginnings of the K show in the 1950s, IKV has been highlighting selected research topics on this international platform. This year IKV will pick up on the show’s main topics, namely additive manufacturing and integrative production technology in the form of a Cyber Physical Production System (CPPS) for plastics processing. In its research projects in the field of additive manufacturing, IKV takes a multimaterial approach that covers a range of different products. On the one hand, it performs fundamental analyses to examine the influence of the processing process on the properties of plastics products. On the other, it looks at the potential of using additively manufactured metal mould elements in the various plastics processing processes. Alongside the practical analysis of different additive manufacturing processes, the focus is above all on the physically motivated numerical modelling. This holistic research approach by IKV aims to create a fundamental understanding of the process. In addition to already established processes such as Arburg Plastic Freeforming (APF) and the Fused Deposition Modelling (FDM) process from German RepRap GmbH, IKV is also building expertise and competence of its own via its own machine developments, and is overcoming existing limitations by linking up various pieces of machinery. The aim is hybrid production for the automated combination of different production processes. In a production cell, the Institute will show not only the automated fine machining of additively manufactured parts, but also various insert operations and the integration of further production steps. On the subject of Industry 4.0, IKV will, in cooperation with a strong industry consortium, address the subject of the application-specific manufacture of function-integrated lightweight parts. On the IKV stand, the Institute will present, up and running, a fully automated production cell based on an injection moulding machine. The versatility and flexibility of the process will be demonstrated through ergonomic interaction with the visitor. Visit: www.packagingeurope.com/News/68863

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K SHOW News

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TER Plastics POLYMER GROUP Presents New LFT Types

Jomar Launches Injection T Blow Moulding Machine omar Corp., a leading global manufacturer of injection blow moulding machinery for the pharmaceutical, healthcare, personal care, beauty, food and beverage, and household products industries, has announced the launch of a next-generation injection blow moulding machine series that incorporates a unique custom-designed servo-driven hydraulic system. The new Jomar IntelliDriveTM Series delivers major improvements in energy consumption, output, and performance while also maintaining the machine’s footprint. The series features precise servo-driven hydraulics that reduces energy consumption by 40%-50% and boasts a dry cycle time of 1.8 sec. which is significantly faster than standard hydraulic machines. Jomar engineers worked in partnership with Bosch Rexroth, Charlotte, N.C., to develop a proprietary use of servo-driven hydraulic technology to power the machine and plastifier. “We’ve taken injection blow moulding to a new level with the new IntelliDrive Series of injection blow moulding machines,” said Ron Gabriele, Sales Manager for Jomar. “We’ve developed a machine that reduces operating costs and increases production, thus delivering more profits for our customers.” Along with the lower energy and utility costs, the IntelliDrive series offers a reinforced main platen which reduces the possibility of deflection. The machine also features a closed-loop system for the machine’s clamping system, which delivers exact control over the clamp’s speed and position. This creates faster speeds for opening and closing while simultaneously reducing impact upon tooling, thus prolonging the lifespan of the moulds. Overall, the IntelliDrive series has a higher degree of control over the machine’s internal functions, resulting in more efficient use of energy. As a result, in addition to the power savings, the machine requires 40% less hydraulic oil, uses less than half the cooling tower water, and emits substantially less ambient heat compared to standard hydraulic machines. These factors all dramatically reduce overall operating cost. “Over the last couple of years, we’ve had numerous inquiries about our intentions in developing an all-electric machine,” said Carlos Castro, President of Jomar. “The IntelliDrive Series is a preferable alternative for Jomar because we’ve achieved energy savings comparable to all-electric machines while also maintaining our robust and versatile hydraulic system.” Energy savings is contingent upon machine model, container specification, and material process. Jomar’s development work in hybrid and all-electric machines consistently hit a roadblock due to components that did not yield optimal benefits and were plagued with high replacement cost, according to Castro. “We feel that the IntelliDrive Series makes more sense for our customers who want energy savings, but not expensive and complicated repairs.” The hydraulic system of the IntelliDrive series vastly improves the machine’s energy efficiency and control, but doesn’t require costly components that could amount to as much as 15% of the entire machine. In fact, the IntelliDrive line of machines will only cost 10%-15% more than the standard hydraulic machine and replacement parts will be available at costs comparable to their entirely-hydraulic counterpart. Jomar’s confidence in the hydraulic system of the IntelliDrive series has enabled the company to extend the warranty by two and a half times the duration of a standard warranty. “Not only are we lowering our customers’ per-part cost with utility savings, but we’re providing a solution that has a very low cost of ownership,” said Castro.” This is consistent with our overall effort of delivering short- and long-term value to our customers.” Other key features include a quick-change mounting system for the preform cylinder which drastically reduces the time required for cylinder maintenance, a digital displacement transducer for better clamp control and speed, and a variable-frequency drive for a secondary motor. The new feature-enhanced IntelliDrive IBM machine has exactly the same footprint as its standard hydraulic counterpart. Visit: www.packagingeurope.com/News/68712

he TER Plastics POLYMER GROUP will present new, highly innovative LFT types from its own production, TEREZ PA66 7500 HGL50 and TEREZ GT2 HGL50, at the K 2016 trade fair. The products are extremely suitable for structural components because of a fibreglass content of 30 to 60 % based on high-performance polymers and a granulate length of 6 - 12 mm. With the TEREZ HT 200 H G30 FR40 type, TER Plastics has added innovative, flame-protected, UL 94 V-0 rated, partially aromatic polyamides to its wide product range and specifically to its own TEREZ product portfolio that focuses on metal replacement, high temperature, water contact and tribology. TER Plastics supports its customers as a design partner, also in terms of colouration. A TEREZ® Compound on PMMA basis featuring an excellent impact strength, special pigmentation and perfect light scattering has recently been developed to allow the customer to do without expensive LED tapes and to save costs. From the portfolio of its strategic suppliers, TER Plastics will present the new high-temperature polyamides, Polyamide Fortii MX (PPA) and Xytron (PPS) from DSM. TER Plastics has successfully worked with the Polyplastics company, the world’s largest POM manufacturer, for two years. The product range has now been expanded with the new DURACON POM types M90-57, M270-57 and EX-09 that have all important approvals for food contact applications. As specialists for the automotive industry, TER Plastics will also present Sarlink from Teknor Apex and Arnitel from DSM as interesting application examples in the TPE area, for example, air ducts under the bonnet or car interior floor mats. For example, Teknor Apex Sarlink TPV / Series 4100 is heat-resistant up to 115 °C and DSM Arnitel TPC / PB582-H has an outstanding long-term heat aging performance. The commodity specialists will present special medical application types with TOTAL’s (PP and PS) Acesco product range and Versalis’ (PE) Pharmalene products. There is also a wide range of types available for the healthcare segment for the manufacture of cannulas, infusion bottles, pill dispensers etc. Visit: www.packagingeurope.com/News/68814

Hall 14, Stand A32

Hall 8a, Stand F33

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Husky Launches a Global Debut H

usky Injection Molding Systems, will be exhibiting its newly launched, next generation system for high output beverage closure moulding, HyCAP™4. Husky originally launched its HyCAP™ platform in 2009 and it quickly became the industry-leading integrated solution for beverage closure moulding. The latest generation features superior engineering advancements, including several new capabilities and features that take machine and mould integration to exciting levels. Combined, these enhancements allow HyCAP™4 to deliver industry-leading performance and productivity, as well as significantly more energy savings. The system is also equipped with intelligent features that make it easier to use, with simplified controls for faster process set-up and improved repeatability. With these advancements, system owners can look to HyCAP™4 to deliver improved returns and increased opportunities. “Husky is committed to reducing our customers’ total cost to produce,” said Gerardo Chiaia, Husky’s President of Global Beverage Packaging. “We do this by focusing our development effort on meaningful innovations that deliver on what the processor needs most. More productivity, increased ease-of-use, reduced energy consumption – these are all achieved by specifically designing the mould, machine, hot runner, auxiliary equipment and software to work in harmony – while adding more automation to make the system fully integrated and intelligent.”

As the industry’s only single source provider of integrated beverage closure injection moulding machines, moulds, hot runners, temperature controllers, auxiliaries and productivity improvement software, HyCAP™4 has been designed so all components work together seamlessly to provide even higher levels of performance and control, while still delivering the best part quality. The Polaris™ HMI has been redesigned with a 19-inch full colour display and more intuitive layout for simplified navigation that provides quick access to vital information and process parameters. Additionally, HyCAP™4 is now available with integrated features to capture contaminants and minimize unplanned downtime. A primary goal for HyCAP™4 is to optimize the relationship between productivity and efficiency, while producing the highest quality, lightest weight closures at industry-leading cycle times. Exclusive adjustments have been made to strike the perfect balance between maximizing productivity and achieving industry-leading energy savings. These adjustments include electrification of the clamp motion, servo-variable pumping technology and a regenerative clamp stroke. Combined, these enhancements deliver up to a 40% improvement in energy consumption over the previous generation system, without sacrificing performance. Visit: www.packagingeurope.com/News/68833

Hall 13, Stand A61

Mould&Matic Presents Latest Blow-Moulding Machine

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ould & Matic have chosen K as the platform to present an innovative new product for the injection-, stretch- and blow-moulding sector. This newly designed machine for single-stage blow moulding convinces on the basis of production quality and individual size configurations. The key features of Mould & Matic’s new Blowliner Medium machine include productivity combined with greater flexibility. This new Kiefel subsidiary will be introducing itself in Düsseldorf with a two-row series

production tool for blow-moulded items. The decisive competitive advantage lies in the single-stage injection/stretching/blowing procedure, which Mould & Matic completes with consistent production quality. All the machine movements of the stretch/blowmoulding station are actuated by a servo-electric system designed for maximum control of the process. Cooperation with a renowned partner guarantees the provision of the best injection moulding technology in the entire sector, while ensuring a combination of maximum productivity, reliable processing and consistent product quality. This combination of production machines delivers a configuration designed for maximum energy-saving. The performance of the Blowliner Medium is such that it can produce approximately 10 to 30 million items (a figure based on 0.5-litre containers) per year. The integrated removal device picks up the blow-moulded bottles and positions them precisely on the conveyor belt for subsequent handling by the stacking system. Mould & Matic offers everything from a single source, from initial product development right up to the fully automated series production of plastic packaging items. This leading system supplier of production items for the thermorming and injection/blowmoulding technology sector now intends to start delivering the Blowliner in various sizes for the individual productivityrelated benefit of the customers concerned. Visit: www.packagingeurope.com/News/68923

Hall 1, Stand C40 | 152 | Packaging Europe


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EREMA Launches Recycling 4.0

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ith CAREFORMANCE, EREMA is set to herald the age of Recycling 4.0 as the first in the plastics recycling industry to present an extensive Smart Factory package for both recyclers and producers. Recycling 4.0 is no future trend; it will be reality starting at K 2016. At the show EREMA will be building on the success of the INTAREMA® technology presented in 2013, this time with its trade fair theme of “CAREFORMANCE – We care about your performance” to grow its pioneering role this year with Industry 4.0 applications. “Building on the high degree of automation of the INTAREMA® systems we have developed a Smart Factory package which enables us to give our customers a clear competitive edge and make them fit for the future,” reveals EREMA CEO Manfred Hackl. Trade fair visitors will not only discover the benefits of CAREFORMANCE in theory, they will also experience them live: EREMA will be recycling the plastic waste of the K show on site at the CAREFORMANCE Recycling Centre in the outdoor area of the trade fair, with machine, quality and process data being transferred in real time to EREMA’s booth. CAREFORMANCE consists of four components, with the INTAREMA® system forming the basis for the further Smart Factory applications. In addition to the previous machine data, specially integrated sensors – the QualityOn package

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– can be used in future to record and evaluate MVR (Melt Volume Rate), colour and moisture. The QualityOn package enables recyclers and producers to make their recyclates with consistent quality in accordance with the special requirements of their customers and document them transparently using online data acquisition and analysis. Recipes recorded electronically can be compared with each other and modified. In order to make use of the vast amount of machine, quality and process data in a worthwhile and userfriendly way, EREMA has developed a sophisticated MES (Manufacturing Execution System). With re360 you can keep track of the productivity of an entire range of machinery in five modules. “A key benefit of re360 is that it works independently of the plant manufacturer,” emphasises Manfred Hackl. “Customers can integrate not only different systems but also their global production locations.” re360 gives you an overview of the capacities/stoppage times of the systems for management, documents key quality data of the recyclates for the location manager and informs the operator about upcoming maintenance jobs. Visit: www.packagingeurope.com/News/68453

Hall 9, Stand C05-28


K SHOW News

ILLIG Showcases Latest Developments I

LLIG, the systems provider for thermoforming solutions, will be showcasing its latest developments in thermoforming, packaging and mould technology and demonstrating its prowess as a systems partner for automated processes. In focus will be the performance of in-mould labelling in thermoforming (IML-T), hygienic production and enhanced productivity through technical optimization, as well as the systematic expansion of automation. For the first time in its latest stage of development the IML-T thermoforming line IC-RDM 70K together with the compact IML unit RDML 70b for flexible decoration of nearly any cup geometry will be demonstrated at the K 2016. Also making its debut at the K stand will be a flexible product handling system. Adapted for the ILLIG IC-RDK 54, this combination accelerates production for enhanced productivity. Visitors will also get to see the latest in ILLIG mould-making technology with new moulds on display. ILLIG is currently the only supplier of IML-T that offers all required modules from a single source that have been optimally designed to interoperate with one another. IML-T machines are deployed together with so-called cup machines of the RDM-K series and also integrated in form, fill and seal machines that comply with the stringent hygiene standards of the dairy industry. An automatic IC-RDM 70K roll-fed machine with a forming area of 680 mm x 300 mm coupled with the IML unit RDML 70b will be on display at the K stand to demonstrate the IML-T technology. The 18-cavity mould has an hourly output of approximately 17,280 rectangular polypropylene cups that are simultaneously decorated on all four sides plus the bottom with a brilliant photo-quality label during the forming process. The RDM-K machines are extremely versatile and can be used for a variety of applications. Equipped with ILLIG-designed coffee-capsule moulds, over 30 RDM-K thermoforming systems produce millions of capsules every day around the globe. The machines’ reliability also underscore the value of ILLIG’s technological know-how. Another new exhibit at the K will be ILLIG’s flexible stacking and packaging system. The product handling system PHF can be easily connected to an ILLIG thermoformer in minimal time and is ideal for applications typically realized on RDK-series machines. The integrated unit allows the removal of stacks, quality assurance measures, and packaging. The removed stacks of formed parts can be packed as stacks in bags in conventional box sizes. Guided procedures for altering settings enable quick retooling, which lets you quickly setup the machine for a new product. At the K trade fair the product handling system will be adapted to an RDK 54 thermoformer. Equipped with a 12-cavity cup mould with a shallow forming segment base, so-called delicatessen cups will be formed out of a transparent APET film with an antiblocking additive. Visit: www.packagingeurope.com/News/68698

Hall 3, Stand A52 Packaging Europe | 155 |


battenfeld-cincinnati Presents Next-Gen Extruder Series A

t this year’s plastics fair battenfeld-cincinnati will be introducing a newly developed series of high-performance single screw extruders: the solEX NG (NG = Next Generation) series. Developed on the basis of the proven solEX series, this new generation features a completely new processing unit which offers a multitude of advantages, such as a lower melt temperature and energy costs reduced by up to 15%. Based on the proven solEX 40 D extruder series, which had already been designed for high-performance applications, the battenfeld-cincinnati engineers have now successfully developed a new groundbreaking processing unit. Barrels, screws, and grooved bush have all been completely redesigned. The major changes are an internally grooved barrel, a screw con-cept that consistently applies the theory of dispersive melting, as well as a feed zone with a completely revised geometry and fitted with spiral grooves. All three components are ideally matched, thus enabling a further improvement in the process attributes. The solEX NG extruder series is available in four sizes (60, 75, 90 and 120 mm) and offers outputs ranging from 1,000 to 2,500 kg/h – an increase of up to 25% for each machine size compared to the original solEX series. One of the benefits offered by the innovative design of the pro-cessing unit is an increase in melting capacity, along with gentle and energy-efficient processing. Thanks to this, the melt temperature in the extruder is reduced by up to 10°C for comparable outputs, while the melt homogeneity remains at a consistently high level. The modification in the conveying mechanism leads to a significant reduction of the | 156 | Packaging Europe

axial pressure profile in the feed zone and the barrel, thus reducing pressure across the entire system and enabling an increase in the specific output level. In addition, the processability of regrind is improved, so that higher amounts of regrind can be processed without impairing process behaviour. Furthermore, it is expected that wear behaviour will also significantly improve, which contributes to considerably higher process reliability when using critical materials. Less wear means lower maintenance costs and consequently higher efficiency. In this context, the reduction of energy consumption thanks to the new processing unit is another decisive factor. Energy cost savings of up to 15% are possible: Firstly, less drive energy is required and, secondly, due to the cooling of barrel and grooved bush significantly less heat discharge is necessary. And the new processing unit offers yet another advantage: As the basic structure of the extruder was retained from the previous series, existing solEX models can be retrofitted with the innovative NG processing unit. The solEX NG series not only complements the wide range of battenfeld-cincinnati single and twin screw extruders, but also the portfolio of solutions for large-diameter pipe extrusion, where bat-tenfeld-cincinnati is the technology leader. The solEX NG extruders with their high outputs and excellent melt processing capacities are ideally suited for PO pipe lines with diameters of up to 2.6 m. Visit: www.packagingeurope.com/News/68685

Hall 16, stand B19


K SHOW News

ENGEL Extends MES e-factory by Energy Module

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ith its new energy module, ENGEL e-factory makes it possible to track the energy consumption of individual consumers in production with greater transparency. In addition, starting at K 2016, the MES from ENGEL is capable of avoiding power peak requirements automatically and reducing power costs across the entire machine pool. The networking and integration of production systems is one of the key features of the smart factory, which forms the core of ENGEL’s inject 4.0 program. With its own MES (Manufacturing Execution System), the Austrian machine manufacturer assists its customers to increase their productivity and efficiency by networking. ENGEL e-factory is tailored to the requirements of the injection moulding industry and therefore ensures very deep vertical data integration down to individual cavity level. New modules are being constantly added to the modular system. ENGEL is unveiling a new module at K 2016 – the Energy module. It permits a detailed display, evaluation and optimisation of energy consumers. Machines from different manufacturers can be integrated to obtain a complete energy balance. At the same time, consumers not integrated in the MES can be recorded manually. These functions form the basis for certification according to EMAS, the European Union Eco-Management and Audit Scheme. An additional advantage of the new module is the intelligent distribution of available power sources to individual consumers. This hall management system is particularly beneficial when the entire machine pool is started up at once after a weekend or a factory shut-down, for example. The dynamic allocation of machinespecific consumption limits prevents energy peaks even in these cases. To ensure the needs-related distribution of power requirements, the Energy module accesses data in the ecobalance energy management system which is included in the functionality of the CC300 control system of ENGEL injection mould-

ing machines. The ecobalance system allocates specific consumption limits and a specific priority to each consumer within the machine or production cell for machine start-up and in production mode. For example, it takes into consideration the high power demand required by an injection moulding machine during warm-up and the high demand for plasticising and injecting the material during production. After each cycle, the system redefines the consumption limits and priorities. The priority of each consumer which received a high amount of power in the previous cycle is reduced and the priority of each consumer which received no or little power is increased. What ecobalance does within a machine or production cell is performed by the Energy module for the entire machine pool. Thereby, the machines and production cells can be grouped arbitrarily to allocate individual consumption limits to different production halls or hall areas. The more consumers and energy sources that are available to the energy management system, the more effective distribution can be. The Energy module provides injection moulding companies with greater leverage to reduce their power costs since power is a significant cost factor, especially at energy peaks. Even when maximum power requirements are seldom reached, they must be constantly provided by the electricity supplier. If the maximum connected load is exceeded, penalties must be paid. As before, energy efficiency is a vital key to achieving low unit costs. In the past, a large number of developments in drive systems have helped reduce the energy consumption of individual consumers. But today, the accent is more on the intelligent distribution of energy. Rapid advances in the networking of machine pools offered by Industry 4.0 open up new opportunities here. Visit: www.packagingeurope.com/News/68996

Hall 15, Stand C58 Packaging Europe | 157 |


K SHOW News Arburg Showcases Allrounders, Freeformers and Industry 4.0 A

total of 27 Arburg machines will be on show at K, presenting innovative applications, processes and turnkey solutions for the efficient production of plastic parts – from single-unit to high-volume batches. On its stand Arburg will present twelve exhibits that demonstrate the current state of the art, including several world firsts. Visitors will have the opportunity to experience for themselves the latest trends in production efficiency, lightweight construction and Industry 4.0, as well as special industry-specific solutions, e.g. for the packaging and medical technology sectors. “Anyone who is familiar with Arburg will know that you can always rely on us to produce a surprise and that we like to keep an ace up our sleeve. Things are no different in this important K year,” says Michael Hehl, Managing Partner and Spokesperson for the Arburg Management Team with a wink, adding: “The electric Allrounder Golden Electric entry level machine series made its debut in March. This was the first product innovation for this year, but by no means the last. Anyone who wants to find out what is driving the industry and how plastic processing will become even more efficient in the future is invited to visit our exhibition stand, A13 in Hall 13. We will be presenting several innovations and trends to international trade visitors – in injection moulding as well as additive manufacturing and Industry 4.0.” Innovative machine manufacturers like Arburg are rebranding themselves as suppliers of flexible production systems for IT-networked production in the “smart factory”. The Lossburg-based company has been working on the practical implementation of this topic for 30 years and already presented a fully automated production system with no manual set-up processes, consisting of several linked injection moulding machines at the K trade fair back in 1986. The individualisation of office scissors has been used on several occasions to demonstrate how Industry 4.0 technologies and the incorporation of online customer wishes in the value chain can be used to achieve new business models. The fully IT networked and automated production line combined an Allrounder injection moulding machine with a Freeformer for industrial additive manufacturing by means of a seven-axis robot. At the K 2016, an innovative application will be on show, which comprises a vertical Allrounder 375 V, a Freeformer and an automation solution. Furthermore, the visitors to stand A13 will be able to find out about future opportunities and Arburg solutions at a central information point. They will learn about how Arburg implements the topics of Industry 4.0 and the “smart factory” in its products and what practical examples are of relevance for plastic part production.] The injection moulding machines from the Golden Electric series launched in March 2016 have been met with a great reception throughout the world. They feature proven, high-quality Arburg technology “Made in Germany” at an attractive price/performance ratio. This is made possible through standardised components, such as a fixed combination of distance between tie-bars, clamping force and injection unit size. The entry-level Golden Electric series is available in four sizes, 370, 470, 520 and 570, with clamping forces from 600 to 2,000 kN. At the K 2016, an Allrounder 470 E Golden Electric with a clamping force of 1,000 kN and a size 290 injection unit will be used to produce a technical part. Profoam is one of the innovative processes that Arburg promotes for the efficient production of lightweight yet strong components from plastic. The physical foaming technique, which enables low-distortion parts with a homogeneous foam structure to be produced using conventional injection moulding machines, will be shown at the K 2016 on the basis of an automotive application. Dynamic mould temperature control will used to produce a high-gloss surface. Innovative cube mould technology specially designed for the packaging industry will be presented in a world premiere. A further complex application is the two-component injec| 158 | Packaging Europe

tion moulding of a wristwatch from two different liquid silicones (LSR), including assembly of the watch casing. Another highlight will be a high-speed application for medical technology, in which a clean room version of an electric Allrounder 470 A will be used. Automation will be used to integrate a growing number of increasingly complex operations to increase added value around the injection moulding process. In addition to injection moulding machines, Arburg, as a supplier of production systems, offers a wide range of automation-related products from a single source. The majority of exhibits in Düsseldorf will be equipped with robotic systems. These will cover everything, from simple pickers to six-axis robots featuring the Selogica user interface and complex turnkey systems. A new product will also be on show in the area of linear Multilift robotic systems. For the industrial additive manufacturing of plastic parts, Arburg will present the Freeformer, which supplements its machine range to cover individualised one-off parts, prototypes and small-volume batches. With Arburg Plastic Freeforming (APF), functional plastic parts can be built up layer-by-layer on the basis of 3D CAD data. One of the key benefits of the Freeformer over conventional processes is the fact that the system can process qualified low-cost plastic granulates, as also used in injection moulding. These include PA, ABS, PC and TPU, as well as blends of these materials with special properties. We will continue to develop the Freeformer and Arburg Plastic Freeforming (APF) on an ongoing and practical basis. The focus is on points such as the qualification of more materials and process stability. The Freeformer now features, for example, an optimised build chamber with improved air and temperature control. A material dryer is also optionally available, which is integrated in the machine control system. We have also significantly extended the maintenance intervals for the discharge system. New applications, materials and parts will be presented on a total of three Freeformers at the K 2016. The exhibits include products to suit practically every industry and every customer requirement: from electric, hybrid and hydraulic Allrounders, robotic systems and complete turnkey systems to the Freeformer for additive manufacturing, service solutions and practical examples of Industry 4.0. The innovative exhibits and world premieres will demonstrate how Arburg technology will enable plastic parts to be produced more efficiently in future. As a preview, a special Arburg “K 2016” microsite will go online on 1 September 2016, offering an initial insight into the exhibits, focus areas and partners (www.arburg.com/ events/k2016). This will be supplemented by a wealth of detailed information from the first day of the trade fair onwards. Visit: www.packagingeurope.com/News/68411

Hall 13, Stand A13


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Amut Comi Live Demonstration A

MUT COMI - thermoforming division of AMUT GROUP - will present in operation a new generation of thermoforming machines, the ACF series, at K 2016. The ACF 820 machine combines the characteristics of V and F series, thus creating an innovative model having a high level of standardization, exceptional repeatability, rugged durability, flexible production for a wide range of articles, and increased high-speed performances. This range of machines is suitable to handle different materials, such as PET, APET, RPET, CPET, OPS, HIPS, PS, EPS, PP, PLA, PVC and to produce many items: trays, lids, fruits and vegetables boxes, flowerpots, clamshells, nursery trays and plates. The ACF series has a modular concept and can be supplied in different configurations such as forming; forming and cutting in the same station; forming and cutting in two stations; and forming, punching and cutting in three stations. Up or down stackers, three-axis robot as well as customized special solutions are available to stack thermoformed parts with different nesting requirements. To fulfil all thermoformers requirements and to meet any potential demands, the ACF 820 can be equipped with a wide range of options, including: servo driven plug assist on upper and lower mould platens, high performance mould clamping and cutting force, quick tools change devices, different heat ovens configuration with power saving heaters and many others. The forming and cutting presses are equipped with counterbalanced platens to increase the machine performances at high speed. This series of machines is completely servo driven and equipped with a new software for cycles control that, along with a HMI friendly use, guides the operator through the settings pages providing full diagnostic analysis.

The ACF machines can be integrated with a T-IML system (In-Mould Labelling for the thermoforming sector), based on a side entry robot to load labels inside the forming mould in order to decorate the articles. The use of steel rule cutting moulds makes this T-IML even more competitive compared to the existing TIML systems based on punch and die mould and to injection moulding technology. Visit: www.packagingeurope.com/News/68666

Hall 3, Stand E40

“The Face of Innovation”

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he Dow Chemical Company will showcase world-class expertise, technologies and award-winning innovations from its Packaging & Specialty Plastics (P&SP), Elastomers, and Electrical & Telecommunications businesses at K 2016. Through its ‘Face of Innovation’ theme, Dow will demonstrate the latest developments in technologies and applications, as well as shine a light on what is behind every innovation – a team of world-class scientists, researchers, marketing experts and value chain partners that together result in accelerating transformative ideas into real-world solutions for customers worldwide. “For us, behind every innovation there is a story of the people who have worked hard to bring that idea or growth opportunity to life. This is what we will be highlighting at K 2016. The Face of Innovation,” comments Diego Donoso, Business President for Dow Packaging and Specialty Plastics. “Dow’s R&D experts, our Pack Studios innovation centres, and Technical Services & Development leadership means that Dow is able to collaborate with our customers to develop solutions that meet consumer preferences. K offers a giant global stage and tremendous opportunity for our customers to see and experience first-hand our latest product advances and how they were created.” Dow is at the forefront of the plastics industry with new innovations for markets ranging from food packaging, transportation, infrastructure and appliances to consumer durables, utilities, healthcare, medical and more. Increasing consumer demand in emerging regions such as the Middle East, Turkey, Africa, India, and Asia Pacific also means new opportunities. Dow invites K 2016 attendees to learn more about global growth and partnership opportunities made possible by its latest | 160 | Packaging Europe

world-scale plastics growth investments. For instance, Dow’s joint venture in the Middle East, the Sadara Chemical Company, has begun ramping up polyethylene production and delivered its first product to India in February. Dow’s investments on the U.S. Gulf Coast will also provide further growth opportunities for customers in the Americas. “We want to highlight customer successes and demonstrate the opportunities for mutual growth that come from our partnerships spanning across the entire value chain and our investments spanning the globe. The Face of Innovation is a great platform to do this,” said Greg Jozwiak, Business President, Dow Elastomers and Electrical & Telecommunications. “Whether customers are looking for technical information, practical advice, or inspiration for their next innovation, they are sure to find it with Dow at K 2016.” At K Dow will provide a dynamic, first-class experience for customers, with a business and hospitality centre, an interactive collaboration zone, and application/sample spaces on its stand. This is the ideal space for Dow customers and other partners to meet with Dow and see the Face of Innovation and industry thought leaders, to engage and learn more about the many exciting innovations happening across the industry. Visit www.faceofinnovation.com to learn more about how Dow is bringing innovation to life. Stay up-to-date with the latest news and events, and find out more about the Dow stand in Hall 8a. Visit: www.packagingeurope.com/News/68260

Hall 8a, Stand K48


K SHOW News

The Show Goes on for Negri Bossi

Milacron to Display Advanced Solutions

egri Bossi starts a yearlong celebration of its 70th anniversary in the manufacture of injection moulding machinery at K 2016. The company’s stand will tip its hat to the past whilst presenting ideas, developments and innovations that will help shape the future of this Italian leader in the injection moulding market. The stand will feature the very first showing of its new generation of all electric “Project ELE”. With both improved physical specification and performance this completely new product is designed to have a wider appeal in areas such as packaging and medical. The machine has the all new Tactum multi-touch controller with features such as remote access, in built camera and of course gesture navigation thanks to the introduction of the multi-touch. The machine also features its new “smart flex 2” locking unit with a different toggle geometry designed to be coupled specifically with electric closing and to have characteristics optimised to its target market. The range has 11 models from 50 to 650. Available to see at the show will be two new X concept clamp units, an 850 unit with hydraulic actuation and 720 with electric actuation. The new clamp units are designed to have all the positive characteristics of a toggle whilst competing with two platen units in such aspects as footprint and cleanliness. The 850 unit will be shown as a complete machine which will highlight certain concepts and technologies that the brand will look to release on future series models. Negri Bossi already at the forefront in controller technology with both the Tactus (single touch) and Tactum (Multi touch) controllers, will also give visitors a glimpse into the future of how new technology can be applied to make the interface more intuitive and easy informative. Visit: www.packagingeurope.com/News/68922

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Hall 15, Stand B22

Hall 1, Stand A39

ilacron Holdings Corp. will be displaying its Advanced Plastics Processing Technologies (APPT) featuring Milacron, Ferromatik and Uniloy product branded injection, PET, blow and extrusion offerings in Hall 15 Booth C06. Milacron’s Melt Delivery and Control Systems will be on show, featuring Milacron’s product brands Mold-Masters, DME, TIRAD and CIMCOOL. Customers will be offered shuttle service between the booths in order to get a full glimpse of the Milacron portfolio working together in the two booths. The industry’s only integrated plastics processing provider, Milacron has combined the individual strengths of industry leading product brands Ferromatik, Mold-Masters, Uniloy, DME, TIRAD, Kortec and CIMCOOL. Technologies such as injection, PET, co-injection, extrusion, hot runner systems, control systems, blow molding and mold technologies have been unified to create the industry’s most comprehensive integrated plastics solutions provider. Milacron will aim to illustrate how its new integrated approach, as well as its rich portfolio of products, provides customers with engineered solutions. Visitors to Milacron’s booths will be able to take a closer look at the future of plastics processing technology. “K 2016 provides us with the opportunity to show the world what’s new at Milacron. There are so many exciting developments happening at Milacron, our focus remains on ensuring our customers succeed. It’s been over a year and a half since we combined the industry’s leading plastics processing brands under one roof,” said Tom Goeke, CEO of Milacron. “K is a truly international trade show and it’s the ideal platform for us to showcase our innovative technologies and products, and demonstrate to customers how Milacron can help them succeed through our innovative, end-to-end service solutions.” Visit: www.packagingeurope.com/News/68954

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World premieres, innovations and highlights from NGR, BritAS and Collin at K2016 FELDKIRCHEN an der DONAU (AUSTRIA): The Austrian-German NEXT GENERATION GROUP, comprised of Next Generation Recyclingmaschinen GmbH, BritAS Recycling-Anlagen GmbH and Dr. Collin GmbH, showcases new processing methods, innovative technology and profit-generating services along the plastics value chain in exhibit hall 9 at the K2016 trade fair.

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ERO SCRAP Production” in live demo. At the booth in the exhibit hall, a new pilot plant solution from Collin will manufacture PP film. The film edge trims and film rolls will be further processed into rPellets by an NGR recycling machine. The processed plastics will then be returned back into film production. An inline melt characterization unit developed by Collin will also provide advanced quality control of the new plastics raw material during the recycling process. In this setup, the processing parameters will be further monitored, recorded and analyzed in real-time on the recycling machine, and displayed for attendees on mobile devices in easy-to-understand charts. This new form of human-machine communication is designed as S.M.A.R.T. DIALOG: it provides for considerably improved equipment utilization, rationalization in terms of service and maintenance, and provides all the data to evaluate the recycling investment.

“Demonstrating the technological expertise of the NEXT GENERATION Group and the resulting opportunities for all of our customers is the focus of the K2016 trade fair,” explains Josef Hochreiter, CEO of NEXT GENERATION Group. “The activities and competencies of the individual companies produce a unique combination that is highly sought after by research institutes, universities, plastic processors and recycling companies,” says Hochreiter. Identifying customer requirements. Responding with innovations. In live operation, Collin laboratory and pilot systems will show how plastics and processing methods, in both the raw materials industry as well as in plastics converting, can provide the basis for even higher-performance product design. Modularity, precision, flexibility and the highest repeatability are all included. This year, Collin will provide a live demo at the NGR booth of an interesting technology for post-industrial and post-consumer recycling. Continual development of filtration technology. The melt filtration system plays a critical role in the production of high-quality post-consumer pellets. BritAS will present the latest version of its successful band-melt-filter, which is easier than ever to operate, supports more flexible applications and allows for minimal operating costs. Widening the lead in plastics recycling technology. S.M.A.R.T. DIALOG from NGR virtually enables the machinery to speak and alongside key operating data it provides the process analyses to ensure recycling success at minimal cost. As part of a live demo, the system will be demoed for the professional audience on mobile devices. Many evolutionary steps are increasing the output of NGR systems while also providing lower energy consumption. The P:REACT series will be presented for the first time; it follows the revolutionary LSP process (world premiere). With this technology, rPellets with better properties than virgin material can be produced and decontaminated reliably and within minutes. Additional offerings in the area of post-consumer recycling further round out the NGR range of products and services.

Read more about the world premieres, innovations and many other highlights from NGR, BritAS and Collin at K2016: NGR + BritAS Booth: Collin Booth: | 162 | Packaging Europe

Hall 09, Booth 9C30 Hall 09, Booth 09C20


Fast Facts: Next Generation Recyclingmaschinen GmbH Fast Facts: BritAS Recycling-Anlagen GmbH

Fast Facts: Dr. Collin GmbH

Company profile

For inquiries for Next Generation Recyclingmaschinen GmbH

Manufacturer of equipment for recycling of thermoplastics, laboratory and pilot systems, filtration systems.

Michael Heinzlreiter CMO Next Generation Recyclingmaschinen GmbH 4101 Feldkirchen/Donau Tel.: +43 (0) 7233 70 107-0

No. of employees: Approx. 250 Locations: Austria, Germany, USA, China, Malaysia Group Sales: Approx. EUR 60 million Year founded: 2014 Homepages: www.ngr.at www.britas.de www.drcollin.de

For inquiries and press relations for BritAS Recycling-Anlagen GmbH and Dr. Collin GmbH Dr. Isabella Pichler Public Relations & Corporate Communications Traunufer Arkade 7/501, 4600 Thalheim Tel.: 0676 / 73 98 955 Email: isabella.pichler@drcollin.de

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The customer is king at Inpak Makina Since its foundation in 2006, Turkey-based Inpak Makina has grown to be a major supplier of thermoforming lines. Elisabeth Skoda spoke to general manager Ridvan Inan, sales and marketing manager Sertunc Gunay, sales engineer Mustafa Eren and sales engineer Robert Purves to find out more about the company’s upcoming appearance at the K Show in Düsseldorf in Germany and its customer-focused approach to business.

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its headquarters in Istanbul, Inpak Makina focuses on the production of high quality and high performance thermoforming machines. The focus is international, with exports to five continents and almost 30 countries. Currently, 90 per cent of the company’s machines are exported, and over 200 machines are being run successfully worldwide. Annual turnover amounts to around €18 million. “Our management team has over 30 years of machine development experience. Today, we are operating with 50 expert members of staff including R&D and Machine Operatives. We span a production area of 4000 m², and we have a production capacity for 50 machines per year,” Mr Inan is proud to point out.

Poised for success Mr Gunay is happy to report that Inpak Makina is the market leader in the thermoforming sector in Turkey and that every major producer in Turkey has Inpak machines. “All of our customers are extremely happy with our machines, which we can tell from customer feedback and from the orders that we have received. Plastic processing is a wide sector that includes different kind of machines for different applications, and we have

achieved increasing market shares within the thermoforming industry around the world, and especially in Europe,” he adds. The company’s international focus is underlined by the regular attendance of international and local trade shows, including K Show in Germany, NPE in the USA and also exhibitions in Turkey. “We will continue to exhibit in targeted and developing markets, and in the future, will also expand our product range with thermoforming machines with larger and smaller forming table sizes,” Mr Gunay says.

Product portfolio Inpak specialises in automatic roll-fed stationary thermoforming lines. “Our core product is the TS-800 machine, which has a maximum tooling size of 800x580 mm. In recent years we have been asked to build different sized machines. Customer requests are important for us, so our R&D department started to design larger and smaller machines. We are about to finish development and starting from next year we will able to offer both these machines to our customers.” Mr Eren says.

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He is keen to point out the company’s unique selling point of being able to offer top quality and top performance machines at very competitive prices. “Our machines have world class technology built into them, which is combined with our engineering and developed software. As a result, we are able to provide a machine which is of top performance in its range. The TS-800 machine is fully equipped with servo controlled forming, cutting, stacking and optional hole punching stations. All machine sections can be easily adjusted and controlled by touch screen.” Customers are offered variable options according to their needs, based on the entry level standard of the machine in order to increase efficiency. “For instance, we have robot stacker options with variable functional modes. Up and down stacking on the same machine will also be available with the usage of robot stacker shortly.” Mr. Eren adds. Inpak’s R&D department are constantly working on new projects and improvements. “We recently completed our upgrade of the new design Pre-Heater unit. The old PreHeater has been phased out and the new model has been available from the beginning of 2016. It now has an increased heater capability, with a higher standard of construction and a more solid casing,” Mr. Purves says.

K 2016 At the K Show 2016 in Düsseldorf, Inpak will be exhibiting a working TS-800/4-R as a 4-station full option machine with a robot stacker. “Our visitors will be able to see all the features and options on the machine and they will be able to get all the technical info from our staff during the exhibition,” Mr Gunay says. “The K Show is the biggest exhibition for the plastics industry and always attracts both visitors and exhibitors from all over the world. It is a great opportunity to meet people from various industries and markets. It is a pleasure to get the chance to meet with many of our customers who over the years have also become our friends. The K Show has always been a driving factor for our business and we are sure that we will make many more good business connections again this year,” Mr Inan adds.

Customer support Inpak is proud of its customer focused approach to business. “Our customers are working on a 24/7 basis, and production continuity is crucial to them, especially in fast moving industries such as food packaging. That is why we are always on hand to support our customers with technical advice and spare parts and we never leave them to their fate. When needed, we react fast, wherever our customer is and ensure continuity of production. We also offer customer specific software development since the software is completely under our control,” Mr Gunay adds. Mr Purves is keen to highlight Inpak’s performance, quality and support level at competitive prices paired with happy customers. “We see that once a customer chooses Inpak, they do not seek for alternative solutions in future investments. This makes us happy as it is an important indicator of customer satisfaction.” | 166 | Packaging Europe

Looking ahead Inpak has always been investing in its technology and improvements in every stage of the business. Providing continuous customer satisfaction over the years resulted in increased growth, and the company expects to be able to generate similar growth in the years ahead. “Our continuous growth over the years generated the need for a bigger facility and because of this we moved into our new rental factory building at the beginning of this year. In anticipation of future business growth we are planning and designing a new factory building and we aim to move our own 10,000 m² factory building next year,” Mr Inan concludes. Visit: www.inpakmakina.com.tr


iPB Printing is a European market leader in the supply of flexible, innovative packaging solutions. Philip Yorke talked to Tom Lavrijssen, the company’s marketing manager, about its recent investments in new technology for in-mould labelling applications and the products it will be showcasing at the forthcoming K2016 trade fair.

Taking in-mould

labelling further i

PB is an independent family-owned business that was founded in 1938 as a dairy company selling milk, butter and eggs. The company moved into the confectionary sector during the 1970s and then established its own packaging and printing business in the 1990s. This sideline quickly developed into the company’s core business and focused on developing and producing flexible, innovative packaging solutions for a broad range of customers. Today the company is still managed by members of the original founding family and is setting new standards in flexible packaging, adhesive labels, and particularly in-mould labelling.

Innovation driving sales iPB has invested heavily in new technology for its in-mould labelling operations and sees this sector as its main driver for growth. The company is constantly developing its IML products in order to remain leaders in this fast growing market sector. All labels are

rotary punched, which means that they are dimensionally stable. The company uses the UV Flexo and digital offset printing techniques which offer many advantages and options for its customers. Lavrijssen said, “Our investments in the in-mould labelling process have been growing steadily and producing the results that we were hoping for. This sector already represents a major part of our turnover. However, we still want to promote our expertise in the manufacture of adhesive labels and flexible packaging items such as sachets and stickpacks, for which we are very well known. We try to invest a lot in new technology and new projects and in the in-mould market, where no two products are the same, we work closely with our customers to achieve the best outcomes. “We have unrivalled expertise in Short-life IML, Mid-life IML and Long-life IML, all of which benefit from the high standards we set ourselves. Our facilities extend to more than 4500m2 and we have recently invested in 2 new HD-UV-Flexo machines. This 10-colour printing press will be one of the most advanced machines on the market Packaging Europe | 167 |


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and will ensure that we can work more efficiently in order to best serve our customers. This high-tech piece of equipment can switch between printing plates automatically, so that we can change jobs ‘on the fly’. This in turn will save a lot of time in setting up the machine, which greatly enhances efficiency and reliability. “Compared to other printing methods, we strongly believe in our advanced UV-HD flexo and digital printing solutions. With these we can combine the highest graphic quality with short lead times and low start-up costs. Also sticky- and mixed labels are no issue with this production method. “We serve some of the biggest European brands and companies. What is more, there is no limit for in-mould labelling at iPB, whether it is 500 labels required for samples, or 5,000,000 pieces needed for a big retail brand – it is all the same to us. Our slogan is: ‘Imagine no limits – we go further’.”

Super clear success Today there is a growing demand for in-mould labels which are crystal clear and require printing with high opacity. iPB has developed a unique concept to satisfy this need: This concept can be used for end products which have been manufactured from a transparent plastic, offering customers the possibility to decorate the final product and also provide it with transparent zones. The label is manufactured with a highly transparent film in combination with an exceptionally clear varnish or laminate, thereby creating a ‘no label look’. On surfaces where there is a decoration, an opaque white layer is applied which gives sharp a contrast to the printing colours.

The company can also print two white layers, which will produce an even better result, a process iPB calls ‘Advanced White Plus’. Lavrijssen added, “At the forthcoming K2016 trade fair we will be showcasing our latest innovations and our broad IML product range. By demonstrating the quality of our UV-HD flexo printed labels and end products, we will be able to convince visitors of our consistently high standards. Our ‘regular’ IML concepts are implemented by our global multinational customers, where millions of IML labels are constantly being processed by the injection moulding machines without interruption.”

More flexible packaging Today flexible packaging has to satisfy increasingly strict legislation and legal requirements. Customers want packaging that is innovative and strengthens their market position and also complies with all the technical and legislative constraints. At iPB Printing the company guides its customers through the process and works together with its clients to create the precise packaging that they require. iPB is also very experienced in the field of EU legislation, especially in relation to food and beverage packaging sectors. The company sees one of its main strengths as being able to be flexible so that a customer gets the same high quality and dedicated service whether it is involved in small, medium or large print runs. For further details of iPB’s innovative in-mould printing and flexible packaging products visit: www.iPBprinting.com

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Total Polymers plant in Antwerp (Belgium)

TOTAL, PIONEERING SUSTAINABLE POLYMER TECHNOLOGY Total is at the forefront of sustainable polymer technologies and a global market leader in this field. Packaging Europe talked to Xavier Bontemps, the Senior Vice President for Total’s Polymers Business Unit, about the upcoming K-Fair, its latest sustainable polymer products and its move into new markets.

Xavier Bontemps, Senior Vice President for Total’s Polymers Business Unit

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Total Polymers plant in Feluy (Belgium)


Total Lumicene Supertough® for weight reduction in packaging

Total Lumicene® grass yarn for synthetic turf,

Excell-Cap® brand polymers for the caps and

a water-saving approach to sport field construction

closures market for weight reduction

“T

he K-Fair is an excellent opportunity to reaffirm our commitment to our customers,” declared Mr Bontemps. “While technical developments and achievements are clearly important in our business, we recognise that our customers and their success is the most critical factor to our own success. Our regional and local presence allows us to work closely with them to understand their specific needs and, in partnership with them, to build solutions over time that add value.

“Our distinct offer is that we can provide solutions which are tailor-made for each customer’s needs. Our customers and their success is a critical factor to our success.” Total’s polymers business unit employs specialist teams in three zones – America, Asia/ Middle East and Europe – to increase their proximity to key global markets and customers. Its industrial production facilities are located in China, France, Belgium, Spain, the US, South Korea and Qatar. The company has a state-of-the-art R&D centre in Feluy, Belgium and supporting facilities in Europe, the US and China, as well as 20 R&D partnerships with universities and promising young companies across the three continents. With the cumulative experience of its founding heritage companies, the current polymers business is backed by six decades of expertise in the field and is a significant entity within Total’s Refining & Chemicals branch.

Driving a sustainable polymers business forward Total’s three families of polymers – polyethylene (PE), polystyrene (PS) and polypropylene (PP) – cover more than 60 per cent of the world market for plastics. Its extensive portfolio serves the vast majority of world markets and applications. “Historically,” stated Xavier Bontemps, “Total has been a pioneer in the world of polymers with novel patents and developments in key areas of expertise, such as catalysis, processes and products. Today, we leverage and apply those developments through our own production and product portfolio as well as through licenses of select PE and PS technologies, including multi-stage processes and metallocene catalysts.”

Mr Bontemps explained: “Our polymers business is backed by a fully integrated industrial Group. This is a significant advantage compared to our competitors. We are the world’s fourth-ranked oil and gas company, a global leader in solar energy and oriented towards the future.”

Examples of successful innovations Total’s new generation of metallocene polyolefins is defined by its Lumicene® brand, an advanced polymer developed by the company to provide next-generation performance for both PE and PP grades in a variety of applications. Total’s Lumicene Supertough® brand of PE products have been developed to allow customers to produce films which are 25 per cent thinner and have lower energy consumption, yet are just as strong as existing thicker films. Total has also developed a number of new products for the caps and closures market; with the Excell-Cap® brand, manufacturers can produce caps that require substantially less raw material. For the insulation market, Total developed TotalExcell-R®, an enhanced grey Expandable Polystyrene (EPS) that provides exceptional thermal resistance (‘R’ values). “We are one of the few majors to continue with polystyrene (PS) developments and innovations that are applied on an industrial scale,” acknowledged Mr Bontemps. “As a result, we are able to offer new and novel ‘step-changes’ in our products that significantly enhance transparency, impact resistance, stress crack resistance and gloss. Currently, Total’s polystyrene sales represent 25 per cent of the total global market demand.”

Delivering on real solutions for a circular economy “The catalyst and polymerisation technologies developed by Total in the past years are the building blocks of our new (high-density polyethylene) Circular Compound product range,” explained Xavier Bontemps. “These compounds containing recycled material outperform virgin materials and actively contribute to the circular economy. In addition, we will soon be offering a new range of PS and PLA bio-compounds that are unique to the market. In summary, along with these developments, we are one of the few companies to offer a complete portfolio of PP, PE and PS products for the plastics markets. Our distinct offer is that we can provide solutions which are tailor-made for each customer’s needs.” Packaging Europe | 171 |


Total Polymers Research Center in Feluy (Belgium)

“Total’s new Circular Compound product range containing recycled material outperforms virgin materials and actively contributes to the circular economy.”

With over 20 years’ experience in biofuel production, Total is also Europe’s leading marketer of biofuel. They have recently invested in a large biofuel refinery where high-quality biodiesel will be manufactured from feedstock primarily consisting of used vegetable and other renewable oils. This investment is a platform that enables Total to provide renewable, bio-based feedstocks for its polymer portfolio for which developments are already well underway. “The world plastics market is growing at more than four per cent per annum,” affirmed Xavier Bontemps. “Whilst plastics are the best alternative to traditional materials in terms of carbon footprint, our pressing challenge now is to scale up to a profitable circular economy. This is why recycling and bioplastics are growing at a rate which is a multiple of the growth rate of plastics in general.” “As far as future growth is concerned,” he concluded, “We will continue to explore both downstream and upstream opportunities and are open to entering into joint ventures and acquisitions, if the synergies are there. Right now, we are seeing renewed profitability and significant growth as a result of our new applications and a lean and more efficient sales and marketing platform.” n Visitors to the K-Fair can find Total at booth E15 in Hall 6. For further details of Total’s innovative polymer products and services visit: www.polymers.total.com | 172 | Packaging Europe

Total Polymers plant in Ningbo (China)

About Total Total is a global integrated energy producer and provider, a leading international oil and gas company, and the world’s second-ranked solar energy operator with SunPower. The Refining & Chemicals division of Total combines refining and petrochemical activities with specialty chemicals and employs almost 45,000 people worldwide. The division is Europe’s leading refining company and second largest petrochemical manufacturer. It boasts 14 refineries, 26 petrochemical and over 110 specialty plants around the world. It produces and provides its customers with a wide range of petroleum products, chemical-based products and polymers, which are aimed at a wide range of industrial and commercial markets.

We are engaged in a process of continuous improvement of all aspects of our business in line with our commitment to better energy. Among the key programmes is the Responsible Care® commitment. The Responsible Care® initiative is the shared commitment of the global chemical industry to responsibly manage its chemical products throughout their life cycle and to promote their role in improving quality of life and sustainable development.


BREYER ThermoFlex extrusion – the modular Breyer

concept

At the forthcoming K-show 2016 in Düsseldorf, Germany, Breyer will present, alongside its regular range of extrusion lines, the Breyer ThermoFlex film/sheet line for the production of PET, PS and PP film.

W

ith the Breyer ThermoFlex system, in a co-extrusion version for 3-layered film, the fast startup of a PET film system and quick changeover to different film thicknesses is made possible. Pure recycling material can be processed with a 120mm single-screw extruder and a 60mm co-extruder with a total performance of 1100 kg/h. For the functional retrofitting of the system, Breyer offers a number of progressively conceived building blocks that save time, raw materials and, hence, money – all of the required preconditions for economically efficient film extrusion.

Setting new standards in film extrusion PP, PS and PET are the dominant materials in the food packaging segment, extruded into film in single- and multi-layers. To increase economic efficiency, additional ground material from the in-house thermoforming production and recycled materials are used. Particularly in difficult markets with strong competition, it is helpful to differentiate with special characteristics. Here, too, better quality always pays off. Since the production cost of the film is largely determined by the raw material (approx. 65 per cent) and not primarily by the investment in the system, it is extremely important to focus on high-quality equipment with operational security, which, above all, saves raw materials and can be quickly readjusted. Drying PET via infrared technology saves time and energy. Up to 100 per cent ground material can be directly processed in the infrared dryer. PP and PS can be processed without the need for a drying process. The combination of a well-tried and simple system setup with advanced Breyer technologies that save time and money enables: fast startup owing to the special melt pump control; and fast adjustment of the film thickness with the BREYER fast&easy polishing nip, making the extrusion economically efficient. The required nip can be adjusted within seconds in a reproducible way, resulting in interesting savings possibilities for the manufacturer, especially in the price-sensitive packaging market. The user profits from a user-guided touch-screen control and the user- and maintenance-friendly system technology. In addition, the technology allows for the production of low-stress flat film, which is a special advantage for the subsequent thermoforming process.

The calender – the quality hub of a BREYER extrusion line: The BREYER ‘fast&easy’ gap adjustment works without any mechanical control parts. A sophisticated system allows for the precise positioning of the rollers – during production and at full load! Any required gap can be precisely adjusted, resulting in speed, precision and operational comfort in one. A maximum in flexibility: BREYER film calenders offer a maximum in flexibility for production. Easy operation with the push of a button: The set values are entered via a touch screen colour display. Fast film thickness setting: In this system, the method of film thickness adjustment is unique in extrusion technology. The gap adjustment has a mode to allow for the precise and automatic adjustment of the gap in between the rollers simply by changing the extrusion speed. The operator changes the speed value appropriate for the new products on the display and has set the required thickness within a few seconds. This represents clear savings in time and cost compared with traditional gap adjustment, where the speed has to be readjusted after the gap correction. At the K-show Breyer will present the Key building blocks of the entire line: Extruder 120, screenchanger, meltpump, die and the calender. For more information, visit: www.breyer-thermoflex.com

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The Evolution of the Bioplastics Industry in Europe European Bioplastics (EUBP) is the association representing the interests of the bioplastics industry in Europe. The diversification of available waste treatment options such as mechanical recycling and organic recycling can contribute to higher volumes of waste being recycled in the EU and are facilitating the transformation to a circular economy in Europe. Libby White spoke with Ms Kristy-Barbara Lange, Deputy Managing Director at European Bioplastics, about the growing duties and focus of the organisation, its successful annual conference, and the increasing involvement in lobbying activities in Brussels.

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O

n their website, European Bioplastics provides comprehensive information and encourages both members and non-members to learn about the opportunities and benefits of bioplastics, their contribution to a resource-efficient and sustainable future, and the shift to a circular economy. European Bioplastics is uniquely placed in the industry with a broad network of businesses, partners, and experts in the bioplastics sector across Europe and beyond. It represents the interests of around 70 member companies along the entire value chain of bioplastics. Ms Lange comments, “In the industry, we are well known as the partner to go to for any questions related to bioplastics. We aim to provide insight knowledge to all interested stakeholder groups. In our daily work, we are increasingly focussing on policy issues and legal framework conditions, gathering policy intelligence, forming industry positions, and representing our members in Europe vis-à-vis the European institutions, while, at the same time, focusing on building and maintaining valuable coalitions with other interest groups. “Since last year, we have paid particular attention to reviving our network with bioeconomy associations on EU level and other bioplastics associations on Member State level in order to work together, exchange information, and join forces to make our voices and arguments heard in Brussels.” For example, European Bioplastics plays an active role in the European Bioeconomy Alliance, an alliance of twelve European organisations active in the bioeconomy. European Bioplastics strongly supports the recently published draft reports of European Parliament ENVI Committee rapporteur Simona Bonafe on the revised European waste legislation. Ms Lange points out that “Ms Bonafe has the right ideas on how to tap the enormous potential of bioplastics within the waste framework of the circular economy package. In particular, she has put great emphasis on encouraging better market conditions for renewable raw materials and promotes the use of bio-based materials in packaging. She has also made very clear that mandatory biobased waste collection is very important.”

Successful events 2015 saw the tenth anniversary of the European Bioplastics Conference, the leading business and networking event for the bioplastics industry in Europe, organised by European Bioplastics, which attracted over 350 delegates and received very positive feedback from attendees such as a score of 94 per cent of good or above for overall satisfaction with the conference programme. This year, the conference will take place on the 29th and 30th November at the Steigenberger Hotel in Berlin and is expected to attract even higher numbers of attendees than in the last years. Ms Lange says, “The full conference programme will be published in September, however we can already confirm a keynote speech from the Ellen MacArthur Foundation who are currently driving the development of the New Plastics Economy with their same-titled initiative, an ambitious, three-year project aiming to transform the current plastics economy into a system that works and is sustainable. “Our conference is strategically timed to take place after the discussions around the circular economy have been held in Brussels. We will hear first-hand insights from Waldemar Kütt from DG Research & Innovation and Hugo Maria Schally from DG Environment of the European Commission.” Another highlight of this year’s conference will be specific topical sessions, such as a session dedicated to the market outlook in Europe as well as an NGO session discussing the potential of bioplastics in a ‘new plastics economy’. In a brand owner session, we will learn more about the end-user perspective on bioplastics and new product innovations from leading brands such as Henkel or Renault. Tetra Pak, for example, will elaborate on their lobbying activities for biobased products in the EU in order to create a favourable regulatory landscape for biobased materials.

Advancements in bioplastics New innovative materials are constantly being developed by the bioplastics industry, for example new packaging solutions with enhanced barrier properties and improved

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Uhde Inventa-Fischer Uhde Inventa-Fischer owns proprietary, cutting-edge polycondensation technologies for producing various grades of polyesters, polyamides and sustainable biopolymers, such as polylactic-acids, with customizable viscosity levels ranging from high over medium to low. It’s know how is based on engineering experience gained since 1924 by constructing more than 250 polycondensation plants worldwide as well as through intensive research and development work in close cooperation with prominent scientific and industrial partners. Uhde Inventa-Fischer is part of thyssenkrupp Industrial Solution’s polymer division with two locations in Berlin, Germany and Domat/Ems, Switzerland. Around 150 polymerization specialists and engineers cover the entire field of professional project execution from R&D trials and studies, via plant engineering with delivery of proprietary- and key- equipment only, up to procurement- and construction- services for turn-key EPC projects strength and breathability, adding to the functions and properties required from conventional plastic packaging materials. European Bioplastics’ role also is to highlight these innovations, such the latest research and development project of NatureWorks, which aims to develop and commercialize a process to produce bioplastics from the greenhouse gas methane. A joint venture between BASF and Avantium focuses on the production and marketing of furandicarboxylic acid (FDCA) based on renewable resources, the main new building block for polyethylenefuranoate (PEF). Compared to conventional plastics, PEF is characterized by improved barrier properties for gases like carbon dioxide and oxygen. This can lead to longer shelf life of packaged products. Due to its higher mechanical strength, the thickness of PEF packaging can be reduced, thus a lower amount of packaging material is necessary. Therefore, PEF is particularly suitable for the production of certain food and beverage packaging, for example films and plastic bottles. After use, PEF can be recycled. European Bioplastics also promotes new applications and products, such as a certified bio-based and compostable coffee capsule for Nespresso systems from Original Food GmbH. The entire capsule, including the cover, is bio-based, free of aluminium, and compostable according to the European standard for industrial composting EN13432. Within 12 weeks, more than 90 per cent of the material will have turned into CO2, water and humus.

Project involvement The European Bioplastics Conference is the leading event for the bioplastics industry in Europe and is an ideal environment for attendees to find new business partners, to form collaborations, or to discuss how to drive bioplastics innovations forward collectively. European Bioplastics itself is often sought to be part of collaborations and EU-funded projects, such as the Swedish project STEPS (sustainable plastics and transition pathways), a project introduced and approved by the University of Lund, where European Bioplastics is part of the board of experts. It is also active in other projects such as Open-Bio, which investigates how markets can be opened for bio-based products through standardization, labelling and procurement. Part of the project is to conceptualize an Ecolabel that can

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in close cooperation with more than 19’000 specialists in over 70 worldwide locations of thyssenkrupp Industrial Solutions.

be applied to bio-based products to strengthen consumer confidence and boost market demand. Ms Lange concludes, “Looking into the future, although there are currently many valuable projects we are involved in, as part of our agenda we aim to create a project to bring together delegates from all over the bioplastics value chain. We have a comprehensive overview and have the tools to establish the industry as one of the main drivers of the circular economy in Europe. This is not going to happen over night and we are supporting this transition with the necessary information, lobbying, research, education, projects, n and of course a focus on future developments.” For more information, visit www.european-bioplastics.org


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The film family Famous for its innovative Internal Bubble Cooling control system, family-owned ‘value added technology’ company D.R. Joseph, Inc. is truly dedicated to delivering the best possible products, service and solutions to its customers worldwide. Emma-Jane Batey spoke to CEO Daniel Joseph to learn how this is being achieved.

F

ounded in Arlington, Texas in 1987, family-owned and managed packaging technology company D.R. Joseph, Inc. truly delivers on its promise of adding value through technology. CEO and founder Daniel Joseph spoke to Packaging Europe to explain how, in a sea of innovative packaging technology companies, D.R. Joseph, Inc. stands out from the competition. Mr Joseph said, “We’ve been totally focused on serving the blown film industry since we started, so that’s nearly 30 years. And since day one we’ve always been improving and developing, always looking for fresh ideas, fresh solutions that keep giving added value to our customers.”

Head of the family CEO Mr Joseph is the best possible advocate for his eponymous company; his passion for providing the blown film industry with the very latest in Internal Bubble Cooling (IBC) control systems means he is both knowledgeable and interesting. He continued, “We’ve always been committed to serving the industry and I feel our long-term, ongoing investment shows that. We’re very much a serious player in the market and will continue to push forward for the benefit of our customers. I love talking to people about what we

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can do to help them; our product portfolio is second-to-none and I know that our teams are the smartest, most informed people – they’re ready to support customers with an IBC control system that will totally work to their advantage.” From its headquarters in Arlington, Texas, D.R. Joseph, Inc. is able to serve customers worldwide. Already a market leader in North America, the company’s increasingly large global footprint means it can provide the same high quality products and services to customers wherever they are located. Mr Joseph explained, “Europe was actually our first export market during the 1990s and we’ve enjoyed excellent growth here thanks to our consistently strong sales representation. Very sadly our European rep passed away and this meant we saw a considerable drop in our European activities, so now we are focused on redeveloping our presence. This is why we are particularly excited about attending the K Show; we’ve always been supporting our OEMs at their booths in the past, but this show we have our own booth too.” Mr Joseph continued to explain how D.R. Joseph, Inc. expects to grow outside of Europe too. He said, “We’ve recently added representation for Mexico, Central America and India; areas we’ve supported without specific representation in the past. We are also very pleased to report that our domestic North American market is still going through a


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period of replacing old equipment, which translates to strong retrofit sales. OEMs in Asia and India are also improving in the capabilities they can provide and our IBC systems fit perfectly into that process. We are also seeing some good growth coming from Mexican and Africa film producers, so all in all it is a very interesting time for us.”

Ready with solutions With D.R. Joseph, Inc.’s company slogan ‘when you need solutions...not just answers’ perfectly illustrating its dedication to guaranteeing added value technologies for its customers, its product portfolio is carefully presented. Exclusively serving the blown film industry, the company offers control solutions for ‘geomembrane to liner bags, food and medical applications and everything in between’. As Mr Joseph said, “I often tell customers – ‘if you can blow the film, we can control it’. If we can’t do it now, we’ll certainly work on it until we can.” It is this positive attitude that makes D.R. Joseph, Inc. a highly valued partner in Internal Bubble Cooling control and bubble stability technologies. With its flagship product the IBC control system, the company is now on its third generation system, which is capable of more than ten different configurations in order to meet the needs of any film producer, from basic IBC control to full management of the bubble. Mr Joseph noted, “It makes perfect sense for an OEM to use our system because it is so easy for us to adapt it to any requirement in order to meet their performance needs. For film producers, we use our product line flexibility to retrofit and upgrade any IBC system on the market to deliver higher production rates, quicker start-ups and improved width control.” Similarly, | 182 | Packaging Europe

D.R. Joseph offers an innovative machine directional sealing unit that exceeds in providing reliable seals from thin to thick films and everything in between. As D.R. Joseph, Inc. is constantly working on improving performance, new capabilities and improving efficiency of all its products, it looks set to cement its position as a leading partner to the blown film industry worldwide. Mr Joseph concluded, “As an auxiliary supplier of equipment, we work hard to guarantee our customers can rely on us and our service. Many of our new developments are centred on process monitoring and reporting as IBC is a difficult process to troubleshoot; our systems are designed especially so that our customers can get help with knowing exactly what happened and why. We’re always able to help, wherever they are in the world, whatever time it is! Our slow, steady growth n will continue as we keep improving and developing.” Visit: www.drjosephinc.com


The new 16:9 HMI allows more inspection modules to be displayed side-by-side

Preform Quality Inspection

When it comes to quality inspection of preforms, several questions occur for the producers: Which kind of inspection is the best? How can it be done not only precisely and quickly but also in order to save time, using as few man-hours as possible? And if it will be made by a machine, will this use up much of the valuable floor space? The PreWatcher III in its updated version including numerous

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improvements in hardware and software


The two way conveyor provides a safe transportation, optimizing preform closing into the centrifugal feeder

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he inspection of preforms is a challenging task and has to be carried out thoroughly. As a preform is an early version of the final product, even very small defects have to be detected as they might become bigger further up the production chain. The challenge for an inspection system is to provide detailed data about the object yet be able to inspect in a comprehensive and objective way without delaying the production. In this regard, there is evidence suggesting that a vision inspection system is the device to choose.

PreWatcher III The PreWatcher III by the German company Intravis is an inspection system especially designed for inline inspection of preforms. It can be installed either behind an injection moulding machine or before a stretch blow moulding machine. The entire system takes up a footprint of eight square metres. Besides the option to use the PreWatcher III inline, it also can be used for offline inspection in combination with a bunker, tipper and octabin filler. The PreWatcher III inspects the quality characteristics of up to 72,000 preforms per hour. The orientation mechanism operating with centrifugal force is integrated directly into the system. Additional space-consuming equipment for preform orientation is not required. Eight cameras ensure all areas of the preforms are inspected: Six cameras are responsible for the thread and body inspection while two cameras inspect the top sealing surface and the gate area.

Exhibition at the K-Fair On this year’s K-Fair in Dusseldorf, the new version of the PreWatcher III will be showcased for the first time. The upgrade contains various improvements and optimisations. | 184 | Packaging Europe

“When we introduced the PreWatcher III at the last K-Fair, it was an entirely new type of inspection system,” states Gerd Fuhrmann, managing director of Intravis. “Within the last three years we have gained a lot of experience with the system in the field, allowing us to present an even more elaborate version. Our goal was to refine the system and make it faster and more reliable.” According to this vision, the PreWatcher III has been updated all over and equipped with many hardware and software innovations. A major improvement is the two way conveyor, which allows for the better feeding of the centrifugal unit and optimises the system for inline use. The centrifugal feeder is always filled in an optimal way resulting in a significantly improved overall performance. Moreover, the customers can now choose from a wider range of personalisation parts. These have been optimised for a gentler preform transportation just as with outside tapered preforms. To boost this effect, a refined running rail has been installed for a smoother preform transport. A broader variety of preforms is now inspectable, including oil preforms. An easier assembly of the V-guide is possible through a mounting bracket.

Easy body length adjustment For the lighting setup, a preform jig is installed close to the sealing surface inspection station. It is an optional extension that can be used to determine and adjust the body length setting without having to measure the preform. The body length setting defines the appropriate distance of the camera and lighting unit from the preform for the dome inspection. To do so, the preform simply has to be inserted along, with the support ring, into the slot in the holder on the preform jig. In addition, some general hardware improvements have been made on the PreWatcher III. These include a new cover for the centrifugal feeding which is more stable and less susceptible to damage; furthermore, noise insulation has been added at the rotation disc


Easy access to the centrifugal feeder: shutters around the housing are easy to open, reducing downtime when exchanging spare parts

Closed shutter

bottom. The transfer guides have been refined for safer transportation, particularly when it comes to larger and outside tapered preforms. All these alterations provide a safer and more stable flow when inspecting at higher speeds. Another improvement is a new 16:9 monitor with a 21.5-inch display, which makes it easier to observe new inspection modules – as in the future, there will be even more possibilities to inspect preforms. But there is also another need for more display space: As an additional innovation, the PLC, controlling and visualizing the status of the entire system, has been integrated into the self-developed software IntraVision. Now the troubleshooting is easier and settings such as the conveyor belt speed are more comfortable to adjust. The system can also be equipped with two monitors, if necessary. The cabinet has been redesigned as well as updated, and now allows for the integration of future enhancements. A new and faster computer has also been integrated.

Access with shutters New shutters with a recess beneath provide an easier access to the centrifugal feeder, resulting in a shorter downtime when exchanging the ring guides. They can easily be opened and removed by simply pulling a lever. The disc separator is yet another innovation on the PreWatcher III. It is positioned right above the centrifugal feeder, being tied to the middle pillar, and separates sticky preforms from one another. When in use, it leads the preforms to the outer gap quickly where they will fit in. This prevents a tailback of too many preforms in the centrifugal feeder, and small preforms in particular can now be put in order even quicker. This means that even faster inspection of small and light preforms is now possible. The day-to-day working environment requires a highly flexible inspection system, especially when preforms of a different colour have to be inspected. The new PreWatcher III offers this flexibility with switchable lighting. The standard lighting is white light for transparent or translucent preforms of any colour. For virtually opaque colouring, as is

Open shutter

often used with beer preforms, infrared light is an additional possibility for inspection. Further lighting has been added to support the cavity number reading, enabling the system to read even smaller or inaccurately engraved numbers. In addition, a spectrometer measures the colour deviations of every single preform precisely, including the absorption of infrared and ultraviolet light.

New neck support ring inspection The PreWatcher III also contains new software: One example is the new inspection module PWN, which inspects the neck support ring of the preform. It does not require any additional hardware equipment and the images taken for the cavity number reading are also used to inspect the neck support ring. Deviations like damages, spallings, notches and bendings are detected, which might otherwise cause greater damage during the production process. With all these improvements and alterations, the PreWatcher III can be seen as one of the most modern vision inspection systems in the world, supporting the customers’ needs in all dimensions. Visit: www.intravis.com

The first version of the PreWatcher III by Intravis was introduced at the K-Fair 2013. It was the first vision inspection system made for inline use that combined a high inspection speed with a very small floor space. The device inspects preforms for criteria like geometrical characteristics such as length and shape deviations, material defects, colour, notches and holes in the gate as well as the sealing surface. It is also the only system on the market that does cavity number reading. On an area of only 86 square feet, the PreWatcher III aligns the preforms gently by centrifugal force, while eight cameras take the images. It has since been continuously developed and is now showcased for the first time, in its upgraded version, at this year’s K-fair.

Preform jig: The object has to be inserted into the slot to determine and adjust the body length setting

About Intravis With more than 20 years of experience and almost 200 employees, the German company Intravis GmbH belongs to the worldwide market leaders in vision inspection systems for the plastic packaging industry. The company offers turn-key solutions for the inspection of preforms, closures, bottles and containers, layers and decoration.

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Kiefel is a global leader in the development and manufacture of machinery designed for processing plastic film materials. Philip Yorke reports on a company that continues to set new benchmarks for innovative solutions that increase productivity and reduce costs while protecting the environment.

High-performance pressure forming K

iefel is part of the multinational Brückner Group of Germany which has manufacturing facilities and sales offices throughout the world. Its international corporate outlook benefits its customers with its in-depth technological expertise and broad flexibility. Kiefel offers core expertise in the fields of forming and joining technologies. As a key supplier to reputable manufacturers in various industries including those in the packaging, automotive, appliances, and medical sectors. The headquarters of Kiefel GmbH is in Freilassing, Germany, however the company runs its own network of sales and service centres in the United States, France, the Netherlands, Russia, Brazil, Czech Republic, China, Indonesia and India.

High performance innovation Kiefel has a reputation for producing cost-effective, innovative solutions for the beverage industry and for many others besides. At the K-2016 Trade Show in Dusseldorf, Germany later this year, the company will be showcasing its latest ‘Speedformer’ machine. When it comes to safe consumption of beverages on the move, a practical click-on-lid is a vital part of the disposable cups used for this purpose. Kiefel’s latest KMD 78 Power machine produces high quality domed lids with a precisely positioned aperture for the insertion of a drinking straw. Domed lids prevent spillage of the liquid in the cup and keep the straw securely positioned in its desired location. The latest Speedformer unit from Kiefel produces such innovative packaging solutions. This smart machine line will be exhibited at the fair along with printing stations and bag-packer devices. Two colour digital printing with a resolution of 360dpi allows customised designs to be applied and individual printed designs are therefore simple to adapt, even for short production runs. The Kiefel Speedformer KMD 78 Power, produces ready-bagged lids straight from the roll of film material with a uniquely complete configuration that includes printing, heating, forming/cutting, as well as stacking and packing options. | 186 | Packaging Europe

Faster cup forming The very latest cup-forming machines from Kiefel, the KTR 6.1 Speed, produces more cups than ever. A significant rise in punching force combined with a greater forming area, increases the number of cavities even more. The newly developed pre-stretching plug is actuated by a powerful linear motor. Faster pre-stretching has a positive effect on material distribution and processing speed, which results in achieving higher quality results in less time.

Smoother hygienic production A new and more sophisticated stacking and picking system allows KTR 6.1 Speed, to produce even thin walled cups in a reliable and cost-effective manner. The KIST vertical stacking system works without the assistance of brushes or rubber elements and the resulting avoidance of friction ensures smooth, hygienic production. This full use of available performance naturally requires top-quality machine tools to match. The tool used has been developed and produced by Bosch Sprang, one of the sector’s most prestigious suppliers. Domed lids designed to fit these cups are produced on Kiefel’s new Speedformer KMD 78 Power machine. Both of these machines will be on show this October at the Dusseldorf K 2106 event.

Pick-up-Stacker Compact to debut at K 2016 Kiefel brings the best producers together under one roof: The K 2016 event will see Mould & Matic present its new Pick-up Stacker Compact at the Bosch Sprang exhibition stand. Both firms have recently become subsidiaries of Kiefel, and this new group dynamic will be reflected in the harmonised corporate design used to mark their presence at the event. The pick-up stacker concept is the leading technology for the production of disposable cups, tubs and capsules. It allows for any type of highly productive further processing, such as hole punching, camera inspection and the automatic packing of stacks of cups into weld-sealed plastic sleeves. For further details of Kiefel’s innovative products and services visit: www.kiefel.com


SiTOR – the world’s leading press manufacturer The company SiTOR Stiskalnice, headquartered in the small town of Pivka in southern Slovenia, is one of the world’s leading manufacturers of hydraulic presses for the production of plastic sheets. This year, it produced one of the biggest presses in the world, and – in order to widen its product range – designed a laboratory press for testing purposes.

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a specialist in the design and manufacture of hydraulic presses, SiTOR is present on the EU and US markets. Innovative solutions, top-quality products and service with short reaction times make the company a reliable business partner. The majority of this mid-sized company’s production (80 per cent) consists of hydraulic presses for the production of UHMWPE, HDPE and PP sheets, followed by presses for the production of rubber products, presses for wood industry and semi-finished products (pressing tools and heating plates). The presses operate under huge forces and are exposed to extremely high temperatures, which result in temperature dilatations. But SiTOR is also an expert in the production of welded moulds – its biggest competitive advantage. The welded moulds, compared to the old screwed design, stand out thanks to their long lifetimes, easy cleaning and minimal maintenance. This design is much more resistant to the forces present during the pressing process. The last screwed mould was produced almost 10 years ago, because the company found that once the customers had ordered a welded mould, they never wanted to go back to the screwed design.

Products delivered in 2016 2016 has been a successful year for SiTOR. Three hydraulic presses for the production of plastic sheets have already been delivered and successfully put into operation, two more deliveries will be carried out by the end of the year. Three projects involve large-scale machines with two opens and four moulds.

The future is already planned SiTOR intends to preserve its place as one of the leading manufacturers of hydraulic presses and plans to upgrade its activity by strengthening its presence in the rubber and wood industries. In order to enlarge its production capacity, the company plans to invest in a new production hall and machinery. The investment will enable it to produce presses of larger dimensions and to offer specific services. However, SiTOR’s main goal for the future is to deliver its high-quality products within the specified time. Visit: www.sitor.si

It’s about making ideas happen In order to constantly improve and innovate, the company welcomes its customers’ feedback and new ideas. One such cooperation resulted in the development of a laboratory press for testing purposes. Production on this innovative press started in May 2016 and will be finished in August, with its main purpose being to test vacuum pressing of different types of plastic material with specific technological and mechanical parameters. The plastic material manufactured using this process boasts better fatigue resistance. More information about this topic will be available at K16 in Düsseldorf, Germany (Hall 14/B09). As a result of another successful business relationship, SiTOR built one of the largest presses for the production of plastic sheets in the world. The 8 x 2 m press with two levels and four moulds was put into operation in Germany.

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Nanocyl’s multiwall carbon nanotube technology

Belgium-based Nanocyl is the leader in the manufacturing of multiwall carbon nanotubes (MWCNT) and formulated products. This article looks at its MWCNT technology for the primerless painting of automotive exterior parts.

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lectrostatic painting is commonly used in the automotive industry to minimise paint waste. The technique is well suited to metallic parts like the metal car body as grounding of metals is an easy process. However, millions of automotive exterior parts are made from plastic to allow weight reduction, design freedom and corrosion resistance. Techniques have therefore been adapted to allow for the painting of exterior metallic and plastic body parts (body panels, bumpers, fenders, wind deflectors, tail gates, mirror housings, door handles, fuel filler flaps) with the same paint and technology. When it comes to plastic parts, an additional process step with a conductive primer is often required to ensure the grounding of insulating plastics during paint application. A cost efficient alternative consists of using plastic containing NC7000™, multi-walled carbon nanotubes (MWCNT) from Nanocyl. The use of NC7000™ suppresses the conductive primer step by giving bulk conductivity to plastics. The removal of the conductive primer results in cost savings and easier grounding/painting. Combined with the improved mechanical properties imparted by MWCNT, these cost and handling advantages provided sufficient incentives for some key automotive equipment suppliers to change technologies and use MWCNT-plastics. Over the past 20 years large serial productions of plastic body parts have been produced using MWCNT technology. Today, additional painted exterior parts using MWCNT – such as panels, bumpers, wind deflectors, mirrors and fuel filler flaps – are under evaluation or qualification in the industry. The MWCNT price decrease, owing to increased global MWCNT production capacity, was a key factor in these new developments. The technical case study below illustrates how NC7000™-reinforced TPO and ABS/PC can add value to automotive painted exterior applications such as bumpers and rocker panels, among others.

based plastic than for a plastic coated with a conductive primer. Both plastics containing NC7000™ exhibit a normalised TE >80 per cent, which ensures minimal costs for the painting operation. Indeed, Volatile Organic Compounds (VOC) emissions and related disposal of waste/costs are relatively insensitive to the transfer efficiency as the latter lies above 80 per cent (Figure 1b).

High paint transfer efficiency at low surface conductivity

NC7000-containing plastics can be used with conventional injection-moulding equipment. Critical mechanical properties (tensile strength, thermal expansion, mould shrinkage, heat deflection temperature, impact strength) and density are not affected, or are only mildly affected, by NC7000™.

Conductive primers are used in paint shops to ensure high paint transfer efficiency on plastic parts (i.e. the amount of paint that coats the substrate compared to the total amount of paint sprayed towards the substrate). This work compares the transfer efficiencies of plastics coated with a conductive primer – as is still used in paint shops – and NC7000™-containing plastics. The amount of NC7000™ in ABS/PC and talc-filled TPO, that would give similar transfer efficiencies to the conductive primer, was minimised. Figure 1a shows the transfer efficiency (TE) of plastic/NC7000™ compounds (normalised to that of the reference plastic with conductive primer) as a function of CNT wt. per cent. Low amounts of NC7000™ (1.0-1.5 wt. per cent) are sufficient to allow the dissipation of the electrostatic charges and ensure high transfer efficiency. Conductive primers generally impart a surface resistance of 104-105 ohm/sq. NC7000™ based plastics provide in-spec transfer efficiencies even with surface resistance as high as 1012 ohm/sq, as long as there is some electrical conductivity in the bulk of the material. Nanocyl demonstrated that the requirement on surface conductivity is much less stringent for a NC7000™| 188 | Packaging Europe

NC7000™: good painted surface quality even without primer Besides transfer efficiency, paint appearance and adhesion are of the utmost importance for automotive exterior applications. Colour was first evaluated by measuring the L*a*b* parameters (CIE LAB) at different measurement angles, as required for metallic colours, and compared to the reference samples with conductive primer. A* and b* parameters (colour channels) were almost unaffected, and lightness (L*) remained within typical tolerance for all measurement angles. Other parameters such as gloss, short waves and long waves (related to surface quality) were also within specification or similar to reference samples. Paint adhesion was evaluated with cross-cut and steam jet tests according to Volkswagen standards (Figure 2). All samples passed the tests, in a similar fashion to the references using primer. The stone-chip impact test was also positive. Altogether, the adhesion tests (also performed after ageing) showed that the paint adhesion is determined by the combination of base resin, paint and flaming conditions when applicable, with no detectable influence of NC7000™ on the adhesion (more information available upon request to Nanocyl).

NC7000™-filled compounds compatible with standard plastic moulding

NC7000™: now a cost-effective option for primerless painting In parallel to technical performances and requirements, cost is another critical component of the material selection. Today, unlike fenders, other exterior parts based on less expensive resins such as impact PP or ABS are still mainly coated with a conductive primer before applying the coat and clear coat. One of the reasons for this was that additional global costs of MWCNT were higher than for the conductive primer process. However, if one looks at the cost/performance ratio of the technologies, the higher cost of MWCNTbased materials is compensated by the following benefits: • Material savings: absence of conductive primer • Reduced installation and maintenance costs (no primer spraying booth and oven for water-based primers)


CROSS-CUT TEST

STONE-CHIP TEST

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Figure 1. Paint transfer efficiency of ABS/PC/NC7000 and TPO/NC7000

compounds, normalised to that of ABS/PC or TPO with conductive primer (stateof-the-art technique to obtain high paint transfer efficiency). The red dashed line indicates acceptable normalised transfer efficiency for key automotive suppliers. b) General evolution of VOC emissions as a function of transfer efficiency.

TPO + NC7000TM

Figure 2. Selected adhesion tests according to Volkswagen standards on non-aged samples. The different conductive substrates pass the three main tests. The damaged area for the stone chip impact test is smaller

• • •

Reduced energy consumption (no drying of water-based primers) or VOC emissions (solvent based primers) Better and easier grounding with bulk-conductive NC7000™ material, requiring less complex grounding bucks and easier painting sequence. Less rejected parts: less dust deposition (antistatic material), better paint wrap at corners and edges (conductive primer can cause conductivity gradients on the edges and local paint accumulation).

Normalized cost per exterior part

Therefore, the evaluation of NC7000™-based plastics should not only focus on bulk material costs but also take into account the above-mentioned performance and hidden value points. Those economic benefits vary a lot depending on the paint-shops of automotive Tier 1 (solvent or waterborne, new or old, etc.), and this variation is represented in the Figure 3 by standard deviations. The latter shows that additional costs per exterior parts have been decreasing since 2010 due to NC7000™ price decrease and a new technical breakthrough evidenced by Nanocyl: a low amount of NC7000™ is sufficient for good transfer efficiency. This combination of factors now makes the use of NC7000™-based plastics both technically and economically attractive for primerless electrostatic painting.

Cost baseline for conductive primer

1,5 1 0,5 0

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Figure 3. Global cost comparison between painted exterior parts with a conductive primer and conductive exterior parts where base coat is directly applied by electrostatic painting. Standard deviations illustrate the sensibility of the cost calculation depending on the automotive Tier 1 (existing or new paintshop).

than 5.5 per cent.

Conclusion: new possibilities for primerless electrostatic painting with NC7000™ NC7000™ can make plastics suitable for electrostatic painting without conductive primer. Low concentrations of NC7000™ are required (1-1.5 wt. per cent depending on the plastic) to achieve a similar paint transfer efficiency as a conductive primer, thereby reducing the impact on mechanical properties and cost. NC7000™ brings electrical conductivity both at the surface and in the bulk of the plastic, which provides additional paths for grounding compared to a conductive primer. The requirement on surface conductivity is therefore much less stringent for NC7000™-based plastic than for the plastic coated with conductive primer. These observations combined with paint adhesion/appearance results therefore open up new possibilities for the primerless electrostatic painting of automotive exterior parts. In addition to reduced cost and VOC emissions, the parts set-up is faster (easier grounding, less connective clips) and the painting is easier (simpler painting sequence with no need to start painting close to a grounding clip), which reduces paint shop maintenance and cleaning costs. With decreasing cost of NC7000™, NC7000™filled compounds are now cost-effective alternatives to conductive primers with several advantage, as follows: • Applicable to most thermoplastics: (mineral filled)-TPO, blends of ABS, PC and PBT, PA-glass fibre, etc • Compatible with existing equipment • Easy grounding and painting without conductive primer • High paint transfer at low conductivity and low NC7000™ loading (1.0-1.5 wt. per cent depending on the plastic) • Paint appearance and adhesion unaffected by NC7000™ • Retained mechanical properties • Cost-effective NC7000™ is the industrial grade of MWCNT by Nanocyl, a worldwide industry leader in the development, manufacturing and sales of MWCNT and MWCNT-based formulated products such as plastic masterbatches and compounds (ex: PLASTICYL™ ABS1501, PLASTICYL PP2001). Nanocyl focuses on the current challenges of the automotive, energy and electronic markets, while developing novel durable solutions for the rubber market. For more information on Nanocyl’s solutions for automotive, visit us at K-fair 2016, hall 8b/D53. Web: www.nanocyl.com. Contact: Michaël CLAES, CTO and Strategic Account Manager, technical@nanocyl.com. Authors: Dr. Marie HURTGEN (Automotive and North America Manager), Michaël CLAES (CTO and Strategic Account Manager), Alexandre CLERBAUX (Marketing & Business Development Manager). Packaging Europe | 189 |


Injection innovation Injection blow moulding machine company Jomar Corporation has over 50 years of expertise contributing to its strong global position thanks to its ‘single focus’ on manufacturing and servicing its high-quality machines. Emma-Jane Batey spoke to sales manager Ron Gabriele to learn more.

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ncorporated in 1968 by Joseph Johnson and his wife Mary, Jomar was established as an innovative force in the development of the pioneering injection blow moulding machines. Having previously worked for famous US manufacturer Wheaton Industries, where he was responsible for its injection blow moulding department, Johnson felt he could take the technology he had developed further and so founded Jomar. Jomar’s sales director Ron Gabriele told Packaging Europe, “Joe improved on the Wheaton machine and launched Jomar, where he created the first commerciallyviable, completely integrated injection blow moulding machines available to the plastic industry. In 1978, Jomar was bought by Inductotherm Industries of New Jersey, a privately-held company now known as Indel Inc., that has built more than half of the induction furnaces in the world. Today, Jomar has its headquarters in New Jersey, where we have a 42,000 sq ft facility and have sold more than 2000 machines to customers across the world.”

Only injection blow moulding Jomar is dedicated to injection blow moulding machines as its sole business. Mr Gabriele explained how this is key to the company’s ongoing success: “We are not the IBM division of a multinational conglomerate. Rather we are a company with a singular focus on manufacturing and servicing the finest injection blow moulding machinery in the world. This is unique in our industry. We’ve been building our machines for almost 50 years so we have lots of accumulated knowledge that we areproud to share with our customers.” The Jomar Corporation product portfolio is clearly all about injection blow moulding machines, with six different size machines ranging from 20 tonnes to 175 tonnes, as well as all of the required moulds to go in the machines. Mr Gabriele explained, “What we’re particularly proud of is the great balance of what we have learned about proven technology over the past 50 years and our passion for innovation. It’s a strong mix because it means we can incorporate the very best of technology together with our inquisitive

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quest for fresh solutions. This is how we have created our latest solution; we refined our already-robust hydraulic technology to create a brand new product.” This brand new product from Jomar is the new line of IntelliDrive machines for IBM that will debut at the K Show this year. Created to capture the best attributes of all-electric machines with a hydraulic machine, the IntelliDrive range uses up to 50 per cent less energy and has an even faster dry cycle time than Jomar’s existing catalogue. Mr Gabriele continued, “We’re so proud of this machine: so far we’ve found it to be successful in every way! It’s faster, it reduces costs, it has low maintenance costs...we’re so convinced of its durability and low cost of ownership that we’ve already extended the warranty on the hydraulics, the heart of the machine, from one year to 30 months. With the new Model 85S IntelliDrive machine set to launch at the K Show, Mr Gabriele noted that the Model 135 is already in development and will be available by the end of 2016, with Models 65 and 175 following soon after. He continued, “The K Show is very important for us; the IntelliDrive machine we’ll be debuting demonstrates our desire to respond to customer requests and that we listen closely to the marketplace. Jomar is already globally recognised as one of the world’s best injection blow moulding machine manufacturers, but I feel that people are not necessarily aware of the amount of development we execute regularly. Jomar is constantly improving and I hope our IntelliDrive series of IBM machines reflects our commitment to innovation.”

Reducing costs as standard Mr Gabriele is clear that the target market for Jomar’s innovative injection blow moulding machines is its high volume existing customers and those potential customers that have high utility costs they wish to reduce. He concluded, “That’s practically everyone! It makes sense to replace ageing machinery with the latest generation of injection blow moulding machines like our IntelliDrive series because they save up to 50 per cent of energy, have faster cycle times and come with a 30-month warranty on hydraulics, which

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is quite uncommon in the industry. I don’t believe there is a more compelling case to replace machinery; the IntelliDrive machines drive down the cost per bottle with savings in utility expenses and then increase the rate of production. Customers could take a mould out of a standard Jomar machine and run it in an IntelliDrive machine and by that simple act alone, they would make more money from the project”. Gabriele added “ Jomar considers ourselves to be in partnership with our customers. We’re vested in the success of our customers and committed to building the finest injection blow moulding machines in the world. We are extremely pleased that we can deliver a solution that provides such a clear path to increased profitability”. Visit: www.jomarcorp.com


INNOVATIONS BY SABIC TO MINIMIZE FOOD WASTAGE, REDUCE WEIGHT, AND LOWER CARBON FOOTPRINT OF PACKAGING MATERIALS Today, an estimated one-third of food produced for human consumption is lost or wasted, equivalent to 1.3 billion tonnes of food every year, according to the Save Food report by the Food & Agriculture Organization of the United Nations. Even in the most developed supply chain systems such as those in Europe, 4 per cent of transported goods are damaged in some shape or form due to low pallet stability. A growing consumer focus on convenience and sustainability will also drive continuous changes and innovation in packaging.

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ith tomorrow’s resource challenges, packaging has a crucial role to play, particularly in helping to reduce waste in the global food supply chain and in protecting goods for consumers while complying with ever more stringent regulations that are put in place to increase food safety and to secure safe packaging. Today’s fast-paced lifestyles also are driving demand for pre-packed food, and for hot filling and microwave use. At the same time, consumer expectations are spurring brands to create packaging that is distinctively shaped, highly transparent, hygienic, easy to open and with excellent graphics. These challenges need to be met

while lowering weight and cost by reducing cycle times, down-gauging and increasing the share of reusable packages to minimise waste and lower the environmental impact of everything we produce. On its stand at the K 2016 plastics trade fair in Düsseldorf, Germany, 19–26 October, SABIC will be showcasing several new products and technologies that help to address these specific market needs. With a strong focus on sustainability and an underlying theme of ‘Chemistry that Matters™’, SABIC will highlight a number of packaging solutions that address the challenges of the packaging industry , including:

SABIC’s multi-layer and polymer blend technology for flexible packaging may enable manufacturers to reduce transport losses, optimise protection of goods, maximise pallet stability by increasing holding force of collation shrink and stretch films used to protect food packaging, making them stronger. They may help reduce the environmental impact of packaging by enabling down gauging whilst improving the holding force. Manufacturers may achieve down-gauging options that reduce thicknesses by up to 20 per cent compared to current film concepts. Packaging Europe | 193 |


Reducing packaging weight remains key and is facilitated by using SABIC’s solutions in flexible pouches for both food and non-food applications. Leveraging the extended SABIC® PE/ PP portfolio in pouches may enable further improvements in stiffness, sealing performance and retortability.

Reducing loss and increasing efficiency

Lighter-weight packaging

SABIC’s multilayer and polymer blend technologies may help manufacturers to reduce transport losses, optimise protection of goods, and maximise pallet stability by increasing the holding force of collation shrink and stretch films used to protect food packaging, while also making those films stronger. The unique combination of SABIC polyolefin building blocks may also enable improvements in efficiency during production. They may offer higher tensile strength and higher toughness to optimise the wrapping process, by reducing film breakage and improving stretch film quality and consistency. SABIC technology may also reduce the environmental impact of packaging by enabling down-gauging that can reduce thicknesses by up to 20 per cent compared to current film concepts. Thinner products reduce plastic consumption and allow for higher processing speeds.

Reducing packaging weight remains key and is facilitated by the use of SABIC’s solutions in flexible pouches for both food and non-food applications. Leveraging the extended SABIC® PE/PP portfolio in pouches may enable further improvements in stiffness, sealing performance and retortability. The new SABIC® PP FLOWPACT Product Family, especially the very high MFI grades, are formulated to help customers with thin-wall food packaging applications where a good balance of high stiffness and high flow is required, thus: • Enabling down gauging, thereby reducing packaging waste • High flow and fast crystallisation generates shorter cycle times, thus lowering production costs.

Reducing food waste SABIC’s flexible packaging solutions already significantly contribute to minimising food waste. The dedicated SABIC® PE/PP resins are essential in building advanced, multilayer barrier film concepts that provide longer shelf lives for fresh and chilled food, cheese and meat. The corresponding reduction in food waste has a significant positive impact on the total life-cycle analysis of a flexible packaging system. | 194 | Packaging Europe

New SABIC® LDPE film grade is a new product from SABIC for manufacturing very thin-gauge packaging: • It offers excellent draw-down ability, running stable at a film thickness as low as12 μm, using less raw material and enabling higher production line speed • Is typically used in both mono and coex films and is available as a certified renewable grade • Provides full compliance with stringent food-contact regulations for a broad range of applications with both fatty and non-fatty foods.


Safer packaging SABIC continues to take a pro-active role in the industry by improving the purity, organoleptic properties and cleanliness of resins used in pet and food packaging, through: • Introduction of new product stabilisers in advanced LLDPE resins • ntroduction of phthalate-free PP solutions, co-developed with international companies in the UAE and Europe • Unique additive-free LDPE product family (with no migration into food). Advanced 5-layer barrier film structures are another new product from SABIC for applications in meat packaging using blown film technology. The use of high-purity SABIC® LLDPE 218BE and LDPE resins was crucial to achieve improved drawability and cleaner operations, with fewer deposits. Customers can maintain water purity with SABIC® HDPE CC860V grade for Caps & Closures for still water: • Rated highly amongst available grades, it is now being used by leading OEM brand owners • Provides excellent organoleptic properties that are important in preserving taste and odour • Complies with new food-contact directives regarding product safety and purity. SABIC’s new range of PP copolymer cast films may offer extra protection with high puncture and tear resistance, excellent sealability, eye-catching optics, and compliance with food regulations.

Sustainability SABIC is proud to be the first chemicals company to offer both renewable polyethylene (PE) and polypropylene (PP) resins that are based on renewable feedstock sources. SABIC’s ISCC Plus-accredited renewable polyolefins help its customers meet increased

regulatory demands. Unlike other products on the market, these new materials from SABIC are created from waste fats and oils using feedstock that is not in direct competition with the food chain. From sourcing to final production, SABIC’s renewable PE and PP require 84 per cent less fossil fuel to manufacture than fossil-based polyolefins, and are fully recyclable. This enables SABIC, and its stakeholders, to reduce their collective carbon footprint and to save fossil feedstocks for future generations.

Superior performance – polyethylene with the NEXLENE™ process technology SABIC produces its new C8 mPE, POP and POE products using NEXLENE™ technology – a cutting-edge technology that combines a solution process and a proprietary metallocene catalyst. The packaging industry will benefit from this new SABIC product family with state-of-the-art molecular design – Bimodal Solution Process with Octene co-monomer – for the manufacture of flexible (food) packaging and wrapping materials that deliver high performance properties, such as: • Outstanding processability – may enhance bubble stability, lower motor load and extrusion pressure • Superior mechanical performance – may improve tear resistance, excellent puncture and dart impact resistance and tensile strength • Outstanding sealing property – may lower sealing initiation temperature (SIT) to enable faster packaging speed • Excellent optics with high clarity and very low haze • Superb hygienic properties with low extractables and outstanding organoleptics. SABIC will be participating at K 2016 in Düsseldorf, from 19–26 October 2016, at Stand D42 in Hall 6. For more information, please go to www.sabic.com/Kshow. Visit: www.sabic.com Packaging Europe | 195 |


Setting the new standards Headquartered in Germany, the Reifenhäuser Group is the leading provider of innovative technologies and components for plastics extrusion. Packaging Europe looks at just some examples of its innovative product offering, from its Cast Sheet Coating and Blown Film divisions, to be showcased at K 2016.

W

ith over 1500 employees working at its six highly specialised business units, the Reifenhäuser Group enables its customers throughout the world to produce blown films, cast films, sheets, nonwovens, monofilaments and strapping tapes of the highest quality.

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Cast Sheet Coating In the past, Reifenhäuser Cast Sheet Coating has presented several innovative line components to the general public that have since become industry standards, and it continues to lead the way in this field. For example, the efficiency of the REIcofeed 2.1 coextrusion feedblock allowed for an optimal adjustment throughout the production of the films/sheets composed of up to 11 or more individual layers. This could still be drastically improved by the integration of a new small element which allows for the encapsulation of a multi-layer film/sheet inside the feedblock to avoid the need for an additional encapsulation device in the flat die and the use of an additional extruder. Reifenhäuser CSC will be showcasing this new REIcofeed 2.2 model type at K 2016. Another example is the new MIREX-MT polishing stack with a patented mechatronic nip adjusting system. The overwhelming success of the MIREXMT-V-AX high performance design series presented at K 2013, which allows, for example, for the production of PET films of less than 150 µm thickness and with an output of more than 2.5 t/h, has led to the installation of this innovative nip adjusting system in all Reifenhäuser polishing stack model types. The smallest, MIREX-MT-HI with a roll diameter of 310mm, will be demonstrated as a key component of a new generation of in-line thermoforming sheet lines. This line, in combination with a high-speed extruder with the lowest space requirement in the market, satisfies the demands of the market for the highest efficiency and smallest possible footprint.


Evolution Ultra Flat At K, Reifenhäuser will be presenting three separate innovations from its Blown Film division, setting new quality standards in film flatness. The first of these is EVOLUTION Ultra Flat. In the past, only film width and profile tolerance were considered a quality feature, but the Ultra Flat has proven that there are other benefits to be considered, as follows: • Flatter film can be printed more easily in subsequent processing steps while the printing quality remains unchanged or can even be improved • Higher printing speeds result in higher productivity (savings of approx. €150,000 per year in addition to 150 hours printing capacity can be achieved) • Less film camber enables a better sealing quality in FFS machines (savings of approx. €25,000 per year are possible) • Higher bond strengths allow a reduced use of adhesive in lamination processes which results in significant additional cost savings • This technology has made its entry in the market: over the past 24 months more than 20 lines were installed and are running • EVOLUTION Ultra Flat is a milestone in the production of lamination film

Evolution Ultra Die Reifenhäuser Blown Film will present at K 2016 the new standard in barrier blown film die head design. The combination of the advantages offered by the stack die design and the spiral mandrel distribution design results in the highest level of flexibility in terms of layer ratios and viscosities in barrier film production. • The new standard in the distribution of layers in the die head. The market only knows spiral mandrel and stack die designs. Reifenhäuser Blown Film will launch now a new standard in die head design by combining the benefits of both technologies • Flow channels are about 70 per cent shorter compared to known die head designs. They present the most compact design in the market because of an intelligent flow channel distribution • Shorter job change time for symmetric or asymmetric barrier structures • Less volume, smaller die head diameter and heating from the inside and outside • This leads to shorter heating-up times for start-up of the line and change of raw materials

• • •

With this design Reifenhäuser Blown Film sets a new standard for the fastest barrier blown film die head in the market Most simple design for upgrades to more layers, which is not possible for competitive designs With this new development Reifenhäuser Blown Film follows the trend of more and more layers, which we have intensified already with the 11-layer blown film line two years ago. The new die head concept now allows the production of even more layers

Evolution Ultra Stretch Stretching of blown film becomes the new standard. What was presented at K 2013 as a prototype has evolved in 2016 to a key technology named EVOLUTION Ultra Stretch which gives Reifenhäuser Blown Film an additional edge over its competitors. • EVOLUTION Ultra Stretch gives our customers an easy way of down gauging with same or better film properties for numerous applications: • Compression bag film produced with EVOLUTION Ultra Stretch: approx. 30 per cent thinner, for example 50 µm instead of 70 µm for diaper packaging • Pre-stretched silage stretch film produced with EVOLUTION Ultra Stretch: approx. 25–35 per cent thinner film, for example 19 µm instead of 25 µm • Breathable back-sheet film produced with EVOLUTION Ultra Stretch: lower investment costs of a blown film line with EVOLUTION Ultra Stretch for the production of breathable back-sheet films compared to a blown film line with ordinary in-line MDO • High process stability due to stretching of more amorphous film, for example less web breaks due to high level of crystallinity • Reduced energy consumption by using the initial heat from the produced film • Significant lower investment costs of EVOLUTION Ultra Stretch compared to conventional MDO (film stretching systems). The system is simple to operate and can be by-passed easily Reifenhäuser Blown Film and Reifenhäuser Cast Sheet Coating will be presenting the new standards for the first time at K 2016 from October 19 to 26 on the Reifenhäuser booth C22, in Hall 17, and live in production at our Open House held in n parallel in Troisdorf. Packaging Europe | 197 |


iMould: The Next

Big Thing When it comes to innovations, the packaging industry has always been ahead. In recent years constant efforts to drive sustainability, aesthetic innovations, global quality improvements and cycle-time reductions have changed the way we all work. But we still depend on machines, after all. And machines break. Luckily, visionaries always try to push the boundaries.

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I

ML Solutions, a company located in Alicante (Spain) claims to be ready to redefine the paradigms. The Spanish company is now one of the key players in the in-mould label decoration market (IML). After mastering the manufacture of robots it is now offering comprehensive solutions to its customers, including all the elements needed in this process. Its next move is to change the way we understand moulds with a revolutionary product called iMould. The official launch is anticipated on October 19th during the K Trade Fair, as we found out from Antonio Molina, Director of Sales and Marketing. “iMould is a game-changing product,” claims Molina. “Industry always relied on corrective maintenance – repair it when it’s already broken – and preventive maintenance – schedule repairing tasks based on the experience and the expected lifetime of the pieces.


But we are going one step beyond with the predictive maintenance concept. With this technology we will be prepared to advise our customers precisely on how to schedule their maintenance tasks based on the behaviour of their iMoulds.”

What is iMould? “It is an intelligent mould with the capacity to process information remotely and in real time. We are committed to helping our customers in all the stages of the IML process by improving each single element. We did it with the robots and now we are doing it with iMoulds.”

How would that work? “All the details will be explained during the official presentation at K Fair. This is something I can’t reveal yet. But the important message is that we will combine technologies to facilitate predictive maintenance for our customers. “If any of the checkpoints we control start presenting irregular figures, we will report to our customer to schedule the required maintenance. Unplanned production stops will be a thing of the past after the implementation of iMould. Our objective is to gain zero downtime and reduce scrap even more.” After being asked about the predictive maintenance concept, Molina states: “We will be controlling the functionality of each iMould remotely. That way we can ensure a perfect response: this is like having a specialised technician 24/7 in our customers’ facilities anticipating the problems.” To control all these parameters, sensors will be required, but according to Molina iMould will be more than that: “Moulds with sensors have been available for years. They collect data from one specific parameter and that can give you a partial impression on the functions. But our solution gives you the full picture. There is nothing similar in the whole industry.

“As a manufacturer, we are responsible for finding out the most innovative solutions for our customers and nowadays this implies integrating intelligent systems like in the iMould. We are in the middle of the 4th industrial revolution and this kind of solution is exactly what the market is demanding.” According to Molina, one of the advantages of the iMould is the personalisation: “We offer an integrated solution that can be adapted to each customer requirement. It is like a tailor-made suit.” This puts traditional moulds in a complicated position. “Moulds without the intelligence existing behind iMould will be soon a reminiscence of the past,” says the executive. “Every manufacturer would rather control the status of their moulds like this. This is the kind of production equipment COOs have always dreamed of. Why should anyone still use outdated machinery?”

“The peace of mind of knowing that your line is working like a charm is priceless. Meeting tight deadlines will no more be a problem for our customers.” Technical restrictions are usually a downside when we talk about new products, but this is not the case with iMould, as Molina says: “iMould has been developed to meet the customer needs, and we are ready to do that. There is no restriction at all. On the contrary, flexibility is one of the key ingredients of this technology: customers will have the faculty to decide the parameters they need to control and how they manage the information. “We are eager to officially launch the product at K Trade Fair in Düsseldorf. Everyone will be welcome in Hall 12 booth C34.”

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Profile

Expanding horizons

Antonio Molina is the Sales & Marketing Director at IML Solutions. He is an MBA professional with over 10 years of international experience in general management and business development. After leading successful projects in five different countries, Molina joined the company in the first quarter of 2016 to consolidate the international expansion. IML Solutions is established in Spain (headquarters), USA, Colombia and Peru.

The In Mould Label decoration technique requires the combination of several elements: injection machines, moulds and robots. “We have mastered the manufacturing of robots and to provide the best service, we started producing our own moulds,” Cano says. “But we always need to go one step further, and that is how the iMould project started. For us, it was pointless using the same technology already existing. We needed to improve the processes to give the best service and applying integrated and intelligent systems was the natural way.” For Cano, “iMould will change the way we interact with our machines. We have always been trusted by the industry as a reliable partner because our core business is delivering state-of-the-art solutions to help our customers. Now, more than ever, we are ready to provide this exceptional service with iMould.”

IML Solutions IML Solutions provides comprehensive solutions in the area of In Mould Labelling. It is one of the few companies around the world that offers the whole service.

The beginnings The company started operations in 2000 after seeing the increasing demand for this decoration technology, claims Sebastián Cano, CEO and founder. “We were pioneers and now we are one of the top players in the industry.” Cano, a robotics and automation expert, established the company in Ibi, a small town in Alicante (Spain). Ibi is definitely a special place: with a population of less than 25,000, it concentrates dozens of companies dedicated to plastic, metal machinery and others. “It all started with toys,” Cano says. Ibi has indeed been the cluster where most of the toys that children throughout the world played with were produced. Some big toy companies still operate in the town, but during the past few years the auxiliary plants initially created to support the toy industry have evolved. “Packaging, and plastic transformation in general are now among the most important in the area.”

The vision “This is our home, but we are a global company,” says Cano. “We maintain the production plant in Spain, because we have access to highly qualified engineers and we can have better control of the quality of our products, but we are serving customers in any country in the world.” The company opened offices in USA, Colombia and Peru to provide a better customer service on these areas.

The products “We started with robots, which were what the customers demanded at that time.” Cartesian and side-entry robots were joined shortly afterwards by hybrid robots. “We were looking for a more versatile way to customise pails with IML. There was nothing like this in the market before. Now the hybrid robot is the most demanded solution in the industry.”

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Visit: www.imlsolutions.com

“iMould will change the way we interact with our machines. We have always been trusted by the industry as a reliable partner because our core business is delivering stateof-the- art solutions to help our customers. Now, more than ever, we are ready to provide this exceptional service with iMould.”


Masters in

masterbatch

innovation F

ounded in 1988, Sukano developed the state-of-the-art market reference product, the slip/antiblock additive masterbach for PET film and sheet applications. Headquartered in Switzerland, Sukano is a family-owned business with a global distribution network and with three modern production facilities located in Europe, the Americas and Asia. Today Sukano is the global partner of choice for plastic converters and brand owners for the development of innovative products and highly specialised industrial solutions. Sukano is the acknowledged expert in the development and production of functional and optical masterbatches, as well as for special compounds and blends for improving the properties of bio and oil-based plastics for the global plastics industry.

Unique innovative formulas Sukano is launching its latest innovative matting agent additive masterbatches for polyester and speciality resins for BOPET flexible packaging applications and for PET rigid packaging bottles, thus enabling a total gloss control of the final desired product. These latest additions to its broad product portfolio enable converters to provide high-performance PET bottles with polyolefin-like low gloss visual appearance, whilst retaining all the benefits of the performance and features of PET-based packaging. For BOPET film applications, Sukano’s experts have specifically developed a new and unique formula of matting agent to make uncoated BOPET films appear very similar to coated flexible packaging items in terms of visual aesthetics and low-gloss effect. This latest innovative product enables customers to finally consider an effective coating replacement.

Sukano is a global technology leader in the development and manufacture of additive and colour masterbatches and compounds for polyester and speciality resins. Philip Yorke reports on a company that continues to set the industry standards with its continuous stream of innovative new products.

Expanding global footprint Sukano has just announced that it is planning to invest heavily in all its global production sites in response to the increased demands for its products. At the same time the company is using this expansion as a platform to launch its new corporate identity. Sukano is a key development partner for customers in several markets and applications, including thick and thin films, as well as for bottles and containers. To further increase its flexibility and product development to provide the highest quality support to customers in these areas, the company is investing in a Karo IV stretching machine from Bruckner and a multi-layer coextrusion flat film line from Dr Collin. Both machines will be installed at the company’s global research and development centre in Switzerland. The company will now be able to produce multi-layered films, as well as oriented monoaxial and biaxial films, in-house for its customers worldwide. This unique offer from Sukano will drastically shorten development times and speed-up the time to market for customers, whilst reducing the development costs. In the Asia Pacific region, Sukano is seeing rapid growth in its operations. As a result, the company is building a new 2200 square metre warehouse for its raw materials and finished goods at its plant in Johor Bahru, Malaysia, which will allow the company to grow sustainably. From a customer point of view the Malaysian facility helps realise the motto ‘develop in one place, deploy everywhere’. Meanwhile, new analytical equipment will enable additional local tests enhancement and report results consistently and standardised within all Sukano facilities. This will help continuously improve the technical service provided to local customers and keep operations up to date. For further details of Sukano’s innovative masterbatch products and services visit: www.sukano.com Packaging Europe | 201 |


Innovative, automatic pilots Dr. Collin GmbH is a global technology leader in the development and manufacture of intelligent pilot and laboratory lines in modular systems for plastic processing companies. Philip Yorke talked to Friedrich Kastner, the company’s CEO, about its latest innovative solutions and the products it will be showcasing at the forthcoming K Show packaging trade fair.

C

ollin Lab & Pilot Solutions was founded over 40 years ago and is headquartered in the Bavarian city of Ebersberg, where it develops intelligent modular pilot and laboratory lines for plastic processing companies as well as for research institutes. As a privately owned company and a premium provider, it continues to set the technical and qualitative standards for the industry. As part of its product lines, which include Pilot Line, Medical Line, Lab Line, and Teach Line, it also provides individual, tailor-made solutions for its customers. The company’s broad procedural expertise is reflected in its products, which include platen presses, roll mills, calenders, extruders, compounders and mono and co-extrusion lines for mono, as well as multi-layer flat, blown, pipe, tube and profile products. All of this is in addition to equipment for quality control, such as those for filter pressure tests, rheometers and optical inspection systems. The Collin product range goes from small scale lines for basic research and medical technology and pilot lines, up to fully integrated production lines. Today Collin employs more than 110 people and in 2015 recorded sales of about €25 million.

Innovation as standard Innovation has been driving the sales at Collins since the company was founded in 1972 and is at the heart of all its business activities. Companies all over the world use Collin technology, for example the packaging industry, which involves every kind of consumer and industrial product from food to pharmaceuticals and from beverages to electrical goods. Kastner said, “When Dr. Collin began we were an engineering company that specialised in the manufacture roll mills for PVC manufacturers and went on to build the presses used for modelling polymers. You have to generate the sample, so you need to

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build extruders and twin screw extruders. We are unique in many respects but probably the most important difference between us and our competitors is that we are the only company that is truly a global entity, with unrivalled know how in many aspects of plastic converting from multilayer film to multilayer pipes and so on “We continue to grow and to innovate and by doing so we satisfy the growing demand for our products. As a result we are building a brand new purpose-built facility close to our existing one, located strategically between Munich and Austria. “We also have a daughter company in Atlanta, Georgia in the USA, which has a testing and pilot capability and acts as a logictic centre for spare parts. This is in addition to our presence in Thailand to service the Asian market. Today we continue to define new products for medical applications where we are also developing innovative new systems and processes. We always use the latest technology in order to stay well ahead of our competitors. “We work in close partnership with our customers, most of whom are leading multinational brands We have access to their R&D departments in the same way as they have access to ours. Later this year we are showcasing a brand new series of presses at the K show and also presenting a new generation of premium extruders as well as a range of ‘Entrance Extruders’. In addition, there will be a 5-layer extrusion line and our latest twin screw extruders. Furthermore there will be a brand new cast/calendering unit on show as well as a new monoaxial stretching unit.” Kastner added, “As far as our future growth is concerned we see big opportunities in the US market as well as in the Asian markets. Customers today are looking for more complexity and up to 13 layers and high temperature polymers, and we see a trend in the speeding up of pilot lines from 50 metres per minute to more than 200 metres per


minute. An emerging field is the development of new technologies for recycling products that match virgin products in terms of both quality and performance.”

and catheters. In the medical sector as in all its other operations, Collin offers the optimal solution with machines for material screening, clinical test phases and production.

High-precision medical technology

Tomorrow’s innovation today

For many decades Collin has been the product of choice for the pharmaceutical and healthcare industries – whether it has been for ‘material screening’ or series production in respect of the optimisation of products that are already on the market. Plastics are essential components in the healthcare and pharma sectors. Due to the company’s high precision capabilities and quality management, the company is an established partner for researchers, scientists and producers of medical products, as well as for packaging companies worldwide. New processes have been developed by Collin for the production of dosage materials such as pills, mono or multi-layer extrudates, including active substance strands and systems for the production of medical tubes

Under the heading, ‘Future is now’, Collin is presenting a wide variety of innovations at the K-Show later this year. The company told Packaging Europe that innovation, efficiency, economy, reproducibility, automation and modularity are taking centre stage at the company’s exhibition appearance at the show. With its unparalelled know-how the company guarantees that the customers of today are developing or testing the Collin products of tomorrow. The line with a total length of 11 metres precisely matches the Collin product philosophy of modularity which includes its Compounder Type ZK 25P, its Innovative Extruder Type 30P, 5-layer feed block with 500mm slot die, and three-roll cast/calender as well as

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a take-off unit with start-up winder and film inspection. In addition, it offers MDO with double stretching gap, a take-off module with various features, such as edge cutting, film edge control and a Turret winder adapted to Collin lines. This unique configuration offers countless advantages for the customer. Also on show at K 2016 will be the Collin special model extruder 30T: T Torque, which is a fast running extruder combining the advantages of Type P. However, its output is increased because of the higher speed and torque, and especially for the development of screw geometry and feeder for this fast-running model. Furthermore, the company’s Innovation Turret Winder offers three different possibilities for winding, which include central winding, contact winding with adjustable pressure and gap winding with adjustable gap. The latest extruder E Series offers a cost-effective alternative to the Collin Extruder P series and is designed for laboratory operation and

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R&D testing. This extruder is mounted on a moveable electrical cabinet, which contains the power electrics, connections and main switch and is economical, flexible, modular and compact. Multi-inspection technology from Collin offers real-time monitoring of the melt viscosity in the form of MFR, iV-value or the apparent viscosity. A 5-layer coextrusion blown film line is yet another new product that offers unique advantages to the operator. It can be fitted into a confined space as it is a very compact product that is bound to create a lot of interest at the K-Show this year. In the medical field too, Collin has developed a number of products that offer considerable benefits to the user. With the newly developed E12, the smallest quantities can be processed, thereby saving material costs, and it n also offers very high accuracy and is fully validated. For further details of Collin’s innovative products and services visit: www.drcollin.de


Plastics in Tune with Nature For more than 20 years, FKuR has committed itself to nature and its uniqueness, with an objective to develop, produce and sell bio-based and/or biodegradable plastic solutions globally. Libby White spoke with Patrick Zimmermann, marketing director, to find out more about the company’s plans to exhibit at two major exhibitions this year and its latest solutions on offer.

“F

rom the very beginning we have followed our commitment and slogan: ‘Plastics – made by nature’,” Mr Zimmermann comments. The company was founded in 1992 under the name FKuR GmbH as a research and development institute dedicated to plastics and recycling with a focus on resource preservation and efficient resource utilisation. In 2003, the company reorganised as FKuR Kunststoff GmbH and to this day has remained true to its values as a privately owned kind of family business.

Extensive portfolio “We have the biggest bio-based and biodegradable portfolio worldwide,” Mr Zimmermann is proud to share. FKuR offers PLA blends, cellulose blends, fibre reinforced materials and Green PE compounds, while also distributing bio polyamide from Evonik and bio PE from Braskem. In addition, it offers bio TPE, (bio-based or partly bio-based thermoplastic elastomers). Packaging Europe | 205 |


With such an extensive range of solutions, FKuR is in a privileged position enabling it to enter a cross-section of markets such as flexible packaging, injection moulding, blow moulding, thermoforming and so on. “We cover nearly all kinds of relevant markets where plastic materials are used from cosmetic bottles, or bottles in general, to containers, blown film applications and so on. We do not really have a specific market focus, as we are so broad we can cover a wide range.” For solutions which need a biodegradable or even a compostable film, it can offer various grades from its Bio-Flex® series. This series includes grades which are certified as compostable according to EN 13432 with a wide range of properties. Films made from Bio-Flex® have characteristics comparable to LDPE or HDPE, depending on the type. FKuR is continuously developing its resins and launching new blends in its Bio-Flex® series.

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Mr Zimmermann says, “We have most recently added two new materials to our range of Bio-Flex®: Bio-Flex® FX 1120 and FX 1130, which are suitable for blownfilm applications. Bio-Flex FX 1120 is a blend that contains more than 50 per cent of renewable resources and is compostable according to the European standard EN 13432. These materials can be downgauged, especially the FX 1130 to a thickness of lower than 10 microns, while still providing qualities such as very good puncture resistance.”

Industry presence FKuR is looking forward to attending two major upcoming trade shows this year: It will present its solutions in its own booth at both FachPack and K 2016, and of course will be presenting its aforementioned Bio-Flex® FX materials.


At K 2016, FKuR will pay particular attention to exhibiting its materials for core markets such as its range for cosmetic bottles, and products for agricultural applications such as tree protection. On the other hand, FachPack is the ideal exhibition for FKuR to showcase its solutions for packaging, as well as thermoformed parts and injection moulded parts, where it will have a mid-sized booth. A key focus for FKuR are the German, Austrian and Swiss markets, and it will be meeting with existing clients at FachPack to present new solutions and enter discussions. Of course, the show is also a great platform for FKuR to meet potential new clients. Mr Zimmermann comments, “FachPack really is a show of interest to us as we can have deep discussions about new materials and possible applications in specific areas, whereas in the case of some larger tradeshows there is more of an overview. However, the K fair is as crucial for us to exhibit as we have a lot of international clients who also attend. It is a great platform to meet for discussions.”

Patrick Zimmermann, marketing director

Future growth Europe is a very important market for FKuR, and Mr Zimmermann highlights that it would be difficult to determine one market as more significant than another. However, he does underscore that biodegradable solutions are important for southern Europe, whereas bio based solutions, especially green PE, are more prevalent in northern countries and Scandinavia. Mr Zimmermann has a positive outlook for the future of FKuR: “The topic of biopolymers is very present in the media, the industry and politics. We are increasingly seeing customers asking for packaging made from renewable resources, for example as they would like to differentiate from competitors, and I think this trend will continue over the next few years. “The demand for biopolymers will continue to rise in its present markets, and also in new markets which are not so deeply involved in biopolymers currently. I see very good prospects for biopolymers in general, and therefore in turn for FKuR.” For more information, visit www.fkur.com Packaging Europe | 207 |


Maximising quality

and performance With slim margins in the PET bottle industry, it is often difficult to produce a quality product while maintaining meaningful profit margins. The Process PilotÂŽ system, from Agr International, offers PET bottle manufacturers a means to reduce PET bottle production costs while at the same time improving overall bottle quality and performance.

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I

nstalled in a reheat stretch blow-moulder, the Agr Process Pilot system makes it possible to operate with a tighter process control than possible with traditional ‘hands-on’ blow-moulder management. With that comes a myriad of benefits, some of which have significant cost saving implications.

Pilot system can adjust one or all of the blow-moulder controls simultaneously to achieve the best possible material distribution. By monitoring the material distribution of the blown container, the Process Pilot is able to account for subtle changes in the process that would normally go undetected by the operator. This prevents the process from drifting out of control before the operator’s next quality sample and averts the loss of precious little processing margin. In the course of bottle production, an untold amount of variables in the production cycle can affect the processing and quality of light-weight bottles. The Process Pilot system can accommodate many types of environmental changes in and around the blow-moulder as well as preform preparation and storage conditions that can occur. Compensation can be made for temperature, moisture content, and minor Intrinsic Viscosity (IV) changes to the preform to maintain a consistent process, within the smallest process window.

Measure, control, optimize Consistent and properly distributed material is the key to the production of high performance PET bottles. The precision of material distribution becomes increasingly critical with bottles when light-weighting programmes are in play. With a multitude of variables affecting the blowing process, producing bottles that have accurate material distribution on a consistent basis is a daily challenge. Agr’s Process Pilot® blow-moulder management system addresses this challenge with a simple solution. Installed within the blow-moulder, the Process Pilot system incorporates a three-pronged approach: 1) measure material distribution on every bottle with high precision; 2) control the blow-moulder based on bottle measurement to maintain desired material distribution; and 3) optimise the material orientation to maximise bottle performance. Unlike operator adjustments, the Process Pilot system can adjust one or all of the blow-moulder controls simultaneously to achieve the best possible material distribution and bottle performance.

Managing crystallinity for optimal performance A recent expansion of the Process Pilot system includes the management and optimisation of crystallinity with the CrystalView™ option. Maintaining appropriate material distribution, and at the same time optimising material orientation, requires great skills, and is difficult to achieve with conventional blow-moulder management techniques. With the CrystalView option, the Process Pilot system has the capability to manage material distribution and material orientation simultaneously, making it possible to produce the highest quality bottles, with consistent material distribution and optimal material properties. CrystalView manages the process to the point where material orientation is ‘just right’, while avoiding the creation of pearlescence. With CrystalView, it is possible to reduce the preform processing temperature to the ideal processing point (as much as

How Process Pilot works Agr’s Process Pilot system works in conjunction with the reheat stretch blow-moulder to proactively manage and maintain container material distribution at a specified thickness to within ~0.01mm. This is accomplished by continuously monitoring every bottle for material distribution, analysing minute changes and adjusting the blow-moulder controls to maintain pre-defined distribution levels. Unlike operator adjustments, the Process

Process Pilot®

Optimisation

Control

Pearlescence

CrystalView™

Traditional Measurment and control

-5

-4

-3

-2

-1

0

1

2

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4

5

Perform Stretching Temperature Packaging Europe | 209 |


10 deg. C) for a given bottle design. By doing so, material orientation is optimised over the entire bottle. Plus, by running colder, excess material can be pulled is moved from the base of the bottle to other areas, reducing the amorphous material and the residual stress that can lead to base failures associated with the transition region.

Simple operation The Process Pilot system operates very similarly to the auto-pilot in an aircraft. The process engineer sets up the optimised process for a given bottle, then a one-time control characterisation is performed (learn mode) to finalise the recipe and establish a baseline. Once set to the defined recipe, Process Pilot manages the blow-moulder as if on autopilot, continually adjusting control parameters to maintain precise thickness distribution as the process changes. Since the Process Pilot system can oversee blow-moulder operation on a 24/7 basis, it provides a continuity in bottle production that is not possible with other methods.

Facilitating light-weighting Light-weighting has been an important tactic in the cost reduction efforts of PET bottle manufacturers. However, as manufacturers continue to remove material, bottle processing becomes increasingly difficult. The process window becomes smaller as weights are reduced. Consequently, on a light-weight bottle, minor changes in the process can have major effects on material distribution. Tight control over the process is therefore imperative and the need to control the location and the thickness of the remaining material is critical for proper bottle performance. Often bottle producers limit light-weighting to a point where bottles can be processed with minimal problems, leaving extra material in place to provide ‘comfortable’ processing safety margins. With the Process Pilot system’s ability to tightly control the process, lighter bottles with ‘just enough material’ to meet performance requirements can be processed with a very high level of confidence. Material distribution is managed precisely throughout the production process, paving the way for maximum material reduction. Additionally, material optimisation through the CrystalView product brings further lightweight opportunities. The ability to produce lightweight CSD and water bottles where the material is fully optimised makes it possible to realise the maximum bottle performance with minimal weight from a given design. Bottles are stronger with better performance and as a result provide greater stability and an increased ability to confidently process without incidence in filling, labelling and capping operations. | 210 | Packaging Europe

Raw material flexibility Another area where Process Pilot can offer cost saving opportunities is in the type and quality of raw material. Lower grade material and/or preforms can have a variability and inconsistency that can translate into processing, quality and performance issues. With the Process Pilot system, blow-molder adjustment to accommodate minor variations in material quality (high AA or variations in IV) is performed on a continuous basis. When material-related process variations are detected, the Process Pilot system pro-actively adjusts the blow-moulder to account for these variations and maintain optimal material distribution. Because the Process Pilot system tightly controls the processing window of the blow-molder, it is possible to increase the percentage of off-spec (wide-spec) material and/or PCR content safely. This capability provides bottle manufacturers with additional opportunities for savings without compromising quality.

Other benefits The Process Pilot system offers a number of benefits in addition to improved light weighting and materials savings. These include the elimination of the need for section weights, reduced scrap, energy savings, improved overall bottle performance and quality, and lower incidences of downtime in the filling, capping and labeling operations.

Summary Agr’s Process Pilot® blow-moulder management system offers manufacturers a means to take the variability out of the bottle blowing process, especially when light-weighting programmes are in place. It also provides the additional process feedback that makes it possible to go the extra step and take light-weighting to the limits with full confidence. Where material is limited and safety margins are very tight, the Process Pilot system can provide the detailed, in-process feedback to manage and maintain bottle material distribution to a very high level of precision, resulting in the production of consistent, quality bottles, even at the fastest production speeds. In the end, with productivity improvements, energy savings, reduced downtime, improved quality and downstream performance, Process Pilot has been shown to have an ROI of less than two years. With an active light-weighting program, ROI can be reduced to a matter of months. Agr’s Process Pilot automated blow-moulder control system has been on the market for several years and has amassed a significant global install base of major bottle converters and self-manufacturing brand owners. The Process Pilot product has proven to be a vital tool in the production of light-weight bottles, while improving overall bottle performance and quality. Visit: www.agrintl.com


Smarter thermoforming and extrusion processes Commodore is a global technology leader in the design and manufacture of machinery and tooling for the production of EPS foam products. Philip Yorke talked to Brad Braddon, the company’s CEO, about their latest innovative products, as Packaging Europe previews what is being showcased at the forthcoming K-Show trade fair in Dusseldorf.

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ommodore is an independent, privately owned company based in Bloomfield, New York with more than 35 years experience in the design and manufacture of machinery for the production of EPS (Expanded Polystyrene) foam-based packaging products. The company was founded by George Braddon in the 1980’s after he was a process engineer at Mobil Chemical in New York. By the late 1980’s, Commodore had become a leading specialist in refurbishing thermoforming equipment, which set the stage to move into the design and manufacture of its own advanced manufacturing equipment in 1988. Since then, the company has seen consistent growth, even overcoming the setback of a major fire in 1991 to emerge as a technology leader in its own right. Today the company sets industry standards worldwide, in particular for thermoformers and extruders for manufacturing foam trays used by the food industry.

Driving servo technology forward Commodore Technology recently introduced two new thermoforming lines for EPS foam in the narrow and wide-web markets. With its flagship product, the SX28S, the company converted the form station from hydraulic to servo operation. In the spirit of introducing leaner manufacturing processes, this completely eliminated the hydraulic systems. With its latest equipment, Commodore has transformed the efficiency of its existing line by eliminating over 50 per cent of the mechanical components of a traditional servo form station. This has been achieved by replacing the toggles on each corner with a center drive for forming platens on a 28-inch wide machine. This form station can run at up to 50 cycles per minute (CPM). Correspondingly, the trim press CPM output has almost doubled by utilizing FEA and vibration modelling tools to isolate/eliminate the reciprocating effects of trimming. Furthermore, a longer movable oven design and a stretched forming platen allows for greater flexibility via more oven shots and longer moulds with extra rows. This unique adaptability translates directly to higher productivity and expands the potential for other applications, including absorbent trays. In addition, Commodore operates a foam production facility and is now using its latest SX-28S for three shifts per day.

Braddon said, “Our equipment is tailor-made to meet the needs of the food packaging industry of today and in particular the requirements of the supermarket retail sector which wants custom sizes for better product fit. We develop and build our own equipment, which is designed for the diverse needs of our customer base.” Utilizing Commodore’s foaming expertise they have expanded their market offerings to extruding PE and PP while introducing annular die co extrusion. This expands their market reach to medical, automotive and building industries. Commodore also offers gas injections systems for new or existing extruders. Traditional chemical foaming gives off CO2 creating small cells and lowers density by 30 per cent. With gas injection of physical blowing agents it dissolves in the process to get much lower densities than chemical foaming. Our machinery foot print is ideal for small producers and for serving regional markets, where we can offer 550mm wide sheets of up to 1.4 meters long.” Braddon added, “We have a lot of experience and knowledge in the foam business, as we make and sell our own trays and we also act as consultants to our clients and other manufacturers. We offer the whole picture concerning thermoforming and extrusion, so we can offer a comprehensive one-stop-shop service.”

Setting the standards Commodore Technology designs and manufactures foam extruders and foam thermoformers, as well as manufacturing tooling and auxiliary equipment, including software for remote machine monitoring and control , at its state-of-the-art facility in Bloomfield, New York. Commodore has the unique opportunity for continuous improvement by having daily feedback from the foam plant operations. Currently, they operate five of their own foam extruders in the Bloomfield plant, and are uniquely aware of the problems that face foam producers on a day-to-day basis. In addition, the global customer base also provides a tremendous insight to the evolution of technology. Having access to this rich feedback loop provides constant innovation. As a result, Commodore’s systems are designed to perform specifically while facing these challenges. For further details of Commodore Solutions’ innovative products and services visit: www.commodoresolutions.com Packaging Europe | 211 |


Creating masterpieces SOLTEX is India’s leading manufacturer of masterbatches and speciality compounds for the processing of plastics for the packaging industry. Philip Yorke spoke to Geet Chadha, the company’s CEO, about its latest mineral based, valueadded products and ambitious plans for the future. | 212 | Packaging Europe


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OLTEX was founded in Mumbai, India in 1997 and is a wholly owned private company, which after almost 20 years of consistent growth operates six stateof-the-art manufacturing facilities in India. The company has its own extensive in-house R&D department and provides a wide range of calcium carbonate, talc and white masterbatches, as well as speciality additive compounds and products for raffia tapes. In addition, the company offers laminations, liners, shopping bags, tarpaulins, jumbo bags and a broad variety of injection and blow-moulded products. As a result of placing great emphasis on precision and innovative engineering, Soltex has emerged as a market leader in anti-fibrillating masterbatches for the raffia industry. Where technology adds value, Soltex aims to be a global leader in the manufacture of filled polymers and compounds to maintain the highest levels of quality and consistency. The company employs the most advanced technology in order to provide its clients with unrivalled quality and value.

Perfect pellet geometry The company’s filler compounds for the production of liners, shopping bags, PE pouches and filled masterbatches for the film industry, consist of a whole range of ‘milky’ as well as natural effects. These are designed for bubble stability at the plant, as well as ‘anti-burn’ at significantly higher loadings than conventional masterbatch-

es available on the market today. These are specially formulated by compounding blended polyolefins and micronised calcium carbonates in the world’s most modern compounding extrusion plants that employ the latest state-of-the-art technology. The facilities are equipped with sophisticated controls to achieve the desired results from a very high degree of dispersion to precise pellet geometry. Chadha said, “We specialise in industrial packaging applications for a broad spectrum of market segments and have a competitive edge because of our researchbased chemical design capabilities. This means we can customise products in-house and carry out in-depth research for an infinite number of applications and have a number of pilot plants where we conduct trials and tests in real-time on behalf of our customers. “We have many flagship products but are probably best known for opur calciumbased masterbatches and today we are in the top five masterbatch companies in India. Another of Soltex’s strength is its ability to produce huge volumes of products of consistently high quality and that offer unrivalled value. Each year we produce more than 100,000 tonnes of masterbatches. We firmly believe that our R&D facility and the economies of scale we offer keep us ahead of the curve.” Chadha added, “Many of our customers are well-known multi-nationals and around 70 per cent of our products are made for the domestic market, with the balance going to overseas markets such as Europe, Africa, South America, Bangladesh,

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Turkey and the UAE. We are able to remain highly competitive owing to our low labour costs and technology-driven R&D processes. We are continuing to achieve growth in excess of 20 per cent per year with much of this growth coming from our fast growing domestic market and developing overseas markets. Much of this will be organic growth; however, we have made several acquisitions recently and are keeping the door open should other opportunities present themselves. Joint Ventures are also something we would consider, in particular for our overseas markets. “One of the most important aspects that differentiates us from our competitors is the fact that we can now produce masterbatches that consist of 80 per cent minerals, making them more environmentally friendly than any other product on the market. We will be showcasing our latest creations at the forthcoming K show where visitors will be able to see our entire product range in our at Booth K 2016.”

Compounding success Soltex PP compounds are based on minerals that are compounded with polypropylene and have been developed in-house after careful consideration for the final properties required in the moulded furniture, cooler body, textile bobbin or washing machine parts. These are specially formulated by compounding PP homo-polymers with micronised minerals in the most modern compounding extrusion plants, employing the very latest stat-of-the-art technology. Soltex’s plants are equipped with sophisticated digital controls to achieve the optimal results which can range from a very high degree of dispersion to finely tuned and precise pellet geometry. | 214 | Packaging Europe

Soltex offers PP compounds for automotive applications and the products include elastomer-modified, UV-stabilised PP compounds, as well as talc filled PP compounds. In addition, the company produces modified UV stabilised separate resistant PP compounds, mineral-filled high impact PP compounds and talc-filled PP compounds. It is also possible to create tailor-made compounds for any individual application. Where technology adds value, Soltex aims to be a global leader in the manufacturing of filled polymers and compounds, maintaining the highest standards of quality, n reliability and precision. For further details of Soltex Petro’s innovative filled polymers and compounds visit: www.soltexpetro.com


High Grade Industries (India) Pvt. Ltd

High Grade Industries are associated with Soltex Petroproducts Ltd. as a regular supplier of Polymer Additives. High Grade Industries(India) Pvt. Ltd was founded by Mr. G. S. Kohli in 2001 primarily for manufacturing, Stabilizing and Processing Solutions for Plastics in the form of Additives and Additive Concentrates. High Grade has offices in Mumbai with production facilities in Silvassa with a network covering major cities to render pan-India services efficiently Our speciality lies in the field of Plastic Additives viz, Anti-Oxidants, Light Stabilizers, Optical Brighteners, UV Absorbers and other allied product ranges. We have also forayed into Plastic Masterbatches with a main focus on Polyester applications such as PET Films, Fibers, Yarns, Straps. Visit: www.highgrade.in

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Packaging Europe Issue - FachPack Special  

Our mission at Packaging Europe is to provide indispensable intelligence on packaging innovation to people looking to solve business problem...

Packaging Europe Issue - FachPack Special  

Our mission at Packaging Europe is to provide indispensable intelligence on packaging innovation to people looking to solve business problem...