Packaging MEA - Jan - Feb 2014 by Packaging MEA

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vol 3, issue 1. jan-feb 2014

Cartons debut for fresh milk in the Middle East

‘Consumers will put more attention on the product quality and environmental benefits’ Riccardo Castagnetti, Tetra Pak Arabia p46

FutureFlex starts up Windmoeller & Hoelscher Heliostar. Nine-colour press part of €3m investment including Nordmeccanica laminator and Ashe kit. p11

NDigitec to distribute D-Board in the UAE. NDigitec is now the country’s sole distributor of the 100% recyclable inverted corrugated carton board. p17

Uteco installs Onyx 812. Eight-colour gearless central impression (CI) flexographic printing press is now running at Omar Packaging Industries Tanzania. p24

First Group stays ahead with Bobst. Bobst equipment and services have helped First Group hit the forefront of Egypt’s paper and packaging market. p42

‘It is almost an industry secret that many presses are running 24/7 with just one set of inks’ Wayne Peachey on ECG p54

Editorial comment

Two trends we cannot ignore We’ve crammed a lot into this issue of Packaging MEA, but it could all be organised under two key themes. One, which is wholly positive, is that the good times are back. The interviews and reports we feature in these pages all agree: the global economy is on the mend and the outlook is especially bright for packaging in the MEA. In Dubai, of course, success in the World Expo 2020 bid symbolises the return of growth. Can we expect a return of the sunshine years from 2002 to 2007? Indeed, why not? Julian Pozza of Victoria Printing and Packaging, whom I interviewed for this edition, puts a persuasive case for investment. “To complement our move towards packaging, Dubai has recently won the bid to host Expo 2020, which is a success for the packaging industry,” he told me. “Over the coming 10 years, the population of Dubai is expected to surge from 9 million to over 20 million, and this huge growth in population means a growth in demand for packaging.” The possibilities opening across the region are also apparent in our interview with Simon Blazeby on the Saudi packaging market. A PCI survey into flexible packaging underscores the trend.

But what is the second key theme? As I hinted, this is not quite so intrinsically benign. This trend is clear from our cover, which illustrates how Al Ain Dairy has switched from PET bottles to Tetra Pak cartons. As is clear from another interview this month, with Mohammed Shaji of Future PET, PET’s soaring growth is not under threat. What Al Ain and Tetra Pak’s collaboration demonstrates is the pace of innovation. While the packaging market is set for expansion, it is also heading for major evolution. Reaping the benefits of growth is not just about adding capacity, but involves adjusting to change. Luckily, as a regular Packaging MEA reader, you are sure to remain up to speed on where the market is heading and how to seize its opportunities!

Published by JJ Media Fz LLC BIZ, Fuj Creative City PO Box 391186 The Iridium, Al Barsha Dubai, United Arab Emirates Phone +971-4-387 3575 Chief Editor Benjamin Daniel ben@packagingmea.com Editor Piers Grimley Evans piers@packagingmea.com Technology Editor Deb Debabrata Contributing Editors Dr George Simonian Nick Coombes Wayne Peachey Piers Grimley Evans Editor Marketing Manager Jill Smith jill@packagingmea.com +971-50-109 1889

Benjamin Daniel Chief Editor

Graphic Designer Ahmed Umrethwala Publisher Usha Benjamin usha@packagingmea.com

Benjamin Daniel

Piers Grimley Evans

Deb Debabatra

Dr George Simonian

Chief Editor

Editor

Technology Editor

editorial enquiries ben@packagingmea.com +971-55-109 1889 printed by Emirates Printing Press, Dubai, UAE © copyright 2014 PMEA All rights reserved. While the publishers have made every effort to ensure the accuracy of all information in this magazine, they will not be held responsible for any errors therein.

Nick Coombes

Wayne Peachey

Usha Benjamin

Contributing Editor

Publisher

UshaJill Benjamin Smith Marketing Publisher Manager

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jan-feb 2014

Contents Regional news Sabic, Oman Plast, Gulfood Express Printing Services, Sharjah Expo FutureFlex, Falcon Pack, MEAPET IST, Moll International-Giffin Graphics Delta Printing, DIPA-Printing and Publishing Group (PPG) Graham Engineering Corp-OrionCo, Gidue-Ali Alhashemi De-Mill and NDigitec Gulf Carton Factory, Label Summit Africa 2014 PCI Films Consulting Victoria Printing and Packaging, Duplas Al Sharq AMI’s Flexible Packaging ME Conference Palletco, Chemco Group PAT ME, Heidelberg MENA Taghleef Industries Uteco Group Manipal Technologies, Valiani Technology-AGE Graphics

Sustainable packaging

Kimoha Entrepreneurs Ltd Enviro Print Borouge, European Bioplastics Association

International news

Cosmo Films Ltd, Intermat Flexible Packaging, Videojet Etiq Color, Esko Uniprint SA, Edale, Flint, UPM-Raflatac KBA, Dupont

Product launches

Flint’s Ultraking XCURA, Heidelberg’s Dymatrix XL 145 CSB KBA-Flexotecnica & KBA-Kammann, Masterwork MK420Q MINI

Design news

X60 NDigitec, Pearlfisher & Cadbury VENTiT, Engro Foods

Business & technology features Luxury packaging Flexo prepress (Kodak Flexcel NX) Rotary die making (Rotometrics) Coding and marking systems (Videojet) Extended Colour Gamut (ECG) for flexography printing Carton packaging (First Group & Bobst) Saudi food and beverage packaging (Reed) Packaging trends European Rotogravure Association

Factory tours

Al Ain Dairy & Tetra Pak Future PET & Husky

New appointments Walter Hartmann, KBA; Mukul Shukla, tna; Marcel Hage, XOL; Matt Adler and John Kulak, Goss; Patrick Van Baelen, Xeikon; Barbara Schulz, Durst 4

jan-feb 2014

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News Regional Oman Plast on 11–13 February targeted the Middle East’s soaring investment in plastics and petrochemical production. The second Oman Plast exhibition, following an inaugural event in March 2012, showcased technologies for making plastics, petrochemicals, rubber and packaging. Silver Star, the tradeshow’s organiser, aimed to pull in visitors from Oman and neighbours such as Iran, Saudi Arabia, Yemen and the UAE. Oman, a leading regional player in petrochemicals, is already set to add production capacity while the Middle East and Africa’s plastics industry is poised to grow by about 30% this year, according to Silver Star. Polyethylene production in the Gulf is on track to hit 21.5m tons by 2015, more than double the 2009 figure, said the firm. Polypropylene capacity is forecast to follow a similar trend to touch 9.5m tonnes by 2015.

Gulfood The Food Processing and Packaging Forum scheduled from 23-27 February at Dubai World Trade Centre will host global industry experts to share tools, trends and technologies that build world class manufacturing businesses that can keep one step ahead of the innovation cycle and grow profit and customers in tandem.

jan-feb 2014

Sabic opens $126m SPADC research base Centre at King Saud university will host over 200 staff KSA Sabic has opened the Sabic Plastics Application Development Center (SPADC), a 42,000sqm research facility at the Riyadh Techno Valley in King Saud University (KSU). Built at a cost of SR472m ($126m), the centre will house more than 200 Sabic scientists, engineers and technicians, who will work with customers and with academic and industrial research communities within Sabic’s Technology & Innovation global network. Prince Saud bin Abdullah bin Thenayan Al-Saud, chairman of Sabic and the Royal Commission of Jubail and Yanbu, said SPADC aims to meet customers’ needs and collaborate with them to create dependable technical solutions. “It is the newest among Sabic’s research centres,” he said. “It comes close on the heels of the recent launch of two research facilities in China and India.” Initiated by the Ministry of Petroleum and Mineral Resources with strong support from King Saud University, the new centre was backed by the government in its determination to make Saudi Arabia a world leader in petrochemical research, he said. Mohamed Al-Mady, Sabic vice chairman and CEO, also spoke at the inauguration. “The new centre is yet another important step for Sabic to evolve further as

Prince Khaled bin Bandar bin Abdulaziz inaugurates the SPADC

an innovation-driven company, besides being an important driver of economic growth within Saudi Arabia’s efforts to become a knowledge-based economy,” he said. “SPADC’s role will be to introduce innovative plastics solutions to Saudi Arabia’s entrepreneurs, delivering new applications for businesses. “Our plans call for further strengthening our innovation footprint. We have just set up a new research facility at the King Abdullah University of Science and Technology; and we now have about 2,000 researchers worldwide, with the number growing rapidly.” Sabic claims to be growing to achieve one of the highest figures for patents per researcher among chemical companies. SPADC will be augmented over time by the establishment of a

Home of Innovation, a meeting ground for specifiers, customers and businessmen for growing new opportunities, in areas such as construction materials and consumer goods, added Al-Mady. Prince Faisal bin Turki bin Abdulaziz, advisor at the Ministry of Petroleum and Mineral Resources, said the research facility would have an important role for Saudi Arabia’s downstream development and for the Kingdom’s overall energy value chain by adding value to its hydrocarbon resources and enabling further diversification of its economy. He said he hoped the centre would be an addition to Sabic’s research and development investments in KSU, and hoped that Saudi universities would attract research and development investments and programmes by Saudi and international companies.

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News Regional UAE has launched a packaging overhaul to fight obesity. Large drinks cups could be banned across the UAE under an initiative to tackle unhealthy lifestyles. The measure is among a flurry of proposals issued by the country’s cabinet, which is also looking to ensure all food packaging displays calorie counts. UAE residents hold an impressive fifth place in the global ranking for soda consumption. Each year, they gulp down an average of 103 litres of soft drinks – equal to 300 cans – according to a study with participation from the World Health Organization (WHO). The global average consumptions stands at only 121 cans. WAM, the UAE state news agency, reported that HH Sheikh Mohammed bin Rashid al Maktoum, Vice President and Prime Minister of the UAE, said the cabinet is looking to develop initiatives endorsed by specialists, experts and the UAE’s people. Sharjah Expo hosted OIC Halal Middle East, featuring about 125 firms specialised in the halal trade at the Expo Centre Sharjah on 16–18 December. The second edition of the OIC Halal Middle East Exhibition & Congress gathering leading players in a global trade estimated to value nearly $3bn. Halal Scheme will cover packaging along with the entire supply chain, Farah Al Zarouni, Esma’s director of standardisation, told a recent symposium.

jan-feb 2014

Express Printing adds to packaging line Dubai-based firm buys MK die cutter and folder-gluer

UAE Express Printing Services has invested in an automated laser die-making solution as well as a Masterwork (MK) die cutter and folder-gluer. The Dubai-based commercial printing and packaging firm is also “in talks” on buying another printing line, said director Abdul Wahab. The investments are coming amid a rising focus on packaging, he added. “With the slow decline in commercial print, we have Express Printing is aiming to grow in line with Dubai’s expansion been giving more emphasis to our But Wahab said that Express Printing would packaging business,” he said. “Since continue to consider European products for solutions, we have over 35 years of experience in this field, the despite a positive experience with these Asian decision to expand our line was not hard to make.” products. “One can’t take anything away from the The firm’s new laser die-making solution has greats of the industry,” he said. “With the amount already enhanced production, he told Packaging MEA. they invest on R&D, they produce some amazing “This provides us with a greater control on the quality pieces of technology. If I needed something specific, we produce,” he said. “In turn, it has increased our something unique, I would still approach the known productivity and reduced makeready times.” reputable suppliers first. But my final decision will An investment in an MK die cutter and folder-gluer be based on all the factors one has to consider before with 4-6 corner options, plasma treat and Nordson investing.” gluing options will form part of a new printing and Express Printing expects continued growth in line finishing line, he added. “Our strategy was to strengthen our packaging with Dubai’s overall economy, he added. business by adding a new line of printing and “The UAE has been and will continue to be a finishing line,” he said. “We have worked backwards business hub for many reasons,” he said. “There are and installed the MK die cutter and folder-gluer first. a lot of positives for all industries to do business with This has helped us tremendously by reducing delivery organisations located in the UAE, especially Dubai. time and being able to execute urgent requirements There will be a lot of growth in the business that our of our valued clients.” clients are involved in. Their growth automatically The choice of the Chinese-made product followed means we will have to grow side by side to ensure a visit by Express Printing’s chairman, Abdul Qadir we can continue to provide them the service they Mohamed, to MK while in China for an exhibition. require. Our success and growth lies in the success “Express’s team carried out a thorough study before and growth of our clients.” we went ahead with this partnership,” said Wahab. Yet he sees challenges from escalating competition “The machines have not disappointed. Mr Abdul from new entrants. “It is not a hidden fact that there Qadir Mohamed took a great decision.” are many newcomers in the market,” he said.

News Regional

FutureFlex starts up W&H Heliostar rotogravure press Part of €3m investment in kit including Nordmeccanica and Ashe machine UAE FutureFlex has installed and started production on an upgraded production line featuring a Windmöller & Hölscher (W&H) Heliostar 9-colour rotogravure press. Following a €3m investment, the company’s kit also incudes a Duplex Compact SL 450, Duplex Compact SL 600 HD solventless laminator from Nordmeccanica that can run at up to 450m/min and is also equipped with automatic reel change facility. In addition, the company has bought Ashe converting machinery, including an Ashe Sapphire S2T 135-65 duplex turret slitter with shaft technology as well as an embossing machine. General manager Mohamad Azzam told Packaging MEA that the company has doubled production through a series of purchases. “The W&H Heliostar has been installed now and is successfully running with perfect results,” he said. “Now, with the addition of this new rotogravure line from W&H plus our existing Cerutti rotogravure line, our flexible packaging laminates production capacity has doubled, with a total production of 700 tons of laminates per annum. The total investment cost in machinery alone is approximately €3m.” FutureFlex specialises in manufacturing multilayer laminated rolls,

Azzam: ‘flexible laminates production capacity has doubled’

pre-formed pouches including stand-up, re-closeable and lap seal co-ex pouches, butter foil and registered cold seal, he added. “Although our supply for the UAE’s requirement is substantial, out main clients and supply is to the wider GCC and to African countries,” said Azzam.

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News Regional

Falcon wins quality logo Falcon Pack is awarded Emirates Quality Mark (EQP) certification UAE UAE-based Falcon Pack, specialised in disposable products for food packaging, storing, serving and disposal, has been awarded the Emirates Quality Mark (EQM). The Emirates Authority for Standardisation and Metrology (Esma) has given permission for the firm to use the EQM logo across a range of products. Falcon Pack is the first company in its category to carry the mark for household aluminium foil, aluminium containers with lids, PVC cling film, roasting bag, baking paper, wax paper, cake board, foil wrap, paper bags and sandwich paper, according to the manufacturer.

Ahmed Al Shamsi, Falcon Pack’s chairman, said the firm has established systems to ensure its customers only receive “quality and food safe products”. “This certification is yet another testimony for the efforts for Falcon Pack, which is already certified for its integrated management systems (quality, food safety and environment) and awarded for economic excellence,” said Al Shamsi. “Falcon Pack has invested in manpower, machines and systems. The modern production facility in RAK [Ras al Khaimah] is a good example of long-term planning by optimising on all available resources. The other

Falcon Pack claims to be the first firm in its category with the mark

facilities in Sharjah are being upgraded accordingly.” With a global headquarters in Sharjah, UAE, the company has manufacturing and distributing facilities throughout the UAE as well as branches in Oman and a presence in North Africa and the wider Middle East. Falcon Pack, the flagship company of the Falcon Group,

claims to be the leading manufacturer and distributor of disposable packaging products for the food service and consumer markets in the Middle East. The company has recently opened two branches – one in Dubai at Nad Al Hammar and another in Abu Dhabi in the Musaffah area – along with delivery facilities.

MEAPET spotlights PET prospects across MEA Show held on 11–12 February UAE The 15th MEAPET on 11–12 February in Dubai will showcase the PET resin trade, applications and recycling trends in the Middle East and Africa. Key converters, recyclers, brand owners, solution providers will share their perspectives on PET demand in Africa, resin supply/ demand in Middle East and Africa, and upcoming new facilities in the region, said the Centre for Management Technology (CMT), which organises the annual event. CMT said the event will tackle the two key questions: Growth or glut for the Middle East PET sector? Will demand in Africa continue to boost the regional 12

jan-feb 2014

PET trade? The event starts with an overview of ‘Global PET Markets with Emphasis on the Middle East & Africa’ by David Swift, managing director of PCI (PET Packaging, Resin & Recycling). Later sessions will include an analysis of ‘the changing PX/PTA landscape’ from Gordon Haire, senior consultant with PCI Xylene & Polyester. Sustainability features in a session on Danone’s efforts to make PET bottles more sustainable from Philippe Diercxsens, packaging and environment manager in the firm’s Waters Division.

MEAPET examined issues such as the impact of Africa’s demand

George A Hanna, president of Hipro Consulting, will cover recycled PET in the Middle East region and other sessions will look at PET trends for energy drinks, soyamilk and dairy products. Ashley Batten, research analyst at Euromonitor International, will present a ‘Review of the Beverage Industry and Challenges for Growth in 2014’. This will be followed by a

session on ‘PET Packaging Trends & Market for Dairy Products’ by Bruce Volmink, head of Packaging, Parmalat South Africa, who will focus on South and East Africa. Koen Weel, project manager Packaging Research at TNO Triskelion BV, will give an ‘Overview & Development of Global Food Contact Legislation Related to PET’.

News Regional

IST-METZ gets a fix on MEA for low-energy UV But LED UV still ‘too early’: sales boss

Moll sees the Middle East as ‘an area of specialised growth’ Jean-Philippe Fournier also sees a need for training in curing

GCC IST-METZ is looking to win more business in the Middle East and Africa through offering low-energy UV curing, says Jean-Philippe Fournier, sales manager for sheetfed applications. The firm’s new LE-UV technology offers a “new concept” for commercial printers and a few entry-level packaging printers who have never used UV inks and UV coatings. The system offers cuts time, investment costs and power consumption, said Fournier. “On the new UV system, you can increase your production through a much faster delivery, with no waiting time between printing and finishing,” he told Packaging MEA. “You gain more added value via some special effects in one pass, but constant availability of correct consumables is key.” IST-METZ’s LE-UV low-energy UV system is “something between the normal UV, which needs a lot of lamps’ energy, and LED-UV”, he added. “For a normal UV system, you need normal UV inks and normal UV coatings. But for the LE-UV technology you need special high-reactive UV inks and high-reactive UV coatings. The same goes for the LED-UV system. You need adapted inks for this technology. “For example: you have an Heidelberg CD 102 5+LX prepared for UV, equipped with a normal UV system (two lamps interdecks interchangeable in all printing units and two lamps end-of-press). We can print a four-colour process with standard UV inks, with standard UV effect varnish, and a standard gloss UV varnish. With our LE-UV technology, you can do the same printing job with only one UV lamp installed in the pile delivery of the printing machine.” The new concept is “all about consumables”, he added. “This concept was born in the beginning for the normal commercial printers with a four-colour process, but we are now moving this towards some packaging printers as the next step,” he said. But, in his view, LE-UV and LED-UV technology will not immediately replace normal standard UV, especially for high-quality packaging, for food or pharmaceuticals. In the Middle East, IST-METZ sees a need for training in curing options, he added. “Operators have good knowledge in the commercial offset side, but with special varnish and coasting with UV, they have less knowledge,” he said.

B&R Moll International picks Giffin as dealer Giffin Graphics to market US firm’s folder-gluers in the lower Gulf

GCC B&R Moll International has chosen Abu Dhabi-based Giffin Graphics as its new distributor for the lower Gulf as it targets the Middle East as “an area of specialised growth”, said Moll’s UK director, Darren Vernon. Moll sees an opportunity especially in “high-quality packaging markets”, he told Packaging MEA. “Giffin is a most respected company here with sales and support staff second to none,” he said. In the Middle East, Moll already has many customers, he added. “Moll has extensive installations in the GCC & Levant countries, with not only our original pocket folder-gluers but subsequent industryleading models like our Vantage range of inline gluers with attachers and window-affixing devices,” he said. “Indeed, when users describe buying a folder-gluer they use the word Moll as a household name.” The company sees the Middle East as a promising area for continued growth, he added. “We see this region as an area of specialised growth, particularly the high-quality packaging markets,” he said. “To this end we have high expectations for future growth coupled with Moll’s ability to come up with the right product at the right time.” Moll sees itself as the leading manufacturer of folder-gluers and specialised bindery in finishing equipment. The company is family owned and operated, involving three generations. Having pioneered simple and affordable folder-gluers more than 40 years ago, the company remains customer driven with manufacturing facilities in Pennsylvania in the US, said Moll. Giffin Graphics, set up in 1978 in Abu Dhabi, aims to supply the printing and graphic arts industry with high-quality machinery, products, and after sales service. Giffin has expanded within the GCC. jan-feb 2014

News Regional Dubai PPG Dubai International Print Award (DIPA) returns to recognise outstanding performance in printing for 2014. Submissions will be accepted until 15 April 2014. The eighth edition of the event is set to be the biggest yet, according to the organisers. In collaboration with Dubai Chamber of Commerce and Industry and organised by the Printing and Publishing Group, DIPA recognises exceptional talent, innovation and excellence in the regional printing industry. The Printing and Publishing Group expects an increase in award entries from last year, when more than 600 entries from eight countries were received from across the region. The award ceremony is taking place at the Madinat Jumeirah Hotel, Dubai, on 28 April and will be attended by professionals and influencers from the region’s printing and publishing industry. A new category has been added for DIPA 2014, which seeks to find leadership in the rotogravure, or engraved images category, relevant to label and flexible packaging material. Chairman of the PPG Mohammad Al Hashimi said: “With the recent Dubai Expo 2020 win, we are expecting a surge in growth in the printing industry as a whole, and we are sure to see even more leading-edge printing technology solutions in 2014.” Mazen El Tibi, sales and marketing director for Heidelberg Middle East said recent years had seen “great improvements in the innovation of printing techniques, to achieve consistent colour management; faster time-to-market; and a range of more cost-effective solutions in the region”. 14

jan-feb 2014

Delta plots growth path with Zünd cutter Colour Byte helps Dubai-based firm’s one-stop-shop shift

UAE Dubai-based Delta Printing Press has invested in a Zünd G3 L2500 cutter for packaging sample making applications, said Group CEO Sujit Vaidya. Zünd’s regional distributor Colour Byte supplied the cutting system, which will aid Delta’s transition into a one-stop-shop solutions provider, said Vaidya. “We have been adding additional machinery and software into our portfolio to services to serve our clients as a complete one-stopshop solution provider,” he told Delta is targeting demand for samples with the cutting system Packaging MEA. to be a tedious job,” he said. “But this machine will “Although we started as a fully help us to get it done with precision and will be fledged commercial printer, we have over the years much faster.” developed into folding carton packaging printers The cutter can be controlled either directly from and lately entered into the labels and labelling the CAD system or with the user-friendly Zünd Cut sector as well. In the near future, we are looking Center Software. into another important facet of the packaging Zünd describes the cutter as designed to give industry.” capabilities that will benefit printers and packagers A key benefit from installing the cutting system, in many ways: from cutting photopolymer will be the capacity to meet demand for samples, flexographic printing plates, offset printing and added Vaidya. “Creative packaging solutions are coating blankets; to plotting steel-rule die layouts easier to sell with professional-looking samples,” he and templates; to cutting ejection rubber and using said. “The differences between sampling and serial any number of cutting, creasing, and scoring tools production need to be imperceptible, the quality identical. Nowadays marketing professionals expect for sample-making. This flexibility leads to better vertical integration and greater independence from to see printed packaging even in the sampling phase. The packaging idea must become visual and external suppliers, according to Zünd. tangible reality from the very first sample. This Founded in May 2005, Delta Group employs about is where the Zünd camera system provides the 450 people working on a shift basis. The firm’s client necessary precision for cutting preprinted materials base spans from local emirates, the Gulf, Africa and cleanly and efficiently.” Europe. The group includes: Delta Printing Press, In addition, Delta aims to use the cutter in Brandscape Advertising, Magic Screen, Print Outs, other corrugated markets, he said. “We do a lot of Sahebson Printing Material Trading, La Vora Book specialised jobs which requires a lot of input, and Binding, Pulp Advertising, Delta & Kumar Labels, the presentation mockups required for those were PrintOuts Printing Press(Tanzania) Ltd, Delta handmade, even making alterations to those used Printing Press FZ L.L.C.

News Regional

Graham picks Orion for KSA, UAE Orion Co adds blow-moulding machinery maker’s kit to its offering for ‘leading’ plastics companies

Graham Engineering is ‘a very good fit for Orion’, said Orion GM Mohannad Naqqasha

GCC Orion Co. is now providing sales representation in Saudi Arabia and the UAE for Graham Engineering Corporation, a blowmoulding machinery maker based in York, Pennslyvania, US. Orion Co. has been a sales representative company in the Middle East for nine years.

Its experience in plastics processing provides a good fit for the extrusion blow-moulding machinery produced by Graham Engineering, said David Yenor, VP for global business development for Graham Engineering. “This collaboration strengthens our position in the Middle East, as Orion is well

known and respected in their markets,” he said. “Their sales and marketing experience will provide a strong support network that will be highly valued by our customers in this region.” Mohannad Naqqasha, general manager of Orion, said Graham Engineering offers equipment “that fast growing companies in the Middle East are looking for”. “This is a very good fit for Orion, as we are committed to finding solutions for the leading companies in the plastics industry,” he said. Graham Engineering offers of monolayer and multilayer extrusion blow-moulding equipment including: shuttle machines up to 10 L capacity; reciprocating screw and shot pot machinery for lightweight HDPE containers; multi-cavity, single and dual parison, rotary wheel blow-moulders for up to 30 L packaging applications; and single and dual head accumulator machinery from 5 to 50 lbs (3 to 30 litres) capacity. Orion has offices in Riyadh, Dubai and Damascus and represents firms that produce machinery for films, profile extrusion and blow moulding, as well as ancillary markets such as laser engraving.

Alhashemi to distribute Gidue across the Middle East Dubai-based firm will set up a dedicated team to cover the entire region GCC Dubai-based Ali Alhashemi Trading has been appointed as GIDUE’s certified distributor for the Middle East. Under the new agreement with the Italy-based manufacturer, Alhashemi will cover Bahrain, Kuwait, Oman, Qatar, Saudi Arabia and the UAE. In November 2013, Mohammad Alhashemi, president of the company, presented a strategy to Maurizio Trecate, Gidue VP Sales, and Cristina Toffolo, Gidue VP Marketing, for spotlighting Gidue’s technical advantages in the region. The action plan will be driven by G Jayaprakash, general manager for sales and marketing, who will select and train a dedicated sales and technical team to cover the entire Middle East. Alhashemi aims to highlight Gidue innovations such as the Excellence digital flexo concept for preparing print cylinders and die-cutting cylinders during production 16

jan-feb 2014

Alhashemi sees Gidue as ‘the right partner we were waiting for’

of preceding jobs. The cylinders are changed ‘on the fly’ without intervention by operators in under a minute with less than 10 metres of related waste, said Gidue. Mohammad Alhashemi described Gidue as “the right partner we were waiting for”. “It is thank to its revolutionary technologies and to its future-oriented soul, that we decided to start the cooperation with the Italian manufacturer,” he said. “Since its birth, Ali Alhashemi Trading Est

has been looking for that kind of product that can really face the market demand for hightechnology machines. Thanks to Gidue presses line, now we are able to cover all kind of necessities. I’m looking forward to seeing the first concrete results, that I know will come very soon.” Alhashemi Trading, set up in 1950, claims to be the Middle East’s largest supplier of equipment for labels and packaging, with a focus on graphic arts kit and consumables.

News Regional

NDigitec to distribute De-Mill’s D-Board in the UAE 100% graphic media board for ad and promo activities

D-Board ‘complements seamlessly’ NDigitec’s existing portfolio

UAE NDigitec is now the sole distributor in the UAE of D-Board, an inverted corrugated carton board which is 100% recyclable and can be used as the integral material for advertisement and promotional activities. D-Board graphic media board is made by DeMill, a Finland-based manufacturer. NDigitec’s marketing manager, Sai Naveen, said the product fits naturally into the company’s existing portfolio. “We took up the sole distributorship of D-Board in the UAE as it complements seamlessly into our portfolio of solutions and we believe it adds tremendous value to our customers,” he said. “End of the day, our

success is the success of our customers”. De-Mill describes D-Board as strong and rigid, which helps in sustaining heavy weight. It can be bent using a V-cut and comes in a bright white colour. The board comes with a full range of accessories, especially edge bands that give it a very unique look, according to the manufacturer. NDigitec’s expertise and skills in machinery, including the latest UV flatbed printers and digital cutting machines, which are all integrated on a NDHD platform, enables the firm to provide the local market with highquality eco-friendly products such as exhibition

stands, furniture, POS displays, partition walls, display counters, product stands and designed applications. By using non-VOC biodegradable UV inks on D-Board material, NDigitec also offers a completely eco-friendly solution. With its PSD (Packaging and Structural Design) team, NDigitec can also customise solutions to suit the needs of its clients with precision. In addition, having an experienced in-house installation team makes NDigitec a quality end-to-end service provider in the UAE. Naveen told Packaging MEA that the PSD can custom-make 100% eco-friendly packaging solutions to a client’s requirements. “The division can create 3D visualisation of the structure to be made via D-Board to help the customer understand its applications better,” he said. “We have the latest flatbed printers which can print directly on the D-Board. We also have the latest range of digital cutting machines which transforms D-Board into a completely cost-effective solution. You can print your marketing communication directly on the D-Board, making it an attractive end-to-end packaging solution for our customers.” Naveen added that D-Board’s versatility in being “both strong and lightweight” makes it an ideal solution to build walls for stands and backdrops.

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jan-feb 2014

News Regional

Gulf Carton buys Mosca kit

Saudi company gets pallet strapping machine through distributor Printech

Summit will feature 13 presentations, case studies and discussions Mosca machines ‘reliable and cost effective’: Al Jabr of Gulf Carton

KSA AlHassa-based Gulf Carton Factory has invested in a KCK131-28 Mosca pallet strapping machine with an auto edge protector inserter option, said general manager Meshari Al Jabr. “We choose Mosca because we have more than 10 years’ experience using their machines,” he told Packaging MEA. “We found the machines to be reliable and hence we choose Mosca again. We will also like to recommend Mosca machines to others because they are reliable and cost effective with low operating costs and very less maintenance.” The deal came through Mosca’s distributor Printech, he added. “We received offers and very good recommendations from Printech, which helped to choose right model for our purposes,” he said. “Their engineer visited our facility, surveyed the area and discussed in detail with us as to our expectations. He was also part of Mosca’s installation team, which ensured smooth running as per our expectation.” Al Jabr added that Printech’s service engineers had delivered “proper coordination for all the matters between the Mosca team and our engineers during the installation”. “Also, we find, with Printech that in case of any breakdown issues they are easily accessible, on phone or on e-mails,” he said. “Further, when we had a need for any spare parts, we have received them quickly either from their stock or from Mosca, Germany, with good coordination by Printech with Mosca to ensure that our machine problem is solved at the earliest.” But he added that the packaging industry in Saudi Arabia can face challenges from raw material, salary and administrative costs. “It’s also not easy to find experienced manpower,” he added. “Another major issue is most of our machinery suppliers are located in Europe/ US/Far East, and do not have any service team locally in Saudi Arabia or the GCC.” 18

jan-feb 2014

Label expo back in March

Label Summit Africa to address critical issues at Cape Town on 10–11 March Africa The speakers and programme for Label Summit Africa 2014 have been announced as the two-day conference and tabletop exhibition prepares to return to the Cape Town International Convention Centre (CTICC) on 10–11 March. As well as 13 technical presentations, panel discussions and customer case studies, the summit is intended to provide ample networking opportunities with a private dinner and reception at Grand Café & Beach in Granger Bay. Label Summit Africa 2014 will also feature more than 20 market-leading exhibitors including Flint Group, HP, MPS, New Africa Inks, Nilpeter, Nuova GIDUE, Omet, Paragon Inks South Africa, Prati and Xeikon, said the organisers. Day one of the conference programme will focus on market trends and new technologies. Confirmed speakers include Tom McGinley, former MD of Self Adhering Products. Rian Moore of Collotype Labels RSA/Multi-Color Corporation will discuss mergers and acquisitions and look at partnerships and joint ventures. Codimag’s Pascal Duchene and Jean-Michel Fouquet of CGPETIQROLL will present a short-run wine label printing case study and talk about digital workflow on a conventional press. An African converter panel discussion will feature Leon Witbooi of SA Litho, Uwe Bögl of RAKO labels Cape Town, Litho-Chrome’s George Pryde and Peter Frost from Associated Printers. The second day will focus on brand development, product design and positioning. Bill Marshall, managing director of Syndicate Graphics and chairman of the IPSA Gold Pack Awards will co-examine the changing landscape of package printing with Gill Loubser. Mark Anley from Indigo Brands will discuss developing innovative and iconic packaging.

News Regional

Flexible packaging set for growth in MEA

PCI Films forecasts 5% expansion each year over 5 years Five nations account for most of the market MEA A new report from PCI Films Consulting forecasts that flexible packaging demand in the Middle East and Africa (MEA) will expand at 5% per year over the next five years. PCI managing director Simon King, who authored the report, told Packaging MEA that tepid growth in Europe and the US is prompting multinationals to turn to the Middle East and Africa. “They can reap larger returns investing in growing economies,” he said. “In addition, the growing population, particularly in Africa, means more and more people will need food. As these people gradually become more affluent, the multinationals want to be in place to take advantage and gain market share.” The MEA region will continue to import in large quantities, although governments and companies are investing here, he added. “Recent commitment from governments and multinationals to invest in infrastructure and food production means that we can be confident that growth in flexible packaging will follow,” he said. The UK-based consultancy expects the market to benefit from inward

investment and an expansion in mass food processing. In 2013, the MEA flexible packaging market totals almost $4bn, said PCI. But per capita consumption in the Middle East and Africa runs at only $3, compared with Europe’s US$30, giving “huge potential for future growth”, said the research firm. Nigeria is pinpointed at the most dynamic market, with flexible packaging demand up by about 12% per year over the past five years, although smaller markets such as Tanzania and the UAE have also seen above average growth. Five countries – South Africa, Nigeria, Iran, Egypt and Saudi Arabia – currently account for more than half of the region’s total consumption. The report identified the following growth factors; a rapidly growing young population and increased urbanisation; increased investment in food production and processing across both regions; significant investments in new flexible packaging converting capacity; increased availability of locally produced and competitively priced base substrates; growth in modern retailing and increased penetration of pre-packed foods.

jan-feb 2014

News Regional

Victoria to add to AED3m Duplas invests $2m in kit investment in packaging More purchases planned after new Ajman-based printer builds on contracts with F&B companies

Pozza: ‘investing further in machinery later this year’

UAE Victoria Printing and Packaging Press, Ajman, is set to continue a push from commerical print into packaging that has already involved AED3m in new kit, said group divisional manager Julian Pozza. “We have invested over AED3m in machinery and we look forward for further investments later this year,” he told Packaging MEA. “We have invested in a Heidelberg CD 102 5-colour sheetfed offset press with inline UV coating, whilst on the finishing and converting front we have invested in a high-speed, versatile straight-line gluing machine capable of running at 4000sph, a window-patching machine, wet and thermal laminate lines, high-speed folder-gluer and fully automatic die-cutting machine.” Most of these machines were supplied and installed by Afra International Fzc, he added. “We started as a small company with a small single-colour printing press before I took over as the divisional manager for Victoria Printing and Packaging earlier in 2013,” he said. “After taking over the responsibility, I did a detailed study of the UAE market and came up with the thought that although commercial printing is good, there is a huge potential for packaging. This opportunity paved way for us to invest into the packaging business extensively over the last one-year and thereby complement our commercial print business along with packaging print.” High demand for food grade packaging from restaurants and fast food joints has enabled the firm to close major contracts with leading food and beverage companies, he said. “We also have invested in machines to produce paper bags for the food industry,” he said. “Victoria Group has also other arms catering to the plastic and aluminum industries. As the demand for packaging is increasing, we have further plans to enhance our production by investing further in machinery later this year.” 20

jan-feb 2014

blow-moulding line for shampoo

UAE Duplas Al Sharq is aiming to continue investing following a $2m purchase of blow-moulding machines from Italy-based Magic for a line for shampoo and detergents, says Mohammad Nofal, general manager of the Dubai-based plastics supplier. In 2014, the company aims to expand its building infrastructure and stores in Jebel Ali, he told Packaging MEA. “We will inject a further AED10 million into this project plus new PET lines to produce clear bottles for milk, water and juice,” he said. Duplas Al Sharq is a subsidiary of Emirates Investment & Development (Emivest), in which Dubai Government holds 30%. The company sources raw materials from suppliers including Borouge in Abu Dhabi and SABIC from Saudi Arabia. Specific products like polycarbonate and PET are sourced from Europe and South Asia, respectively. In 2014, the company expects to keep growing despite increased competition, he added. “New players are coming into the market, but it is not just people adding new machines and factory in order to compete in the existing industry,” he said. “In this industry you have to compete in quality, service and total sales value and not only in price and the production lines. You have to compete in terms of service in the sector that you are supplying. We are servicing high quality customers like Shell, Enoc, Total in the lubricant sectors. We are supplying to Henkel and other big companies.” Duplast Al Sharq is a plastic manufacturing company that produces plastic bottles servicing the entire packaging industry, he added. The firm produces polypropylene, polyethylene, PET and polycarbonate and its bottles are used for lubricants, detergents, water and milk. “Primarily, we cover UAE and also supply to Saudi, Bahrain and Oman,” he said. “Some of our products are also exported to East Africa. But 80–85% is to the UAE because of the nature of the industry. With plastic bottles, the transport cost is high compared to the product. There are limitations exporting to the other countries, although opportunities are still there.”

Duplas Al Sharq is poised to expand its infrastructure and stores

News Regional

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MEA The 5th edition of AMI’s Flexible Packaging Middle East conference at the Sofitel Hotel in Abu Dhabi, UAE, on 9–11 December, underscored the region’s progress in flexible packaging, said Andrew Reynolds, AMI Consulting research director. “I think the Middle East is really catching up,” he told Packaging MEA. “Five years ago, most of the products were copied from other parts of the world. Today, it’s more sophisticated and moved on.... When you look at consumer packaging, there is a lag but not the kind that was before.” He also noted an improvement in barrier materials and the understanding of the local consumer needs. “Today people understand that the consumer drives,” he said. In his view, the event underlined “increasing innovation and development”. “It’s remarkable for me in an industry which many people call relatively mature, the pace of innovation, of machinery of printing, of polymers and additives is very remarkable and at a very high level,” he said. The quality of packaging demanded by consumers in this region “has elevated enormously in the last two years”, he said. “So the consumer is looking at a better experience both with the pack and with the quality of the product that comes out of the pack.” In flexible’s competition with rigid packaging, he suggested flexible is winning in the Middle East. “Because the region is growing and the region is dynamic, your market could be growing in volume terms or value terms and by natural fact could be losing market share,” he said. “This is what the rigid is facing. There has been at least an 8–10% growth in the flexible market. If you are talking about the growth of the rigid packaging it is a lower number, maybe 5–7%... Flexible has a lot of advantages like light weight, ease of use, shelf appeal.”

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jan-feb 2014

News Regional

Palletco signs up at Kizad AED90.7m investment into a plastics plant at Abu Dhabi UAE Officials from Khalifa Industrial Zone Abu Dhabi (Kizad), a wholly-owned subsidiary of Abu Dhabi Ports Company (ADPC), and Palletco, a leading manufacturer and supplier of plastic packaging products, have signed a 50-year Musataha Agreement. Under the deal, announced in December, Palletco’s investment into its manufacturing facility in Kizad will total AED90.7m. The investment guarantees Palletco, which plans to start production in early 2014, a 23,000sqm plot of land in Kizad’s Mixed Use Cluster. Specialised in industrial packaging and storing, Palletco is also seen as a pioneer in manufacturing plastic pallets in the UAE. The production of plastic crates, used in the food and beverage or logistics sector, is a further part of the company’s high quality product portfolio, making Palletco a well-known and highly reputable name in the industry, especially in the Middle East, said Kizad. Commenting on the signing of the agreement, Engineer Khaled Salmeen, CEO and Managing Director of Kizad, said: “Palletco’s long-term commitment and sizable investment in its upcoming manufacturing facility is a further confirmation of Kizad’s attractive industrial profile. With its innovative, low cost

Chemco sets up in Bahrain Indian group plans $20m PET plant at Salman Industrial City Bahrain Chemco Group, an Indian PET manufacturer, is to set up a plant at Bahrain International Investment Park (BIIP) in Salman Industrial City with an expected investment of $20m by 2017, it was revealed on 22 December. The announcement follows an introductory visit led by the Bahrain Economic Development Board (EDB) who provided support, according to the Bahrain News Agency. Chemco Group’s plant will serve both local and regional companies. HE Kamal bin Ahmed, Minister of Transportation and Acting Chief Executive of the Bahrain EDB, said Indian companies have found Bahrain to be “an ideal location for investment, in terms of its business environment, transparent progressive legislations, and of course the cultural and environmental similarities between the two countries.” Chemco’s investment in Bahrain is expected to reach $10m with systematic expansion up to 2015 and then rise to $20m by 2017. Chemco Group chairman Ram Saraogi said Bahrain offers “a unique business environment, a diverse economy as well as a vibrant location that acts as a gateway to the Gulf market”. “This is a big and important step for us,” he said. “Through this deal, 22

jan-feb 2014

Palletco is aiming to start production at Khalifa Port this year

infrastructures, state-of-the-art ICT environment and excellent market access through its adjacent deep water Khalifa Port, Kizad offers fantastic business opportunities, and we are delighted to have found another strong partner on our way to support Abu Dhabi in diversifying the economy.” Aboobacker Ponneth, managing director, Palletco, added: “The services, facilities and location of Kizad are ideal for Palletco’s next stage of growth in the regional and international market. We look forward to establishing our manufacturing facility in the industrial zone and to developing new business partnerships with surrounding industries. Khalifa Port will help us tremendously to expand our distribution lines and develop our import and export activities.” we are able to develop the group’s business and provide our various products to different clients in Bahrain and the region.” Chemco Group, which was established in 1980, claims a 26% share of PET preforms in Asia, inclusive of exports. The group specialises in manufacturing bottles and jars ranging from 15ml to 25,000ml all under one roof. Clients include Coca-Cola, Pepsi and Reckitt Benckiser. The GCC’s plastic packaging industry is estimated to value $400m, with growth in plastics consumption forecast to grow 8% by 2020. Bahrain has a large Indian community and in 2011 trade with India totalled $1.7bn, according to the International Monetary Fund.

Chemco Group sees plant as ‘a big and important step for us’

News Regional

PAT ME starts construction One Pack Systems factory at Kizad set to complete in 2014

MENA demand focuses on setting up new print shops: Heidelberg

Polymer plant will produce pelletised additives for plastic production

UAE After signing a 30-year Musataha agreement with Kizad, a subsidiary of Abu Dhabi Ports Company (ADPC), PAT ME has laid the foundation for its One Pack Systems (OPS) manufacturing plant within a mixed use cluster at Kizad and covering 18,300sqm, it was announced in December. The plant, set to complete in 2014, will focus on producing polymer stabilisers called Songnox One Pack Systems. An initial capacity of 7,000 tonnes per year could be expanded to meet demand. PAT ME describes its One Pack System as a multicomponent blend of additives in a pelletised form. Additives are critical in plastic production to ensure ease of processing, UV resistance and protection against heat degradation. Polysys Additive Technologies Middle East (PAT ME) is a joint venture between Polysys Industries Abu Dhabi and Songwon Additive Technologies AG, Switzerland, a leading global supplier of OPS with plants in Europe and USA. More than 40 investors have now starting constructing facilities at Kizad, said Khaled Salmeen, the zone’s CEO and managing director. “With Polysys Additive Technologies Middle East we have won another strong business partner that will tremendously benefit from our excellent market access through Khalifa Port, stateof-the-art ICT Services and vertically integrated clusters which provide most time and cost effective production lines,” he said. Mohamed Al Muhairi, director of the board of PAT ME, said the plant will serve regional demand for OPS. “With its right location and excellent infrastructure Kizad provides the perfect platform for operating our business,” he said. “The JV partners bring a combination of regional market knowledge, latest technology and key raw material access. We are looking forward to growing our business and facility together with Kizad.”

Heidelberg bags MENA sales Print giant lands major deals in Egypt, Jordan and Tunisia MEA In line with growing demand in the Middle East and North Africa for packaging, labels and security printing, Heidelberg has clinched milestone deals in Egypt, Jordan and Tunisia, the firm annonced at year-end 2013. In Egypt, Heidelberg closed several orders for its Linoprint C at a launch event. Sales in Jordan include the country’s first Speedmaster XL 106, while a fit-out for a new printshop in Tunisia features North Africa’s first Diana 115 X folding carton gluing machine. Demand for printed products in MENA is being fuelled by an increase in consumer goods to be labelled and packaged, said Heidelberg. In contrast with established markets, MENA is seeing demand for new print shops. Wolfgang Roth, responsible for distributors at Heidelberg, said the company is seeing in MENA “a general increase in the amount spent on digital and packaging printing”. In MENA, Heidelberg claims a market share of over 30% for CTP, over 60% for presses, and over 40% for postpress kit. More than 7,500 one-, two-, and multi-colour presses from Heidelberg covering all formats are installed in MENA. In Tunisia, the new pharmaceutical packaging specialist Medpack has invested in a Suprasetter A106 CtP platesetter, a Speedmaster CD 102-5+LX, Tunisia’s first Speedmaster SX 74 four-colour press with coating unit, a Stahlfolder Ti 36 and Ti 52, a Varimatrix 105 C die cutter, and a Diana 115 X folding carton gluing machine. Early in 2013, Heidelberg installed Jordan’s first Speedmaster XL 106-5+L at Central Press, where it joined a Speedmaster XL 105, a Speedmaster CD 102, and a Speedmaster CD 74. The Al Shurook print shop in Amman – focused on packaging for foodstuffs and detergents – has also ordered a Speedmaster XL 1056+L, a Speedmaster SM 52-5-L, and a Suprasetter A105 platesetter with a G&J online processor. Both presses are designed for UV and water-based printing. jan-feb 2014

News Regional

Tagleef opens BoPP line

8.7-metre line at 6th of October City raises Egypt plant’s output to 48kt/a

Ti Egypt has more than doubled BoPP production with the new line

Egypt Taghleef Industries (Ti) has commissioned a new BoPP line at its Egyptian production site in 6th of October City. Until 2013, Taghleef Industries S.A.E. (Ti Egypt) had a BoPP net extrusion capacity of around 20 kt/a. With the new extrusion line, the capacity will soar to about 48 kt/a, although one older BoPP line has been decommissioned already during 2013 to cut costs.

The new machine is a 8.7-metre-wide Brückner stretching line to produce a wide range of BoPP films at high manufacturing speed. In addition, a new centralised recycling facility has been installed, in which PP scrap from the whole plant will be regranulated for reprocessing on the extrusion lines. The investment also includes a roll-handling system with conveying of slit reels from two primary slitters into a new centralised packing area. Soon after the production site became part of the Ti group in 2006, the need to expand the BoPP production capacity in the medium term became clear. While the country went through some turbulent times, Ti took the decision to strengthen the unit and invest close to $50m for new production equipment, buildings and site infrastructure. The strategic location of the country justifies this investment: Egypt bridges Africa, the Middle East and Europe. Egypt is a hub for maritime traffic with commercial ports on the Mediterranean and Red Sea. With its location near the capital, Cairo, the revamped plant will cover the growing demand of BoPP films in Africa and in Europe. Local BoPP demand has also been quite robust and Ti claims to have always had a strong position serving domestic customers. With the new production facilities, Ti’s aim is to further increase production flexibility, shorten lead times, and bring product quality and consistency to an even higher level. As part of the overall strategy of the Ti Group, Ti Egypt is fully integrated with the European operations, and benefits from the established sales and distribution structure already in place to better serve customers, not only in Europe, but worldwide.

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News Regional

Uteco installs in Tanzania

Onyx 812 flexo press to print mainly on BoPP, BoPET for Omar Packaging Tanzania Uteco Group has delivered an 8-colour central impression (CI) Onyx 812 flexographic printing press to Omar Packaging Industries, one of 19 companies within Tanzania’s leading Dar es Salaam-based Bakhresa Group. The new Uteco Onyx 812 flexo press will print mainly on BoPP (biaxially-oriented polypropylene), BoPET (biaxially-oriented polyethylene terephthalate) and metalised BoPP/BoPET, all of which Omar Packaging manufactures and laminates. But the press will also be used for paper of up to 100gsm. Uteco describes its gearless press as the state of the art in flexography, with a patented DD EVO® (Direct Drive) on the CI drum as well as quick-sleeve job changing for both the anilox as well as the plate axis. The press runs at up to 400 m/min. To cut changeover times and material waste at job start-up, the press features Kiss&Go automatic printing press regulation along with viscosity controls and the SpritWash automatic washing system. For visualising the print, the setup comes with a GFK 2200 video camera from Grafikontrol, a major Uteco partner, which is totally integrated with the press supervisor, said Uteco. The press also includes a fully automatic splicing unwinder and rewinder for reels up to 1000mm in diameter. Omar Packaging is one

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Uteco has supplied an Onyx flexographic press to Omar Packaging

of three specialty packing companies within Tanzania’s Bakhresa Group and focuses on flexible packing materials. The company began in 1998 as a small bag-making concern but has grown steadily and now employs 150 staff. About 70% of Omar Packaging’s products are for sister companies such as Azam Bakeries Company Ltd and Bakhresa Food Products Ltd for packing products such as breads, biscuits, cakes, ice cream, fruits juices and bottled water.

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jan-feb 2014

News Regional

Manipal aims for the MEA Merger with Utility Printpack creates packaging group with export goals

MEA A merger of the packaging businesses of Manipal Technologies (MTL) and Utility Printpack has created an India-based packaging group with Africa and the Middle East firmly in its sights. Manipal Utility Packaging Solutions (MUPL) will have manufacturing operations in India at Manipal, Ahmedabad and Chennai but will also produce from Manipal’s plants in Kenya and Nigeria. In an official press release, MTL and Utility Printpack promised an “unbeatable customer value proposition” through the combination of “India’s largest print solutions player” (Manipal) with “India’s leading and most innovative packaging solutions player” (Utility Printpack). Gautham Pai, MTL’s managing director, said the new firm would target markets outside India. “Packaging solutions is identified as one of our high growth businesses for the future, and we aspire to build a global packaging business spanning emerging markets in Asia, Africa and Middle East,” he said. “The partnership with Utility Printpack provides us the capabilities

Manipal and Utility Printpack vow ‘unbeatable value proposition’

to accelerate the growth and achieve our long term vision in this business.” Manoj Mehta, chairman of Utility Printpack, also spotlighted overseas opportunities. “The partnership with Manipal further reinforces our vision and commitment towards focused growth in the packaging business in India and globally,” he said. “The new entity will unite our strengths and provide a resounding resource to our combined customers in India and over 40 countries worldwide with added manufacturing capacities and capabilities”.

Valiani brings ‘in between’ cutter option to the Gulf

Italian firm has tied up with AGE Graphics to break into regional markets GCC Following a successful participation at the SGI tradeshow in Dubai, at which it sold its exhibition machine, Valiani is looking to develop fast in the Middle East through its new dealer AGE Graphics. Valiani’s technology offers Middle East packagers an attractive middle path in die-cutting, said Luca Bartalini, product manager at Valiani. “Everybody has questions about the size of the machine, the cutting capability,” he told Packaging MEA. “In the market before there were two applications: roll-roll printers that also do die-cutting and the big plotting machines like Zünd, involving a huge investment. There was nothing in between that could cut a thin foil like a roll-to-roll or a plastic material. So we are in between for the price, for the cutting capability.” The Valiani digital cutter also provides “a good step” for anyone who wants to invest in finishing “without knowing anything”, he added. “Our machine goes in that mid-range,” he said. “It’s good for short run jobs, it’s good for prototyping and even for special jobs. The number of materials that the machine can process is very wide. We start from a very thin piece of paper for folding cardboards to flute corrugated boards, everything below 5mm. We also cut plastics like polypropylene, leather.” A further application is in spot UV for cutting double-layered blankets, he added. “You can set blade depth for a particular height and then you can cut only the top layer and then you can peel out the rest,” he said. “Right now people are doing it by hand. It becomes very easy with this machine. With some special products like plastic laminates you need 26

jan-feb 2014

Luca Bartalini, Valiani, with Jay Krishna, AGE Graphics

more power on the head and the blade.” At SGI, Valiani sold the die-cutter it was exhibiting and an additional machine is “90% sold”, said Bartalini. “I am expecting a very good job from Jay [Krishna of AGE Graphics] and all his staff”, he added. Jay Krishna, sales manager at AGE Graphics, described the machine as “a fantastic choice”. “We don’t have a lot of produts so we are very particular of what we choose,” he said. “This product fits in very well with the offset segment, within the designers, within the graphic industry. It is our responsibility and goal to make sure that customers will realise the benefit of this machine.”

CMY

Sustainable Packaging

Kimoha wins CSR award Label specialist’s ethos impresses Dubai Chambers

Receiving the award from HE Hamad Buamim CEO Dubai Chamber

MEA Kimoha Entrepreneurs Ltd, a member of the Al Ansari Group, Oman, has been bestowed with a corporate social responsibility (CSR) certification. Dubai Chambers gave away the CSR label after detailed assessment of the firm’s contributions to society. Vinesh K Bhimani, Kimoha’s managing director, told Packaging PackagingMEA_half_Feb2014.pdf 2/21/14 1:23 PM to continue to MEA that the certification would 1prompt the company enhance its social and environmental programmes.

“I am really delighted with this recognition, not because of our contributions, small though, to the cause of CSR, but for the recognition of our belief, which is imbibed in our Kimoha culture that we practise in our day-to-day activities,” he said. “This recognition has also helped us in identifying what more we can do and excel further, ”he added. Kimoha – a printer and converter of paper, self-adhesive labels and flexibles – has already garnered several certifications for its processes and low environmental impact. The firm’s new headquarters in the Jebel Ali Free Zone has been awarded a Green LEED Gold Certification, a pioneering recognition for a printer in the region, awarded for the building’s exceptionally low carbon footprint. Kimoha also holds an ISO 9001-2008 certification. The company specialises in the manufacturing and marketing of self-adhesive labels and flexible packaging applications, paper products for retail and office use, complemented by providing auto ID equipment and solutions for most industries. In addition to that, it has made the UAE proud, by producing and supplying baggage tags and boarding passes which fly to more than 60 airlines/ground handling companies throughout the world. After more than two decades of committed excellence and performance, Kimoha aims to be seen as synonymous with impeccable quality and promptness. With consistently upgraded production facilities and a team of qualified professionals dedicated towards quality assurance and customer delight, Kimoha has established a firm position in virtually every market segment.

Sustainable Packaging

Enviro Print banks on a ‘sensible’ approach

Doha-based pioneer aims to meld green values with high efficiency Qatar With a slogan of ‘A sensible way to print’, Doha’s Enviro Print is looking to convert packagers to environmentfriendly printing through technologies that are more efficient as well as cleaner, says managing director Mazhar Khan. Founded after “persistent” challenges, on 25 September 2013, the company features webto-print as well as a streamlined offset workflow to achieve its twin goals, he told Packaging MEA.

Mazhar Khan, MD, Enviro Print

“The-new technologies of digital press gave us our first taste of how technology can be used not only to increase efficiency, but also to reduce environmental impact,” he said. “As printing operations became more computerised, the concept of digital press gave us a major head start when we decided to venture into offset printing technology. Colourmanagement systems and digital press controls allowed us to shape an offset printing operation that was far less 28

jan-feb 2014

wasteful than traditional shops.” Enviro Print has also “as a value addition” invested in what he calls “the region’s first webto-print”. “To this we added variabledata printing,” he said. “By allowing customers to customise orders, get pricing, place and track orders, and set up deliveries and shipments anytime they wished, we realised we had seized upon a powerful and efficient new way to conduct business. Hence our slogan ‘A Sensible Way to Print’.” Khan embraced the concept of sustainable green printing 18 months ago after switching from a corporate career overseeing advertising. “As a marketing veteran, I have served in top Qatari corporates managing ATL/BTL [above-the-line/below-the-line] deliverables,” he said. “I am inherently a hands-on person. I’d rather be on the shop floor than be perched in a luxurious office. I got myself fired and associated with a small design agency, which led me to the sustainable green printing project. “‘Sustainable green printing’ were just words that I started with. I craved for ideas and understanding of the process. The answers were not easy to come. I was not comfortable and had to find a solution. I started my own research, attended umpteen conferences and exhibitions to get a better understanding of on-demand

Khan: Valiani offers ‘niche services’ including merchandising packaging

short-run sustainable green printing.” Enviro Print’s investments, including a Valiani flatbed cutter from AGE Graphics, have opened up “niche services” in short-run, on-demand jobs. “Clients walk in with unimaginable requests from complex invitations and greetings cards, display boards, POP, POS, customised tissue boxes, confectionery, gifts and merchandising packaging,” said Khan. “The orders are small and the time on hand is acute. Hence we cannot use conventional methods, which are time consuming and not sustainable. Post a tedious research we sourced the Valiani plotter. Inherently, Valiani has decades of experience in the photo-frame industry with an esteemed reputation. To them the print and packaging industry is new but their products and service are second to none if compared on price and performance.” In packaging, Enviro Print’s services have a key market in producing prototypes for fast-moving consumer goods (FMCG). “There is a niche demand in the packaging industry where FMCG product managers and product design companies need to prototype packaging prior to mass production,” he said.

“Clients are ready to pay a higher cost for small trial orders. Though the cost per unit may be high, the overall cost is low.” A specialised set-up, free of “time-consuming and expensive” conventional technology, streamlines this aspect of Enviro Print’s operation. “The recipe for success is to align and set up a digital press, plotters and allied small machinery like Duplo 745 within a large commercial print and packing press to work as a profit centre exclusively,” said Khan. “I reckon it’ll pay for itself within a short period of time. Apparently, owners and managers of these establishments need to open their minds and embrace change.” While the sector remains sceptical about environmentfriendly technologies, Khan is convinced it can be converted through a combination of sustainability with quality and value. “Both the buyer and the suppler are not in synch with the concept of sustainable green printing,” said Khan. “It’s much more than just ink on paper. Then again, a little knowledge is dangerous. I believe, it is the print supplier’s obligation to educate print buyers ethically.

Sustainable Packaging

Borouge plans MoU on waste management Deal with Tadweer would promote public awareness and combat litter

Biobased non-degradable bioplastics is set to spearhead growth

Bioplastics to surge to 6.2m tonnes by 2017 Borouge took part in World Future Energy Summit’s EcoWaste expo

UAE Borouge, which promoted plastics waste management and recycling at the EcoWaste Exhibition at the World Future Energy Summit on 20 January 2014, aims to soon sign a memorandum of understanding (MoU) with Abu Dhabi’s Centre of Waste Management (Tadweer) to collaborate in raising awareness of waste management best practice. At EcoWaste, Borouge’s delegation included Herbert Willerth, board member, and Wim Roels, CEO of Borouge’s marketing and sales company, as well as representatives of senior management. About 19% of the UAE’s municipal solid waste is plastics and Borouge promotes the proactive collection, segregation and recycling of waste. Too much litter is still being discarded indiscriminately and in illegal landfills, which is very harmful to the environment, said Borouge. “As plastic bags are considered the most visible form of litter, reusable plastic bags are the most sustainable and environmentally friendly solution to reducing plastic litter in the environment,” said Craig Halgreen, vice-president for corporate sustainability at the EcoWaste conference. “These can either be heavy weight polyethylene bags or non-woven polypropylene bags that are fully recyclable. For this solution to be effective, society needs to adapt to a responsible and discipline role in the way they carry their shopping items and goods.” A first step towards reusable plastic bags is to enforce a charge for plastic bags, said Halgreen. “Far too often, small grocery stores give these single-use plastic bags away indiscriminately for minor purchases and these are very quickly disposed of, often into the environment”. Inducing fines for littering also supports the elimination of plastic litter, however, it is vital that adequate collection facilities are in place.

European Bioplastics association sees ‘continuous growth’ for all materials Germany The bioplastics market is poised to grow from about 1.4m tonnes in annual production in 2012 to about 6.2m tonnes in 2017, according to the latest annual forecast from European Bioplastics, which was published in cooperation with the Institute for Bioplastics and Biocomposites of the University of Applied Sciences and Arts Hannover in Germany. But the land needed for sourcing renewable feedstock for these bioplastics will amount only to about 0.02% of global agricultural area, according to the association. François de Bie, chairman of the Board of European Bioplastics, said the report affirms “above average growth in the bioplastics industry around the world.” “Continuous growth can be expected with regard to all bioplastic material types and in a range of very diverse market segments – from packaging to fibres to consumer electronics,” he said. By far the strongest gain is expected in the biobased, nonbiodegradable bioplastics group, according to European Bioplastics. Biobased versions of bulk plastics like PE and PET, in particular, are significantly increasing capacities. These ‘drop-in’ solutions differ from their conventional counterparts only in terms of their renewable raw material base. Biobased PET contains biobased monoethylene glycol (MEG), which accounts for about 30% of the PET equation. Capacity for biodegradable plastics, which can support biowaste collection, is set to climb 60% by 2017. Packaging will remain the leading segment for bioplastics applications. Here, the bioplastics industry offers a growing range of mature applications to cut carbon footprint and offer additional recovery and recycling options. jan-feb 2014

News International Videojet has introduced new UV fluorescent ink for its 1000 Line of continuous ink jet printers. Videojet’s V458-D UV ink is formulated for dual-purpose applications that require both machine readable fluorescent and human readable codes. “Videojet continues to increase its ink offerings in order to help meet expanding customer needs,” said John Kirschner, Videojet supplies business manager. “By launching a new UV fluorescent ink that produces both machine and human readable codes, we can better serve customers with multipurpose applications. The ink imparts unique code properties to enable automated product validation and to assure correct product routing and usage throughout the supply chain. These features help to drive increased productivity and enhanced uptime.” Customers implementing Videojet 1000 Line printers can now print UV fluorescent codes easily readable by machines and humans. The new ink enables reading and authentication on a variety of background colours and materials. V458-D ink produces a red, lightemitting fluorescent code when illuminated by a UV light. These red fluorescent images can be read on high-speed production lines immediately after printing, even on multicolour surfaces, which can be challenging for conventional fluorescent inks and camerabased reader systems. The ink also produces a human-visible pink colour making it easy to conduct immediate visual code quality checks during production or downstream in the distribution supply chain. 30

jan-feb 2014

Cosmo Films’ new high-speed line will run at up to 1,000m/min to produce 45,000 tonnes/year

Cosmo opens ninth India BoPP film line

8.7m-wide line at Shendra also with two slitter-rewinders India Cosmo Films Ltd, one of the world’s largest producers of BoPP and thermal laminating films with operations in three locations in India, as well as in South Korea and the US, has inaugurated its ninth BoPP film production line on a new greenfield site in the Special Economic Zone in Shendra, close to Aurangabad in India, about 450km north east of Mumbai. In conjunction with this latest huge investment project, Atlas has commissioned two slitterrewinders: one 8.7m-wide Atlas CW984AP primary film slitter at the end of the film line and a 2.8m-wide Atlas CW800 secondary film slitter for processing narrower widths of BOPP film. Both machines will be running at speeds of up to 1,000m/min. The new, high-speed film line is 8.7m-wide and is expected to produce up to 45,000 tonnes of BoPP

film per year. The line will be processing thinnergauge films particularly used for lamination in flexible packaging applications. Both Atlas slitter rewinders feature an unwind splice table for high quality splicing and the CW984 primary slitter is working with a slit roll conveyor system to transport the rolls to both the Atlas CW800 secondary slitter and the packing/storage facility. “We are very pleased with the quick installation and commissioning of the two new film slitters which was carried out by the Atlas Service team based in India,” said Sanjay Chincholekar, VP of Sales, Marketing and Projects for Cosmo Films. “We are also pleased to be working in collaboration with Atlas again for our new film line. We now have 12 Atlas film slitters operating in several locations, some of which have been in service for more than 25 years,” he said.

Intermat picks Comexi Nexus laminators Two Evo machines start up at Turkish company

Turkey Intermat Flexible Packaging has started up two Comexi Nexus Evo laminating units, Comexi announced on 28 January. Comexi Group said it is strengthening its presence in the Turkish market through an agreement signed last year with Mensad International Trading Co, which is now its representative in Turkey. Muzaffer Incekara, general manager at Intermat The Comexi Nexus Evo laminating unit Flexible Packaging, said: “The Comexi Nexus Evo paper, according to the manufacturer. allows us to work with a high degree of reliability and Comexi Group is a leading company with a simplicity at high-speed levels.” worldwide presence and more than 400 employees. The Comexi Nexus Evo features the most advanced It has been committed to machinery manufacturing control systems and application of adhesives and, for the flexible packaging industry since 1954. The thanks to its simplicity and ergonomics, makes an firm describes its mission as leading the conversion ideal solution for short and long runs, said Comexi. of the converting industry into a clean, emission-free This machine allows configurations with industry that makes the smallest possible impact on simple shaftless or ‘turret’ type unwinders and the environment. Comexi says it has a commitment to rewinder to suit different production needs. offering global solutions unique to a world with everMoreover, it allows working on a variety of increasing flexibility and efficiency needs. materials such as plastic film, aluminium or

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News International

Edale eases Etiq into flexo Esko opens online store Algerian label printer switches from letterpress with FL-1 and FL-5 kit

Etiq Color has moved into UV flexo to ensure it ‘stays competitive’

Algeria Etiq Color, a well established family-run label printing company in Algeria, which previously operated several letterpress machines, has moved into flexo with two high-specification presses from UK-based Edale. “It has been time to move into UV flexo to benefit from the many advantages it can offer, especially increased productivity and profitability – to ensure our business stays competitive,” said Mr Arezki, Etiq Color’s founder and managing director. The company started its expansion with the purchase of an Edale FL-1 twin stack press for self-adhesive labels, which brought a huge increase in productivity from previous letterpress machines, he said. Alongside the compact press, Etiq Color also purchased an FL-5 Flex Pack fully servo-driven flexopress for packaging applications and long-run label jobs, ideally for substrates of 12–450 microns. Together with his three sons, Mr Arezki decided to expand the business into three label printing divisions for different applications. Packaging products also prompted the shift into flexo, to print on a wider range of materials, such as unsupported film for wraparound labels, shrink sleeves and other more exotic substrates. The drivers for Etiq Color’s FL-5 Flex Pack purchase was the versatility, print quality, short setup time and minimum wastage, said Arezki. “We performed a lot of tests with a number of different manufacturers and, after a lot of thinking, we decided to purchase the FL-5 Flex Pack because the machine matched our requirements in terms of innovative concept, and the fact that additional options are available to be retrofitted should our demands change in the future, meaning to us, the press is not only flexible but futureproof.” GIC, Edale’s agent for France and North Africa, was instrumental in securing this order. Its dedicated personnel in Algeria is offering them technical support, said Bruno Vitali, GIC’s managing director. Areski said the FL-5 Flex Pack is now in two-shift production, because the print quality has allowed the company to win “new market shares”. 32

jan-feb 2014

Kongsberg cutting table parts and platesetter consumables on sale Belgium Esko has opened an online store with an intelligent storefront that simplifies bits, blades and underlays purchasing for users of Kongsberg cutting tables and consumables purchasing for CDI flexo platesetters. Esko Store, currently available in English, is at www.esko.com/store and publicly available for new and existing Esko customers around the world. “Come shop with us!” said Christian Korte, Esko senior vice president Sales. “Our intelligent storefront features a state-of-the-art shopping experience that makes it easy to find the right bits, blades and underlays quickly and easily. This is a unique capability among digital cutting table suppliers, again demonstrating Esko’s leadership in this field. Visitors to the store will find not only the best materials, but also the best know-how, service and shopping experience.” Kenny Van Bogaert, Esko business development manager for e-commerce, said built-in intelligence is especially useful when searching for Kongsberg accessories. “Find the best bits and blades for a specific job by entering material, quality and finishing method specifications,” he said. “And for each bit and blade, the Esko Store advises the setup you require on site, including which Kongsberg table, tool insert and adapter you need. In My Store Account, customers will see the Kongsberg table(s) they own. Simply selecting a specific Kongsberg table provides immediate access to ordering underlay fittings for that table. Our customers pointed out the value of this new capability and for further improvements of the store we will continue to take suggestions from visitors into account.” The Esko Store features advanced filtering options so visitors can narrow their search when browsing a category as well as a compare functionality that enables side-by-side comparisons of products within a category. Visitors can use the one-step search by product code or name to quickly reach a detailed product page. With the recently viewed items feature they can access previously visited product pages. While browsing, visitors get an immediate indication whether an item is in stock. Finalising the order, multiple shipping methods and tax calculations are available at check-out.

Esko claims an ‘intelligent storefront’ makes shopping easy

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Unpacking the world of packaging

jan-feb 2014

News International Flint Group’s Flexographic Products has launched its nyloflex ACE UP Digital flexo printing plate for outstanding printing quality and efficiency, especially with water-based inks. During the past years, the demands on flexo printing plates have changed significantly. The plates have to be more and more specialised and adapted to the substrate as well as inks. The new plate is especially designed for use with water based inks in corrugated preprint and aseptic packaging printing, and it’s also suitable for UV flexo printing. The new digital photopolymer printing plate, nyloflex® ACE UP Digital will be available to the market by the middle of February 2014. Flint has a wide gamut of solutions for the packaging print industry. UPM Raflatac has launched a new label film for logistics and transport applications. While many label printers and end-users in this segment use a standard matt-white polyester film which exceeds their requirements, the new Polylaser Logistics Fit label stock is strictly fit for purpose, said the firm. The film provides all the required properties without unnecessary weight, which also makes it a more environmentally responsible choice, said UPM. In label conversion, Polylaser Logistics Fit runs at high speeds on-press without matrix breaks. It has good pre-printing properties, and the RP FH adhesive has low bleed to keep converting lines clean and smoothly running. For label endusers, excellent monochrome and colour laser printability combines with good toner anchorage for durable print. 34

jan-feb 2014

Uniprint buys South Africa’s first FA-4

10-colour Nilpeter press picked to cover many substrates South Africa Durban-based Uniprint has bought a Nilpeter 10-colour multi-substrate flexo press. Uniprint chose the Nilpeter FA-4 flexographic press to assist its diverse production, covering self-adhesive labels, shrink sleeves, film wrap-around labels and litho-printed wet-glue labels. “This Nilpeter FA-4 press is the first one of its kind in South Africa, featuring the latest technology,” said Del Wiggill of CSM Machinery Sales, Nilpeter’s local agent. “Uniprint has invested heavily in this multi-substrate press. It’s able to run on substrates from 12µm upwards.” Leal Wright, Uniprint’s GM for labels and packaging, said the multi-substrate capability was

Nilpeter FA-4: ‘First one of its kind in South Africa’

an important reason for buying this press. “We run a range of substrates – both supported and unsupported – from 12µm film to pressure-sensitive label material and right up to 180µm board,” he said. “In addition, the press was specified with

10-colour capability so as to meet growing demand for more colours from our multinational customers.” Quicker makereadies and a reduction in material waste were also key factors as waste minimisation is a looming issue.

Edale adopts Fujifilm inks for flexo line UVivid Flexo JD inks deliver UV curing for narrow web UK Edale has picked Fujifilm’s UVivid Flexo JD inks for its ‘Flexo Line’ presses on display in its showroom in Whitely, Hampshire, in the UK. UVivid Flexo JD is a highquality UV-curing flexo ink system for narrow-web printers, which has been developed for an extensive range of UV flexo machinery, complementary press products and substrates. James Boughton, managing director at Edale, said the inks’ high colour strength has enabled his firm to cut ink volumes without compromising image quality. “UVivid Flexo JD inks guarantee consistent colour reproduction across the different flexo presses available

UVivid Flexo JD inks guarantee ‘consistent colour reproduction’

in our showroom and allow us to achieve reliable and stable performance,” he said. Fujifilm’s UVivid Flexo JD inks are designed for a wide array of applications, including self-adhesive labels, sachets and pouches, unsupported films, low shrink sleeves and inmould labels, and are available

as Pantone mixing, process or metallic colours. Edale has also adopted Fujifilm’s UVivid Flexo Supernova White, an ultraopaque flexo printable ink that can replace rotary screen white ink, and allows fine text and opaque solids to be combined on the same plate.

News International

KBA tie with montex-print DuPont’s Cyrel marks 40th Partnership aimed at developing sheetfed rotary die-cutters

montex-print will create ‘DC R105’ die-cutter from KBA’s Rapida 105

Germany The Radebeul facility of Koenig & Bauer AG (KBA) has entered into a partnership with montex-print ost druck- und papierverarbeitungs-maschinen gmbh & co. kg in Lindlar near Cologne (montex-print) to develop, manufacture and market new, high-performance sheetfed rotary die-cutters. In December 2013, Ralf Sammeck, executive vice-president for the KBA sheetfed offset product house, and montex-print managing director Eberhard Fuchs signed a deal for montex-print to distribute single- and double-unit rotary die-cutters under the product name DC R105 based on the technical platform of the medium-format sheetfed KBA Rapida 105 press. Upon receipt of an order from montex-print, KBA will supply all the modules required for a sheetfed rotary die-cutter (feeder, infeed and die-cutting unit, together with the associated drive systems, electrical equipment and air supply) as a ready-assembled machine, at the same time already incorporating montex-print’s proven, highprecision magnetic cylinder into the die-cutting unit. Transport, installation, commissioning, training and customer service are to be handled by montex-print. The first DC R105 die-cutter is expected to be ready for demonstrations at KBA in Radebeul at the end of May, and customers can look forward to the first deliveries from early autumn. In terms of productivity, precision, makeready times and ergonomic operation, it will be far superior to the used offset and letterpress models otherwise re-equipped for such die-cutting work. The whole setup is operated from a control panel at the delivery, as the console normally installed with an offset press is not necessary for a pure die-cutting machine. Montex-print has been repairing and overhauling used printing presses since 1978, and has built up a good reputation in the industry for the conversion of used sheetfed offset presses into rotary die-cutters over recent years.

Manufacturer celebrates the flexo printing system’s anniversary

USA DuPont is marking the 40th anniversary of the DuPont Cyrel flexographic printing systems this year by commemorating its past, celebrating its present and looking ahead to a future of continued innovation. In 1974, DuPont introduced the first elastomeric photopolymer printing plates under the Cyrel brand to the printed packaging industry. Forty years later, DuPont has played a leading role in shaping the industry, consistently advancing flexography through its Cyrel systems and working to provide printers with the best balance of quality, productivity and sustainability to help them succeed, said the company. “Over the last 40 years, forward-thinking printing companies have used Cyrel systems because they represent the best balance of quality, productivity and sustainability,” said John Chrosniak, global business director, DuPont Packaging Graphics. “The flexographic printing market adopted Cyrel as the industry standard and DuPont continues to deliver innovative new products such as Cyrel Performance Plates, and invest in continued R&D to meet the needs of this growing market. We are honoured to be celebrating the 40th anniversary of Cyrel this year with our customers. Together we achieved this milestone through our shared commitment to advancing flexography.” After inventing the first elastomeric photopolymer printing plates along with the first solvent workflow equipment in 1974, by the 1980s DuPont began developing automated inline platemaking and processing systems. Light finishing replaced chemical finishing and DuPont commercialised the first safer alternative plate processing solvents in 1990. DuPont introduced the DuPont Cyrel Digital Imager (CDI), the first digital Cyrel plate, and a fully digital prepress workflow at DRUPA in 1995. DuPont Cyrel FAST, the first thermal plate system, was unveiled in 2000, and 11 more new products were rolled out at DRUPA in 2012. The latest innovation from DuPont was the 2013 commercialisation of the Cyrel DFP and DSP Performance Plates.

Dupont sees Cyrel plates as a key innovation in packaging jan-feb 2014

Product launches

Flint launches LE UV inks Ultraking XCURA designed for sheetfed and webfed offset USA Flint Group has launched Ultraking XCURA, a UV low-energy (LE) curing, highly reactive inks and coatings system. XCURA’s key features including printing on certain non-porous, as well as standard coated and uncoated substrates, which Flint describes as a real winner where printers need quality and flexibility on tight schedules. The system’s products have a very high colour strength, display excellent ink/water stability and require lower levels of energy to operate, said the firm. They also comply with ISO 2846-1 and are suitable for printing to ISO 12647-2 standard. Considerable ecological advantages are derived from the new low energy lamp technology, not least of which is that the lamps filter out or eliminate wavelengths below 290nm. As no ozone is created, no exhaust is needed. In addition, heat is controlled due to unique lamp design and control technology. Rod Balmer, the group’s director of global research and product development, said the inks are formulated using a selection of photoinitiators that absorb at the higher end of the spectrum and are optimised for high speed curing. These inks are highly reactive, so multiple UV lamps are unnecessary, reducing operating costs

Flint Group sees the inks as ideal for ‘fast-turnaround’ printing

Richard Wilson, UV product management director, Flint Group, said XCURA would appeal to fast-turnaround conventional printers who can save energy costs by eliminating infrared drying and warm air drying for water based coatings, turning around work in a matter of minutes, saving on work-in-progress and improving delivery times. “As commercial printers are pushed to offer shorter and shorter lead times, work-in-progress must be kept to a minimum and jobs have to be turned-around for next day delivery,” he said. “Low-energy UV curing will allow the conventional commercial printer to manufacture to these new targets. We can see the webto-print sector in particular being early adopters of this technology because of the dramatic reduction in manufacturing time and the lower entry cost than traditional UV.”

Dymatrix XL 145 CSB debuts Heidelberg die-cutter aimed at industrial-scale carton makers Germany A peak-performance format 6 die-cutting machine from Heidelberg has been unveiled for industrial-scale carton manufacturers: the Dymatrix XL 145 CSB (cutting, stripping and blanking), which will be available from mid-2014 to augment the Dymatrix 145 CSB range. Hepack, a Germany-based folding carton printer, which has ordered two of the die-cutters, is the machine’s first user. Managing director Peter Heim of Hepack has ordered two new Dymatrix XL 145 CSBs Peter Heim said he expected the machine to be “highly accurate, less The new machine supports grammages of between 80 and 2,000gsm likely to develop faults, and thus more productive”. and processes materials 0.1 to 4mm thick. A sample machine is A new Dyset XL optical feed system plus new pneumatic chase installed at the Print Media Centre at Heidelberg’s Wiesloch-Walldorf and additional preset modules gear the new die-cutter for maximum site. productivity and optimum precision, said the German print giant. Operating according to Heidelberg’s patented moving upper platen Using tried-and-tested technology from the Dymatrix 106 CSB diecutter, the new device features preset modules such as fine adjustment principle, the new machine features the new Dyset XL feed system, under which each sheet is measured by three cameras, and the circumferential of the die-cutting plate position and format setting at the feeder. and lateral registers are automatically aligned in the feeder. The chase changer and the quick-action clamping system for the Sheets can be measured from the top and, optionally, the bottom. stripping and blanking stations ensure short makeready times during Either the sheet edge, the printing mark or the print image is used for job changes, according to the manufacturer. A redesigned main gear alignment, giving maximum precision with a perfect die-cutting register mechanism increases the speed to 9,000 sheets per hour. As with the Dymatrix 106 CSB, the gearing is based on technology used in presses. of plus/minus 0.1mm (0.0039”), fast makeready times, and less waste. 36

jan-feb 2014

Product launches

KBA focuses in on packaging Kammann and Flexotecnica takeovers lead way into sector

Masterwork is also to debut two die-cutters over next half-year

The new KBA Family: KBA-Kammann and KBA-Flexotecnica.

Germany KBA has declared its commitment to growing in the packaging sector, which it sees as benefiting from increasing levels of prosperity, consumption and the trend towards self-service markets in rapidly expanding industrial countries such as China, India, Brazil and Turkey. In addition, packaging is unaffected by the growing popularity of online media, said KBA, a long-established leader in printing systems for folding carton and metal packaging with its sheetfed offset facility in Radebeul near Dresden and subsidiary KBAMetalPrint in Stuttgart. KBA entered the expanding niche market for directly decorating luxury glass packaging and other hollow containers with the majority takeover of Kammann Maschinenbau in Bad Oeynhausen, Germany, concluded at the beginning of September. Following a long period of negotiations, the majority acquisition of Italian press manufacturer Flexotecnica based in Tavazzano near Milan was finalised in early December. This paves the way for the broadlypositioned press manufacturer into the key print market for flexible packaging (especially films). Next year the two youngest KBA subsidiaries will be renamed KBA-Kammann and KBA-Flexotecnica. Both companies have a total of some 280 employees in development and engineering, assembly, sales and service, while most of the manufacturing activities have been outsourced. Together the firms generate annual sales in the mid-double-digit million euro range. Along with the predominant screen-printing systems, Kammann’s flexible transport systems can also be equipped with hot-stamping, inkjet and other decorating processes. The firm recently presented its first digital solution at K, the trade show for plastics and rubber in Düsseldorf. Directly decorated glass containers are mainly used for cosmetics, perfume and spirituous beverages in the top price class. In 2012 Kammann, which was founded in 1955, generated annual sales of over €30m ($39m).

Masterwork’s MK420Q MINI inspection to launch at Ipex Off-line system for cartons

USA At Ipex on 24–29 March, Ipex will launch into Europe its new MK420Q MINI high-speed/precision carton inspection system, which provides 100% continuous inspection 24 hours a day, said the company. Handling stock from 180gsm to 350gsm in weight and from 70x70mm to 420x350mm in size, the MK420Q MINI offers a maximum speed of 75,000sph (250x100mm) making it one of the most efficient off-line inspection systems on the market, according to Masterwork. The use of high-resolution CCD cameras allows the detection of defects down to 0.2x0.2mm. This enables even minute deviations from the approved standard to be identified immediately, with substandard sheets automatically rejected during the inspection process. The system can identify a huge selection of defects, from basic scratches and stains to variations within the embossing or coating and even irregularities in foil patterns. Masterwork’s patented light source filters reflected light from sheets to ensure an extremely clear image on the CCD camera. The light source can be adjusted precisely to suit the printing process used for that particular job, such as laser, holographic foil stamping. The MK420Q MINI allows the user to store data and images of defects for subsequent analysis and monitoring can be set for individual jobs, shifts or specific periods of operation. Data can easily be provided to customers to enable them to carry out their own analysis. In the next six months, Masterwork will introduce machines including the MK1450ER automatic platen die-cutter with stripping facilities and the MK1060e high speed die-cutter, said European sales manager Ken Farnsworth. “Masterwork manufactures an unrivalled range of post press equipment, from die cutting, foiling and embossing to gluing, stripping and packing systems,” he said. jan-feb 2014

News design

X60 brings CGI to the Gulf New NDigitec division makes images without cameras UAE X60, established in 2013 as a CGI division of Dubai-based NDigitec, is pioneering a shift from photography to CGI, says its founder Dutch photographer Rob Marinissen. In the next 5–10 years a lot of commercial photography will be replaced by computer generated imagery (CGI), which enables X60 to make photorealistic imagery without the help of a camera, he said. The image to the right illustrates a design study for a dairy bottle. X60’s visual pitches for local firms also feature, for instance, computer-generated fruit. A 3D model is available indefinitely and visuals can be generated using the same model,

but with a different lighting or angle, said Marinissen. A range of products based on the same design can also be created in a very short time to update a design or bring a product range to life in film. CGI gives X60 full control over the visualisation of products, from dairy products to electronics to jewellery. Based out of Dubai, the X60 CGI studio serves the Gulf, Europe and Russia, said Marinissen. He foresees a sharp growth in demand for computer generated photography and hopes to employ talent from all over the world within the next two years. The biggest challenge is to find talent, he added.

Dairy Milk debuts new look Cadbury rolls out packaging revamp from Pearlfisher

Cadbury Dairy Milk is overhauling its look with ‘joyful’ designs

UK Pearlfisher has created a new look for Cadbury Dairy Milk, which is rolling out internationally and launched in the UK at the end of 2013. Inspired by the idea of ‘say what you see’, the new designs replace 38

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A CGI image of a dairy bottles by NDigitec’s X60 division

product shots with ‘imaginative, joyful expressions of each flavour’. The Cadbury Glass and a Half logo is retained, and has been updated by Pearlfisher, and brighter colours have been introduced to improve on-shelf presence. The new packaging also uses an on-pack QR code which will deliver ‘joyful content designed to make people smile’, according to Cadbury. Cadbury says the new look is the 21st major redesign since it launched Dairy Milk 108 years ago, and creates ‘a more modern and joyful look, while proudly keeping the identity that has been a part of its heritage since 1905’. The revamp follows previous designs created by Pearlfisher in 2009. Matthew Williams, marketing director at Cadbury owner Mondelez International, said: “With our new packaging, we hope to bring out the personality of the Cadbury Dairy Milk brand in a generous, optimistic and spontaneous design, while celebrating the links with our past.” The new packaging is rolling out internationally and launches in the UK this month. The Dairy Milk range’s overhaul follows Cadbury’s recent defeat in a legal battle with rival chocolate Nestle in which Cadbury attempted to secure exclusive rights to the Pantone 2685c purple used in Dairy Milk packaging. Cadbury, a British multinational confectionery company owned by Mondelez International, is the second largest confectionery brand in the world after Wrigley’s.

News design

Engro switches to Ecolean

Pakistan food firm relaunches milk in lightweight packaging Pakistan Market-leading food company Engro Foods in Pakistan has relaunched its flagship milk brand Olper’s in Ecolean’s lightweight packaging. Engro expects the unique shape and large printing surface of Ecolean’s 250ml Aseptic package to make Olper’s brand stand out on store shelves in a category dominated by traditional carton packaging. Earlier this year, Engro rebranded Olper’s to further differentiate it from other brands in conventional packaging. Ecolean’s lightweight package offers easy tear-off, pouring and handling. In addition, the package can be used in microwave ovens,

perfect for a country with a strong tea drinking tradition. Waqas Azhar, general marketing manager at Engro Foods, said Olper’s has quickly become the preferred milk brand for the modern consumer. “Ecolean offers innovative packaging that stands out both in the store and the home environment, with its combination of unique shape and user experience,” he said. Ecolean CEO Peter L Nilsson said Engro Foods has become a market leader in just seven years. “And we’re naturally delighted that our innovative products will be widely available in one of the most dynamic markets in the world,” he said.

Olper’s milk in Ecolean 250ml Aseptic lightweight packaging

Vinay Mehta with his award winning VENTiT pizza box

The world’s best pizza box? Mumbai businessman lands title with ‘ventilated’ design India A Mumbai businessman has revolutionised how hot take-out food is delivered. His solution: making sure the packaging has proper ventilation. Tired of soggy pizzas, in 2006 Vinay Mehta took a pen knife and cardboard and designed VENTiT, which has now been judged the world’s best pizza box. Mehta’s container was accorded the honour by Scott Wiener, a New York-based pizza aficionado and author of Viva La Pizza! The Art of the Pizza Box. Wiener has collected about 650 boxes from around the world since 2009 and is the Guinness World Record holder in this category. But Mehta’s design is best suited to delivering steaming pizzas, he said. “It’s smart because it doesn’t add any hardware, just rethinks the common construction of a box and rearranges it,” he wrote to Scroll. Trapped steam in poorly ventilated packaging can pose a major challenge for take-out restaurants, as it condenses on food, making it unappealing and dampening its aroma. Mehta’s solution reflected his experience in dealing with corrugated cardboard boxes for 35 years. His firm, Reproscan, offers printing services to packaging firms as well as the advertising and publishing sector. He realised that most pizza boxes are ineffective because they have holes on the side to release steam, while the heat is actually released from the top and bottom of the pies. Mehta’s boxes have holes in the two outer layers of their cardboard but not the middle, corrugated layer. Steam can therefore escape through the grooves in the middle corrugated layer. Importantly, no additional material is required to manufacture the box. He already manufactures about 100,000 boxes a month for clients in south Mumbai. Smokin’ Joe’s, a 21-year-old pizza outlet, was his first customer, but he has added several other pizza makers to his list, including Francesco’s Pizzeria and Pizza Metro Pizza. jan-feb 2014

Business luxury packaging

The Art of Luxury Juilee Thakare, Manager - Creative, Nabeel Perfume Industries (FZE), tells Benjamin Daniel how Nabeel develops the packaging for new products such as its Pulse of the Gulf perfume. PMEA: How does the design process start for a new Nabeel product in terms of packaging? JT: The first step in design process begins with analysing the product positioning. The design of bottle is an important factor while developing the outer packaging. Our products are positioned under different collections in order of Premium, Elite and Heritage under our Brand Nabeel, Premium being the topmost range. Keeping abreast of latest materials available and keeping the functionality of the packaging in mind, our design team works to create visually engaging concepts with a tactile appeal. We collaborate with our suppliers to understand the latest offerings in the packaging industry and develop design in synch with our brands

The bottle, box is the initial visual stimulus to wow the customer and drive him to purchase 40

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Packaging is very elaborate in this part of the world contrary to Western counterparts. This region is about opulence, extravagance and it is well exhibited through their packaging identity. Based on the collections, we will develop our packaging. If a product is positioned in a Premium collection, we ensure that each product packaging is developed with an innovative concept: rigid boxes with superior finishes and textures, MDF, faux leather, magnetic closures, fancy inserts, satin or flocking inner trays. Premium category products are targeted to the niche market so every aspect of packaging reflects luxury and has a stunning shelf display. Our Elite collection is positioned for upper mass market. The packaging for this range is elegant with lots of finishing effects, multi-level embossing, patterned design textures. There’s a different style of showcasing the bottle in the box to have a striking product display. For our Heritage brand we use simple yet attractive designs with food boards, metallic boards with certain finishing effects. PMEA: What were the inspirations for the packaging for Pulse of the Gulf? JT: Nabeel wanted to develop a fragrance as a tribute to Gulf peninsula. The Gulf region has grown from strength to strength over years and is known for its ‘richesse’. While developing this product we wanted to imbibe the traditions, culture while capturing the spirit of the Arabian lifestyle. The architectural heritage crystal bottle design reflects the opulence of this region. The flacon has an intricate design with vibrant golden metal embellishments contrasting against the sea green transparent crystal. The outer packaging is made with fancy textured paper with gold foiled delicate design embossed on it with magnetic closure. The box was designed with a window and an outer sleeve that flaunts the extravagant bottle inside. Not to forget, the perfume contains the mystical pure Indian agarwood oil, the most coveted fragrance in this region, and the packaging does justice to the olfactive experience. PMEA: What do you see as distinctive about the Gulf market’s taste in and response to packaging? JT: The packaging is very elaborate in this part of the world contrary to Western counterparts. This region is about opulence, extravagance and it is well exhibited through their packaging. The Gulf region is synonymous with luxury flamboyance. The colour hues of brown, gold, black, silver are predominant. Perfume is primarily

a luxury commodity, and the packaging needs to exude this facet. Packaging is the main purchase driver; it is an important marketing tool to communicate to consumers the essence of your brand. Attractiveness of the packaging can solely be instrumental in stimulating a purchase decision: Looks should be as good as it smells. PMEA: How has Nabeel developed its packaging in line with new packaging technologies? JT: We work closely with our suppliers to gauge the new packaging technologies. We monitor closely the latest trends in global markets and adapt it to suit local needs. We team up with French designers with high calibre for our designs. We work with new materials, finishes, accessories while maintaining the brand’s heritage. Our packaging is eco-friendly and biodegradable. PMEA: What are the core aspects of Nabeel’s brand identity in its packaging? JT: Every element associated with our packaging – bottle silhouette, box design, finishes, typography, fonts, logos, colour scheme – conveys our brands core values of quality, expertise, prestige, value for money, heritage and sophistication. The entire selection process relies on communication of these values at consumer touch points. The essence of luxury is transmitted via our unique creative packaging. PMEA:Where do you see yourselves as different from or ahead of your competitors? JT: Product pricing is our USP. We offer true value for the purchase. We offer luxury at unbeatable price range and this has been our forte since the beginning. The fragrance is crafted with finest and natural raw materials sourced globally and blended to perfection by our master perfumer, Asghar Adam Ali (Al Attar), founder and chairman of Nabeel Group. We have been trendsetters in this market. Our packaging reflects creativity and artistry, with unique concepts, bottle designs and décor which sets us apart from the cluttered market and our competitors. Product differentiation is another driver. We have products which cater to wide range of consumer segments.

The outer packaging is made in velvet flock paper with gold hotstamping with black and white colours inspired from the royal attire of sheikhs

The Gulf region is synonymous with luxury flamboyance. The colour hues of brown, gold, black, silver are predominant PMEA: In your view, how critical are the perfume’s box or bottle in the purchasing decision? JT: The box or bottle is of paramount importance and plays a pivotal role when it comes to purchasing a perfume. Perfume is perceived as a luxury and brands need to ensure that the product creates this perception through its bottles and boxes. The bottle, box is the initial visual stimulus to wow the customer and drive him to purchase. PMEA: How do you calculate the appropriate cost of packaging when developing a product such as Pulse of the Gulf? JT: Pulse of the Gulf is a special premium product offered by Nabeel. This niche product is designed specifically to cater to Arabic customers. The prime focus for this product is the fragrance ingredient oud and, given the fact that it is the most expensive ingredient in perfumery, costing for the packaging is done according to the premium price bracket. PMEA: With this specific product, were any other design paths examined and rejected? JT: Yes we had around six to seven designs concepts with different materials, specifications, ornamentation for this product. We screened these concepts shortlisted around three designs and developed their prototypes. Considering this product had to harmonise with the rich olfactive structure, we developed the final box which resonated with luxury and prestige outlook. PMEA: What do you see as your firm’s greatest successes or most iconic products in terms of packaging? JT: Our Nabeel range of products has been a breakthrough success since its launch, with Bakhoor Nabeel being the best selling bakhoor in the world. Some of our bestsellers have simple packaging with touch of elegance. Khaltat Al Shyookh is another product which is doing very well in the market, especially in Dubai Duty Free. The outer packaging is made in velvet flock paper with gold hotstamping with black and white colours inspired from the royal attire of sheikhs. The crystal bottle epitomises royalty of the region. To name a few iconic products in terms of packaging we would list: Jaziyah, Mais, Qawafi, Heritage, Wadeema, Mumaiyaz al Nabeel. jan-feb 2014

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Technology: flexo prepress

Kodak targets regional opening for FlexcelNX The technology giant is aiming to win converts in the MEA with its platemaking technology’s high-quality images, reports Benjamin Daniel. For Grant Blewett, stragetic accounts manager, packaging for Kodak EAMER (Europe, Africa, Middle East and Russia), the appeal of the firm’s FlexcelNX platemaking technology is equally potent on brand owners and packaging professionals. “When we first introduced FlexcelNX, like our customers we were absolutely blown away by the quality that we could Grant Blewett achieve,” he told Packaging MEA. Kodak EAMER “This is not a new product anymore and has a good track history behind it. Whatever plates the printer uses, when they get to press they all behave the same way. But FlexcelNX has fundamentally changed the way print behaves in a pressroom.” Meanwhile, brand owners are equally keen, in his view. “We also see a push for our technology from the brand owners,” he said. “We get more and more contacted by brand owners who ask us to convert their jobs from a lamps printed environment to NX based environment.” For Blewett, “the industry revolves around the brand owner”. “If we can bring to the brand owner a product that’s better with a lower cost, this will interest the brand owner and these are the things we are delivering,” he said. “We have brands that have changed from seven- or eight-colour work to four- or five-colour process work. The concept is to reduce the number of spot colours in flexo production, which requires a lot of colours because of the inherent limitations of the process itself. “With FlexcelNX we can give excellent quality with reduced use of spot colors. We have well over 300 installations of FlexcelNX worldwide, a greater percentage being from the EMEAR market. We are far more successful in the EMEAR region, which is a far more quality driven market. “Europeans come from a gravure market and are used to high quality. So we enjoy the biggest market share in this region out of all our installations. We simply need to identify the game changer within this market region.” But spreading the word on FlexcelNX also involves tackling some misconceptions about the process, he added. For Blewett, the system is far more accessible than is often supposed, with its benefits available without purchasing an entire workflow. “We have a very open architecture, although we are blamed of having a very closed system,” he said. “Our concept in the market is

FlexcelNX has ‘fundamentally changed’ how print functions

The competitors who once thought flat-top dots and oxygen removal are not possible are now producing the latest solutions using this technology

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Technology flexo prepress very open. So whatever workflow the customer has we are going to assume that in any point in time he is going to rip that into some sort of one-bit-tiff. We will walk in with a tiff spooler to take his one-bit-tiff and put it into our system and the customer will get as much benefit of this robustly produced plate as though he had produced it through a Kodak device. “We believe that Kodak workflow has tremendous value, but we also understand that if our customer has all these investments, trained all his staff and bought all the licences, he doesn’t want to reinvent the wheel. We don’t manufacture processing equipment so we allow the customer to use either his existing provider that can be qualified in terms of quality or we refer him to any provider. “So a customer has a workflow system, an output device and a whole finishing process. Kodak comes in and says you put your file and choose your provider for output device. So it’s a relatively small investment that the customer has to make to enjoy all the benefits of FlexcelNX.” In addition, there are opportunities for packagers to profitably run a FlexcelNX operation alongside their established workflow, he said. “Honestly, many customers all around the world continue to use their existing equipment for the lower quality demanding work and for the higher and more premium work he uses FlexcelNX,” he said. “He can do this on two levels. One by looking at the challenge of the work he physically puts a job in one of the device, and on another level he does it in a marketing perspective. He adds another whole element to what his business is able to offer. “Trade shops have created a separate business unit, a separate skilled sales force that targets work specifically for FlexcelNX. They target gravure work because that is very difficult to do. They target multi-colour flexo work. FlexcelNX allows you to significantly change the way you address the market. Our model is offering something unique that offers production and quality benefits.” Making the switch Blewett also forcibly rebuts the suggestion that the FlexcelNX system hinges on the operator’s skill. “No, we disagree,” he said. “These are some of the misconceptions that are mostly spread by our competitors. The difference between standard lamps manufacturing process and FlexcelNX manufacturing process is the lamination and a delamination stage, which is mostly an automated procedure. “Yes, we need an operator to physically feed into a lamination section but the lamination is an automated process. When we consider the total manufacturing time of the FlexcelNX plate, it’s no more than and at times even less than standard lamps manufacturing process. In a standard lamps plate manufacturing process you still need the operator for loading and unloading the plates. “We are producing as many plates in as much time with no additional skills required. Once the customer realises this and actually sees this in production, their doubts will be removed. The 44

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The only technology that when implemented in a press room brings fundamental differences in the way in which we print Kodak claims its platemaking technology has ‘a very open system’

competitors who once thought flat-top dots and oxygen removal are not possible are now producing the latest solutions using this technology. “For Kodak it is not a threat. Though the flat-top dot is the most important thing of what we are doing, it is the first of a number of things we are doing. With FlexcelNX, we directly take the bit map code, the perceived perfection, from the pre-press dept right to the press and visibly on print.” Installations in the MEA Blewett added that the technology’s advantages are steadily winning installations in the Middle East and Africa. “We are signing up a new partner in South Africa,” he said. “One of the most successful installations we made was in Morocco, who are very pleased with the installation, and the biggest one is in Turkey, where within one year’s time we have had very good success. “So the first installation happened in the last quarter of 2012 and within 12 months that customer has moved about 25% of his work on FlexcelNX. He had three ThermoFlex wide systems and a NX wide. So he added 25% more business to his production. “In Pakistan we now have the second one. So we have four wide units now in the market. We also have a second mid-machine in Kenya. It’s a small country for packaging yet we have two NX systems installed and running. Hopefully we will have another sale from our new partner in South Africa as well.” In sum, Blewett sees FlexcelNX as “the only technology that when implemented in a press room brings fundamental differences in the way in which we print”. “On the pre-press side, it’s the only technology that brings predictability and stability in the platemaking,” he said. “You know exactly day-in and day-out what you are going to get on that plate, because of which you allow your pre-press people to proof and be able to do colour management on the proofing device instead of in the press room. “We bring the colour management back into the repro. Kodak FlexcelNX is the only one-to-one reproduction system in the world. In flexography we rely a lot on many skilled people from concept to final job but if one of the people is absent the process breaks down.”

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Technology: Rotary die making

RotoMetrics pushes into new markets RotoMetrics is growing in the MEA through delivering dies as swiftly as next day, reports Nick Coombes.

RotoMetrics supplies its tooling to markets in Oman and Pakistan from Thailand, while the remainder of the Middle East, including Saudi Arabia, is supplied from its European HQ in the UK. On a recent visit, James Wellsbury, RotoMetrics’ UK Director for the Packaging Market, who visited a number of converters in Dammam, Jeddah and Riyadh, commented: “It’s a buoyant market, with companies looking for new opportunities to grow their business.” Although most cartons produced in Europe are still printed sheet fed offset and finished offline with flatbed die cutters, there is a noticeable new trend according to Wellsbury. “In the UK now, all the big supermarket chains are producing their sandwich packs on inline flexo presses and converting to finished products in one pass – it makes so much more sense to do it rotary,” he said. Wellsbury says there are substantial benefits in switching to this new style approach. “Middle East converters are currently producing cups on sheet fed offset presses and then die-cutting them on flat bed machines, when they could be producing them rotary flexo, roll to finished product, at speeds of 80 to 120 m/min. This method provides a major increase in productivity, because printing speeds are faster and the cartons are die cut inline in one pass,” he explained. 46

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According to Wellsbury, converters in the Middle East could make significant gains if they changed from flat bed to rotary die cutting. “There are a number of die makers offering an online service, but this treats the die a mere commodity. At RotoMetrics, we believe that the die offers a means of adding value to a product, and offer technical support from both the factory and onsite at the customer’s plant,” he said. “We use a flexible die calculator to show converters how they can work out their own tooling costs, and demonstrate how high specification flexible dies with laser hardening and chrome really do boost productivity.”

Middle East converters are currently producing cups on sheet fed offset presses and then diecutting them on flat bed machines, when they could be producing them rotary flexo, roll to finished product, at speeds of 80 to 120 m/min A global approach By using couriers to ensure next day delivery, RotoMetrics has enjoyed significant business growth in Saudi Arabia and the UAE. “RotoMetrics is global company,” said Wellsbury. “If we’re over

capacity at any of our production sites, we can just switch manufacturing, for example from Australia to the UK or vice versa, and ship the dies the next day.” Wellsbury is planning to return to MENA and Africa in early 2014, and has a list of 15 converters to visit in the region, in addition to making his first business calls in Jordan and Lebanon. “I’ll be showing converters some samples of products and talking about what’s being done in Europe,” he said. “There is market share to be gained In the Middle East, and opportunity for growth into new markets, and I’ll be advising customers on how they can improve their production capacity and innovate new products.” RotoMetrics’ Accu-Series With increasing pressure on converters to reduce waste and cut costs, the leading manufacturer of precision die-tooling, RotoMetrics, has launched its new range of Accu-Series flexible dies. Four distinct types are available: • AccuSmart – the economical choice for most of today’s short and medium run lengths; • AccuPrime – for converting a wider range of substrates; • AccuStar UltraFilm – for high precision on today’s challenging synthetics • AccuStar Life – for abrasive materials.

RotoMetrics manufactures both solid rotary and flexible magnetic dies to meet every converting need

The introduction of the Accu-Series marks a major rationalisation of the RotoMetrics’ range of flexible dies. Following the acquisition of Gerhardt in 2011, the company had a portfolio of 11 flexible die models with 28 variations – a bewildering choice for manufacturer and converter alike, and one that soon elicited a rethink, said Peter Emerson, RotoMetrics’ European managing director. “It was a major undertaking, but one that has brought very positive feedback from the market place,” he said. “Just as printers and converters constantly monitor their equipment to ensure maximum productivity so we, as a manufacturing supplier, need to be responsive to changes in demand.” The chrome coating RotoMetrics applies to its flexible dies is based on knowledge and experience it has acquired over decades of chrome plating its solid CNC tools. The Accu-Series’ flexible chrome offers excellent durability, increased life and wear resistance, said Emerson. “It’s tried and tested, and while we now see our European competitors introducing the chrome process, we also offer induction hardening, core hardening on our solid dies, and laser hardening on our flexible range,” he said. The key to the successful rationalisation was establishing customers’core requirements. Renowned as a problem solver, RotoMetrics’ unmatched technical know-how and expertise enabled it

tooptimise performance of the new Accu-Series dies. By reducing much of the complexity that bespoke dies require, and focusing on the key elements of die life, blade geometry and speed, RotoMetrics has created what it believes is a simplified choice that responds exactly to most of converters’ needs. The prime advantages of reducing the complexity of the range are lower production costs, which translate into faster delivery at highly competitive prices. Emerson sees three main drivers in today’s market that have influenced RotoMetrics’ product development: the increasing number of digital presses in the narrow web sector; the rise in popularity of thin filmic substrates for printed packaging; and the growing strength of competition in the global market. The use of digital press technology to satisfy the demand for ever-shorter run lengths effectively redefined the production and delivery chain for suppliers like RotoMetrics. Faster turnaround to cope with more frequent job changes meant traditional practices needed to be rethought. By concentrating on lean manufacturing techniques and workflow optimisation, the company achieved ISO 9001 and ISO 14001 across all its manufacturing plants in 2013, effecting the most streamlinedordering and production process in the world. The cost and waste savings offered by the use of thin films for face stocksand liners is too tempting for the printed packaging

We use a flexible die calculator to show converters how they can work out their own tooling costs, and demonstrate how high specification flexible dies with laser hardening and chrome really do boost productivity industry to resist, but these materials pose problems for die tooling with blade geometry and tighter tolerance levels. In response, RotoMetrics developed the new AccuStar UltraFilm, which meets the demands of converting 19- and 23-micron films, making it the most precise flexible die available. To meet the rise in competition around the world, where price is often the deciding factor in converters’ purchases, RotoMetrics took a more holistic view at ‘whole life’ costs with its new AccuStar Life flexible die. Following extensive field tests it proved that, in commercial production, the Accu-Star Life offers more revolutions per $/£/€ than its competitors, and therefore makes a bettercase for investment. “Testing and customer involvement were key elements in the development of the new Accu-Series,” said Emerson, “By listening to their comments and adapting the designs as we went along, we believe the new flexible dies deliver the right combination of price and performance for our customers, and provide the functionality and capability they asked us for. We see the process as ongoing – which means we’ll keep listening!” jan-feb 2014

Gallus ICS 670 â&#x20AC;&#x201C; Efficient board converting Print, add value, die-cut in a single pass

jan-feb 2014 48 www.gallus-group.com

A partner of Heidelberg

Technology: coding and marking systems

Reducing the costs of coding errors Systems are now available to help packagers contain the serious risks that coding errors can pose to their margins and reputation, writes Colin Morgan, product manager for Software Solutions at Videojet Technologies.

A Videojet survey found that up to 70% of coding errors are due to human error

As manufacturers are faced with a wide variety of new packaging types and formats, ranging from cartons, bottles and various flexible films including re-sealable pouches, they face increasing pressure to optimise productivity and increase profits while minimising downtime. A common factor that impacts all three areas is coding mistakes – although many manufacturers are still unaware of the true costs to their operations. Our own survey found that up to 70% of coding errors are caused by human error. Despite most manufacturers’ efforts to follow robust quality assurance processes, mistakes are still being made. Incorrect data entry and job selection accounted for 45% of all coding errors. These can have serious and costly repercussions for the entire business. For instance, a wrong date inserted could expose unsuspecting consumers to a health risk, and the food producter to a large regulatory fine – not to mention damage to their brand

reputation. There is also the added cost of scrapped products or work to rectify a coding error, plus the loss of production while the issue is resolved. For all these reasons, accurate product coding is critical, and it is becoming essential for packaging manufacturers to implement proactive coding and marking solutions that can help them eliminate and prevent coding errors occurring. Many coding and marking systems are now designed to overcome this challenge through built-in software or integrated solutions that help ensure that the correct code is applied in the correct location on the correct product and packaging. These solutions link on-product coding to a central message database, which removes message creation and management from the production floor and simplifies printer setups, increasing control and efficiency. User interfaces have been developed to make job selection as easy as possible, so only the correct message is selected for

a given batch of products on a specified production line, restricting the operator’s input to the absolute minimum. Messages are automated as much as possible, with pre-defined rules that help prevent incorrect entries. In addition, diagnostic tools, which present on-screen fault information, enable the identification of the most frequent causes of labelling and coding faults to proactively prevent mistakes occurring and make sustainable improvements. Coding errors are common and many manufacturers experience them on a frequent basis, but this issue can be addressed with the right coding and marking solution. By reducing the need for human intervention, coding and marking systems can help drive productivity and improve efficiency. Such systems can reduce costly product recalls and give manufacturers the ability to track and trace products, while preserving their brand’s integrity through increasing customer satisfaction with code consistency and quality. Videojet Technologies is a leader in the product identification market, providing inline printing, coding and marking products, application-specific fluids, and product life cycle services. The company aims to partner with customers in the consumer packaged goods, pharmaceutical and industrial goods industries to improve their productivity, to protect and grow their brands, and to stay ahead of industry trends and regulations. With our customer application experts and technology leadership in continuous inkjet (CIJ), thermal inkjet (TIJ), laser marking, thermal transfer overprinting (TTO), case coding and labelling, and wide array printing, Videojet has more than 325,000 printers installed worldwide. Customers rely on Videojet products to print on more than 10 billion products daily. jan-feb 2014

Technology: ECG

Extended Colour Gamut: fewer inks, better margins Flexo packaging printers should explore the advantages of Extended Colour Gamut (ECG), which can brighten up their finances as well as their output, argues Wayne Peachey of SGS International.

It could be said that Extended Colour Gamut (ECG) is the Hawaiian shirt of printing. Every few years there is a buzz, with new products and new ways of working. Tests are set up and run on presses, lots of excitement ensues, and then ECG is put away to the back of the printing wardrobe for a few more years. So it may seem. However, the benefits of ECG have been realised in many markets and it is almost an industry secret that many presses are running 24/7 with just one set of inks, with minimal press changeover times, minimal ink inventory, and hugely increased press uptime. Extended Colour Gamut Printing has many different names, such as Multicolour Printing or trade names such as Opaltone. At its core, the technology uses a standard set of colours in the printing press that seldom change. When a spot colour – such as Pantone 485 – is needed, a mix of two or three colours will be used to get ‘very close’ to that specific red.

Which additional colours are used? Typically CMYK is used, plus two or three colours that help to significantly increase the achievable colour gamut. Cyan, magenta, yellow and black normally form the basis of the colour set. Then two or three colours are added – and these never change in the press, so the initial choice of the additional colours is really important. Normally, colours much brighter than CMY are added, and these are typically chosen 50

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from orange, red, violet, blue and green. So the ECG set could be combinations such as: CMYKRGB, CMYKOGV, CMYKRB, CMYKOG or CMYKOV.

How to get the greatest colour gamut? Colour gamut is the size of the colour space that can be achieved, when calculated as an L*a*b* colour space. The addition of orange, green and violet provides the greatest colour space (depending on the colours chosen). However, when these are mixed on press (using screening), they can present more registration challenges than colour sets such as CMYKRB. Red and blue are the most common special colours used. Using CMYKRB, small blue text can be achieved. But in a CMYKOGV colour set, the small blue text would need to be made up out of cyan and violet, which could present a registration challenge. If colour gamut is a priority, then the brightest colour set would appeal. If a customer’s brand colour is more important, then you may not want a colour set that gives you better registration and better colour consistency.

In practice, what do printers use? Some customers have specified a colour set, such as CMYKOGV. Other customers just want good quality print, but at a reasonable cost. Therefore they are happy to switch their

Extended colour gamuts vs CMYK, with Pantone library overlaid

work to a printer’s own ECG workflow, reaping savings in printing costs. CMYKRB is very popular, as red and blue are used often in packaging printing. Green can be added. However, unless you want your images – such as lettuce – to be perfect, green doesn’t add as much to the impact of the work. Printers sometimes adopt a CMYKRGB (for instance) workflow, and then only use green if absolutely required. Achieving Pantone colours as accurately as possible takes a CMYKOGV colour set. Testing with an ink company would be the best way to achieve the largest colour gamut, and therefore the best colour match to as many Pantone colours as possible.

So brighter colour sells? Yes it does. If a package is brighter than its competitors, then it attracts shoppers’ attention. However, ECG can sometimes fail if the colours are too brash, or if the product images are not realistic, or if colours are not consistent.

Spot colours can great benefit is that the plates are then be predicted relatively inexpensive, so jobs can be run using tools such as in combination, with lots of spot colours Xrite’s ColorPicker, represented as ECG. Screening is very fine which will provide a with litho so screened spot colours are not best-colour-breakdown noticed, and registration is typically good. and a prediction of DE Gravure could realise some benefits, but as Many presses are running 24/7 with just one set of inks colour accuracy. Spot cylinders are delivered to the press complete with their ink trays, changeover delays are What are the benefits in the pressroom? colours can also be shown as a large ‘swatch book’, so designers can select colours with less prevalent. Gravure could suffer from A typical flexographic ink room will contain confidence. every colour being screened, and so suffer many hundreds of partly used ink pails. With Colour separation of images is less with moire issues. I have not personally come ECG, you just have seven inks, plus white. across gravure printers who use ECG but no When you finish a job, you do not need to straightforward. It is often a subjective doubt someone has found benefits. return the ink to the ink room, mix up fresh decision whether a CMYK image actually ECG has a place in printing. It has a colours, and then put those in the press. needs to be separated into seven colours. foothold in flexo that I believe will grow due to On press you would remove the plates (on Skin tones do not normally benefit from extra price pressures and its flexibility. It’s a win-win their printing sleeves), install the new printing colours, but if the image contains vegetables, for many customers and printers. sleeves, and then start up the press. The same for instance, the addition of green in lettuce inks are used, and so other than some minor and red in peppers can really improve the adjustments the job is ready to run. image. Therefore colour separation can cost Summary and benefits: The savings depend on specific situations. a little more, due to the additional time Quality: Enhancement of images; additional For instance, if you already run jobs for involved. and more vibrant colours; increased tonal 24 hours or more, you may not see a huge range; increased ‘POP’; consistency of print improvement in press uptime. If your typical process. And plate and press technologies? runs are an hour or two, and then you have Time & cost: Makeready time and material In the past, flexography struggled to achieve two hours of press downtime while the press is good solid density. Therefore when a dark spot reduction; inks are always in the press; print cleaned up and the inks changed, plus colour colour was used, a heavy matched, then you would see significant anilox would lay down savings. lots of ink. Some customers are fully aware of the Modern printing potential savings and are happy to encourage means HD flexo plates printers to move to an ECG workflow. For can achieve densities instance, supermarkets print a large range of that compete with litho items for which quality needs to be acceptable, and gravure. These types but costs must be absolutely minimal. of plate can be matched Changing a four-colour job, for instance, into with low-volume aniloxes a seven-colour job simplifies nothing, but can (matched with highadd cost. Also, running ECG only part of the quality inks) so that time can be a disruption. Printers who take this midtone tone values are onboard typically dedicate one or two presses kept under control. Once An example ECG colour swatch book that can be printed out and to this type of work, and print others with this is achievable, ECG shared with designers traditional techniques. can be considered. ECG relies on good consistent results, and rotations pre-determined; ink ‘wash-ups’ not good registration. Repeatability is the key required after every run. What about colour separation, colour and jobs can then run one after the other, Ink: 6-7 base colours; no spot colours; reduced prediction and colour matching? with the minimum of press adjustments. The ink inventory; lower ink management costs; With modern prepress colour profiling benefits to the printer are that their presses no special colour matching; greater ink batch techniques, a seven-colour ECG process can can achieve greater uptime. The customer gets consistency; leveraged ink spend for 6-7 base be profiled as easily as a four-colour process. a lower-cost product with the same or higher colours. Special seven-colour targets are printer on quality. Print mix: common ink colours enable press and the resulting profiles (created using combination print forms; brand families can Xrite’s Profilemaker or similar) can then be be ganged together in a combination run; used in conjunction with a colour rip such as What about other print processes? reduced finished goods inventory. GMG. Litho has adopted ECG for years. The jan-feb 2014

Factory tour Al Ain Dairy

Top UAE milk producer switches to cartons

Al Ain Dairy is pioneering Tetra Pak’s Tetra Top One Step Opening cartons in the Middle East to gain convenience and market share while cutting costs and waste, reports Benjamin Daniel. Al Ain Dairy – the UAE’s largest dairy producer and one of its leading juice producers – is now distrbuting its fresh chilled milk in 0.5-litre and 1-litre cartons made of more than 60% renewable sources in what could be the first of several collaborations between the dairy and Tetra Pak. The shift from PET bottles was implemented on 1 November 2013, following the dairy’s research into earlier applications of the Tetra Top One Stop Opening cartons outside the region, said Shashi Menon, chief operating officer at Al Ain Dairy. “It was definitely Tetra Pak’s idea, a product they have used extensively in North America and Europe,” he said. “It is tried-and-proven technology and we visited them, saw some of the examples and 52

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decided to use it here.” In fact, the dairy could also make the switch to cartons across more of its range of milk products, he told Packaging MEA. “The rest of the SKUs of Al Ain Dairy still continue to be in PET, because it’s the acceptance in the real life in the market that matters,” he said. “We want to move in phases to see how successful we are and then build it up. We can go for other SKUs but 2-litre Tetra Pak is not ergonomic for customers to handle. There is scope for it to go in the 200ml and the 250ml single serve packs category.” Tetra Pak is also optimistic that the regional debut for its Tetra Top One Step Opening carton for fresh milk could open up futher opportunities for its products in the Middle East, said Riccardo Castagnetti, Tetra Pak’s marketing director, Arabia Area.

“For Tetra Pak it was a fantastic opportunity to launch this innovation in the market with the No.1 producer of fresh milk in UAE,” he said. “Our wish is that with the advantages of Tetra Top OSO on convenience, consumers will recognise product protection and environment and the package will become a preferred alternative to plastic bottles.” Tetra Pak and Al Ain Dairy had worked together on launching new products in the fresh milk market in UAE for two years, he said. “This is the first step of a co-operation that will bring the two companies together to launch a full range of new products in the market in the coming years,” he said. “Tetra Pak and Al Ain Dairy share many common values and strong drive for quality and innovation.” Within the UAE market, the new

packaging has won acceptance, overcoming the issue of its unfamiliarity partly through Al Ain Dairy’s dominant position in the market, said Menon. “One of the key issues that we have had to face is managing the customer perceptions,” he said. “Tetra Top is not a very familiar product for customers in this region. So we had some perception issues especially from customers from certain areas like the labour camps, who misinterpreted and misread the product to be a long-life milk. To overcome this and to reassure customers that it’s the same Al Ain milk coming in a different pack, we did marketing and ad campaigns and physical samplings in supermarkets.” In his view, Al Ain’s leading market role gives it both an opportunity and obligation to lead innovation, he added “We feel that as leaders in fresh milk in the UAE, it is up to leaders to take initiatives for change and drive it forward,” he said. “For a company with less market share

than us it would have been a challenge to overcome this [acceptance issue] because there is an amount of credibility customers give to a certain brand.” Al Ain Dairy is also committed to spearheading new technology in the region, with a track record in leading the wider adoption of innovative packaging, he added. He confidently forecasts the dairy’s shift will inspire its competitors to make the same move from PET. “One of the differentiators that we have is to look at ourselves as pioneers in the

way we approach our customers by offering them better product services,” he said. “Al Ain was the first company to move from HDPE to PET packing 8–10 years back. We led the change then. Then everybody migrated to PET. I think we have kept the trend by being the first to change from PET to Tetra Top and I can assure you that within two or three years there will be many more followers on this. “We also tried to lead the change in the

visual graphics and design on the labels and competitors follow us. We try to incorporate more information to our customers through our labels. “It’s a brand ambassador and conveys a lot to the customer. It also improves the look and feel of our company. We try to align ourselves with the best practices worldwide. If a visitor comes to the UAE for the first time, he or she should feel at home with the product. Al Ain Dairy belongs to the Abu Dhabi fund food development.”

Performance gains In terms of performance, he praised the cartons for introducing benefits in performance as well as in cost and waste. When asked if the switch to cartons had brought savings, his reponse was: “Yes, definitely. We are sourcing this from Tetra Pak-KSA and Tetra Pak-Sweden. The complete packaging material is coming from there. It is cheaper than PET bottles.” Barrier properties have also been enhanced, he added. “It is better than PET,” he said. “The vitamin and nutrient loss is very minimal in this. The product remains fairly in same condition from production to expiry. In addition the bacterial load is about one third of that in the PET bottles. For example, if the bottle has 100 bacteria, this Tetra Top pack will have only 30.” For now, though, this longer shelf life is not reflected in the packs’ expiry

The vitamin and nutrient loss is very minimal in this. The product remains fairly in same condition from production to expiry date, which is set by local regulations that have yet to recognise the new category. In Europe, the packs would carry a two-week expiry. “The four-layered carton is ideal for the region as it keeps milk fresh, offers protection from sunlight, which can taint milk flavour, and is less susceptible to rapid changes in temperature,” said Menon. “The new package also offers shoppers greater convenience as it has tamper evident one-step opening and closure and its shape makes it easier to store in the refrigerator, while the handy pack sizes help to reduce milk wastage.” The new package should also find favour with retailers because it is simpler, easier and cheaper to transport, store and display, according to Al Ain Dairy and Tetra Pak. In European markets where the package is common, it has resulted in less milk wastage through lower ‘returns’ – product returned to the dairy and simply flushed away. In addition to the consumer benefits of a simple opening and secure closure screw jan-feb 2014

Factory tour Al Ain Dairy

We want to move in phases to see how successful we are and then build it up top, the new package has been designed with a low environmental impact by minimising the amount of raw materials and maximising the use of natural and renewable paperboard. “The carton board comes as a reel,” said Menon. “The Tetra Pak machine forms fills and seals the bottle so there is no chance for external contaminants to enter it. Every reel coming inside the factory has a barcode with details of its production date, the storage temperature, the handling instructions... and we have an incoming inspection on it. We also check the paper and its thickness. “Later, after production, we do an in-process checking involving weight and volume checking, microbiological checking etc. We also have a packaging integrity testing that is done on the spot to check whether the sealing is perfect.” The cartons’ improved performance also comes from a sterilisation stage, enabled by the move from bottles to cartons, said Kurian, production manager Al Ain Dairy “We sterilise the Tetra Top packaging material,” he said. “The normal bottle we 54

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just rinse with normal air. The packaging material is first treated with 1% peroxide, after which it is treated with UV light. With this, 100% of the bacteria is killed. So we ensure that before filling the packaging material is 100% sterile. This increases the product shelf life. In a normal PET bottle, bacteria is not 100% removed.” Looking ahead For Al Ain Dairy, the cartons present an

I can assure you that within two or three years there will be many more followers on this opportunity to expand on its 27% share of the UAE’s fresh milk market in the UAE. Milk could also be a growing market in the country, as its rate of milk consumption currently ranks among the world’s lowest at just 16 litres per person each year. Al Ain Dairy products are 100% Emirati, with the dairy located on the outskirts of the Garden City, where it has a herd of 6,000 Holstein Freisian cows kept in free roaming, open, temperature-controlled barns under

the watchful eye of the farms manager, Pat O’Dwyer from Ireland. Each day, the cows consume 130 tonnes of the feed shipped from the United States and Spain and produce 125,000 litres of fresh milk, which is pasteurised and packaged on-site before being transported immediately to distribution points and retailers all over the UAE every single day of the year. Al Ain Dairy was established by His Highness Sheikh Zayed bin Sultan Al Nahyan, who donated the land where the farm stands on today. Under the guidance of the Abu Dhabi Fund for Development, the dairy has become a national institution that produces the largest range of world class dairy and juice products locally with half of the profits being distributed among 12,000 marginalised UAE national families. New solutions in the Gulf Like Al Ain Dairy, Tetra Pak sees collaboration over the Tetra Top rollout as a stage in an ongoing process of innovation. Castagnetti points out that the launch

Consumers will recognise product protection and environment and the package will become a preferred alternative to plastic bottles of Tetra Top for fresh milk in the Middle East followed an established pattern in his company’s development in the region. “Tetra Pak develops and launches new products with key customers all across the Middle East,” he said. “We have an incredible portfolio of packages, openings and sizes matching consumers’ needs in different segments. We continue to collaborate with our partners in the food industry to make ‘food available everywhere’, keeping the quality of products even in nonrefrigerated conditions longer.” He also sees wider potential for the firm’s packages to encroach on alternative packaging approaches. “Tetra Pak packages have efficiently replaced cans and glass jars in several segments thanks to their advantages in terms of distribution, convenience, shelf-space and communication area,” he said. “Our main goal is to grow in the main segments we are present with our customers and explore new interesting niches where the full potential of carton packages in terms of functionality and protection of the packed products have not been exploited.” The Al Ain Dairy project is also a template for other potential projects in its environmental aspect, he said.

“Environment is one of the focus areas for Tetra Pak strategy,” he said. “Our packages mainly consist of paperboard, a renewable resource that increases

The cartons’ improved performance also comes from a sterilisation stage, enabled by the move from bottles to cartons

dramatically the environmental profile and decreases the impact on waste and pollution. We believe that consumers will become more discerning and will put more attention on the product quality and

environmental benefits related to carton packages.” Liquid dairy products constitute more than 60% of the firm’s business worldwide and have a similar importance in Tetra Pak’s Middle East and African operations. But in the MEA, nectars, still drinks, tomato paste and cheese are all growing categories, he added. “Tetra Pak has been very close to its customers in the area,” he added. “We have established regional sales offices, a technical support network and production facilities in all the main markets in MEA and our local presence has been one of the main advantage over the competition.” Within the region, Egypt, despite its political tensions, remains a fast growing market, he added. “Iraq could become another rising star thanks to increasing population and stability,” he said. “Saudi Arabia still offers great opportunity to develop the business as well as Yemen, a market that has been growing double digit every year for Tetra Pak since late 2000. “Our local presence in the region is very solid and widespread. We are looking at opportunities when they arise to consolidate our production facilities and improve our service to customers.” jan-feb 2014

Factory tour: Future PET

PET preforms and closures specialist moulds a template for growth Future PET’s general manager, Mohammad Shaji, tells Benjamin Daniel why the firm is looking to almost double its revenue in 2014.

UAE-based Future PET is one of the youngest divisions in the ENPI group, but it is determined to take full advantage of its sector’s soaring opportunities, says general manager Mohammad Shaji. This year, the company is aiming to grow its revenue to almost double its 2013 figure, and nearly six times its total for 2009, its first year of operation. “In 2009 it was AED60 million,” he told Packaging MEA. “Our 2013 closing was AED185 million. For PET, our target figure for 2014 is AED340 million. We have a tough target to achieve but since we are going to add two more machines we think we can do it.” Future PET specialises in manufacturing PET preforms and HDPE /PP closures. The firm started in 2009 in Sharjah, UAE, with a preform and a closure line. “The preform injection machine is from Husky, who is the world leader in preform 56

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machines,” said Shaji. “Initially, we started with compression closures catering only for the mineral water bottling segment – i.e. configurations 3025 and 3025 for closures and preforms respectively.” But the company has now diversified and expanded production through a series of investments, while developing the quality standards that can enable the firm to cater for the leading international soft drink companies. Future PET’s investment in machinery is also set to continue in 2014, said Shaji. “We have most of the sizes to cater to water and carbonated soft drinks (CSD) areas,” he said. “We hope by March 2014 to have the tools for the new CSD short neck, the 1881, and to start its production. The 2925 shortest closure neck for water is already with us. Within this division, we are also looking to further downsize from 12.5g to 9.8g and 10.3g. These moulds are already arrived in the port and we are expecting

its delivery in a couple of days. And, hopefully, we may start its production by the end of February 2014 after the trials. “We have already expanded in the water and CSD segments. We now aim to divert our business to other areas beverages such as milk and juice packaging, which are the wide-neck bottles. The machines we have are compatible and we need to only change the moulds. We have the best machines which produce 96 injections of a small gram in 6 seconds. The faster the machines inject the preforms, the less the acetaldehyde content and odour.” The firm’s expansion picked up pace back in 2010 with the addition of four lines. “In terms of tonnage, we produed 600 tons of preforms and 100 tons of closures in 2009 as it was the first year,” said Shaji. “In 2010, there was a 400,000 increase in the tonnage of preforms and closures. We have four preform machines, two here in Abu Dhabi and two in Riyadh and one

fully fledged laboratory”. “We have an in-house testing facility for acetaldehyde and IV testing,” said Shaji. “Along with our shipments we ensure that the acetaldehyde, IV, and moisture content levels are within the limit. We also do a pre-blowing to test match the colour of the

closure line. We had now started catering to the 1810 preforms and closures PCO markets for the CSD. Our production has increased from 600 tons of preforms in 2009 to 2400 tons of preforms in 2010, including the Riyadh production.” But by 2011, the company was already running its machines at full production. “So in 2012, we added another closure line increasing our closure production from 100 to 300 tons,” said Shaji. “In the beginning of 2013 we added another preform line here in Abu Dhabi, our fifth preform machine. By the end of February 2014 we are expecting another preform line. All these preform machines are Husky machines with 96 cavitation capacities. We are also expecting another closure line.” Product innovation Meanwhile, Future PET had tied up with Emirates Water and started what Shaji calls “the smallest and first of its kind in the GCC”: 2925 preforms and closures. “We have given all the technical support to them and we also supply the preforms and the closures to them,” he said. With the introdution of new machinery, Future PET has steadily developed more economical products using less raw materials, said Shaji. “When we started our business, our preform manufactured to pack 500ml weighed 18g,” he said. “Now we produce the same neck in 17g and 15.15g. We worked in parallel on the 2920 short closures, where the same packaging is done in 12.5g. So there is a high percentage of saving. Not just us, but our machine suppliers also did a lot of research on this project and together we were able to achieve perfectly blown preforms with good strength to the bottle.” In addition, the firm has introduced a printing line for printing over the closures as well as “a

preforms. Besides this, other physical tests are also carried out in our lab. This is one of the best labs in UAE.” Ensuring quality In hitting its sales targets, Future PET will rely on exports, which make up the vast majority of its sales, said Shaji. “We target the volume business not the 0.03% of the market requirement,” he said. Less than 20% of our production is for local markets because most of the local plants are fully integrated. For example, Masafi, Al Ain and others have their own preform machines. Yet we do supply to them as well to balance their quantities and to supply them sizes they don’t have. “Our major market share is in the African countries. We supply to all parts of Africa, parts of Europe, Philippines and Australia. We do almost 440ft (134m) containers’ worth of shipment every month.” To realise its ambitious growth objectives, Future PET relies on achieving the highest production standards, which can unlock orders from the largest drinks companies. Already, the firm holds “all the certifications, namely, ISO 22000, EHS 14000 and the FSCC certifications”, which enable Future PET to meet the criteria of the FDA, which brands see as crucial, said Shaji. Yet the company is still in the process of winning approval from key potential customers, he added. “Our main target is the beverage industry

where the top leaders are Pepsi and Coca-Cola,” he said. “For them, we have to go through a tough audit process. For Pepsi we have already received a plant approval and the product approval will be done soon now. Approval from Coca-Cola is still going on. We have complied and have been approved by all other packaging buyers in the food and beverage sector.” In his view, Future PET can count on its customers’ trust in its quality and service. “To cater to the market we have an experienced sales team,” he said. “We use 100% virgin material and do not dose with any recycled material. Most of big clients have visited and audited our plant and are very happy with the system and procedures that we follow. “We also have the best machines. Husky are very expensive, and the best machines available in the market. The closures we use are compression closures, which are leak proof and easy to release from the bottle. “We produce 1 billion closures a year, all produced without human touch and each of these closures pass through the camera. It automatically rejects any piece with contamination or defect. We also have an experienced technical team who are knowledgeable in both the injection as well as the blowing line. They are consulted by our customers during issues or fly within 24 hours to resolve them. “Therefore our customers know that they can trust Future PET 100%. They are used to contacting us on issues apart from the products we supply to them and our technical team would fix it for them. PET packaging is a new technology. It was earlier done using PVC. Our technical person has been around with us since the inception of PET technology, so has close to 26 years of experience.” jan-feb 2014

Business carton packaging

First Group stays ahead with Bobst Bobst equipment and services have helped First Group hit the forefront of Egypt’s paper and packaging market, where it’s set to stay throught a focus on quality, service, competitive prices and innovation, reports George Simonian.

Many of these products have been new to the Egyptian market or, if they were already here, they were imported First Group made its first investment in Bobst kit in 2007 and now operates the company’s machines across 12 production lines

The relationship between First Group and Bobst began with the opening of its First Carton subsidiary and has proven to be a long and very strong one, said First Group CEO Louai Abd El-Wahed. “After many discussions, tests, visits and research, we came to find that Bobst is not just the leading company in their sector but also a company you can rely on,” he said. With its origins in Packline, a corrugated converting plant established in El Obour City on the north-east edge of Cairo in 2000, First Group now employs 3,500 staff and has a turnover of EGP1bn. In 2003 the Packline board reviewed the substantial progress that the company had made in its first three years of operation and initiated an investment programme to increase capacity and secure upstream supply. By establishing First Paper and First Carton, the Group achieved these objectives, doubling its packaging production capacity and ensuring a large portion of the raw material needed for its printing and converting lines would be produced in-house. Within two years, First Group saw the opportunity to 58

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provide high-quality offset printed packaging, establishing First Print to serve this market. First Group signed its first deal with Bobst in 2007, for 10 machines, and, following four years of successful production with this equipment, the group invested in a further two machines. The 12 lines within First Group plants include four SPO corrugated diecutters (of which two feature Power Register technology), a large format SPeria die-cutter, a Foilmaster 104 hot foil stamping press

We came to find that Bobst is not just the leading company in their sector but also a company you can rely on and six folder-gluer lines including two high performance ExpertFold 11 A2s. Eng. Reda El Aasal, production manager at First Print, said the decision to invest in Bobst equipment was made because the Bobst machines are seen as delivering high productivity, quality, consistency and durability while also being easy to install, be trained on, operate and maintain.

This capability has helped the group guarantee high-quality, on-time delivery and competitive prices for its range of products, he added. These characteristics have also helped First Group to become one of the leaders in the Egyptian paper and packaging market.

Opening up new markets A further factor was that by investing in Bobst equipment, First Group has been able to produce a wider range of products, said Eng. Khaled Abd El-Rahman, commercial sector manager for First Group. “Many of these products have been new to the Egyptian market or, if they were already here, they were imported,” he said. “The Bobst equipment has allowed us to open up such new markets both in Egypt and abroad.” Delivering new products fits perfectly into the vision that El-Wahed has for First Group. “We cherish a set of everlasting values and principles which enable us to present products achieving our customers’ satisfaction,” he said. “We relentlessly seek what is suitable for our customers’ current and future needs. Development and continuous improvement

constitute our core strategy and form our basic objectives.” Ensuring the bulk of the test liner and fluting medium supply to First Group’s companies is First Paper, which has two paper mills. PM1 is a 5m-wide unit with a state-of-the-art stock preparation unit, something which also features on the 2.5m-wide PM2 mill. By the end of 2013, the capacity of First Paper is planned to reach 160,000 tons per year. The First Carton plant produces 120,000 tons of A to F-flute board each year on its modern, 2.45m corrugator, 45,000 tons of which are converted next door at First Group’s original company, Packline. First Carton has a number of four-colour flexo printing presses, in-line and off-line box making, and specialty gluing. Both First Carton and Packline use Bobst flatbed die-cutters, ensuring that that the group is able to deliver the conventional and shelf-ready corrugated products that the market requires. Nearby, the First Print plant specialises in producing high-quality litho-printed packaging. Although a latecomer to the folding carton market in Egypt, First Print has become one of the leaders in the field, producing 30,000 tons of such products each year. Using KBA offset litho presses with the ability to print up to six colours plus UV varnish

Bobst SPO 160-Vision die-cutter: ‘ideally suited to convert all litho-laminated boards’

Along with being highly productive, the plant’s two Bobst SPO 160-Vision Power Register diecutters are ideally suited to the conversion of litho-laminated board thanks to their ability to register to the print on the sheet, removing the problems caused by litho-sheet overhang.

within the country as well as exporting to the wider region. To satisfy its multinational customers, First Group has driven a programme of accreditation to international standards in occupational health and safety, hygiene, quality and the environment, paving

Mohamed Hassari (left), communication manager for Bobst A & ME, with the management of First Company Egypt

and special colours, First Print also has the sheet-to-sheet equipment needed to produce litho-laminated board, as well as having Bobst hot-foil stamping, die-cutting and gluing lines.

Litho-laminated packaging is one of the products which until recently had not been readily available in the Egyptian market and First Carton is successfully supplying clients

the way for such customers to increase the volume of work they entrust to the Group. Investing in Bobst equipment proved to be the right decision for First Group said El-Wahed. jan-feb 2014

Business Saudi food & beverage packaging

Q&A: The keys to the Kingdom... Simon Blazeby, director, Reed Sunaidi Exhibitions, shares his tips for entering the Saudi food and beverage packaging market.

Simon Blazeby, director of REED Sunaidi

How do Saudi tastes in food and packaging differ from other markets?

Saudi Arabia has specific labelling requirements for all imported and local food and beverage products. The product(s) must have a label or sticker showing the statutory information such as product name, country of origin, producer’s name and address, production and expiry dates, in both Arabic and English languages. It is essential that exporters adhere to Saudi quality standards and labelling guidelines to avoid rejection of products at a Saudi port of entry. The method for writing production and expiry dates is to put the day of the month first, followed by month and year. Displaying the month first is not acceptable in Saudi Arabia and products that do not meet established Saudi standards are either re-exported to the country of origin or destroyed at the importer’s expense. Saudi Arabia implemented a voluntary shelf life standard (manufacturer-determined use-by dates) for most foodstuffs with the exception of selected perishable foods (fresh or chilled meat and poultry; fresh milk and fresh milk based products; margarine; fresh fruit juice and baby foods) that must meet the Saudi Arabian Standards Organisation’s established mandatory expiration periods. The revised standard (SASO 457/2005) will no longer ban imports 60

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of food products with less than half of its shelf life remaining. Shelf life can only be shown by clear and unambiguous production and expiration dates. The use of any of the following statements for expressing expiration date is permissible. ‘Expiration Date Use by (date)’, ‘Fit for (from the day of production)’, ‘Use Before (date)’, ‘Sell by date’ (for food products having an expiration period exceeding 3 months). Culturally, there are some differences in Saudi food packaging compared to other parts of the world. Of course no women or women’s faces are to appear on products. Also no pigs, dogs or other prohibited animals should be used. This leads, in some cases, to an inventive way of communicating brand identity to Saudi audiences.

What potential is there for large brands to expand in the Kingdom?

There is a lot of potential for large F&B brands to expand in the Saudi market. With a growing population, increased consumer spending and significant public sector investment in new malls, restaurants and hotels, Saudi Arabia’s rapidly expanding F&B industry is a goldmine waiting to be tapped. Food sales in the Kingdom account for around half of the domestic retail market and are expected to be worth almost $70bn by 2016, with food consumption growing at a CAGR of 2.6% from 2012 to 2017. Despite being the largest F&B market in the GCC, the Kingdom relies heavily on imports to meet its growing consumption requirements. Brands like Nestlé and General Mills initially established their presence in the Saudi market through distributors, then they set

Saudi Arabia’s rapidly expanding F&B industry is a goldmine waiting to be tapped up subsidiaries which maintained various brands and managed distributors. Now they are in the stage of consolidating their subsidiaries to assume control over all major product lines. The next phase will see these brands set up manufacturing and/ or bottling or repackaging plants in the Kingdom. This is something MARS has done, for example. The brand started with a central office in the UAE and has now set up a manufacturing facility in King Abdulla Economic City. The same goes for Danube and many others.

Are Saudi producers set to expand their liquid packaging exports to the GCC into other categories?

Yes, Saudi Arabia is already starting to export other F&B categories to the rest of the GCC. In fact, food processing is one of the fastest growing segments in the food industry supply chain and Saudi Arabia, which relies mostly on imported raw materials, is expanding considerably in this area. This has prompted many international companies to set up licensing agreements with local manufacturers in the Kingdom to produce their brands.

‘The world’s biggest F&B brands have been in Saudi Arabia for close to half a century’ The economic freezones, like King Abdullah Economic City, have also helped attract major international FMCG brands who see Saudi Arabia as a potential re-export hub to the rest of the region. Similarly, Jeddah’s strategic geographical location and position as the second largest retail destination in the Gulf after Dubai, is contributing to the Kingdom’s growth in F&B processing facilities.

Is the global shift from rigid to flexible packaging underway in Saudi Arabia?

While packaging in KSA is developing, it still lags behind developed markets. Flexible packaging can already be seen in local supermarkets, but this tends to be driven by multinational brands that import this innovation to KSA rather than created by homegrown brands. However, as the Saudi F&B market grows, we are starting to see more collaborations among local food companies and international packaging companies. Tetra Pak, for example, chose to launch its ergonomically designed drink opening ‘DreamCap’ with Saudi drinks company Al Rabie, its first customer in the world to adopt the new drinks closure. Given the food consumption demands in Saudi Arabia, flexible packaging in the Kingdom is expected to grow significantly in the coming years. The rapidly growing young population and increased urbanisation will see demand for convenience and pre-packed foods rise. Increased investment in food production and processing will also result in more flexible packaging converting capacity being introduced, which offers Saudi Arabia an avenue for downstream petrochemical diversification.

Have international firms spotted the Saudi market’s potential?

The world’s biggest F&B brands have been in Saudi Arabia for close to half a century, but certainly as the Kingdom has opened up to more international trade and investments, other companies are starting to recognise the growth potential the market offers.

Saudi Arabia is on the cusp of a new era in dining and mass grocery retail The internationalisation of Saudi taste preferences and ‘premiumisation’ of the Saudi F&B scene presents lucrative opportunities for international food and packaging brands, especially in the emerging categories of organic, gourmet, convenience food and non-alcoholic beverages. Saudi Arabia is on the cusp of a new era in dining and mass grocery retail. Those brands that cater to the changing dynamics of the Kingdom can look forward to yielding significant returns.

What are your tips for entering the Saudi market?

• Do your research regarding compliance with the Saudi Food & Drug Authority and the Saudi Arabian Standards Organisation guidelines. • Research the consumer trends for your categories. • Speak to other companies already established in the market. • Speak to your embassy and business groups. • Don’t go with the first partner you encounter. Make sure you meet many potential partners to cover your core business objectives. • Attend industry trade shows like Foodex Saudi. This is one of the most effective sales and marketing solutions for companies looking to enter the most dynamic emerging F&B market in MENA. Foodex Saudi Foodex Saudi is Saudi Arabia’s first and biggest international trade event dedicated solely to the food and beverage industry. Owned and organised by Reed Sunaidi Exhibitions, under the patronage of the Ministry of Agriculture, it provides an unrivalled platform for local regional and international suppliers, manufacturers and service providers to access the fastest growing F&B market in the MENA region. jan-feb 2014

Business packaging trends

Packaging enters the digital age Six ‘mega trends’ are transforming the packaging sector as digital technology takes hold, according to a report on the future of packaging from Karstedt Partners.

Shoppers now receive online ads, Facebook posts, blogs, tweets &YouTube videos as they provide the first product/package experience

The digital age is changing our world. Forces driving the change are: people, information and technology. In our report ‘Is Digital Printing Part of Your Brand, or Operational Strategy?’ we describe how technological advances with the web, computers, mobile phones and tablets enable billions of people to connect all over the world, including a burgeoning number of consumers in emerging markets. And this worldwide connectivity has led to continued growth in methods of electronic information exchange. We now live in the social media world of Facebook, LinkedIn, blogs, tweets, Skype and streaming video, all feeding into daily tidal waves of information. We receive news and information right in the palm of our hands in near real time. The ease and immediacy of social interactions make the world a smaller place and are having a significant impact in packaging. Digital media is now being used to enable brands to engage and energise shoppers and consumers in new ways that can elevate the shopping experience. 62

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Shopper behaviour changes Until the early part of the last decade, TV and publication advertising heavily influenced shoppers’ buying decisions. Viewers would develop their first opinions while watching TV commercials or seeing publication advertisements. Buying decisions would often be made prior to entering a retail store. The digital age has changed our buying influencers. The emergence of satellite, cable TV, DVR, eBooks and computers has caused a major decline in the conventional forms of advertising. In 2002, Procter & Gamble publicly announced a corporate focus on First Moment of Truth (FMOT). This focus emphasised packaging that would stand above the clutter on the store shelf. Shoppers began to shift their product purchase decisions to the retail space as they roamed the aisles. Stopping shoppers in the aisle, holding their attention and closing the sale are the critical components of FMOT. Shopper behaviour at the end of the decade changed again. The shift toward shoppers living in the real world and living in the

virtual world has created the Zero Moment of Truth (ZMOT). Shoppers now receive online advertisements, Facebook posts, blogs, tweets and YouTube videos of what others think and, many times, these provide the first product/package experience. More purchase decisions are made through these first online experiences. Cyber Monday 2010 recorded, what was then, the single largest retail sales day ever with $1 billion in online purchases. Just last year, comScore, a company that provides ‘Analytics for a Digital World’, reported Cyber Monday sales at $1.735 billion, up 18% from 2012.

The Future of Packaging Shopper behavior will continue to evolve and likely be shaped by the ‘Big Six Megatrends’: 1. Want it now ‘Want it now’ is a trend born out of the fact that everything is connected and is on-demand. Online users expecting faster and more convenient connections to their favourite sites have downloaded more than

10 million apps. Online music and movie purchases reinforce the point that when you click, you can have your product instantly. Consumers want their products as soon as they have made their decision. Consumer product companies need to improve their response times to meet delivery expectations. Packaging lead times need to be cut to meet the new delivery speed requirements.

2. Consumer expects more Never in the history of the world have people been as connected as we are now. Consumers connect online to their brands across the world. The world is a smaller place and has a greater sense of social awareness. Consumers expect their brands to have meaning and stand for a cause. Causes include the pink ribbon campaign, healthy drinking water or fair treatment of the coffee bean farmers; the fact is consumers expect more. There is a growing trend with co-creation of brands, enabled by the internet. Consumer product companies are reaching consumers and involving them online with the revitalisation efforts of their brands. There are numerous case studies of personalised products and package possibilities including Nike sneakers, Harley-Davidson bikes, My Kleenex and even My Extra Gum packs. Consumer product companies need to create agile supply chains that allow more than just a long run of a few classic brands appearing in a big box store. 3. Innovanomics You won’t find the word ‘innovanomics’ in the dictionary, but it’s one you’ll get to know as it describes the changing times we live in. The meaning is simple… the economics of innovation. The rate of product and package obsolescence continues to pick up. Consumers dispose of products prior to the end of their useful life, just for the mere fact that a more fashionable option has become available. Companies must deal with an innovation migration plan so as to continually improve and satisfy consumers’ unmet needs. The alternative of doing nothing means others will innovate past you with a preferred product or package position. 4. Green is normal What started in the early part of the last

No more guessing when it comes to which graphics have the potential to elicit most sales

decade as a trend has now moved to the mainstream. First we saw the self-policing efforts coming from the trade (e.g. WalMart, Target, Carrefour) to consumer product companies. Now you see CPCs providing scorecards to their suppliers. There is now an app for monitoring and keeping track of your own personal carbon footprint. Don’t be surprised when we start sharing these stats at social gatherings.

to determine which graphics elicit the best emotional response. There will be no more guessing when it comes to which graphics have the potential to elicit the most sales.

5. Growth in emerging markets There has been much media coverage on this topic so we will not belabour this well-recognised point. Even with recent difficulties and growing pains in some of these sectors, significant growth will come from emerging markets in Brazil, India and China (BIC), just to mention the most noteworthy. 6. Neuroscience Scientific advances in the ability to sense, measure and record brain waves from the frontal lobes have made it possible for us to take a look inside the brain. There are several competing companies that have developed the capability to quantitatively measure emotions. The technique is done by wearing a cap or strand around the forehead fitted with sensors that measure emotional responses to package graphics. The measurements are validated, rendering the approach reliable. In the future, CPCs will use this technique

Keeping track of carbon footprint

This is an edited excerpt from Karstedt Partners report Is Digital Printing Part of Your Brand or Operational Strategy? The report was co-produced with Mike Ferrari of Ferrari Innovation Solutions, a former Procter & Gamble executive. This article was originally published on Whattheythink.com jan-feb 2014

Business Report ERA Packaging & Decorating Conference

ICR, which makes more than 18,000 cylinders each year, has developed a concept for gravure cylinders that eases logistics by using aluminium

Gravure responds to 21st century market pressure

What is happening in today’s market for gravure printing? Nick Coombes reports from Novara in Northern Italy, where the European Rotogravure Association (ERA) recently held its Packaging & Decorating Conference. Introduction

ERA growth

Saueressig Gelenium

Welcoming more than 100 members and delegates to the biennial Packaging & Decorative Conference, ERA Secretary James Siever announced that the global gravure industry was actually growing, with more plants and presses in use than in 2011. Setting the scene, he said that gravure continues to enjoy many advantages over other print techniques, namely: speed, colour consistency, infinitely variable cut-off, excellent repro and half tones, and the capability of handling a wide substrate range, and with the rapid growth areas of Asia and India being major users, as well as the Middle East and South America, the future for technology manufacturers looks bright. Only in North America, often considered the heartland of flexo printing, is gravure’s market share stagnating. In Europe, where gravure and flexo hold an approximately equal market share (for flexible packaging), Germany continues to dominate, with Italy, Russia, France, Spain and the UK making up the top six, and accounting for the vast majority of plants and presses.

The ERA, which is approaching its 60th birthday (in 2016), was originally established as a forum for gravure printers. In 1969, it created an Associate Membership to accommodate suppliers of technology and consumables, and more recently, in 1996, it acknowledged the growing importance of packaging by creating a special category. A good cross-section of members were at Novara to hear presentations from leading suppliers, all of whom spoke of their confidence in the future of gravure as it adapts to a changing marketplace. The Conference presentations began with Nikos Stamatis and Michalis Vardavoulias of ICR Ioannou. The company, which went on to win one of this year’s ERA Awards, has developed a new concept for gravure cylinders that eases logistics by using lightweight aluminium. By solving the bonding problem between copper and aluminum, ICR has produced a cylinder that is both easier to handle (typically a 1.2m cylinder weighing only 20kg), and significantly reduces the costs associated with freight shipping.

Saueressig, represented by Alwin Göring and Stefan Heßeling, also explained how their lightweight cylinder technology m-Roll, although based on steel, has achieved a substantial weight reduction by being foam filled. The lighter weight combined with smaller volume results in warehouse costs savings, while traditional copper plating and engraving techniques can still be used. On the subject of print quality, Esko, Daetwyler SwissTec, and QuadTech each explained how its company’s technology had raised the benchmark. Giovanni Vigone, from Esko Italy, explained how the key values sought by brand owners are: right colour, first time, every time, and time-to-market savings. The latest system is ‘colour by numbers’ he explained with the new spectral data creating the DNA of a color. By making use of The Cloud, all parties involved have access to the approved standard that is integrated into the workflow. For converters this means faster makeready, reduced waste, and more a consistent colour quality.

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Daetwyler SwissTec AG Kishore Sarkar spoke of how modern doctor blade technology is responding to the rapidly changing market of FMCG, citing Amazon and the growth of mini supermarkets at petrol stations as prime examples. With retailers and brand owners needing to respond instantly to changes in demand, the need for transparency at all stages is obvious. The advent of QR coding, and other techniques that allow manufacturers to target their consumers more precisely, places greater emphasis on production techniques. In the case of doctor blades, this means the ability to cope with a new generation of inks and varnishes with their inherent chemicals, with new and often abrasive substrates, with downgauging, new cylinder surfaces and shorter runs. It’s a high-tech world these days, he said.

QuadTech Inspection System Stephan Dopplehammer of QuadTech explained that 100% web inspection is now available and considered essential. His company’s modular system uses a 3-CCD RGB line scan camera, with proprietary LED lamps that are water-cooled. The system tolerates web wander, marks slow-growing defects, and supports all substrates. Faults detected include: splashing; streaking; missing print; mis-register; colour variance; hazing; and contamination. Simple to control from a 19” touchscreen, with a 5-step set up wizard, it offers improved quality, reduced waste, increased yield and colour consistency. Moving on to the press technology, Cerutti, Bobst and W&H all spoke to the delegates

about how they are responding to the changes in demand, notably for shorter run work.

Cerutti Group Arturo Bergamaschino introduced Cerutti’s two families of presses, designed with different production environments in mind. The R972 range is highly automated and aimed at countries where labour costs are high, whereas the R980, and in its latest guise the R98X, is aimed at regions where labour and associated costs are lower. Pre-setting, to reduce changeover times, is crucial, with improved drying technology that suits the shorter web path under the hood. By cutting waste, which encompasses substrate, energy, time and manpower, Cerutti claims its latest technology is a match for any flexo operation.

Bobst Bielefeld GmbH Bobst Bielefeld (better known as Fischer & Krecke) continued the theme with its MW range of packaging presses. According to the company’s Thomas Reckert, minimising waste is the key to short run efficiency, and with 30 machines of this series already installed, he said runs as short as 300 metres are viable. The press, which is operated from ground level, thus obviating the need for a gallery, is therefore well suited to smaller production areas, and Bobst claims early successes highlight the trends for a press specifically focused on short run, fast changeover work.

Windmöller & Hölscher Presenting the case for Windmöller & Hölscher, Markus Bauschulte described

the company’s ‘Efficiency Accelerator’. By offering fast data input that gives higher press utilisation with short set-up times, W&H claims that a higher degree of consistency can be obtained. The system effectively removes some of the variables created by manual inputting, and substitutes these with a series of fixed parameters that are actioned automatically, giving a more secure and reliable end result. Highlighting one aspect of how small things can make big savings, Bauschulte said the latest design washed the ink trays within the press, without using spray nozzles.

Conclusion The conference concluded with two presentations on health and safety. Osvaldo Bosetti of Goglio updated the delegates on the SAFEMTECH project, which is examining the impact of adhesives on food packaging. Supported by the European Union, and carried out in cooperation of the University of Zaragoza (Spain), the research indicates that ethyl vinyl alcohol polymers (EvOH) can be used as an effective functional barrier against the migration of non-intentionally added substances (NIAS). An ongoing theme for the gravure industry and one of major concern is the authorisation process for chromium trioxide, which is currently listed as a dangerous substance by EU REACH legislation. Without authorization, chrome plating will be banned, and the ERA is working closely with the consortium to secure an acceptable outcome for the industry.

Cerutti Group, Windmöller & Hölscher and Bobst Bielefeld: ‘responding to the changes in demand notably for shorter run work’

jan-feb 2014

New appoinments

Mukul Shukla, General Manager, tna

Packaging specialist tna announced on 1 January the appointment of Mukul Shukla as general manager for the Middle East. Based in Dubai, Shukla will oversee all aspects of tna’s Middle Eastern operations, including sales, customer service and support in countries from Libya to Sri Lanka. Academically trained in mechanical engineering and

Walter Hartmann, Head of Marketing, KBA

On 1 January, Walter Hartmann took over as head of marketing for sheetfed offset presses at the Koenig & Bauer (KBA) plant in Radebeul, Germany. He succeeds Jürgen Veil, who took up the role of key account manager packaging in September 2013. Hartmann worked at Köselbuch printing firm and for AZ Druck und Datentechnik, a book and commercial printer, where he installed one of the first Rapida 105s. 66

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machine dynamics, with a bachelor’s degree in engineering and master’s in technology, Mukul brings almost 20 years of experience in the engineering and packaging industry, as well as sales and project management expertise to the role. “I’m delighted to be returning to the tna team in the Middle East,” said Shukla. “My previous experience, both in the food packaging industry and as regional sales manager for tna in the Middle East, gives me the perfect platform with which to connect with customers and take tna’s business to the next level here.” Michael Green, tna’s managing director, said the Middle East “holds great promise” for tna. “We’re keen to support our customers in the region with a high level of on-the-ground support,” he said.

Marcel Hage, chairman of XOL Automation, a diversified engineering company serving industrial/manufacturing companies in the Middle East and North Africa, has joined the Board of Directors of Unilux Inc., a leading designer and manufacturer of strobe lights for surface inspection. “Marcel is an outstanding addition to our corporate advisory and management

team and sets us up for a major growth effort,” said Mike Simonis, president, Unilux. “We will deploy his highly respected technical and financial expertise in our core industries to help us acquire and develop complementary products and services for new and existing customers. We believe the time is right to look at both organic and acquisition growth.” Hage said the continuing development of Unilux’s LED-based strobe lights opens up many new inspection possibilities, especially the ability to custom-design inspection systems to meet very specific production needs. “Materials, production processes and end products are constantly evolving – some faster than others.”

Matt Adler and John Kulak, Goss International

Patrick Van Baeleen, Vice President – Marketing, Xeikon

Barbara Schulz, CEO, Durst Phototechnik AG

Matt Adler has joined Goss as director of packaging sales in the Americas, while John Kulak is now heading the new Goss Packaging Technology Center in Durham, New Hampshire (US). The two newly created positions show how Goss is evolving its business, said senior vice president of sales and marketing Jacques Navarre. “We are diversifying our product portfolio to drive revenues in new, neighbouring markets,” he said.

Marcel Hage, Board of Directors, Unilux Inc.

Xeikon has appointed Patrick Van Baelen as vice president marketing and member of its Executive Committee. Van Baelen will head global marketing for both the labels and packaging and the document and commercial markets. His credentials include 25 years of experience in digital printing with global equipment suppliers and print service providers. He joined Xeikon in 2010 as sales director document printing, responsible for sales in Europe.

Barbara Schulz has succeeded Klaus Schneider, who died in spring 2013, onto the executive board of Durst Phototechnik Digital Technology in Austria. Shulz moves from Ipsen, where she was CEO of subsidiaries in South East Asia and India. “Durst’s plans regarding its long term strategy are as exciting as they are challenging,” she said. “At the same time, I am inspired by the great commitment which the company has to this region.”

THE NEW EXPERTCUT 106 LIKE AN EXPERTCUT ONLY BETTER

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