The Packman | March-April 2021

Volume 3 l Issue 5 l march-aprIl 2021

rs. 150

Leveraging robots in tube packing

Nilpeter India ships 30 label presses in FY-Covid

Passion for pharmaceutical packaging

Rossini revolutionizes gravure printing

ACOPOStrak

Conveyor meets track system www.br-automation.com/acopostrak

Conveyor

ACOPOStrak

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OEE

TTM TTM

Enabling manufacturing flexibility.

Like no other transport solution can.

OEE

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Editorial

From the editor’s desk!

T

ubes have been used in the packaging of liquids with high or low viscosity, making the handling of such liquids easier in transport and dispensing. The manufacturing units for tube production and decoration are usually different from the manufacturing unit for filling and sealing. This creates a demand for a safe, dustfree and hygienic transport of tubes from one location to another. Such industries demand uncontaminated packaging or preventing entry of dust in tube manufacturing and transport. Technoshell Automations provides solutions to tube manufacturing units for their various needs, such as tube capping, labeling, hot foil stamping and packaging. Read in this issue how Technoshell Automations achieves the desired accuracy and precision in their highly complex machines by using the most innovative and technologically advanced solutions from B&R. Based in Weiden, Germany, Heidelberg Web Carton Converting (HWCC) is the webfed flexo press division of Heidelberger Druckmaschinen AG (Heidelberg). Providing integrated inline webfed solutions, HWCC complements Heidelberg’s market-leading position in the world of packaging. Utilizing the most powerful sales and service network in the industry and overseeing the biggest installed base in the market, HWCC provides the longest experience and broadest application know-how to enable packaging printers not only to cope with new challenges but also to exceed customer expectations. Recently, UFlex ordered its second Heidelberg Intro web flexo press from HWCC. The highest quality and reliability of the machine combined with the best performance parameters are proven facts of Heidelberg Intro. Therefore, Intro was UFlex’s first choice for the second machine as well.

Rossini confirms its technological leadership and launches a highly innovative solution in rotogravure printing.

The large Italian manufacturer of rollers and sleeves has found the alternative to the hexavalent chrome coating of printing cylinders by finalizing a research and development work personally supervised its president Felice Rossini over the last ten years. The chrome surface of the printing cylinders guarantees today the high quality of the work carried out with this technology, but at the same time generates environmental and health problems, so much so that the competent authorities will prohibit its use within a few years. Engineer Flavio Losa, Rossini, explains the new solution in this issue.

In this issue, also read about Varun Beverages, part of RJ Corp group, one of the largest franchises for PepsiCo globally, which has installed Sidel’s Aseptic Combi Predis in its newly established plant in Punjab, India. The pivotal project aims to expand PET bottling capacity and provide production flexibility for the private label milk brand Cream Bell as well as Pepsi’s Tropicana juice range. By choosing the new aseptic dry preform sterilization technology, RJ Corp is commercializing its liquid dairy products (LDP) in PET for the first time in India.

The March edition of The Packman carries several stories focused on the ink industry, sustainability and recyclability, caps and closures, and new installations. Enjoy reading the latest issue.

– Mahan Hazarika, Editor, editor@thepackman.in

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3

CONTENTS Design and Marketing

PAGE 8

PAGE 24

From the editor’s desk!-------------------------- 3

Sale of Gallus Group to benpac holding fails------------------------------27

EDITORIAL

DESIGN AND MARKETING

Burger King unveils first complete rebrand in over 20 Years--------------------------------------- 6

Shreedhar Labels installs India’s first Guardian PQV 100% print inspection system---------------------------------30

MONOCARTON

Xeikon adds two entry-level label presses to its portfolio---------------------------31

Miraj Multicolour invests in Bobst and Heidelberg------------------------------------------- 8 Rave Scans installs Bobst Ambition 106 A2------------------------------------ 9 UFlex invests in Heidelberg Intro Web technology------------------------------------------10 RMGT partners with GEW for UV LED------12 Baumer introduces FFG go--------------------12 Toyo launches GMP-compliant offset inks for food packaging------------------------------------13

FLEXIBLES

Rossini revolutionizes gravure printing------14 Is vinyl printing ink market shrinking in India?--------------------------------16 Yansefu introduces innovative bio-based regulatory compliance pigment dispersant-------------------------------------------18 Impact of web offset technology in food and beverage sector----------------------20 EcoCortec introduces compostable electrostatic dissipating anti-corrosion film---------------------------------22

Temperature-controlled packaging industry outlook-----------------------------------49 Indian packaging industry reeling under unprecedented RM cost increase------------50

EVENTS

Indoplas, Indopack and Indoprint rescheduled----------------------------------------52

CODING AND MARKING

Ink raises standard of continuous inkjet coding for FMCG----------------------------------36

AUTOMATION

Leveraging robots in tube packing-----------38

SUSTAINABILITY

BillerudKorsnäs launches recyclable paperbased flow wrap-----------------------------------40 Mondi creates sustainable paper-based packaging for Goood-----------------------------40

FILLING AND SEALING

RJ Corp implements Sidel’s aseptic PET technology-------------------------42

United Caps reports on progress in Asian markets-------------------------------------46

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Interview with Heiner Klokkers of Hubergroup and chairman of EuPIA---------48

Ultra Foil implements Flexibiz ERP----------34

Passion for pharmaceutical packaging------32

LABELS

THE PACKMAN | MAR-APR 2021

INSIGHTS

New date for 15th Printpack India announced------------------------------------------52

CAPS AND CLOSURES

Nilpeter India ships 30 label presses in FY-Covid------------------------------26

PAGE 34

PHARMA PACKAGING

Toppan develops fire extinguishing film for lithium-ion batteries------------------------------23

UFlex Holography Business brings unique anticounterfeiting and brand enhancement solutions--------------------------24

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Sai Digistik installs HP Indigo 6900 digital press----------------------------------------28

MARCH - APRIL 2021

New 3Corações Cappuccino package uses Aptar’s BAP technology------44

Schwarzwaldmilch first to opt SIG’s combiMaxx closure-------------------------------47

The date for interpack 2023 is set------------53 Miraclon extends entry deadline for 2021 Global Flexo Innovation Awards--------------53

INDUSTRY NEWS

Tresu reveals new coating circulator for sensitive and special coatings------------54 Miraclon strengthens innovation leadership team-----------------------------------54 Flint Group launches XSYS--------------------55 Rotometal appoints sales manager in India----------------------------------55 Michelman joins International Molded Fiber Association-----------------------55 Ramakrishna Karanth joins Siegwerk India as the new CEO--------------56 Highcon and EFI announce global partnership-----------------------------------------56 Tresu’s new range of doctor blades and end seals----------------------------57

Design and Marketing

z NEW LOGO TO PACKAGING TO COLOR SCHEME

Burger King unveils first complete rebrand in over 20 Years

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merican fast-food restaurant Burger King has rebranded for the first time in 20 years with a revamped logo, packaging and uniforms designed by creative agency Jones Knowles Ritchie.

Burger King’s current logo was launched in 1999. The new option takes a minimalist approach that “seamlessly meets the brand evolution of the times and pays homage to the brand heritage with a refined design that’s confident, simple and fun,” Burger King said.

Burger King said the modern look “will more authentically represent Burger King values,” and is inspired by “real and delicious food.” Additionally, the announcement signals a commitment to digital-first expression and recent improvements to product quality, including the removal of colors, flavors, and preservatives from artificial sources. Also, there’s an “ambitious pledge to environmental sustainability.”

Burger King’s fresh color palate was inspired by its flame grilling process and ingredients. New photography is hyper textured and dials up the sensorial aspect of the food, the company said. Burger King also created a proprietary font called ‘Flame,’ which is built from the shapes of Burger King’s food.

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Employees will wear new uniforms that reflect “flame

grill masters,” mixing contemporary and comfortable style with distinct colors and graphics. The company plans to feature real crew members in its new advertising as well. The packaging showcases Burger King’s revamped logo, as well as the colors and illustrations of ingredients.

“Design is one of the most essential tools we have for communicating who we are and what we value, and it plays a vital role in creating desire for our food and maximizing guests’ experience,” said Raphael Abreu, parent company Restaurant Brands International’s head of design, in a statement. “We wanted to use design to get people to

Design and Marketing drive-thru lanes, configured to reduce the building’s footprint. Drive-thru customers can even have their order delivered via conveyor belt system.

In Q3, Burger King’s same-store sales declined 7% globally (down 3.2% in the US and 10.3% internationally). Those figures lapped difficult comps of plus 5% and 4.7%, respectively, in Q3 2019. Revenue dropped from US$ 457 million in 2019 to US$ 433 million this year.

As of September 30, Burger King had 18,675 units (7,216 stateside).

crave our food; its flame-grilling perfection and above all, its taste.”

moment of ordering, providing remote, contactless payment to speed up drive-thru lanes in the near future.

Burger King has more than 6,500 US drive-thrus. And, naturally, the channel has surged during COVID. This past quarter, drive-thru mix lifted to more than 85% of total sales versus two-thirds in 2019.

Additionally, creating weather-proof installations to withstand the heat of the southern U.S., the cold of Canada’s north, and the corrosive, salty air from cities along North America’s oceans, RBI said.

The initiative includes presenting menu options on digital screens tailored to each guest, as well as the integration of the company’s loyalty program at the

Months earlier, Burger King unveiled restaurant designs for the future, including a fully contactless model with a suspended kitchen and dining room sitting above

For the whole, RBI generated more than 94% of prioryear systemwide sales in Q3 with 96% of restaurants open globally. Cash flow from operations increased to more than US$ 400 million.

In more recent moves, Burger King announced December 21 an integration with Google on food ordering. Now, Burger King guests could order via Google Search, Google Maps, and Google Pay from more than 5,000 Burger King restaurants nationwide. A week later, it lifted the lid on a new US$ 1 Your Way menu.

The menu features the Bacon Cheeseburger, Chicken Jr., Value fries, and Value soft drink. z

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Monocarton

z HEIDELBERG 7-COLOR UV PRESS AND BOBST FOLDER-GLUER AND DIE-CUTTER

Miraj Multicolour invests in Bobst and Heidelberg

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fter commissioning a brand-new Heidelberg Speedmaster CX 102 7-color plus coater UV combi offset press in July 2020, Rajasthan-based Miraj Multicolour has strengthened its converting department for both monocartons and corrugated cartons with a Bobst Ambition folder-gluer and Bobst Novacut die-cutter.

The last time the company invested in Bobst machinery was in 2015. Today, the company has four die-cutters and three folder-gluers from Bobst.

For corrugated and litho laminated cartons, Miraj has also added and commissioned a Zhongke flute laminator, a Zhongke stripping machine, and a stripping machine from Suba Solutions. These installations took place in the past two months in the last quarter of the 2020 calendar year.

KG Sharma, director of Miraj Multicolour, said, “We recently added a Heidelberg 7-color offset press to

KG Sharma with Mantra Raj Paliwal

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meet our print production demand, so we needed a strong set-up in finishing to keep up with the new press. We believe post-press capacity should always be a notch higher so that we avoid any bottlenecks, or we are forced to reduce the printing machine’s speed, which is the more expensive proposition.”

The Bobst Novacut 106 E 3.0 version has some great new features and increased automation, which can enhance production, and reduce changeover times and machines stoppages. The Bobst Ambition 106 A2 has been installed with a collection table and corrugation attachment to fold and glue corrugated boxes as well.

Miraj’s partnership with Bobst started in 2013, when it was still relatively new in packaging and printing, and its post-press capabilities were not strong. Sharma said the Bobst team played a major role in the selection of products to match their needs. “Sturdy and robust machines, maintenance and after-sales services

are the key points to continue the journey with postpress specialists,” he added. “After all, it was the best investment of our money even in such tough times.”

According to Sharma, Miraj Multicolour has invested more than Rs 250 million in the calendar year. The investments include the folder-gluer and die-cutter from Bobst.

Miraj converts around 2,000 tonnes of paper, board and kraft every month, with a team of more than 400 staff in its 24/7/365-operation. Sharma noted that under the leadership and vision of the group chairman Madan Paliwal, the company is growing at a CAGR of 20%.

Today, Miraj Multicolour serves as a printing house with printing and packaging solutions from pre-press to post-press, with a production capacity of 20 to 25 million cartons per month and exercise book capacity of 350,000 per day. z

Monocarton

z VK GLOBAL ACQUIRES RAVE, TURNS INTO A PROFITABLE BUSINESS

Rave Scans installs Bobst Ambition 106 A2

D

elhi-based printing and packaging company Rave Scans has added a Bobst Ambition 106 A2 folder-gluer to increase its production capacity. The folder-gluer can handle most box styles, including four and six corner folding cartons, and light corrugated board.

A part of VK Global Group, Rave Scans is a fast-growing commercial offset printer, which was founded in 1993.

Over the past two decades, it has acquired several offset litho presses and bookbinding equipment.

In 2014, the company invested in a full-sheet X-Y scanner for quality control, along with new converting equipment from Bobst and other suppliers. At the same time, it entered into the rigid box segment.

“Rave Scans has always been associated with the best technology within each of its segments and our various Bobst installations have maintained that tradition,” said Namit Jain, director, VK Global Group. He added that the company already has a Bobst Novacut 106

E die-cutter with stripping and a Bobst Visionfold 80 A2 folder-gluer.

“In our short printing experience, we have gained insight into the premium quality of the Bobst machines.

With our expanding business, the expectation of timely delivery coupled with top-notch quality became our priority. So naturally, we decided to expand our inventory with another Bobst folder-gluer.”

Under the leadership of Rahul and Rohit Jain, VK Global Group was established as a publishing house, having over four decades of leadership in the area of economics and commerce. With the goal of diversification, the group ventured into another niche area of packaging to specialize in creating 3D effects using holographic films and fresnel lenses. The business offshoot, established in 2014, caters to the international market.

VK Global Group’s acquisition of Rave Scans in October 2018, via the National Company Law Tribunal resolution

proceedings, is its most recent business venture. VK Global has been successful in transforming Rave Scans into a profitable production house, promising structured and systematic growth by building a respectable clientele within the FMCG and pharmaceutical space.

The new management is a strong advocate of employing state-of-the-art printing technologies to help customers create a clear differentiation in an otherwise competitive marketplace. Combining its expertise across the board, VK Global has created a novel business capable of delivering completely recyclable end products by integrating Fresnel lenses and other holographic effects.

Rave Scans boasts a collection of excellent machinery in all aspects of production. Having created a name for itself in the packaging space, it converts about 200 tonnes of board each month for its packaging clients and an estimated 1,000 tonnes of paper in the commercial space. z

Namit Jain of Rave Scans; and Chandrashekhar Dhote, Bobst India

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Monocarton

z PRODUCTION CAPACITY TO REACH 7 BN PACKS PER ANNUM

UFlex invests in Heidelberg Intro Web technology

U

Flex, India’s largest multinational flexible packaging and polymer science company and the first Indian manufacturer of aseptic liquid packaging, has announced to double its Asepto plant’s production capacity from 3.5 bn packs per annum to 7 bn packs per annum. To achieve this, the company has decided to invest in a second printing line from the Heidelberg Web Carton Converting. This investment is part of its larger growth strategy in the liquid packaging space on the back of its ambition to expand its global footprints. Investing in the Heidelberg Intro Web printing technology is thus the first among many steps toward achieving its production capacity.

UFlex, established in 1985 and after becoming extremely successful in flexible packaging, it was time to diversify with offerings within the packaging business and aseptic liquid packaging emerged as an obvious choice for the scope of innovation in the segment.

The decision was taken and the greenfield plant in Sanand with 85,000 sqm packaging area and a current printing capacity to produce 3.5 billion packs per annum was commissioned. Now, the company aims at doubling the production capacity with the second printing line in the plant. Asepto plant, within a few years, has become a subject of interest in the Indian subcontinent. Therefore, it was necessary and a definite requirement to increase the existing capacity.

Asepto’s 200 ml aseptic liquid packaging printed on the Heidelberg Intro

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When the factory was completed, the investment was only in the latest technology and state-of-the-art machinery. One of the key-suppliers is Heidelberg Web Carton Converting, which delivered an Intro web-flexo printing press. The high-class machine prints 7 colors at a web-width of 1320 mm with a speed of 500 MPM for all packaging materials of Asepto products. The highest quality and reliability of the machine combined with the best performance parameters are proven facts of Heidelberg Intro.

Therefore, Intro was the first choice for the second machine as well. The new custom-built Heidelberg Intro will be installed this year and will double Asepto’s printing capacity.

Monocarton

The first Heidelberg Intro web flexo press at Asepto´s plant in Sanand, India

Ashwani Kumar Sharma, president and CEO, Aseptic Liquid Packaging, UFlex, says “Asepto is on a significant growth path. Heidelberg’s Intro Web-PrintingPress machine is the perfect fit to meet all our, and our customer’s requirements. Not only are the expectations for the machine, but also the seamless after-sales service factors makes Heidelberg Intro an ideal system to give a push to our growth plans. The partnership shared by the two market leaders over the years has created a win-win situation for both of us. Once the commissioning of the project is complete, we will be looking at global expansion. Asepto Sanand will certainly act as a benchmark.”

HEIDELBERG WEB CARTON CONVERTING

Ashwani Kumar Sharma, president and CEO, Aseptic Liquid Packaging, UFlex

Based in Weiden, Germany, Heidelberg Web Carton Converting (HWCC) is the webfed flexo press division of Heidelberger Druckmaschinen AG (Heidelberg). Providing integrated inline webfed solutions, HWCC complements Heidelberg’s market-leading position in the world of packaging. Utilizing the most powerful sales and service network in the industry and overseeing the biggest installed base in the market, HWCC provides the longest experience and broadest application know-how to enable packaging printers not only to cope with new challenges but also to exceed customer expectations. z THE PACKMAN | MAR-APR 2021

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Monocarton

z FACTORY-FITTED UV CURING SOLUTION

RMGT partners with GEW for UV LED

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yobi MHI Graphic Technology (RMGT) has announced the introduction of GEW’s LeoLED system as its factory-fitted UV curing solution for new sheetfed offset machines, with immediate effect. In pursuit of continuous technology improvement and after many months of assessment of all major UV LED manufacturers, RMGT formally adopted the high performance GEW product as its definitive new solution.

Katsushi Hirokawa, president at RMGT, explains, “RMGT is committed to building relationships of trust with customers, peripheral device manufacturers and all others involved in the industry. We continually work with our partners to refine and perfect technologies, and to bring innovative new products to the world of printing. Inspired by this corporate philosophy, we have pioneered LED UV and it is our in-depth experience and knowledge of this technology that has enabled us to make a sound judgment about our future UV curing partner.”

The foundations of this new partnership were formed in 2018, following GEW’s drive into the sheetfed offset market. GEW is well known for its performance in the label and narrow web arena. The expertise gained from 30 years in this sector, and experience supporting all the major machine manufacturers, provided a strong base from which to expand into the offset business. The 2019 introduction of GEW’s compact, high performance LeoLED UV curing system, which is perfectly suited to sheetfed applications, drew attention from RMGT’s distribution network and this ultimately led to the first test installation at the company’s headquarters in Hiroshima in early 2020. The LeoLED system was exhaustively tested on several presses, in multiple configurations and the results surpassed all existing performance criteria.

Robert Rae, managing director of sales at GEW, says, “This announcement affirms GEW as the leading supplier globally for UV LED curing systems. Our latest LeoLED system offers a very high power and is used

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The GEW LeoLED UV Lamphead is water-cooled with a compact 40 mm x 100 mm profile, and can be customized to seamlessly integrate into any sheetfed press

in one form for all markets and applications. This means that it is produced in high volumes, bringing outstanding reliability at a highly competitive cost. In a sheetfed environment, GEW’s Modular Lamp Array (MLA) allows any number of lamps to be positioned and quickly moved anywhere throughout the press.

This means the same LeoLED product can be used for

Typical configuration of a GEW LeoLED Modular Lamp Array (MLA) system is complete with a Rhino power supply unit, chiller unit and HMI touchscreen

low, medium and high-performance applications but arranged in single, double or triple MLA configuration dependent upon the application and speed requirements – always guaranteeing performance. It is this concept that appealed to RMGT, both for ultimate reliability and for the flexibility of configurations across their wide range of presses.” z

z NON-CONTACT GLUING FOR CORRUGATED

Baumer introduces FFG go

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aumer has introduced FFG go for glue application in flexo folder gluers. This latest member of the company’s ‘go’ product line offers simple, intuitive operation, but meets a variety of sophisticated demands on non-contact gluing in the corrugated industry. Developed for applications requiring gluing only, all the ‘go’ products achieve an excellent price/performance ratio. They give customers entry-level access to the world of Baumer and its products, in operation in thousands of systems around the globe, demonstrating their

capabilities and reliability every day. The FFG go is a perfect addition to this family.

The FFG go can operate 2-bead application heads based on DLK go technology for simple applications, or a 3-bead configuration based on P-500 technology for more demanding tasks. These multi-application heads can be flexibly adapted to customer requirements and are currently in use in over 1,500 flexo folder gluers around the world, according to Baumer.

Monocarton the gluing process – giving customers the option of applying dots or lines. Programming the individual glue beads via the intuitive menu-driven interface couldn’t be easier – or more reliable – for machine operators: All they have to enter on the touchscreen is the top flap dimensions and the flap length. The Xact FFG go also supports gluing on angled or slotted flaps.

The Xact FFG go controller is the heart of the FFG go solution from Baumer for adhesive application in the corrugated industry.

Programming the individual glue beads via the new controller’s intuitive menu-driven interface couldn’t be easier – or more reliable – for machine operators.

The heart of the system is the Xact FFG go controller, backed by the latest software and hardware technology. Its range of functions is geared entirely to

With its Glue Save mode, the FFG go further ensures sustainability and cost efficiency. This function converts the system from continuous to intermittent gluing, which can reduce adhesive consumption by up to 50%, without compromising the adhesive strength of the glued areas.

“With the Xact FFG go, machine operators can limit setup to the most essential settings, but they don’t necessarily have to, because the new controller gives them the option of entering any additional settings required for a production order in subsequent menu levels. When it comes to programming glue patterns and parameters, the Xact FFG go basically offers all the functions of our higher-end Xtend range,” says Andreas Schneiders, corrugated business development manager at Baumer. z

With the FFG go, customers have a choice of application heads from Baumer for applying two or three glue beads. They offer corrugated board manufacturers all the technical and economic advantages of non-contact gluing.

z LOW ODOR AND LOW MIGRATION

Toyo launches GMP-compliant offset inks for food packaging

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oyo Printing Inks has brought to market the LP-9000 Toyo Life Premium Food LO/LM, a new series of sheetfed offset inks with low odor and low migration characteristics.

Engineered and manufactured in accordance with EuPIA (European Printing Ink Association) guidelines and the GMP (Good Manufacturing Practices), the LP-9000 LO/LM product is suitable for use in printed packages for the food, cosmetic, pharmaceutical, and other sensitive applications. This new low-migration offset series has been specially formulated for printing on the non-food contact surface of paper and cardboard media.

agents. Instead, drying is achieved purely by substrate penetration without releasing any hexanal while drying, resulting in reduced odor intensity.

According to the company, the LP-9000 LO/LM ink series is composed of raw materials from plant and renewable sources, which do not contain any drying

Rukiye Kiter, offset R&D manager of Toyo Printing Inks said, “We are extremely pleased to announce our latest food packaging innovation that complies with all

The new LP-9000 LO/LM inks have passed migration testing based on EU Regulation No 10/2011 and have been certified by the Germany-based ISEGA Institute.

In addition, they adhere to the regulatory requirements of EC 1935/2004, EC No 2023/2006 and all national and international regulations within the scope of the Swiss Ordinance (Nestle Guidance Note on Packaging Inks) and the EuPIA Exclusion Policy for Printing Inks and Related Products.

applicable packaging material legislation in Europe.

The LP-9000 Toyo Life Premium Food LO/LM series was designed and produced with food safety in mind at our Manisa R&D Centre. We also worked with the national science and technological research agency TUBITAK on R&D projects that focus on our common vision of delivering innovative food packaging solutions through advanced science. TUBITAK was influential in facilitating the practical application of Toyo Printing Inks’ new ink systems to the global market, in particular the EU. This is important as we look to make greater inroads in strategic markets in Europe.” z THE PACKMAN | MAR-APR 2021

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Flexibles

z AN INTERVIEW WITH FLAVIO LOSA OF ROSSINI

Rossini revolutionizes gravure printing

R

ossini confirms its technological leadership and launches a highly innovative solution in rotogravure printing. The large Italian manufacturer of rollers and sleeves has found the alternative to the hexavalent chrome coating of printing cylinders by finalizing a research and development work personally supervised its president Felice Rossini over the last ten years.

Rossini confirms its technological leadership and launches a highly innovative solution in rotogravure printing

The chrome surface of the printing cylinders guarantees today the high quality of the work carried out with this technology, but at the same time generates environmental and health problems, so much so that the competent authorities will prohibit its use within a few years.

The solution developed at Rossini is called Ecograv System and replaces the copper and chrome cladding with a special polyurethane-based technopolymer that has passed all the tests of quality and machinability on industrial lines, and can be engraved electromechanically. Moreover, Rossini has developed and built the production plant to make the new type of cylinder, or rather a complete and automated line, which starts from the raw material to be ‘poured’ on the roller to reach the product ready for engraving. For the spring of next year the pilot plant will be in operation at the manufacturer’s Technology Center, where customers will be able to verify the prerogatives and performance of the system. The Gerosa Group – development partner of the project – has already signed the purchase commitment for the supply of the first Ecograv System.

ICR, a well-known supplier of rotogravure cylinders, has also supported the development for the engraving part.

Here is how engineer Flavio Losa, Rossini, presents it, in preview in converting.

AT THE BASE OF THE SYSTEM, THE CYLINDER...

Dr. Losa, as often happens, also at the origin of your project there was a problem to solve - in this case find a new type of

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coating, alternative to chrome, for the rotogravure printing cylinder. Why is this so important?

The rotogravure cylinder has a steel core and engraved copper coating, and ultimately a hexavalent chromium protection. The latter has a surface hardness of 1000 – 1200 Brinell. Even without being an expert we can understand the importance of this data if we compare it with the hardness of a doctor blade, which is around 700 Brinell: since the function of this coating is first of all to protect the roller from the rubbing of the doctor blade, extending its life and preserving its characteristics, the effectiveness of chrome is evident. But that’s not all. Having many open bonds, chromium 6+ has a superior uniformity, which allows the management of a particularly well defined and constant layer. All these characteristics together ensure the perfection and durability of the engraving.

What material is the alternative coating developed in Rossini Spa made of? And how does it behave?

It is a polyurethane-based technopolymer, pat-

ent pending, conductive and, of course, grindable. It has an extremely low surface roughness value, not far from that of chrome, and above all it can be engraved electromechanically. This data is particularly important because until now the experiences made on plastic compounds involved laser engraving. However, there are very few laser machines on the market: almost all engravers work with electromechanical systems. So our goal was to develop a cylinder that could be engraved by everyone, without having to change technology, and we succeeded. This does not exclude the fact that in the near future Ecograv will be able to be engraved using laser technology.

So the novelty is not only about the coating...

That’s right: it is rendered by a set of elements including materials, engraving techniques and equipment involved that do not negatively impact the health of operators and the environment. The new polymer at the base of the Rossini Ecograv System, once removed, can be disposed of in exactly the same way as segregated plastic household waste.

Flexibles AN AUTOMATIC AND ‘CLEAN’ PRODUCTION LINE Ecograv System also includes the line to produce the new cylinder. What is the line-up?

The production line consists of a station where the distribution, i.e. the deposit, of the new polymer that is cast on the user’s roller (casting station) takes place, followed by the part of the line where the heat treatment takes place that helps to stabilize the crystalline structure of the product. Finally, grinding and smoothing are carried out. The roller is then ready for engraving.

Felice Rossini, president, Rossini Spa

Had a solution of this kind ever been developed before?

No, we are the first.

To test the performance of the new cylinder you have involved a very well equipped engraver and converter. With what results?

Firstly we carried out the tests on our small single color rotogravure machine that we installed in our research center and we printed 370,000 m of printing with a 12 micron polyester. With a cruising speed between 200 and 250 m/min and standard recipe, with a very normal steel doctor blade and roto inks on ethyl acetate base, without any problem. To our and our partners’ full satisfaction, we have obtained a very high quality high definition image with a uniform ink density throughout the entire print run. But that’s not all: the constancy of the ink transport is correlated to the fact that even the cells empty evenly, quickly and without large residues on the bottom. The printing dot is better: perfectly round, without any dragging thanks to the doctor blade. Of course we did the calibration curve for the engraving, which allowed us to obtain an absolutely level tone gradient and, overall, results equivalent or above those of a standard chrome-plated steel roller.

Coming developments?

We will soon start the most difficult tests. Gerosa will print a 7-color subject with all the most challenging difficulties: solid background, barcode, Arabic wordings, fine and coarse detail and a number of pantones.

A challenging job, which will verify both print quality and production output.

What advantages does this bring?

It is a highly automated and simple to use process, with a modular structure, which generates a roller ready for mechanical engraving, a shows the overall advantage of the new solution: it not only responds to the need to replace the hexavalent chromium, shortly to be banned, but also an alternative to a highly pollutant production system that is also expensive to manage at various levels, not least that of the healthiness of the working environment and the disposal of toxic substances used in traditional processing.

MDC GAMUTSTAR

And on an economic level?

The cost of the Ecograv print cylinder will be competitive with the current standard and will use the converter cylinders. Of course it will require a new diameter management, because our coating is 2 mm.

A printer’s cylinder magazine contains thousands or tens of thousands of parts so there will be no difficulty in finding the correct diameter for each job.

But you also need to calculate the plant investment....

The matter of ROI, as everybody knows, must be contextualized and accurately calculated, data and variables to hand. The entire Ecograv System line at the most takes up the space of a galvanic line, and requires a lower investment than a traditional process, in addition to presenting a simplicity of management that makes it a truly ‘user and environmental friendly’ process. Suffice it to say that it does not require permits for emissions or periodic medical analysis of the health of the personnel, and above all it eliminates all the problem of the management of galvanic baths, wastewater, chemical products. z THE PACKMAN | MAR-APR 2021

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Flexibles

z YANSEFU’S CUSTOMIZED POLYURETHANE BINDERS AND RAW MATERIALS

Is vinyl printing ink market shrinking in India?

T

he Indian flexible packaging market has seen expeditious growth within the past few years and has estimated potential to grow approximately to a value of INR ~ 640.38 billion

by FY 2023, up from its FY 2017 value of INR 375 billion, expanding at a compound annual growth rate (CAGR) of ~10% from FY 2018 to FY 2023.

This is predominantly due to increase in demand and sales of FMCG goods – the fourth-largest sector in the Indian economy representing huge opportunity for flexible packaging – and sub-categories such as food and beverage industry, pharmaceutical industry, personal care industry, and material (plastic, paper, and aluminum) among others. Another major reason for the growth of the Indian flexible packaging market is the increased use of food-service outlets and beverages in India.

The printing ink resins market is experiencing moderate growth which is expected to continue in the near future, mainly driven by the highly growing Asia-Pacific regions. Characteristics include solvency, good flow, remarkable gloss, resin stability, dilutability, and provides good surface appearance and ink performance – these will be the key influencing factors for the global ink resins with an increased emphasis on its different applications and ink resins types.

The Indian printing ink industry has also been growing proportionally with the increasing growth of the Indian flexible packaging. Among different resin systems, the vinyl-based printing inks hold the largest share of nearly about 70-80% of the flexible packaging. Since Poly Ethylene Terephthalate (PET) film is the most frequently used substrate in the multi-layer packaging of the products including food and beverages, personal care and others. The vinyl-based printing inks are proved to be the most suitable printing ink option for PET films, as vinyl resins are versatile,

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compatible and inexpensive due to their solubility in solvents like toluene.

Ethylene Vinyl Acetate Co-Polymer resin is the most extensively used vinyl-based resin in designing the vinyl-based printing inks. Traditionally, in Indian and Asian subcontinents, Vinyl acetate-Vinyl Chloride-vinyl alcohol terpolymer (popularly known as vinyl resin) and Ethylene Vinyl Acetate (EVA) based inks are known as vinyl inks. Vinyl resin aids in pigment grinding and EVA (Ethylene Vinyl Acetate) assists in promoting the adhesion of the printing ink. One of the major characteristics of vinyl resin is that it is soluble in toluene.

A co-polymer of Ethylene and Vinyl acetate, Ethylenevinyl acetate or EVA is an extremely elastic and tough thermoplastic owning characteristics such as excellent clarity and gloss and with little odor. EVA possesses many attractive properties including low cost, excellent adhesion to many polar and nonporous substrates.

This thermoplastic resin with low melt index (MI) offers high strength, superior viscosity, good flex-crack and puncture resistance and hot tack (relative melting and bonding strength) and heat sealing as compared to its high melt index counterparts. EVA co-polymers containing about 10% to 30% vinyl acetate, with the remainder being ethylene, are used for innumerable applications in the packaging and plastic goods industries.

Basically, there are three different types of EVA copolymer, which differ in the vinyl acetate (VA) content and the fashion the materials are used. The EVA co-polymer having a low proportion of VA (nearly up to 4%) may be referred to as vinyl acetate modified polyethylene, which is processed as a thermoplastics material – just like low-density polyethylene. It contains

some of the properties similar to low-density polyethylene but increased gloss (useful for film), softness and flexibility. The material is generally considered non-toxic.

The printing ink resins market is

experiencing

moderate

growth which is expected to

continue

in

the

near

future, mainly driven by the highly growing Asia-Pacific regions. include flow, resin

Characteristics solvency,

good

remarkable

gloss,

stability,

dilutability,

and provides good surface appearance

and

ink

performance – these will be the key influencing factors for the global ink resins with an increased emphasis on its different applications and ink resins types.

Flexibles In India, Ethyl vinyl Acetate-based Copolymer resins are colossally imported from countries including China, France, Europe, UAE and others for manufacturing printing inks, particularly for FMCG applications to a large extent. Elvax 40 W by Jotun UAE Ltd, Evaflex EV40 W by Mitsui & Co. Ltd and Evatane; Grade 42-60

by Arkema France are the known brands consumed by the printing ink manufacturers. A large quantity of these EVA resins is imported to India. Japan, France and UAE are the largest exporters of EVA based resin worldwide. Nearly, 272 MT of Evaflex EV40 W, 220 MT of Evatane; Grade 42-60 and 30.35 MT of Elvax 40 W are imported to India every year.

The major issues associated with vinyl resins are many.

Vinyl-based printing inks (approximately 70 to 80%) are majorly toluene-based inks. But, the circumstances are straightway changing due to the new updates in Food Safety Regulations and standards in India. In July 2020 BIS revised the IS 15495 for printing inks for food packaging applications and included toluene in the negative list called Annexure A. This means that the toluene-based printing inks are no longer allowed to be used for food packaging applications. Technically, these vinyl inks are suitable for PET substrates and BOPP films, it requires additional additives that are added during the printing process; it not only involves costly imported material but also the availability of these additives these days. Besides, vinyl inks are limited performance in the medium-high, and highend lamination and packaging requirements due to inadequate lamination strength and other post-print requirements. Another issue linked to vinyl inks is their low performance at higher printing speeds, thereby limiting its use in high-end printing machines.

Today, the printing ink manufacturers are shifting towards polyurethane-based printing inks as an alternative. Generally, polyurethanes have three basic building blocks a polyol, diisocyanate and the chain extender. They are versatile polymeric compounds formed by reacting a polyol (an alcohol with more

than two reactive hydroxyl groups per molecule) with a diisocyanate or a polymeric isocyanate in the presence of suitable catalysts. The properties of the polyurethanes are determined with the segment flexibility, chain entanglement and inter-chain forces. The following factors affect the properties of the polyurethanes- molecular weight, intermolecular forces, blocking units. PURs can be designed to range from very hard to soft to tacky.

The molecular weight of the polyurethanes is one of the most important characteristics. As the molecular weight varies, the properties of the polyurethane resin change. Intermolecular forces between the polymeric chains is another factor that greatly influences the nature and properties of the polyurethanes. Further, polyesters and polyethers are usually two types of building blocks that also determine the properties of these polymeric compounds. Polyethers, on the other hand, provide good elasticity, flexibility and in-can stability. Polyesters provide toughness good weathering, good abrasion resistance and chemical resistance. Last but not the least, the variety of isocyanate used for formulating the PUR is also crucial. Usually, aliphatic isocyanates improve hydrolytic stability and resist UV degradation.

Since a range of diisocyanates and polyols can be used to produce polyurethane, a broad spectrum of materials can be produced to meet the needs for specific applications. For instance, for retort or highend lamination packaging where the packaged food is subjected to high temperature while microwave cooking, PUR resins that can provide high heat resistance and bond strength and have the ability to grind pigments without any hard resins such as nitrocellulose under such challenging conditions are required. In such conditions, nitrocellulose based inks having the potential to promote the formation of nitrosamines when subjected to high temperature cannot be used.

The various performance requirements of an ink, packaging design and end-user application often demand that the ink maker utilizes two or more resins in a formulation to be successful. For example, nitrocellulose/polyurethane, nitrocellulose/ acrylic, PVC derivatives, PVB and polyamides are some simple generic examples of the resin systems required to meet the demands of the converters and brand owners.

Basically, there are three different

types

of

EVA

copolymer, which differ in the vinyl acetate (VA) content and the fashion the materials are used. The EVA co-polymer having a low proportion of VA (nearly up to 4%) may be referred to as vinyl acetate modified

polyethylene,

which is processed as a thermoplastics material – just like low-density polyethylene.

It contains some of the properties similar to lowdensity

polyethylene

but

increased gloss (useful for film), softness and flexibility.

The material is generally considered non-toxic.

However, it becomes highly inconvenient and confusing to both the ink manufacturer and converter as well to maintain a large inventory of various resins and inks to solve the myriad of customer demands. Nonetheless, this is not an issue with polyurethane resin since they can be customized based on the requirements. In recent years, urethane polymers have received intense attention in the ink, coating and adhesives industries, resulting in the synthesis of many specialized forms.

Further, polyurethane-based printing inks provide better bond strength in multilayer packaging, enhanced printability even at high-speed printing presses, affinity to different types of substrates, lamination compatibility with both solventless and solvent-based adhesives. These inks are also suitable for the extrusion lamination process. PUR are easily soluble in both aromatic and non-aromatic solvents.

As the Indian printing and packaging industry has been shifting to toluene-free printing, PUR based inks are emerging as the most suitable option among other resin solutions available.

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17

Flexibles And unlike solvent-based adhesive laminations, they also do not require much energy to dry. However, the chemistry of the solventless adhesives introduces the challenge of smearing the print. Polyurethane resins that provide greater resistance to solventless adhesives will make for a more robust ink system.

Along with toluene-free printing inks for food packaging, another factor that influences the growth of polyurethane resins is the rise in the utilization of solventless adhesives in the lamination process and the evolution of high-speed presses. Solventless adhesives contribute in reducing VOC emissions.

YANSEFU’S CUSTOMIZED POLYURETHANE BINDERS AND RAW MATERIALS Yansefu designs and manufactures customized polyurethane binders and raw materials at their in-house

production facility for designing high-performance cost-effective and innovative printing ink and adhesives to accomplish the customer’s specific requirements.

Most of the indigenous polyurethanes developed at Yansefu R&D, have been protected through patents.

Yansefu develops its ink technology to the highest standards of product safety. At Yansefu, the team focuses more on its customer’s and market requirements. The dedicated sales and technical team constantly monitor the current and future trends that eventually help us to understand the needs better and develop the most optimum commercial and technical solutions possible. z

– JK Sharma, CEO; and Neelakamal Mohapatra, VP, R&D, Yansefu Inks and Coatings

z SARJOADD-HDA

Yansefu introduces innovative bio-based regulatory compliance pigment dispersant

C

ontinuous price fluctuation of crude oil and eco-friendly approach has stimulated the development of products from renewable resources as an alternative; among which, vegetable oils are one of the most preferred because they are easily available, sustainable, and cost-effective. India is a major source of various vegetable oils. The anticipated vegetable oil production from 45.64 million tonnes of oilseeds in the year 2022 is 13.69 million tonnes. Thus, efforts are being made to achieve a renewable approach via the utilization of vegetable oils as a fundamental material for the synthesis of raw materials.

High molecular weight pigment hyper-dispersants with a molecular weight greater than 1000 Daltons and flexibility towards application into different binder and pigment-based printing ink formula-

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tions are particularly suitable for food packaging application.

Keeping this in mind, the R&D team of Yansefu recently developed a high-end hyper-dispersant SARJOADDHDA primarily aiming at various ink systems including polyurethane-based inks for gravure and flexographic applications. SARJOADD-HDA is intended to provide a strong attraction for pigment surfaces and stabilizes against re-aggregation of the dispersed pigment particles.

This hyper-dispersant uses cutting-edge dispersion control technology which can stabilize both organic and inorganic pigments from flocculation and thereby increases the shelf life of inks. It also supports stabilizing a narrow and uniform particle size distribution of pigments inside the ink matrix, which improves the ink printability.

SARJOADD-HDA is a biobased regulatory compliance pigment dispersant by Yansefu

“Innovation and sustainability should go in parallel and our team is fully determined to meet these challenges.

Focus on sustainability and development of regulatory compliance products is in the DNA of Yansefu,” says JK Sharma, CEO, Yansefu Inks and Coatings. z

Flexibles

z NEWER TRENDS IN THE PACKAGING INDUSTRY

Impact of web offset technology in food and beverage sector

T

he organized food and beverage industry in India, valued at INR 400,000 crore (2019 figures), is expected to grow to INR 10,00,000 crore by 2025 fueled by growing population, increased urbanization and higher standard of living. The pandemic, on top of that has proved to be a blessing in disguise as the emphasis has shifted more towards ordering through eCommerce portals and home delivery. There is a growing demand for hygienic and tamper-proof packaging with higher shelf life.

Lifestyle change is impacting the type of food we consume – people are shifting more toward packaged foods that can be easily consumed on the go. Because of this, brands are required to respond effectively by

Reel printing vis a vis sheet printing

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providing options that can stand in for breakfast, lunch, and dinner including for those smaller in-between meals. Snack-size bags of chips and variety packs with different flavored snacks are more prominent at events and occasions, allowing flavor and proper portion to match the taste of everyone in the guest list. Packaging is driving the change.

As per Mckinsey’s report (9 May 2019), the top five trends that are reshaping the packaging industry are – eCommerce, changing consumer preferences, FMCG and retail-margin compression, sustainability, and digitalization and Internet of Things (IoT). Preparing for these changes requires new ways of thinking – ‘intuition resets’ – about a packaging company’s focus and market approach.

This rising concern of the environmentalist and the drive towards circular economy principles has made the packaging industry focus on plastic waste that has come under particular scrutiny because of its non-biodegradability. Appropriate steps need to be taken to make the packaging industry more sustainable. As sustainability has become a key motivator for consumers, brands are increasingly keen on packaging materials and designs that demonstrably show their commitment to the environment.

As a preferred substrate, paper and board will continue to benefit from eCommerce growth and are ideal for integrating digital and IoT solutions (using quick-response codes, radio-frequency-ID tags, nearfield-communication protocols and so on). Today,

Flexibles per margins (leading to a savings of 0.8-1.8 % depending on repeat length).

– Reel printing can have an output either in the form of a rewound reel or sheet, hence giving rise to more flexibility especially in post-printing operations like blanking, punching, die-cutting etc.

LOW PRESENCE OF WEB OFFSET IN PACKAGE PRINTING – WHY? Well, the answer lies somewhere between the lack of interest amongst major OEMs of web offset (due to erstwhile ever-growing newspaper/commercial print sector) to adaptation of the technology to suit the needs of printing on heavier substrates.

WHAT ARE THE OPTIONS AVAILABLE TODAY? The Varioman c:line by manroland Goss web systems is one such option available today. Launched in 2018, it has established a foothold in two leading printers in Europe and is sure to go a long way in changing the dynamics in the packaging printing world.

AUTOMATION Automation is an important consideration today as IoT and conformity to Industry 4.0 has become imperative.

Varioman has a unique feature PECOM -X, an automation system that structures the entire networking and automation offer into clearly organized product groups for the five core competence workflow sections – from evaluation via networking and operation up to the production process and its control.

THE ROAD AHEAD paper- and board-based packaging – be it pizza boxes, milk/juice cartons or delivery boxes – are printed on sheetfed offset presses. With the increased volume, printers face a dilemma on whether to invest in more lines, newer plants or to let go of high volume orders.

Some of the difficulties faced by the printers using sheetfed technology are: – Speed restriction up to 18,000 sheets per hour.

– Less flexibility in size due to fixed cut-off of cylinder.

– Multiple lines lead to the need for more manpower.

– Huge warehousing space required to store pallets of card/paper.

HOW DOES WEB OFFSET DEAL WITH THESE DRAWBACKS? Web offset as a technology has always been a highspeed one compared to sheet offset printing. Press speeds up to 400 m/minute result in a direct advantage of 180 to 200% higher productivity. Web offset reels have quite a few inherent advantages compared to sheets. For example: – They can be stored vertically, one on top of the other and do not require pallets.

– The price is less compared to sheets as the reels can be transported directly without any need to cut them further into sheets.

– Paper savings during production due to no grip-

Even when the pandemic is over, we are bound to face what some would like to call ‘the new normal’.

The world would change and so would the industry as a whole, and the F&B sector in particular. The packaging industry must also change to keep pace with it. So it would become imperative for the players to look for a solution that brings about cost efficiencies, economies of scale and newer product innovations while maintaining the highest standards of health safety protocols. z – Sudeep Bhattacharjee, managing director, manroland Goss web systems (India) THE PACKMAN | MAR-APR 2021

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Flexibles

z PACKAGING TECHNOLOGY FOR ELECTRONICS INDUSTRY

EcoCortec introduces compostable electrostatic dissipating anti-corrosion film

E

coCortec has introduced the world’s first Eco-Corr Film ESD – biodegradable, compostable static dissipative films and bags powered by ‘Nano’ VpCI. The latest film technology is targeted mainly for electronics, telecommunications, packaging, and electric car industries seeking environmentally friendly packaging solutions. In anticipation of new EU regulations penalizing sales of non-recyclable plastic packaging materials, EcoCortec is offering commercially compostable alternative to conventional polyethylene electrostatic dissipating (ESD) films.

According to the company, Eco-Corr Film ESD products are high performance anti-static, corrosion inhibiting films and bags intended for disposal in a commercial composting environment. They are designed for use in the protection of static sensitive multi-metal items such as electronics.

The film contains permanent anti-static properties to immediately reduce or eliminate static buildup as long as the films or bags are in use, independent of the presence of humidity. Eco-Corr Film ESD forms a molecular corrosion inhibiting layer on metal substrates and does not interfere with the physical or chemical properties of electronic components. The film and bags replace conventional rust preventatives such as oils and desiccants and allow the film to be used immediately without cleaning or degreasing.

Eco-Corr Film is commercially compostable, meaning that when the film is placed in a typical commercial composting environment it will disintegrate within months. The exact time is dependent upon the conditions and activity of the disposal environment (temperature, soil quality, activity of microorganisms). Eco-Corr Film ESD is shelf stable and will not break down prematurely until disposed of in a proper composting environment.

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Engine parts wrapped in EcoCorr film

Flexibles A Czech subsidiary of one of the world’s three largest car manufacturers, selected Eco-Corr Filmas a biodegradable substitute to reduce the amount of conventional plastic packaging they use. They tested Eco-Corr Film as part of their new ‘green’ logistics project aimed at decreasing plastic consumption.

Eco-Corr Film was tested as part of the pilot project of packaging car parts for shipment to their plant in Pune, India. Several tests were conducted for compliance with strict conditions for transport in sea containers. Quality control did not show any damage or traces of corrosion on the components wrapped in Eco-Corr Film upon arrival in India.

EcoCorr extrusion

In order to test if the film were able to be composted according to plan, the staff built compost bins near the plant. After six months, the foils had largely disintegrated in the compost bins, helping them to eliminate plastic waste. Eco-Corr Film successfully replaces conventional plastic films they used previously and provides the same effective corrosion protection. Composted packaging material will be used as soil improver at the plant’s logistics park. Manufacturer was able to cut the amount of conventional plastic packaging in half thus eliminating a significant amount of plastic waste (as much as 500 kg per month). z

z RESPONDS TO HEAT BY EMITTING AEROSOL PARTICLES

Toppan develops fire extinguishing film for lithium-ion batteries

T

oppan Printing, a global leader in communication, security, packaging, decor materials, and electronics solutions, has developed a fire extinguishing film that responds to heat by emitting aerosol particles. This new film is an addition to Toppan’s ‘Smart Life-Value Packaging’ lineup, which is part of the recently launched ‘Toppan S-Value Packaging’ range targeting added value for society and fulfilling living. The fire extinguishing film is on sale from February and targeted at manufacturers of batteries and electrical appliances.

With applications for rechargeable batteries expanding to such fields as mobile devices and mobility, lithiumion batteries are becoming more widely used and offering higher power levels. However, this increases the risk of fire-related accidents, not only during use but also after disposal. Toppan has combined its advanced coating technologies and transparent vapor-deposited GL Barrier film with a highly effective fire extinguishing agent from Yamato Protec Corporation to produce an

adhesive film with outstanding long-term durability and workability.

Toppan’s fire extinguishing film is highly effective in extinguishing fires at an early stage or preventing their spread in the event of equipment problems or short circuits. It is lightweight and compact, meaning it can be used with ease in enclosed spaces and locations in which there is a fire risk. Potential applications include attachment to the inside of lithium-ion battery cases, switchboards and power distribution equipment, outlet covers, or waste containers at public facilities. The film uses no substances that pose a risk to humans or the environment and produces no harmful gases when it is activated.

The film works by filling an enclosed space with fire extinguishing aerosol particles in response to the heat generated by a fire. The aerosol particles extinguish the fire through negative catalysis. This makes it an effective solution for putting out fires promptly and

containing their spread to prevent further damage.

“This film enables greater fire safety without any negative impact on people or the environment,” said Yoshimitsu Anamizu, managing executive officer of Toppan’s living & industry division. “We intend to develop more products based on this technology to contribute to accident and disaster prevention and a safer, more sustainable society for everyone.” z THE PACKMAN | MAR-APR 2021

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Labels

z AN INTERVIEW WITH YOGESH KAPUR OF UFLEX

UFlex Holography Business brings unique anti-counterfeiting and brand enhancement solutions DEV KUMAR DUTTA

U

Flex’s holography business developed a range of new products recently. Its R&D team has been working constantly to produce holograms with new and unique security features. More recently, the holography business won five awards at SIES SOP Star Awards 2020. “There are multiple technologies we are working on,” said Yogesh Kapur, executive vice president, holography business, UFlex, during our recent visit to the holography plant in Noida. With a current production capacity of 60 crore hologram per month, the holography business plans to add more capacities as it acquires more clients.

Kapur said, “Holography has come a long way in the last two decades. You might still call it a hologram but the hologram is not the same hologram that was 20 years ago. Today, a hologram is far more advanced with multilevel security features. For example, hybrid holography is one unique development where we have combined multiple masters, and along with printing and chemical technologies combined, we have made it very unique and very difficult for counterfeiters to replicate. We have not seen this technology being counterfeited yet.”

Like its other group businesses, UFlex’s holography business is always ahead of the curve when it comes to innovation and new product development. The holography business has been contributing vastly to the anti-counterfeiting market for the last many years.

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Yogesh Kapur, executive vice president, holography business, UFlex.

Photo: The Packman

Today, what makes UFlex a strong value proposition as a total packaging solution provider is the ability of its businesses to work in close coordination with each other by extending their respective expertise to produce holistic packaging solutions for its clients.

aluminum lidding foil commonly used for blister packs.

The holographic foil has overt features that are easily recognizable to the end-user. The foil also allows the use of covert features on this solution lending authenticity to pharma company drugs.

HOLOGRAPHIC ALUMINUM LIDDING FOIL FOR PHARMA INDUSTRY

HOLOGRAPHIC THERMAL FILM FOR BOOKS AND PUBLICATION

To arrest the counterfeiting threats in the pharma sector, UFlex’s holography business developed robust anti-counterfeiting solutions through holographic

The publication industry is one of the worst victims of counterfeiting where duplicators impinge sales by undercutting price and damage authentic brand reputation. In order to address publications’ concern,

Labels

One of the multiple Gallus label presses at UFlex’s holography plant

an eco-friendly transparent holographic thermal film was developed for lamination on book covers that besides protecting it from counterfeiting, also boosts the aesthetics with excellent gloss on the book, enhances cover transparency and fosters good bond strength.

HOLOGRAPHIC FILM FOR GHEE PACKAGING Ghee is a part of daily consumption in every household and is highly prone to counterfeiting. To fight the menace of duplication, UFlex has developed a customized holographic film for outer carton packaging replacing the use of plain metalized film laminated cartons for a prominent ghee brand thereby helping differentiate pure ghee from the fakes. Anti-counterfeiting features are ingrained in this film’s design, such that it not just prevents it from counterfeiting but also offers a unique look to the carton and adds shelf impact.

ECOMMERCE, REVERSE LOGISTICS AND FRAUDULENT RETURNS A huge challenge that eCommerce companies are

facing today is reverse logistics. Fraudulent returns are a serious concern for retailers. “With counterfeiters becoming more and more sophisticated, eCommerce companies are looking for solutions that can be incorporated as an anti-counterfeiting feature which can only be read by retailers at their end to identify whether the product is genuine. We embed hidden transcripts in these holograms – these companies can identify whether the product returned is an original product by using a certain method. These challenges are unique, so we have to get ahead of the curve,” said Kapur.

CHALLENGES AND CHAMPIONS Innovating new security features and successfully commercializing it is not always easy though, said Kapur. “There are numerable challenges. For any new technologies to be successful, you need champions.

People, almost 80%, don’t accept new technologies instantly. They take their time and see others using the technology instead. But there are those 5 to 10% who accept new technologies, go ahead and become the cheerleader – they are the ones championing it. That is when the ball starts rolling. We have identified those

champions, whom we are pushing our innovations to.

These champions are from multiple fields – liquor, garments, lifestyle, cigarette, etc., where people are very concerned about counterfeiting because it affects their brand.

BACKWARD INTEGRATION UFlex uses advanced technologies and specialized equipment to produce holograms. The company possesses in-house capability of offering packaging solutions for premium-category products. “In-house technology and backward integration are the pillars of our strength. We make our own polyester, we have our own metallizer, printing lines, lab, and R&D facility – everything we do is done in-house under a highly controlled environment,” said Kapur.

Speaking about sustainability, Kapur said, “Sustainability is not big an issue in the holography industry because here the value of the product is high but the quantum of product used is less. However, from a corporate point of view, we are very concerned and focused on making sure that all products we produce are environmentally sustainable.” z THE PACKMAN | MAR-APR 2021

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z SOLD OUT TILL JULY 2021

Nilpeter India ships 30 label presses in FY-Covid

T

he Covid year has been quite exceptional for Nilpeter India. “We have received a good number of orders from both overseas and India markets. Currently, we are completely sold out till July 2021. By the time we close our sales in March 2021, we expect to ship around 30 presses of which about a dozen presses will be shipped within India,” said Manish Kapoor of Nilpeter India.

Today, Nilpeter India is the global hub for the FB series which is manufactured only in India, as production in the US was discontinued in 2017. Earlier, the FB series was manufactured both in the US and India. After years of successful operation in India, the Danish printing press manufacturer opened a new manufacturing and development facility in Chennai, India. The 3,500 sqm modern building houses manufacturing and assembly lines, R&D environment, Customer Care Center, and a large Technology Center.

ALREADY A SATURATED MARKET On being asked about the prospect of commercial printers diversifying to the label industry, Kapoor said, “There has been a lot of interest among commercial printers to move to the label segment because the commercial print market has become highly saturated. Besides, the pandemic has hit them the most since during the lockdown they were not allowed to operate their plants for not being covered under the essential services sector. Even after the lockdown, many commercial printers today are facing problems in meeting their operational expenses, thanks to the highly saturated market.”

Kapoor added, “In an ideal world, commercial printers should definitely look at diversifying to the labels segment, and likewise, existing labels players should look at further diversifying to other packaging segments like flexibles, etc. However, it is easier said than done

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“People have to find newer segments,

niche

markets,

and develop new markets at the same time because if you continue to feed on the same pie, then at some point of the time somebody will have to go hungry.”

Manish Kapoor of Nilpeter India

because everything needs preparation, homework, and money. And on all these three counts, the pandemic has not helped at all. Although it has given time to people to reflect upon things and their future, it has also drained their resources in terms of money. So yes, it is a challenge for commercial printers to just get up one fine morning and start printing labels. It is not so simple because the label market, as everybody knows, is already saturated in India. But people have to make effort and develop new markets – that is the only way forward. There is no other way out.”

TAKE THE PLUNGE WITH EYES OPEN “A lot of commercial printers have been talking to us.

We have even sold our presses to a couple of them.

Of course, these commercial printers were not new to the label market. They were already printing labels on sheetfed presses and already had substantial clients to cater to. So, they had just shifted from sheetfed to

flexo. As responsible salesman, we have to guide them correctly so that they can take the plunge with their eyes open. Nobody should assume that if they invest in a machine, they will have plenty of jobs from day one.

I strongly recommend to my prospects and customers that until and unless you have a substantial amount of assured business in your hand, you should think, and think twice, before investing your hard-earned money in a new segment,” said Kapoor.

INDIAN LABEL INDUSTRY – STREAMLINING LONG DUE Kapoor feels that streamlining the Indian label industry is long due. He said, “Everyone needs to pull up their shocks as it is a very competitive market and is about the survival of the fittest. People have to find newer segments, niche markets, and develop new markets at the same time because if you continue to feed on the same pie, then at some point of the time somebody will have to go hungry.” z

Labels

z GALLUS GROUP REMAINS WITH HEIDELBERG

Sale of Gallus Group to benpac holding fails

T

he sale of the Gallus Group by Heidelberg to the Swiss company benpac holding ag has not been completed. benpac holding did not make the purchase price payment of EUR 120 million agreed at today’s closing, although all the necessary conditions were met. Heidelberg had to assume until the very end that the transaction would be completed successfully. Heidelberg will assert its rights.

The five sites and around 430 employees of the Gallus Group will remain with Heidelberg. Nothing will change for Gallus customers. Heidelberg will continue handle sales and service for the Gallus portfolio and their personal contacts will remain the same. Heidelberg will now be examining various options for the corporate

future of Gallus. In any case, Gallus will continue on its path to boosting operating performance: With an independent setup and specific focus on its flexographic printing market, Gallus made good operational progress last year under the Heidelberg umbrella.

Irrespective of the Gallus transaction, which has not been completed, Heidelberg is already benefiting considerably from the transformation program launched in the current 2020-21 financial year to further stabilize the company financially in the challenging COVID-19 environment and to align it in a future-proof manner in its profitable core business. Since March 2020, net debt has been reduced by more than EUR 250 million from a peak of EUR 390 million, and liquidity has been improved by around EUR 450 million. As a

result of the accelerated M&A program, Heidelberg will generate proceeds in the mid-double-digit million euro range from the transactions completed in December 2020 alone.

The market remains challenging due to the currently worsening Covid 19 situation. Heidelberg is therefore systematically continuing its transformation course with the measures initiated for this purpose in order to create further financial scope.

In operational terms, the third quarter of the current financial year saw a continuation of the upward trend in sales and incoming orders that has been ongoing since May 2020. Heidelberg continues to expect to achieve its targets for financial year 2020/21 (ending 31 March 2021). z

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Labels

z HIGH PRODUCTIVITY, WIDE VERSATILITY, AND INTELLIGENT COLOR AUTOMATION

Sai Digistik installs HP Indigo 6900 digital press

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P has installed its Indigo 6900 digital press at Sai Digistik in Sonepat, Haryana. A leading player in the print and packaging industry, Sai Digistik has been looking to upgrade its premium offerings for small and medium business customers. Installation of the new HP Indigo 6900 digital press, Sai Digistik hopes to deliver print work to its customers at a shorter turnaround time.

The Indigo press delivers high productivity, wide versatility, and intelligent color automation. The press enables Sai Digistik to offer innovative printing solutions for self-adhesive labels, shrink sleeve labels, pouches and IML. The flexibility and reduced turnaround time results in significant saving on power, media wastage, inventory, labor and helps cater to dynamic changes in orders received, without compromising on quality.

Speaking on the installation, Harish Gupta, managing director, Sai Digistik said, “Every customer wants premium quality labels, even at low costs and volume.

During the pandemic, we decided to utilize the downtime by investing in upgrading our capabilities in a

sustainable manner by reducing our carbon footprint, while being able to effectively print on any surface so that recycled and biodegradable products can be used.

The HP Indigo 6900, with its highly versatile printing capabilities, with zero carbon emissions, was just the answer we were looking for. HP has helped make Sai Digistik not only a variable data printing wizard by improving our efficiency of scales but has also aided us in becoming an even more sustainable choice for our customers. Today we are generating good faith in the market by enabling our customers’ businesses to fulfill their deliveries faster to gather customer loyalty.”

A Appadurai, country manager, HP Indigo, HP India said, “HP is always committed to bringing innovative solutions, and we are devoted to provide best technology in market to meet the production needs of our customers. We are giving them the benefits of speed, customization, personalization and ensuring that clients’ budgets aren’t overrun. While the pandemic shoved us all behind closed doors, demand has had to be met at varying scales, to the remotest of places and often with volatile and fluctuating ETAs. We are

HP has installed its Indigo 6900 digital press at Sai Digistik in Sonepat, Haryana

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excited to partner with Sai Digistik with the latest HP Indigo 6900 Digital Press. With its capability for printing variety of labels, packaging applications, high productivity with accurate color management we are creating a win-win situation for our customer, as well as their clients and brands.”

The HP Indigo 6900 digital press prints at speeds up to 40 meters per minute in full color. The HP PrintOS delivers highly customizable solutions for printers with the capability to coordinate print operations from anywhere globally. In addition, HP Indigo 6900 Digital press is a unique solution that supports any narrow-format label, flexible packaging, sleeve, IML, wrap-around labels or folding cartons job, with easy and quick changeovers. It supports 12 to 450-micron materials, including standard substrates with in-line priming. The digital press also offers high resolution printing using HP Indigo ElectroInk with minute ink particles, delivers crisp line work, attractive images and smooth vignettes with a very thin ink layer that gives uniform gloss between the ink and substrate. z

International Exhibition on Printing and Allied Machinery Industries

Of the Printers - For the Printers - By the Printers

23 - 26 March

2022 Bombay Exhibition Centre, Goregaon, Mumbai

Labels

z ACHIEVES ‘ZERO REJECTION’ LEVEL OF PRINT QUALITY

Shreedhar Labels installs India’s first Guardian PQV 100% print inspection system

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hmedabad-based Shreedhar Labels claims that it has achieved a ‘zero rejection’ level of print quality, after installing India’s first Guardian PQV 100% print inspection technology from Baldwin Vision Systems. The ISOcertified Shreedhar Labels is one of India’s premier labeling specialists, with more than three decades of experience providing advanced and customized solutions to its clients.

While this is the first installation of the technology in India, the Guardian PQV has reportedly years of proven performance in the Americas and Europe. PQV is a feature-rich inline defect detection system that enables printers to find and remove defects quickly, and monitor their processes to prevent defects from occurring in the first place. The system provides complete print quality verification from prepress through production, reporting, and archiving for perfect runs.

“The system is designed to perform without fail to the most rigorous inspection requirements, with almost any substrate, and for all printing applications including converting, label, packaging, sheet and web,” says Amit Desai, regional sales manager for Baldwin Vision Systems. “Its state-of-the-art camera systems can be mounted on one or both sides of the substrate to perform 100% inspection for print quality, variable data, and even the most challenging security print features. When properly equipped, a Guardian PQV system can inspect for missing decimal points and broken characters on font sizes down to 4 pt. text typically, or even smaller in special circumstances.”

Bhavya Shah, director of Shreedhar Labels, notes that his company’s processes have been greatly improved since the installation of the Guardian PQV. “Before installing the system, we were not getting optimal

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L to R: Bhavya Shah of Shreedhar Labels; Amit Desai of Baldwin Vision Systems; and Manish Patel of Shreedhar Labels with the Guardian PQV 100% print inspection system

productivity. Many defects were going out. In particular, font size changes were not detected before the printed product was shipped to our customers,” says Shah “After installation of the Guardian PQV technology, we are able to guarantee our performance and our customers are very happy with the print quality. We now have zero rejection of printed substrate from our customers. Our operators are using the system for every job, and say it is very user-friendly. The tiniest font size variations are detected, and no defective product is sent to our customers,” Shah adds.

According to Shah, Shreedhar Labels chose Baldwin Vision Systems over other options because Baldwin Vision Systems is well known for quality and provides local support and excellent service in Ahmedabad.

“The process of installing the PQV system went very smoothly, and we now are realizing higher speeds, better print quality, and our operation is more productive,” he says.

After Shreedhar Labels, India’s second PQV installation is now underway at printing giant Pragati Graphics. z

Labels

z XEIKON CX30 AND XEIKON CX50

Xeikon adds two entry-level label presses to its portfolio

X

eikon has announced the addition of two new digital label presses – the Xeikon CX30 and Xeikon CX50. Building on its 6th generation platform and based on Cheetah 2.0 technology with new generation interfaces and cloud connection, the new presses are designed to offer maximum OEE. The Xeikon CX30 and Xeikon CX50 fit perfectly in the Xeikon portfolio between the Xeikon 3030REX and Xeikon 3050REX entry-level presses and the higher-end Xeikon CX300 and Xeikon CX500.

Xeikon has designed and developed the two new presses to suit label printers operating on ‘middle capacity’, that is: 20,000-40,000sqm or 30,00055,000 MSI in all end-use segments but excelling in the pharmaceutical, food, and wine and spirit label sectors. The new machines are available for physical and online demonstrations at Xeikon’s Global Innovation Center in Antwerp, Belgium, and globally commercially available as of Q1 2021.

Filip Weymans, VP marketing at Xeikon, says, “Part of the Xeikon strategy going forward is to make sure

every label printer and converter has the maximum choice to purchase a Xeikon press which can help them drive business growth. A successful and costeffective investment in a digital production solution works best when it is based on expected, realistic print volumes. Xeikon’s Cheetah 2.0 series offers competitive running costs, and printers have the opportunity to successfully expand the capabilities of their press (by upgrading either in speed or width, or both). The Xeikon CX30 and Xeikon CX50 are an appropriate choice for printers and converters looking at digital for the first time with future plans to expand and grow their operation – also for online label printers who are seeing their business explode.”

Cheetah 2.0 technology is based on Xeikon’s scalable press architecture that includes five print stations and a full rotary process with a variable repeat length.

Each station utilizes Xeikon’s dry toner process and a variety of print widths up to 512 mm (20.3 inches) using an LED imaging head operating at 1200 x 3600 dpi and delivering offset/gravure image qual-

ity. The two new presses use Xeikon’s QB dry toner based on Cheetah 2.0 technology, which excels in the digital print landscape by offering superior color consistency across the web and ensuring the highest volume of output with reduced waste. The toner is available in CMYK, red, blue, green, orange, extra magenta (gamut extension colors), super black, plus technical colors such as One-pass opaque white, UV and reflective clear as well as colors produced at the customer’s request.

The Xeikon CX30 and Xeikon CX50 are both driven by Xeikon’s powerful and intelligent X-800 digital front end for ultimate efficiency and full automation. Xeikon’s Digital Front End (DFE) workflow is a true differentiator and enabler and can be integrated with common ERP and MIS systems. Accuracy of color reproduction over time and between presses is guaranteed by an integrated on-press inline spectrometer. Xeikon’s X-800 workflow holds variable data capabilities unseen in the current market, allowing the label printer and converter to explore a variety of high value applications with a basic press investment. z

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Pharma Packaging

z GROWTH WITH NEW MACHINE GENERATION

Passion for pharmaceutical packaging

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apierwerk Landshut Mittler, whose highquality packagings are found the world over, can be summed up in three words: quality, reliability, and passion. Targeting further growth, the company was the first folding carton printer last year to invest in a Speedmaster XL 75-7+L from the new 2020 generation. A new Diana Smart 115 folder gluer from the partner MK Masterwork completed the investment in the latest packaging solutions from Heidelberg. Using state-of-the-art and innovative technologies makes it possible to combine top quality and high productivity.

“To enable us to produce the best folding cartons for our customers, we’re constantly on the lookout for the most innovative equipment,” explains Günther Berninghaus, the third generation of the family to manage plm. “Our slogan ‘Beyond the box’ says so too, and we’re proud that we’re still independent.”

The trained letterpress printer and printing engineer has worked in the company for 40 years, and says he has “always invested in the right machines.” plm has been in existence since 1914, with medium-sized pharmaceutical companies and contract manufacturers in Germany, Austria, and Switzerland accounting for 80% of its production. The remaining 20% is split between folding cartons for cosmetics and general consumer goods. plm also works with an internationally renowned pharmaceutical manufacturer to develop and produce complex color guides to guarantee globally harmonized production.

Since 1996, the company has been based in Wörth an der Isar – where it has enough space for both a structured production process and further growth.

“We have always focused on one site, where we maintain a high level of productivity. What’s more, we invest heavily in our own training and are proud of our rate of 10%,” says Günther Berninghaus in explaining his recipe for success. And there is one other special thing about plm: almost half of the 134 employees are women.

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Günther Berninghaus (right) and his son Daniel

PARTNERSHIP WITH HEIDELBERG AS A WIN-WIN SITUATION The partnership between Heidelberg and plm goes back decades, and has benefited both sides. For example, plm was one of the first concept customers in 1992. As a field test customer, plm has been involved in several major projects with Heidelberg – whether the expansion of the substrate range and the first coating unit in the Speedmaster SM 52 or the Prinect Inpress Control inline color and quality measurement system on the Speedmaster CD 74. Other field tests were conducted on the Prinect Press Center XL 3 and its LED daylight lamp, which Günther Berninghaus says makes it easier to approve sheets by simply switching from D50 (5000K daylight) to D65 (6500K daylight). plm has focused on the medium-size format 50 x 70 for many years. In the press room you will now find a Speedmaster XL 75-6+L from 2008 as well as a Speedmaster XL 75-5+L that was added three years ago and most recently the Speedmaster XL 75-7+L

from the 2020 generation one year ago. All three presses run at a speed of 18,000 sheets per hour and have a sheet format of 605 x 750 mm (23.82 x 29.53 in.), which is perfect for packaging companies.

Prior to its most recent investment, plm had scoured the printing press market and was also considering a change to the next bigger format. It soon turned out, however, that another Speedmaster XL 75 was the best solution. What clinched it were the innovative solutions in the new 2020 generation – the clear operating concept with the new Heidelberg User Experience (UX), the good accessibility, and the high print quality thanks to the perfectly optimized inking unit for this press series. The large diameters of the cylinders ensure that the cardboard is transported smoothly through the press.

“We consider ourselves in a good position with the three almost identical presses from Heidelberg. The printers can work on all the presses, we operate a standardized printing process, and can offer our

Pharma Packaging

Papierwerk was the first folding carton printer last year to invest in a Speedmaster XL 75-7+L from the new 2020 generation

customers fast production with zero defects,” says Günther Berninghaus in summary. “The medium-size format is the perfect fit for us as well at the moment.

This is confirmed by our profitability calculations. We have faster setup times, greater color stability, and uniformity of colors over the entire sheet, which helps us with the many gang runs we have.”

All of the presses have a service agreement in place and the Heidelberg technicians are held in high regard at plm. The washing fluids and aids are from the Saphira range.

Production operates on a three-shift schedule on all but the oldest Speedmaster XL 75, in some cases also at weekends. An active sales force and the additional demand from the pharmaceutical industry as a result of the coronavirus pandemic resulted in growth of 12% last year. Turnover in 2020 was 20 million euros.

Further growth came from the increasing substitution of plastic packagings and from monoblock cartons.

MODERN WORKSTATION AND INCREASED PRODUCTIVITY Print shop manager Günter Zöttl keeps an eye on the productivity gains offered by the three presses. The new Speedmaster XL 75 is 30% more efficient than the 2008 press. The new press is also 5% more efficient that the 2018 one. All in all, what sets the new 2020 generation press apart is its reliability, stability,

quality, and good accessibility. “When I ask my printers what their favorite press to work on is, it’s always the new Speedmaster,” confirms Günter Zöttl. “They’re big fans of the new operator guidance system, and the new 24-inch touchscreen makes their work more direct and straightforward.” The company is also taking advantage of the navigated printing: Intellistart 3 compares two jobs and suggests the best production approach to the printer. Intelliline, the system of optical guidance by means of LED strips on the printing units, provides outstanding navigation and support for the assistance system.

The average run length is just under 8,000 sheets. The main material processed is primary fiber cardboard with grammages from 220 to 500 g/m².

Spot colors account for 80% of the inks used at plm and the colorfulness of the jobs is on the increase, which means frequent colors changes. This is now much easier with the new Wash Assistant and its artificial intelligence. The Wash Assistant selects the right washup program for the inking unit and dampening system, blanket, and impression cylinder based on corresponding job and press parameters. When washing ink rollers, it can, for example, identify when switching from a dark color to a light one, and initiates the optimal washup program. If necessary it can even automatically initiate deep cleaning. Apart from saving time, this also saves washing fluid and washup cloths. Any inking units not needed are continuously supplied with roller protection liquid by the new “Auto Protect” function. Once ink is added again, the roller protection is removed fully automatically in the Intellistart 3 workflow without any input from the operator.

TEAM SPIRIT AND GOOD COLLABORATION

Production also runs on a three-shift schedule in postpress, with four die cutters and four folder gluers from the Diana series. The latest – a Diana Smart 115 – is a replacement investment and is expanding the product portfolio by adding new gluing options for the folding cartons. The new Diana also made it possible to further increase the quality and productivity.

Looking forward, plm wants to improve and expand the integration between the data provided by the Heidelberg presses and the packaging workflow.

These are then also projects for the next generation.

Günther Berninghaus’ son Daniel has a degree in business administration and has been working in the company as operational excellence manager for three years. “We’re a company with a strong team spirit, open exchange, and great collaboration – fast, flexible, and agile,” he sums up. These attributes are fundamental in achieving the objectives set – to continue as an independent medium-sized company with a profitable business that offers the customers the best-possible quality. z

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Pharma Packaging

z AUTOMATION COMPLYING WITH PHARMA REGULATIONS

Ultra Foil implements Flexibiz ERP

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ew Delhi, Mundka-based Ultra Foil has implemented Flexibiz ERP to streamline its business processes.

Started in 2014, Ultra Foil is a preferred choice for supplies of alu alu foils and tropical blister foils.

The company also produces laminates for powder drugs. The company is GMP, ISO 9001:2008 and DMF certified.

Mohit Lapra, director at Ultra Foil, said, “Our continuous focus is to produce quality materials at affordable price.

As we battle the economic impact of the pandemic,

it becomes equally important for us to automate our business process. But we always wanted to leverage on a proven and established enterprise-ready ERP software which can address complex processes with ease and provide great back-end support – Flexibiz ERP turned out to be just that.”

Ultra Foil is also planning for an expansion. Lapra adds, “Ultra Foil has gone a step further in adding an aesthetic dimension while taking care of hygiene.

In the process, we bring value addition and brand enhancements for our clients.”

Gaurav Bansal of Kiran Consultants said, “Covid 19 pandemic has positively impacted the ERP software market. While things are getting better, a positive market sentiment can be felt, and people are realizing the importance of digitization and automation across their manufacturing units. Our Flexibiz ERP solution will help Ultra Foil to manage material traceability, wastage control and seamless flow of information across various departments. In addition, the ERP will also help Ultra Foil to comply with various norms and regulations specific to the pharma industry.” z – Dev Kumar Dutta

Mohit Lapra (center), director at Ultra Foil with team members of Ultra Foil

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W W HH EE RR EE TT HH EE W WO O RR LL D D

CONVERGES

15 PRINTPACK INDIA

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th

December 20-24, 2021 India Expo Centre, Greater Noida, NCR Delhi

VISITORS’ REGISTRATION

CONCURRENT EVENT

INDIA SIGN & LED EXPO 2021 India’s Biggest Exhibition on : PRINTING I PACKAGING & FLEXIBLE PACKAGING I CORRUGATION I LABEL PRINTING I SCREEN & TEXTILE PRINTING I SIGNAGE & LED I PAPER & NON WOVEN I PRE-PRESS I DIGITAL I POST-PRESS I CONVERTING I SERVICES & SOFTWARE I CONSUMABLES & SPARES I OTHER INDUSTRY PARTNERS: Corrugation:

FEDERATION OF CORRUGATED BOX MANUFACTURER OF INDIA

SUPPORTED BY: Label:

Signage:

Screen Print:

Paper:

Global Print AIFMP

MEDIA SUPPORT:

99 PLAST PRINT PACK

ORGANIZER : INDIAN PRINTING PACKAGING & ALLIED MACHINERY MANUFACTURERS’ ASSOCIATION

Plot No C-54, Sector-62, Institutional Area, Noida, 201 307 U.P, INDIA I Mobile: Mr. G. Sankaranarayanan - +91-9717199385, Mr. Vikram Sharma - +91-9717199388 I Ph: +91-120-2400109/4292274 I Fax: +91-120-4207076 Email: admin@ipama.org; info@ipama.org; marketing@ipama.org I Website: www.ipama.org, www.printpackipama.com

Coding and Marking

z EB588 INK SETS THE NEW STANDARD

Ink raises standard of continuous inkjet coding for FMCG

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MCG manufacturers face high expectations. Consumers want products which are as sustainably made as possible, at a good price, while retailers and distributors are quick to issue fines for poorly coded items which jeopardize traceability, data collection and/or automation. The ink launched delivers on all these objectives by enabling better performance and sustainability, with no overall cost increase. Paired with the company’s flagship 9450 coder, the EB588 ink sets the new standard for FMCG inkjet coding.

MEK-based inks generate Volatile Organic Compound (VOC) emissions, contributors to greenhouse gases.

This new MEK-free alternative, made of Methyl Isopropyl Ketone (MIPK), supports product sustainability by generating 40% fewer VOCs under comparable operating conditions at 20 0C. It also promotes a safer work environment for workers.

Black, multi-purpose ink enables safer, more sustainable fast-moving consumer goods (FMCG) coding, with fewer errors – all for the same total cost of ownership (TCO) versus traditionally-used, MEK-based

Designed for use in Markem-Imaje’s 9450 continuous inkjet (CIJ) coder, one of the market’s leading inkjet printers, the ink also streamlines inventory and reduces waste. The multi-purpose, black ink codes many different packaging types including metal, glass, cardboard and several types of plastic. Ordering, logistics and stock management are thus easier as there are fewer items to store and oversee.

Furthermore, as MEK-free inks use fewer consumables than MEK-based inks, manufacturers will have 40% fewer bottles and cartridges to throw away. Waste is further minimized, as is rework, through the ink’s smart consumable management system which enables quick, mistake-free coding. There is no longer any risk of inserting an unsuitable ink which generates a poor-quality code, or worse, seems to code an item, only for the code to disappear hours later, or be easily rubbed off in the marketplace.

All operators need to do is insert the EB588 ink car-

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options.

tridge, something which can be done with the line running to avoid downtime. The coder takes it from there to check and set up parameters automatically, no further human intervention required.

For even greater efficiency and productivity, all consumable-related operations can be directly monitored on the user interface. Touch screen menus provide access to previous maintenance and production history, including data on availability rates and consumption.

An accurate, consumable level display, bolstered by real-time warnings, lets users know the precise quantity of prints remaining, so production time is not lost due to the ink or additive running out.

This is in addition to the marketing and quality-enhancing capabilities already available through the 9450

coder itself. For example, Markem-Imaje is currently the only major supplier to offer built-in promotional coding, serialization and ‘mark & read’ code checking in a CIJ printer. And, with a large graphical printing capacity, QR code printing is easy and efficient. Production sites can thus better meet the demands of brand teams to use complex codes to support a wide range of marketing objectives, all with full confidence in code quality and accuracy.

Even better, the above benefits are available for the same TCO as other comparable MEK-based ink and printer combinations. This enables manufacturers to improve their sustainability credentials without negatively affecting their profitability – a win-win situation for consumers, retailers, distributors, manufacturers and the environment. z

Automation

z MEETING CUSTOMER DEMANDS AND FASTER TIME TO MARKET WITH B&R

Leveraging robots in tube packing NINAD DESHPANDE

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ubes have been used in the packaging of liquids with high or low viscosity, making the handling of such liquids easier in transport and dispensing. The manufacturing units for tube production and decoration are usually different from the manufacturing unit for filling and sealing. This creates a demand for a safe, dust-free and hygienic transport of tubes from one location to another. Such industries demand uncontaminated packaging or preventing entry of dust in tube manufacturing and transport. Technoshell Automations provides solutions to tube manufacturing units for their various needs, such as tube capping, labeling, hot foil stamping and packaging. Technoshell Automation is a recognized name in building complex multi-axis machines for various such applications. To achieve the desired accuracy and precision in such highly complex machines, they trust the most innovative, technologically advanced solutions from B&R. Technoshell Automations is a 28-year-old company based in Nasik offering complete solutions to its divergent customers for their printing and packaging needs. “Today with our global standards engineering capability to manufacture high-quality workhorse machines, we offer solutions to meet various decorative printing and packaging needs of our customers,” says Nikhil Baste, director, Technoshell. “Our machines are aesthetically designed keeping customers’ needs in mind, with stress on quality, productivity, and affordability.” With in-house design, machining, software development capabilities coupled with state-of-the-art production capacity backed by hi-tech machines and the latest technology, they are experts and leaders in their business and offerings.

ROBOTS FOR HYGIENIC PACKING Over the past few years, packaging lines have seen

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With B&R’s mapp Technology, Technoshell is able to efficiently and effectively meet their customer demands and achieve a faster time to market

an exponential increase in the use of robots. Some applications have arisen out of the need for avoiding tedious repetitive work for humans, whereas some have arisen out of the need for avoiding contamination. “Use of robots in our tube packers help avoid tube contamination via human touch and entry of dust during transportation. It helps us cater to the demands of our customers and help them comply with the stringent hygienic standards and needs of their customers,” says Baste.

Usually, the location of tube manufacturing differs from the location of filling and sealing. This gives rise to the need for safe and uncontaminated packaging while packing tubes in cartons for dispatch and during transportation. However, human intervention could lead to contamination. “We addressed this issue by introducing a robot in our packer unit.

This not only speeds up the process of packing but also keeps it hygienic and contamination-free,” says Baste.

A conveyor run by a servo feeds the packer robot.

The servo provides the feed quantity to the robot for picking and placing the tubes in the carton.

Occasionally, the round tubes stacked vertically need an even and odd count for cartoning, which is handled by the feeder servo. A 6-axis robot is used to pick and place the tubes in cartons. The synchronization of servos, VFDs and robots enabled the accuracy in packing.

MAPP TECHNOLOGY REDUCING DEVELOPMENT TIME Customers demand new products and today the rate of new product launches in any industry is very high.

“To cater to such changing demands, it becomes a challenge for machine builders,” explains Baste.

“Thanks to B&R, our design team can handle such requests easily and be ready for any change without us spending time on customer site. Thanks to mapp Technology from B&R, we are able to efficiently and

Automation proprietary platforms, these standards are updated continually and remain usable for decades – ensuring maximum return on investment. mapp View relies 100% on web standards to ensure content can be viewed optimally on any output device or even customized for specific users or user groups.

“Operators on the shop floor do not have to depend on a single display unit mounted at a fixed location. They have the freedom to walk around the machine and have the same display on their tablets and smartphones.

This gives us a lot of flexibility and high performance,” says Baste. “mapp View reduces development time and ensures maximum reusability, making it the ideal solution for our modular and flexible machine designs,” he adds.

INTEGRATED ARCHITECTURE

Nikhil Baste, director, Technoshell Automations with his team

effectively meet the customer demands and achieve a faster time to market.”

The tube packers from Technoshell Automations utilize the technologically advanced and powerful hardware and software from B&R. A Panel PC, which acts as an integrated display unit and PC, controls the entire machine. This is coupled with remote X20 I/Os, ACOPOS servo and VFD over a real-time Ethernet POWERLINK network. Besides, a robot is also interfaced with the Panel PC. Technoshell has utilized mapp Technology in all aspects for developing the machine, with mapp View being an important aspect of this machine. Technoshell has used mapp Technology in other machines and is well aware of its features and benefits. Configuring

more and programming less drastically reduced the machine development time and mapp View provided a different dimension to the display.

MAPP VIEW – WEB MEETS AUTOMATION Duplicating a display on a tablet or a phone was previously unthinkable on a shop floor. With mapp View, B&R now offers direct access to the wide world of web technology right from the engineering environment.

For the first time, automation engineers have all the tools they need to create powerful and intuitive HMI solutions. mapp View is built on the globally accepted web standards HTML5, CSS3 and JavaScript. Unlike

Use of robots in tube packers help avoid tube contamination via human touch and entry of dust during transportation

“We have been using B&R for around 10 years and we have thoroughly appreciated their integrated approach several times,” says Nikhil Baste. “In all our machines we have effectively used Ethernet POWERLINK as the vendor-independent networking protocol. It helps us to choose from a list of vendors for various components and yet be able to program, commission and diagnose them in Automation Studio.”

The use of ACOPOS drastically reduced the footprint in cabinets by around 69%. Ethernet POWERLINK network helps in running a single Ethernet cable across the panel to Panel PC. This reduces cabling effort and improves maintenance. All the systems are tightly linked together with Automation Studio, the single programming tool for all B&R hardware.

COLLABORATING FOR NEXTGENERATION TECHNOLOGIES Today, factories demand machine builders provide machines that are ready for Industrial IoT. Technoshell Automations have been providing their customers with various features for many years including remote diagnostics and maintenance, integrated and connected machines, usage of open source technologies, scalable and flexible machines and much more.

“We build machines, which satisfy various complex demands of printing and packaging industry. Our focus has always been on technology and providing next-generation machines to our customers,” says Baste. “With B&R technology and solutions coupled with our industry expertise, we have consistently and successfully provided such advanced solutions to our customers.” z THE PACKMAN | MAR-APR 2021

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Sustainability

z CHALLENGING THE STANDARD IN CONFECTIONERY PACKAGING

BillerudKorsnäs launches recyclable paper-based flow wrap

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n September 2020, BillerudKorsnäs and Syntegon Technology partnered to launch recyclable flow wrap, a paper based packaging solution that enables a shift from conventional plastic to renewable and recyclable materials. Flow wrap is a type of flexible packaging used for many products in the FMCG sector and today plastic film flow wrap is standard for FMCG. BillerudKorsnäs’ recyclable flow wrap is an innovative paper packaging solution, based on primary fibres from well-managed forests and with high barrier performance that can be recycled as paper.

The product enables the shift from conventional plastic to paper and is suitable for medium to high barrier requirements such as those posed by chocolate bars and other confectionery as well as bakery product. A patent application for BillerudKorsnäs’ recyclable flow wrap is pending. The recyclable flow wrap is verified

by Syntegon Technology and tested with their retrofit upgrade kit ‘paper-ON-form’.

“We are happy to launch a paper based flow wrap solution. The product is recyclable as paper and brand owners don’t have to compromise neither product shelf life nor converting productivity in comparison to plastic packaging options,” says Peter Åström, project manager recyclable flow wrap.

With the Syntegon upgrade kit paper-ON-form it can be installed on existing horizontal flow wrapping machines and new flow wrappers from Syntegon Packaging Systems. The solution was engineered in Syntegon’s development center in Beringen, Switzerland, and consists of a flow-wrap forming unit and sealing tools or paper cold-sealing applications.

The kit is already being used on existing lines from international manufacturers for packaging chocolate bars in paper.

“To make flow wraps future-proof we have to take a holistic approach. In our test lab, we are concentrating

on three elements – avoidance, recycling, and recovery. Our retrofit kit allows customers the transition to paper packaging on their existing Syntegon Packaging Systems horizontal flow wrapping machine – without any restrictions regarding speed compared to the existing for cold-sealable paper,” says Christoph Langohr, project manager of sustainability horizontal packaging.

By introducing recyclable flow wrap, BillerudKorsnäs brings forward innovation based on renewable and biodegradable materials meeting brand owners and legislators’ need to reduce littering and increase recycling without compromising on the barrier characteristics. z

z BAGS WITH A FUNCTIONAL PLASTIC BARRIER

Mondi creates sustainable paper-based packaging for Goood

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ondi is launching two new paper-based bags for German pet food producer Interquell, delivering both consumer convenience and sustainability benefits. The pet food manufacturer asked Mondi to create two sizes of paperbased packaging bags with a functional plastic barrier for its sustainable premium Goood dog food. The innovative FlexiBags meet Interquell’s goal to reduce the amount of plastic used while ensuring premium product protection

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and convenient handling for consumers.

Georg Müller, CEO Interquell Petfood, says, “Sustainability is key for us: we invest heavily in the protection of natural resources and work with as many local materials as possible. We also support environmental initiatives, such as with our partner One Earth – One Ocean, who remove 10 kg of plastic from the oceans for every 10 kg of dry food we produce. At the same

time, it is essential that our products are protected in their packaging so that our high-quality pet food can be transported, stored, and easily served.”

Mondi uses up to 50% renewable resources to produce the re-closable paper-based bags. In addition, the base paper production, film creation and final conversion are all managed in-house by Mondi, resulting in a significant reduction of the carbon footprint of the bags. z

Filling and Sealing

z COMBINES DAIRY AND JUICE FILLING ON SAME BOTTLING LINE

RJ Corp implements Sidel’s aseptic PET technology

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arun Beverages, part of RJ Corp group, one of the largest franchises for PepsiCo globally, has installed Sidel’s Aseptic Combi Predis in its newly established plant in Punjab, India. This pivotal project aims to expand PET bottling capacity and provide production flexibility for the private label milk brand Cream Bell as well as Pepsi’s Tropicana juice range. By choosing the new aseptic dry preform sterilization technology, RJ Corp is commercializing its liquid dairy products (LDP) in PET for the first time in India.

Since the early nineties, the privately owned Indian company RJ Corp has made itself a multinational powerhouse with thriving businesses in beverages, fast food restaurants, retail, ice cream, dairy products, healthcare and education. Through its operating company Varun Beverages, the group is one of the largest bottling partners for PepsiCo in the world, currently holding 36 plants on the Indian subcontinent and in Africa, and producing carbonated soft drinks, water and hot-fill juices as well as LDP.

WHEN PRODUCTION FLEXIBILITY MATTERS With Indian consumers looking more and more for nutritional beverages, the market keeps shifting towards so-called ‘better-for-you’ drinks. To remain competitive in light of this trend, RJ Corp decided to diversify its portfolio and put more emphasis on its 100% juices with pulp and ultra-high temperature (UHT) LDP, thus gaining more production flexibility to switch product categories easily. “Managing both juices and dairy products on the same PET packaging line flexibly was essential for us, and we could make it happen only by producing in aseptic,” says RJS. Bagga, director technical and operations at RJ Corp. “High-level food safety and hygiene standards were must-have features to answer Pepsi’s demanding quality protocol as well as to pass internal and external validations.”

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To face these challenges, RJ Corp decided to go with Sidel’s Aseptic Combi Predis, including dry preform sterilization. They were convinced that it is a very safe and easy-to-operate solution while visiting a French copacker that has used and trusted this technology to handle both juices and milk for more than 10 years.

The technology, approved by the FDA for low-acid production since 2017, allows the beverage producer to switch easily and safely between four UHT milk flavors (white UHT milk, coffee, chocolate and mango) and various kinds of juice recipes (i.e. orange delight and 100% orange juice with pulp, mixed fruit delight and 100% mixed fruit juice, guava, apple delight and 100%

apple juice, and lychee delight) on the same line. This represents a major turning point for the companies in India, which were previously producing juices in PET bottles with the hot-fill process and milk in cartons.

UP TO 200 HOURS OF CONTINUOUS PRODUCTION The investment in Sidel’s Aseptic Combi Predis marks two major achievements for RJ Corp in India – not only is this the company’s first step into aseptic PET bottling, but also its first experience with dry preform sterilization. Employing the injection of hydrogen peroxide (H2O2) before the oven, Sidel’s patented Predis technology requires no water consumption and can reduce the use of chemicals significantly.

This is a lighthouse project for PepsiCo. worldwide regarding the processing and bottling of its high-acid products – the Tropicana juices. The Aseptic Combi Predis also features a similar dry sterilization for caps, Capdis, as it was very important to optimize the cleaning process and the handling of the caps themselves to avoid deformation and ensure tightness between the cap and the bottle.

Filling and Sealing tles per hour. Overall, it expands production capabilities in terms of volume as well as a higher number of SKUs.

ENSURING PACKAGING PERFORMANCE ACROSS THE SUPPLY CHAIN Traditionally, in India, milk is packaged in pouches, glass bottles or cartons. By choosing Sidel’s aseptic PET packaging technology, RJ Corp has widened packaging options for its LDP products. The brand-new PET bottle assures high food quality standards and outstanding customer experiences, along with PET being a cost-efficient and sustainable material. During the implementation of the packaging line, Sidel also shared its experience in PET packaging and helped design the new PET bottle, enabling the same shapes and caps to be used for both Cream Bell UHT milk and the Tropicana juices. The cap size for all bottle formats is 33 mm, which is a common width for LDP, but quite uncommon for juices. As a result, Sidel’s packaging experts developed and designed an iconic bottle shape in three formats – 200 ml, 500 ml and 1 L.

“RJ Corp chose Sidel because of our long-standing expertise in PET and aseptic technologies. Their new line allows for up to 200 hours of continuous production without any stoppages for cleaning, keeping the production running steadily without any compromise on product quality. Moreover, the equipment is easy to manage, and the operators find its functions intuitive and easily accessible,” says Rohit Sawhney, sales director for Sidel India.

Optimized and efficient aseptic PET packaging line In addition to the Aseptic Combi Predis, the complete line at RJ Corp in Punjab is equipped with a very competitive and flexible end of line. It features the seamless shrink-wrapper VersaFilm Access, offering the best combination of production quality, performance and price at medium speed. It also includes the automatic and safe PalKombi layer-by-layer palletiser working with a steady low-level pallet infeed and allowing easy access and control.

To understand its line operations and maximize overall equipment effectiveness, RJ Corp also invested in Sidel’s Efficiency Improvement Tool (EIT). This modular and scalable software provides the most significant performance indicators, reports and analyses, based on live and historical data, to better understand line flow, uncover sources of efficiency loss and achieve in-depth performance evaluation. It monitors quality, losses, consumption, accumulation and traceability, and interfaces with inspection devices and business systems.

All of the bottle shapes and formats have been qualified internally. They were submitted to Finite Element Analysis (FEA) and on-site validations prior to industrial production in order to ensure the bottles’ strength and performance across the supply chain. Sidel also designed specific preforms to reach optimised bottle weight in order to withstand the dry preform sterilization technology and avoid any thermal stresses on the bottle. Produced in white monolayer barrier PET, the new packaging ensures a shelf life up to nine months for UHT milk. Furthermore, all the transparent Tropicana juice bottles passed the demanding PepsiCo validation protocols.

Taking into account the good experience and satisfaction with Sidel’s complete aseptic packaging solution installation in Punjab, Varun Beverages again chose Sidel for the exact same scope of supply for a different plant, located in Central-Eastern India. z

To make the most of this line, specific training was delivered to enable all RJ Corp technicians to get the right understanding of aseptic PET packaging, including the Hazard Analysis Critical Control Point system (HACCP), and thus avoid any risk of contamination or detect root causes efficiently in case it happens. Since its implementation and validation, the line has been working successfully with an output up to 36,000 botTHE PACKMAN | MAR-APR 2021

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Caps and Closures

z NEW PACKAGE FEATURES WELDED-ON CLOSURE AND PULL RING

New 3Corações Cappuccino package uses Aptar’s BAP technology

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ptar brings to Brazil Bonded Aluminum to Plastic (BAP) technology that offers convenience and functionality for food packaging. The technology, which is brand new in Brazil, is featured on the new packaging of national favorite Cappuccino 3Corações. For the development of this new package, Aptar and 3Corações surveyed cappuccino consumers and identified three main areas of focus in regards to the consumption experience – a tight seal between the closure and bottle, ease of opening and closing, and a wide opening for easy to access to the content – all of which are addressed with this new package.

TIGHT SEAL Designed for the most diverse food categories, BAP, as its name suggests, is made of plastic and aluminum.

In the manufacturing process, the aluminum foil is welded to the plastic of the cap and, after filling, is welded back onto the container itself. This gives the lid an excellent seal, ensuring optimum food preservation, and helping to prevent leaks. Because the lid is attached to the package, and cannot be separated, it is easier to maintain the hygiene and integrity of the product inside.

EASE OF OPENING Easy to open and close, the cap, which has a flip-top lid, is integrated directly into the package. Together, they form a one-piece solution, with fewer removable and disposable parts. Opening the package is now more convenient and intuitive, thanks to the ergonomic pull ring which is attached to the aluminum foil, and comes out in one piece, leaving no sharp edges. This helps to improve the use occasion for consumers of all ages, and leaves them with an enjoyable packaging experience.

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allowing for easier access to the product. Because the product is easier to access, this change in neck size also helps to decrease the amount of product that is wasted.

The new package, featuring a welded-on closure and pull ring, offers convenience and functionality for food packaging

Designed for the most diverse food categories, BAP, as its name suggests, is made of plastic and aluminum. In the manufacturing process, the aluminum foil is welded to the plastic of the cap and, after filling, is welded back onto the container itself.

WIDE OPENING Thanks to BAP technology, a screw thread was no longer needed, and the neck finish was made wider, following the design of the container, and

In terms of manufacturing, BAP brings better efficiency to the production lines of Grupo 3Corações, optimizing – and even eliminating – steps in the cappuccino manufacturing process. The elimination of the screw thread made the packages 16% lighter, and made for easier accommodation at the points of sale. Due to the improved design, which uses less plastic, 3Corações estimates an annual 40 ton plastic reduction with the new packaging compared to the previous design.

Another key factor is the harmonization of a single cap for the two container sizes (200 gm and 400 gm): since it also serves for both versions of the product packaging; reducing the need to control different inventories.

Technology also contributed positively to the equity of the brand, increasing awareness and strengthening the positioning of the 3Corações Group as a leader the manufacturing of cappuccinos in Brazil.

“We were able to develop a completely customized solution that brought greater convenience to the final consumer. We kept the classic elements of the brand, such as color, layout base and heart shape,” explains Gisele Sousa, president of Aptar Food + Beverage for Latin America.

“3Corações cappuccino has been an innovative product since its launch more than 25 years ago.

The heart shape, a very important icon of the brand, reinforces the ties we maintain with our consumers, which endorses us with each repeat purchase. With a sophisticated simplicity, we hope to surprise the consumer with this new packaging, the result of tireless and passionate work,” says Lucila Garcia, executive manager of research and development at Grupo 3Corações. z

A Knowledge Company For Information, Technology and Business Volume 3 l Issue 4 l January-february 2021

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Bobst AluBond at Sparsh Industries

Nuflex on a mission to bring the best in flexo prepress

Yansefu India develops bio-based products

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Caps and Closures

z NEW PLANTS IN DINNINGTON AND VALFRAMBERT

United Caps reports on progress in Asian markets

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nited Caps, an international manufacturer of caps and closures, has reported that it is meeting its strategic growth initiatives despite the pandemic, enabling the company to continue to provide exceptional customer support, both in terms of implementation of existing caps and closures for new products, as well as continuing to generate 50% of its business from bespoke development of caps and closures to meet specific customer needs.

“In 2019, we opened our new plant in Kulim, Malaysia in furtherance of our Close To You strategy, and this has helped position us more strongly in the Asian region as well as to provide improved support to our Asian customers. In addition, we opened two new state-ofthe-art European plants during 2020, Dinnington in the UK and Valframbert in France. These actions were critical to both our ongoing Close To You strategy and to our ability to meet our strategic growth objectives,” said Benoit Henckes, CEO.

United Caps takes safety and security seriously, especially for sensitive products such as infant nutrition QR Codes, outlined images and sequential or random codes add value to caps and closures

In 2020, United Caps added two more state-of-the-art plants in Europe in Dinnington and Valframbert

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The Dinnington and Valframbert locations were carefully selected in line with United Caps’ Close To You strategy to enhance service to customers in the respective regions. Henckes welcomed the UK team to the United Caps family in December via Zoom as the Dinnington lines came online, due to Covid-19 restrictions. “We have special plans for an official inperson launch day as soon as the pandemic situation allows,” Henckes said.

Today, United Caps serves its customers from 10 production plants (including the Kulim plant in Malaysia) and 16 sales locations globally. At the end of 2020, the company reported turnover of over €156 million and employed almost 750 people around the globe. Henckes added, “We continue to enhance our infrastructure to support some of the world’s biggest brands, who look to United Caps caps and closures to help create new markets, safeguard product integrity, assure safety and consumer health, and ultimately protect brand reputation. For exam-

Caps and Closures United Caps opened its first Asian plant in Kulim, Malaysia, in 2019

ple, our Kulim plant offers excellent logistics and supporting services, including road transportation to Singapore, Malaysia, and Thailand, as well as proximity to Butterworth Port to serve the entire ASEAN region with caps and closures for infant nutrition. There is further ability to add production of closures for beverages, medical nutrition, edible oils and vinegars and non-food products.”

“We are especially proud of our 127 SAFE-TE closures that will be made in Asia for Asia ensuring safety and convenience for infant nutrition. This product was recognized as Most Welcomed Packaging Solution of the Year 2019 by Duxes,” Henckes concluded. z

z NEW CLOSURE MEETS GROWING DEMAND FOR CONVENIENCE

Schwarzwaldmilch first to opt SIG’s combiMaxx closure

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he first commercial launch of SIG’s innovative and highly convenient closure combiMaxx has taken place in partnership with well-known German dairy Schwarzwaldmilch.

Consumer demand for more convenience in packaging is constantly growing. According to SIG, the new wider closure combiMaxx is a solution that takes convenience to a new level, while also ensuring smooth and easy implementation on existing SIG filling lines.

Schwarzwaldmilch now offers combiMaxx on all its dairy products in SIG’s combiblocSlimline 1,000 ml carton packs. Due to its large opening with a 25 mm inner diameter, the new closure offers optimal product flow, perfect stream controllability and easy handling.

Other benefits include a tamper-proof ring and the reassurance of resealable and leak-proof storage.

Andreas Schneider, managing director of Schwarzwaldmilch, said, “Meeting the convenience needs of the consumer is important to us. Incorporating SIG’s new combiMaxx closure on our dairy packages offers outstanding performance for consumers, while also strengthening our brand position. Our close cooperation with SIG enables us to take consumer

combiMaxx was possible without significant investment by Schwarzwaldmilch, as the company was able to use its existing closure applicator.

Only a minor technical upgrade to the existing closure applicator and sorter unit is required via an upgrade kit and, once installed, customers can run combiMaxx and SIG’s best-selling closure solution combiSwift on the same applicator. Just one small setting change is required by the machine operator.

SIG’s innovative combiMaxx closure

convenience to the next level without the need for a new closure applicator or any major investment.” combiMaxx can generally be combined with all existing mid- and large sized combibloc and combifit carton packs from SIG, starting with combiblocSlimline, combiblocMidi and combifitMidi. The upgrade to

Frederic Faber, marketing manager D-A-CH at SIG, said, “Our combiMaxx closure is certainly a game changer for the food and beverage industry when it comes to consumer convenience. Our close cooperation with Schwarzwaldmilch has turned the challenge of meeting ongoing consumer needs into a reality.”

The partnership between SIG and Schwarzwaldmilch offers true product innovation and differentiation as part of SIG’s value proposition, which aims to deliver innovative product and packaging solutions that enable businesses to satisfy everchanging needs. z THE PACKMAN | MAR-APR 2021

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Insights

z INK INDUSTRY DURING THE TIME OF PANDEMIC

Interview with Heiner Klokkers of Hubergroup and chairman of EuPIA EuPIA is the European Printing Ink Association and was founded in 2003 as a division of CEPE, the European Council of the Paint, Printing Ink and Artists’ Colours Industry. EuPIA represents the interests of the European manufacturers of printing inks and related products.

The corona pandemic affects many industries. How did the printing ink manufacturers experience the last six months?

When will the industry be able to catch-up to the volumes of 2019?

Heiner Klokkers: I think the industry will not be able to catch-up the missing volumes of 2020.

Commercial printing is already experiencing a steady decrease over decades and Covid-19 pandemic has accelerated this decline. We will see a further constant decline. This scenario was underlined by the news in 2020 that the production of the biggest print product worldwide – the Ikea catalogue – was stopped. The only segment which might have a chance of a catch-up to the volumes of 2019 level is the packaging segment.

Heiner Klokkers: I think none of us has ever experienced such a situation before. It is still a challenging time for most of us. We have experienced a real digitization boom in the last six months/last year. This will also be the case more and more in the future. It includes the trend away from print media to online media. While social media, for example, has become an increasingly important part of our daily life, print media has decreased in relevance for many consumers.

In addition, the entire industry has faced special challenges in terms of the global supply chain, for example, a shortage of raw materials led to rising prices in the short and mid-term. Due to the lockdown in many countries, freight traffic is severely restricted in some cases. This, in turn, leads to a bottleneck in freight space. But despite these adversities, there are no significant failures in the supply chain in the industry.

Are there segments that benefit from the situation?

Heiner Klokkers: At the start of the first lockdown, packaging printing saw growth because of “panic” buying for FMCG. At some point it reached a certain level, which remains stable. But I do not see a sustainable growth in any segment.

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Heiner Klokkers

Are there segments that suffer particularly from the situation?

Heiner Klokkers: Commercial printing has definitely suffered as a result of the pandemic. The printing ink industry records a decline in sheetfed and web offset (heatset/coldset) and publication gravure. In these segments I do not expect a rebound. Another segment which is strongly affected by the pandemic is luxury packaging and cosmetics since people have been staying at home most of the time.

The pandemic is a health crisis where people are worried about their health. How does the industry protect its workers?

Heiner Klokkers: We can state for the whole printing ink industry that we have coped quite well with the pandemic so far. We have not recorded any bad case of infection. This is due to our constantly high precautionary measures. Most companies offered their employees hygiene material (disinfection/sanitizer, masks, etc.) as well as remote working wherever it is possible. In the laboratory or production, we implemented shift working to minimize the risk of infections. To ensure a high level of protection many governments implemented strict measures.

Insights Did or do they affect the business and what would you demand from politicians?

Heiner Klokkers: There were and still are government measures that affect our business. As most trade fairs were canceled and travel restrictions were imposed, the Commercial Printing business has been the most affected by the pandemic. But as EuPIA Chairman I can say that all members handle the pandemic very responsibly. We do not wait for the government to impose restrictions. Our actions are driven by our approach to deal with it in the very best effective way to protect our employees and our customers.

Beside the current pandemic: Are there other topics that raise the concern of the industry?

Heiner Klokkers: Even if Covid-19 remains at the forefront of our minds throughout our daily professional life, there are, of course, many topics that continue to occupy us. We would like to take these further – also within the framework of our EuPIA association activities. For example, the topic of availability for raw materials is currently occupying us intensively.

Due to the constant expansion of the regulations for raw materials on the part of the EU, we, as printing ink manufacturers, are occasionally required to use alternative raw materials and adapt formulations accordingly which drives costs.

While we in principle welcome the overall targets of the ‘European Green Deal’ as introduced by the EU Commission, our industry will be heavily impacted by certain policy areas of the Green Deal, e.g. the Chemicals Strategy for sustainability and the Circular Economy Action Plan. We are advocating that the measures foreseen by these policies are sciencebased and balanced. In addition, and as part of the European Green Deal, the scheduled revision of the Food Contact Material legislation will be of great importance to our sector, as it shall include a new Union legislation regulating the printing ink layer as part of printed food contact materials. The FCM revision is foreseen for the end of 2022 and the preparatory work and our engagement has already started. Since food contact materials are traded across Europe, we welcome a European solution instead of national measures as planned by Germany. Finally, we are also very curious to see how the Brexit (UK REACH) will affect our market in the long term. z

z GROWTH ANALYSIS IN NEXT 5 YEARS

Temperature-controlled packaging industry outlook

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any products manufactured by the food and beverage, chemical, biomedical, and healthcare industries are temperature sensitive. Any fluctuation in temperature can degrade the quality of the product.

Temperature-controlled products consist of an outer protective layer, an inner insulation layer and refrigerants that surround the actual product. This addresses the problem of preservation and helps in maintaining the quality.

According to ResearchCMFE, the global temperaturecontrolled packaging market reached a valuation of approximately USD 10.0 billion in 2019. It is estimated to register a compound annual growth rate of over 9% from 2020 to 2026. At this rate, the market’s expected valuation would be around USD 20.0 billion by the end of 2026.

Some of the key factors propelling market growth include significant surge in demand from healthcare and pharmaceutical industry, rise in disposable income of the individuals, accessibility of medical facilities, increasing demand for fresh and frozen food products and growing investment towards the improvement of cold chain infrastructure. However, high capital investments and high maintenance cost are likely to hamper the market.

RECENT DEVELOPMENTS IN TEMPERATURE-CONTROLLED PACKAGING INDUSTRY In February 2020, NanoCool was acquired by Pelican BioThermal that is a leading manufacturer of thermal insulation solutions. This acquisition is expected to help Pelican expand its market presence.

UK-based Softbox launched Tempcell Eco temperature control parcel container. This container amalgamates sustainability and an environment-friendly design without compromising performance.

MARKET DRIVERS 1. Rising consumption of perishable foods: The global demand for fresh fruits and vegetables has been steadily rising over the past few years. Countries such as China and South Africa have registered significant growth for fresh foods. This, in turn, has coerced supermarkets, hypermarkets, convenience stores, etc. to invest heavily in packaging technology.

Temperature-controlled packaging technologies are thereby gaining ground in various regions across the globe thus aiding the growth of the temperaturecontrolled packaging market.

2. International trade: Netherlands, United Kingdom, Belgium, and many more import fresh fruits and vegetables from emerging countries. Also, the North American and European regions are the highest consumers of bananas. The temperature-controlled packaging market is projected to witness an upsurge since it resolves the issue of preservation of products during travel.

3. Proliferation in various industries: The widespread use of temperature-controlled packaging in the medical sector such as transport of medicines, donor organs, blood transfers, clinical trial distribution products, and many more are estimated to augment the market.

Soaring application scope from the pharmaceutical as well as food & beverage industry will create numerous expansion opportunities.

MARKET RESTRAINTS – HIGH COSTS The manufacturing of temperature-controlled packaging solutions requires huge capital investment for procuring raw materials, machinery, R&D and so on. This deters the entry of many small and medium enterprises into the business. Moreover, the maintenance of these products is expensive. As a result, the growth of the temperaturecontrolled packaging market is heavily reliant on eliminating the investment and maintenance costs. z THE PACKMAN | MAR-APR 2021

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Insights

z MAJOR IMBALANCE IN DEMAND-SUPPLY

Indian packaging industry reeling under unprecedented RM cost increase

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lobally, with the advent of COVID pandemic, demand for manufacturing sector plummeted drastically, chemicals being no different faced the dearth in demand. Industry experts believed the recovery will be slow and sluggish, therefore many industry majors in the chemical sector went for a planned shutdown in mid-2020 while some faced force majeure. However, now when economies are recovering, the market is witnessing an unprecedented increase in demand. A sudden surge in demand has led to a major imbalance in the demand-supply scenario. Due to this demand and supply gap, the price for raw materials cost has increased multiple folds. Besides this, the situation is being compounded by a current global shortage of containers which has led to a sharp rise in transport costs thus further restricting supplies.

This complex mix of higher demand, capacity and supply problems together with restricted availability of transport resources is increasing uncertainty in the market and driving up feedstock prices exponentially.

RAW MATERIAL/ PETROCHEMICAL PRICE INCREASE Petrochemical raw materials and their derivatives, which include UV resins, Polyurethane resins, Solvents, acrylic resins, Adipic Acid, Glycols, Ethyl Acetate, PPG, MDI/TDI, Phthalic Anhydrid have recently experienced an extreme price increase.

Epoxy resin prices have witnessed a sharp increase since the latter part of 2020. Similar to petrochemical products, prices around the globe have witnessed an exponential increase for pigment raw materials, including titanium dioxide (TiO2).

Similar challenges are affecting the market for polyester resins with factory closures in Singapore and

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Sweden as well as an explosion at a factory in China adding to the difficulties further. This in turn has resulted in suppliers diverting products to their local markets, further pushing up prices.

The raw material scenario is reaching a peak and news is getting worse by the day.

– Adipic Acid, Phthalic Anhydride and Isophthalic Acid are on a constant upswing – All glycols have escalated, DEG, MEG – The price of PPG has increased three folds – Ethyl Acetate has increased by 45-50% and is culminating daily – MDI prices have doubled along with the scarcity of material

ECONOMIC RECOVERY IN CHINA Strong demand from certain markets is driving up prices while an unexpectedly rapid V-shaped recovery in China is also fuelling demand for these essential raw materials.

All this has severely impacted the price for printing inks, coatings and laminating adhesives used in various packaging and printing applications. At large, the price for primary feedstock has increased as mentioned below.

CHANGING FREIGHT RATES It’s not unusual for the ocean freight rates to be changing, and it happens on a regular basis. What is not that usual, however, is the reason behind the changes this time.

At India’s two largest ports, JNPT and Mundra, carriers have introduced new general rates. We’re seeing this increase because of the equipment shortages and the reduction of vessel capacity in the Indian subcontinent.

This is leading to an increase in ocean freight rates that started at the beginning of Jan’21.

Looking away from India, these ports aren’t the only ones, where the ocean freight rates have gone up.

Containers from Jebel Ali, the United Arab Emirates, and the ports of Qingdao, Shanghai, and Nansha, China, with a destination to different parts of the world have also seen an increase in freight. With the

Insights covid-19 pandemic, the market in container shipping has been turned on its head.

all units in Texas including 330,000 tons of MDI and 220,000 tons of TDI will be impacted.

CONSEQUENCES DUE TO FEEDSTOCK AND FREIGHT COST INCREASE

FORCE MAJEURE NOTICES ARE STACKING UP

Another key raw material Acrylic acid is in shortage globally due to the on-going shutdown of LG-Korea (no update on production till March), force majeure of Sasol-South Africa & fire accident of China’s Zhejiang Satellite Petrochemical. LyondellBasell, INEOS declare force majeure. IQ declares force majeure on butanols, butyl acetate

– Inordinate delay in the shipment execution from different overseas suppliers due to vessel space/ container shortage. Current ocean freights are more than 4 times as compared to Jan. – These unprecedented dynamics have resulted in significant inflationary pressure which requires raising prices to offset these costs – Some of the raw material suppliers are now resorting to the monthly price. Inks, adhesives and coatings also plan to implement the same, instead of quarterly pricing – At this stage, this extreme situation looks set to continue till June/July 2021 at the earliest.

Although it could be extended. z

Companies have been cutting capital budgets, in response to the slowing global economy. That’s the only conclusion to be drawn from the last 4 months’ review of force majeure. Force majeure has been climbing steadily for months. Thus it is worth keeping a careful eye on force majeure, as they provide an early indication of problems ahead.

To worsen the scenario further, in late February US Gulf coast had been hit by a rare severe winter storm and ultralow temperature impacting the production and operation of MDI and TDI plants located in Texas, Louisiana, Mississipi, Alabama and Florida. Covestro announced that the supply of MDI, TDI units in North America encountered force majeure, production of

9890-0475_OhioGT_PSA_FebMar_fonts.indd 1

CONCLUSION Key drivers for the increases include high demand across all industries, greater domestic supply requirements and broad demand pressures and higher costs. While the actual costs vary widely from region to region, higher than average per ton costs have been aggravated by significantly higher freight costs.

– Rajesh Srivastava, vice president sales and marketing, UFlex Ltd, Chemicals Business, Noida

1/27/2021 11:45:42 AM

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Events

New date for 15th Printpack India announced

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he Indian Printing Packaging and Allied Machinery Manufacturers’ Association (IPAMA) has announced the new dates for the Printpack India – 20 to 24 December 2021. IPAMA. The 15th edition of Printpack India was originally scheduled at the India Expo Centre, Greater Noida, from 3 to 8 February 2021.

With the improvement in the prevailing conditions and fast declining trend of Covid-19 cases, and the country’s vaccination drive rollout, the industry is keen to get back to business. Exhibitors, visitors, and other stakeholders had started making emphatic inquiries regarding the Printpack event’s revised dates.

Except for the new dates, the terms and conditions for participation in the Printpack India exhibition will be as earlier. The revised dates for Early Bird Discount and other benefits, which are to be allowed by the as-

sociation, will be finalized shortly. However, considering the Corona impact on the market and supporting the industry, IPAMA has decided to further lower the exhibition charges compared to earlier editions subject to terms and conditions.

The tariff for bare space is Rs. 8,000 per square meter. Exhibitors can avail 15% membership discount (5% for new members) and an Early Bird Discount of Rs.1,000 per square meter. Printpack has also announced motivational discount for members – Rs. 1,000/Rs.500 per square meter. z

Indoplas, Indopack and Indoprint rescheduled

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he Indonesian International Plastics, Packaging and Printing Exhibition will be moved to the second half of the year and will take place from 11–14 August. As Indonesia’s leading all-in-one exhibition focusing on innovative technologies and solutions from the co-related plastics, packaging and printing sectors, the venue for Indoplas, Indopack and Indoprint remains unchanged at Jakarta International Expo (JIExpo), Indonesia.

Gernot Ringling, managing director, Messe Düsseldorf Asia, said, “The international trade exhibition is recognized for its depth of products and services on the show floor, vibrant line-up of local and international conferences and seminars, and unique platform for networking. With the ongoing uncertainty surrounding Indonesia’s domestic border openings and restrictions on international travel and large-scale events, which are likely to continue in the first half of the year, we

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travel preparations. The August dates will also ensure better returns on investment and marketing value for exhibitors and visitors,” he added.

Rini Sumardi, director, Wahana Kemalaniaga Makmur, said, “In these evolving and dynamic times, adaptability and flexibility are key and we strongly feel that the Indonesian market will be better positioned to do business and manage large-scale events safely and successfully in the second half of the year.”

feel a reschedule was necessary in order to meet the standards of an international trade exhibition that our stakeholders have come to expect.”

“We hope that moving the exhibitions to August 2021 will give greater market confidence and optimism and give more time for international participants to make

“We remain committed to meet the business needs of our industry partners, exhibitors and trade visitors, and will stay steadfast in nurturing these trusted relationships for an even more successful participation in August. We will continue to work closely with our stakeholders and are taking immediate steps to provide the required support necessary,” she added. z

Events

The date for interpack 2023 is set

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he next interpack will take place from 4 to 10 May 2023 at the Düsseldorf Trade Fair Centre.

Messe Düsseldorf set this date in agreement with its partners and committees. Interested companies from the packaging sector and the associated processing industry will be able to register online at www. interpack.com from the end of March/beginning of April provided all goes to plan. Exhibitors who were approved for interpack 2021, which was canceled due to the pandemic, have already been able to reserve their stand positions for 2023 and will now be able to rebook when they register. components will take place in parallel with interpack. It is oriented towards the supplier sector for the packaging and processing industry. You can register for components in the same period as interpack by accessing www.packaging-components.com. z

Miraclon extends entry deadline for 2021 Global Flexo Innovation Awards

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iraclon is announcing a new deadline for its Global Flexo Innovation Awards, allowing Kodak Flexcel NX users to submit their entries until 26 March 2021, with an additional two months to finalize their submission afterwards. Recognizing the feedback received on the additional priorities, challenges and demands the industry is facing due to the global COVID-19 pandemic, the new deadline offers an extended opportunity for companies to participate in the awards.

Chris Horton, lead judge, says, “Many companies have continued driving the transformation of the flexo printing industry – even during this challenging period – and I am inspired by the entries we have received to date. Some businesses have expressed their interest in taking part in the awards but have simply been overwhelmed with other priorities until now. By moving the deadline, we give them the additional time they need to prepare and refine their submission as they navigate through this pandemic period.”

Horton hopes that once the final submission process closes, the international judging panel can safely convene in person to judge entries before announcing the winners later this year. “We are following up with companies on their submitted entries to clarify comments and gather additional information where needed to ensure their statements fully describe the innovation and are of the highest caliber. I hope that this highly experienced judging panel can bring their expertise, see the entries, and share their unique take on the judging criteria face-to-face – depending on travel restrictions and state of the pandemic, of course.”

The Global Flexo Innovation Awards celebrate prepress providers, printers and brands that are pioneering the transformation of the flexo industry. With high quality considered a pre-condition, the ‘one of a kind’ program looks beyond the print sample and recognizes innovations that deliver value across the print production value chain. Entries have to demonstrate how flexographic printing, Kodak Flexcel NX plates and the company’s own innovative approach resulted

in outstanding achievement in the use of creative graphic design, production workflow improvements, print process conversion to flexo and commitment to sustainability. z THE PACKMAN | MAR-APR 2021

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Industry News

Tresu reveals new coating circulator for sensitive and special coatings

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he new Tresu XL5i G3 peristaltic coating circulator ensures precisely regulated and stable flow for uncontaminated coating with sensitive or special aqueous or UV coatings for all printing applications.

coating types depends on relatively large layers, which are delicate to handle. Tresu’s new XL5i G3 coating circulator ensures, that these coating media are carefully transferred at precise viscosity, flow and pressure levels, securing that desired print and coating results are achieved and repeated with full automation and no disturbance at high production speeds.”

Introducing a new range of opportunities in automation, connectivity as well as level- and pressure control, the new XL5i G3 coating circulator builds up a new pressure in the industry and now enables full and automated control of a range of high-quality coating applications with sensitive and special coatings such as opaque white, gold and silver metalure, pearl luster, blister, high-gloss, scented or silky soft touch effects.

Used in combination with a chamber doctor blade system and customized open cell anilox roll, the Tresu XL5i G3 features separate built-in supply and return pumps, that provide full control of the enclosed circulation from the bucket to the chamber, where the coating fills the cells of the anilox roller. This Control Pressure Technology system from Tresu prevents any contamination of air inside the chamber and eliminates

Furthermore, the HMI with the new graphical user interface with intuitive universal icons, signals and colors optimizes operators’ time with fast and easy guidance to basic start up and operation commands and the ability to go one step deeper and access a range of automated operation modes. micro foaming and undesired blistering of the print.

Henrik Kristensen, VP Tresu Ancillary, says, “Coatings responsible for high gloss, brilliant colors and appealing tactile effects are powerful ways to add brand value – especially for luxury and personal care packaging, where a differentiating Point of Sale impact is crucial. However, the functionality of these

Comprehensive data logging with statistical insights for Industry 4.0 operations is now a real opportunity using the Ethernet connection of the Tresu XL5i G3.

Furthermore, the entire platform of the new circulator is 100% modular and ready to adapt to future needs and modes of operation by unlocking additional features on demand. z

Miraclon strengthens innovation leadership team

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iraclon has announced the appointments of Dr. Reid Chesterfield as chief technology and innovation officer, and Dr. Zaki Ali as chief technology advisor to the CEO, affirming the company’s commitment to innovation and expanding the executive leadership of the technology and innovation organization.

Zaki Ali, fondly known as the ‘godfather’ of the Flexcel NX Technology, has led the technology invention and product development from the very beginning of the flexo journey at Kodak that enabled the business growth and subsequent creation of Miraclon. He holds several patents for this unique technology that has helped transform the flexo printing industry.

Reid brings a wealth of industry, leadership, and commercialization experience to Miraclon, having most recently been global director of thermal interface materials at Henkel since October 2016. Prior to joining Henkel, he worked at DuPont for 13 years in a variety of technical and management roles.

Chris Payne, Miraclon CEO, says, “The expansion of our technology and innovation leadership team is an important step for Miraclon. Reid brings the right knowledge and experience to the team as we continue building on our rich heritage of development and innovation. Together with Zaki’s expertise, I am confident

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Dr. Reid Chesterfield, chief technology and innovation officer, Miraclon

that together they will help Miraclon continue to lead the transformation of flexo and drive our customers’ businesses to greater success.” z

Industry News

Flint Group launches XSYS

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lint Group has announced the launch of XSYS, a brand-new division, the result of combining Flint Group Flexographic with Xeikon Prepress. Although the two groups have been working closely for some time in support of the flexographic and letterpress markets, this formal alignment will bring even more collaboration and innovation to the group and to its customers. With the tagline Be Brilliant, the new division will work with its customers to honor its claim of Print Solid. Stay Flexible.

“With the integration of Xeikon Prepress with Flint Group Flexographic, we are now connecting the dots and are implementing an important step of our strategy to become a full solution provider for the flexographic prepress industry,” said Dagmar Schmidt, president of XSYS. “In forming this new division, we bring together what belongs together: plates, processing equipment (solvent-and solvent free), imagers, sleeves and adapters. And with this move, we expand our expertise towards our customers. The name derives

from ThermoFlexX, nyloflex, Xpress and other brands that feature the X, combined with Systems to form the name XSYS.” The existing products and brands that will be incorporated into XSYS include nyloflex flexographic solvent and thermal plates and equipment, nyloprint letterpress plates and equipment, nylosolv, rotec sleeves and adapters, ThermoFlexX TfxX Imagers, ThermoFlexX Catena Plate Processing equipment, and surface screening solutions. All will operate under the divisional brand XSYS, keeping in place all existing brands and continuing to leverage them in the marketplace. “We are confident that by joining them together, we will further strengthen that position. Our division is primarily focusing on the prepress part of the value chain complemented by sleeves, which gives us excellent access to the printing press room. We are organized in three subdivisions which will work closely together – prepress, plates and sleeves,” said Dagmar Schmidt, president of XSYS. z

Rotometal appoints sales manager in India

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hupesh Tilwani joins Rotometal after six years with Avery Dennison. In his previous role he was responsible for identifying new customers and working closely with key channel partners and distributors within India. Bhupesh previously worked at 3M in a sales role.

“Due to the ongoing growth, we made the decision to bring on a full-time employee in India to help us build our in-market presence. After settling into the business, we’re incredibly happy to announce Bhupesh Tilwani as our team member that is looking after the region” said Agnieszka Przybysz-Andrasz, head of sales for Rotometal.

“By bringing Bhupesh into our team, we can provide even better local support to our customers and partners in India.” Bhupesh will be based from Gurugram, covering the whole country and will report directly to Agnieszka Przybysz-Andrasz in Poland.

Rotometal produces bespoke magnetic and print cylinders for flexographic printing machines. Rotometal exports 80% of its production around the globe, including Asia, the Middle East and Africa. z

Michelman joins International Molded Fiber Association

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n its continuing effort to enable more sustainable packaging solutions for the circular economy, Michelman has expanded its network by joining the International Molded Fiber Association (IMFA). IMFA’s mission is to promote the global use of molded fiber products and advocate for environmental sustainability.

Explains Rick Michelman, Michelman’s chief technology officer and EVP, Americas, and printing and packaging, “We want to help transition the industry into more sustainable packaging. Our barrier coatings help improve fiber-based packaging’s functionality and performance while managing its end-of-life.”

The company has been opening new markets for paper and film packaging ever since creating their first repulpable water-based coating over 50 years ago. Their current barrier and functional coatings for paper and film make it possible to develop recyclable, repulpable, and industrially compostable packaging.

Michelman continues, “Because IMFA’s members include manufacturers of molded fiber products, industry suppliers, and service providers, Michelman has surrounded itself with like-minded organizations that will help accelerate the pace of product innovations for molded fiber applications.”

Like molded fiber, Michelman’s water-based coatings offer opportunities to increase sustainable practices, reduce waste, and deliver product performance using fewer raw materials, with repulpable, recyclable, compostable, and renewably-sourced options. z

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Industry News

Ramakrishna Karanth joins Siegwerk India as the new CEO

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iegwerk, one of the leading global suppliers of printing inks for packaging applications and labels, has announced the appointment of Ramakrishna Karanth as the new chief executive officer of Siegwerk India. This announcement comes soon after Ashish Pradhan was named president Asia, Siegwerk.

Ramakrishna’s experience spans over 30 years, starting with a Short Service Commissioned tenure of 6 years with the Indian Air Force in Surface to Air Missiles division and a total industrial experience of 28 years. He has held several leadership positions with packaging companies both in and outside India.

Apart from handling responsibilities in maintenance, projects, operations, and general management in Huhtamaki PPL over a tenure of 15 years, he has headed P&L responsibility in Rotopack UAE and the India BU of Weener Plastics, Netherlands. His last

assignment was with Kimoha Entrepreneurs FZCO as chief operating officer, based out of Dubai, where he was responsible for the profitability of business units in UAE and Saudi Arabia.

Welcoming Ramakrishna Karanth, Ashish Pradhan said, “We are confident that Siegwerk India will benefit immensely under the leadership of Ramakrishna. His extensive packaging industry knowledge and experience will help Siegwerk India achieve greater success.”

“I am excited to join the Siegwerk India team and look forward to contributing towards the continued success and growth of Siegwerk in India. The Indian packaging segment is seeing an evolving, great growth story and my efforts will be to work with the Siegwerk team to participate in this growth, with a focused approach on sustainability and environment-friendly solutions,” said Karanth. z

Ramakrishna Karanth, the new chief executive officer of Siegwerk India

Highcon and EFI announce global partnership

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ighcon Systems and EFI has announced that the two companies have entered into a global partnership agreement. With a common group of core customers, together with EFI’s ability to deliver industry-focused ERP software solutions, the goal is to offer customers an integrated, end-to-end business productivity and workflow solution, providing a flexible foundation for digital growth.

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release, Highcon customers will be able to integrate with the EFI MarketDirect PackCentral online customer ordering portal and EFI Auto-Count 4D software, which automatically collects accurate, up-to-the-minute production data for digital presses and cutting devices.

EFI Packaging and Corrugated Suites deliver off the shelf productivity benefits that target specific business areas to reduce waste and inefficiency in the packaging production process, driving cost savings with integrated eCommerce, ERP and shop floor data collection.

This exciting partnership will significantly improve lead times for printed material development by delivering a fully optimized supply chain that brings together buyers, converters, and digital converting equipment through robust two-way connectivity. This comprehensive platform delivers real value to businesses looking to improve efficiency, manage and optimize paper and inventory, reduce process waste and improve profits by leveraging automation.

In the coming Highcon Euclid and Beam software

Ken Hanulec, EFI VP worldwide marketing said, “We

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see the digital corrugated market as being a strong growth area. The EFI Nozomi solutions have really begun revolutionizing the industry and as part of our holistic view of the marketplace we identified Highcon as being the leader in the next step in the digital process – digital finishing. Their digital cutting and creasing solutions enable the kind of on-demand production that drives customer success. We are excited about the potential of addressing the market together.”

Gaby Matsliach, Senior VP, general manager, EFI Productivity Software added, “At EFI we have constantly focused our efforts on driving customer productivity and have released a comprehensive Suite of productivity solutions for the packaging industry. I have been impressed by Highcon’s similar drive for customer

Industry News efficiency and we are delighted to partner with them in optimizing digital procurement and production workflows.”

Shlomo Nimrodi, Highcon CEO said, “We are excited about working with EFI towards a genuinely end-toend digital solution, Nozomi and Beam platforms, coupled with workflow automation that will answer the market needs for sustainability and Industry 4.0 manufacturing efficiencies. Collaboration with other industry players in the digital space is a critical part of our go to market strategy and we will continue to drive this strategy demonstrating our commitment to provide the best comprehensive solution to the inherent limitations in the conventional process.” z

Tresu’s new range of doctor blades and end seals

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lexo machine manufacturer and printing equipment supplier Tresu has extended the range of doctor blades and end seals for chamber doctor blades systems for all printing and coating applications.

Tresu has launched an updated and complete portfolio of genuine Tresu end seals matching all applications in coating and printing. Based on more than 40 years of developing and supplying technology for printing and coating applications all over the world, a selection of end seals is manufactured and distributed, in order to help customers obtain the most uptime and output from their chamber doctor blade systems. The range of seals features a range of different materials, compounds and shapes in order to cover all printing and coating applications.

To ensure that customers always have a wide selection of doctor blades to choose from, Tresu has expanded the range of doctor blades to cover all applications. Doctor blades are available in polyester, carbon steel or stainless steel. Here even small details matter, and it is strongly recommended to match the choice of doctor blades with the customer’s specific application.

Tresu. This is the natural choice of washing detergents for water-based and UV-based inks and coatings and these Tresu cleaning detergents are low foaming, non-aggressive and biodegradable. They enable faster cleaning cycles and less downtime – and provide a sustainable solution to customers.

Completing this new portfolio of consumables are special recipe washing detergents, only supplied by

“Today’s production environment is far different than it was only a few years ago. Repeatable quality,

shorter runs at short notice, reliable workflows and optimal uptime are what printers need, to compete effectively today,” says Allan Rasmussen, vice president, Tresu customer care. “These and other issues like sustainability and reducing waste are what our customer care program helps customers to achieve. In short, by using genuine and proven parts, customers can extend the performance of their printing equipment.” z THE PACKMAN | MAR-APR 2021

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Services

Events Calendar DATES

EVENT NAME

PLACE

26 to 28 November 2019

CPhI India (P’Mec)

Greater Noida, India

3 to 6 December 2019

Paperex

Delhi, India

6 to 8 December 2019

Print & Packtech

Bangalore, India

12 to 14 December 2019

Pacprocess Food Pex

Delhi, India

6 to 9 January 2020

Pamex 2020

Mumbai, India

16 to 20 January 2020

Plastivision 2020

Mumbai, India

28 Feb to 1 March 2020

PacProTech

Kathmandu

19 to 21 March 2020

Asia Packaging & Printing Industry Expo

Shenzhen, China

PLEASE VISIT OUR WEBSITE FOR THE UPDATED EVENTS CALENDAR

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20 to 22 March 2020

PackPlus South 2020

Hyderabad, India

21 to 23 April 2020

Label & Flexible Packaging & Film Expo 2020

Shanghai, China

24 to 26 April 2020

Food Pack India Expo

Chennai, India

5 to 9 May 2020

Metpack 2020

Messe Essen, German

7 to 13 May 2020

interpack 2020

Dusseldorf, Germany

3 to 4 June 2020

Innopack Pharma Confex

Mumbai, India

16 to 26 June 2020

drupa 2020

Dusseldorf, Germany

19 to 22 June 2020

Plastasia 2020

Bangalore, India

6 to 9 August 2020

PackPlus Delhi

Delhi, India

17 to 19 September 2020

Pharma Pro&Pack 2020

Hyderabad, India

30 September to 2 October 2020

IndiaCorr Expo

Mumbai, India

8 to 10 October 2020

ProPak India

Delhi, India

25 to 27 November 2020

CPhI & P-MEC India

Greater Noida, India

29 October to 1 November 2020

Labelexpo India 2020

Greater Noida, India

29 October to 1 November 2020

Brand Print India 2020

Greater Noida, India

9 to 11 December 2020

pacprocess India

Mumbai, India

3 to 8 February 2021

Printpack India 2021

Greater Noida, India

4 to 8 February 2021

PlastIndia 2021

Delhi, India

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RNI UPENG/2018/76741 Editor Mahan Jyoti Hazarika editor@thepackman.in Cell: +91 9910189285 Senior Desk Editor Sunil Jain Senior Associate Editor Dev Kumar Dutta Associate Editors Pranay Mathur Manash Das Guest Editor Anwesh Koley Design and Production Biswajeet Chaliha Sales and Marketing Mahan Jyoti Hazarika Subscription Address E448, Gaur City 1, First Avenue, Greater Noida West, Gautam Buddha Nagar 201301, Uttar Pradesh, India Issue Published on 8 March 2021 Printed at JK Offset Graphics Pvt. Ltd. Printed, Published and Owned by Mahan Jyoti Hazarika, and Printed at JK offset Graphics Pvt. Ltd., B278 Okhla Phase I, New Delhi 110 020, India and Published From E448, Gaur City 1, First Avenue, Greater Noida West, Gautam Buddha Nagar 201301, Uttar Pradesh, India Editor: Mahan Jyoti Hazarika

Industry News

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Partnership

RNI UPENG/2018/76741

adds true value to our business

We have been working with Nilpeter for years now, their commitment and attention to detail is unparalleled.

Bill Cheringal & Jeff Levine Control Group

visit nilpeter.com