Page 1

‘SUITE’ SPOT: Co-packer invests in QC production 28

RECOVERY MODE: Is EPR recycling’s savior? 54

April 2013

WINNING PLAY: Dell’s packaging vision looks beyond ordinary 18

www.packagingdigest.com

Dispensing efficiency Liquid filling line leans on continuous improvement 22 Closing the ‘soft skills’ gap 16 Decorating with lasers 42

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contents APRIL 2013 volume 50 no. 4

trends PACKAGING CONCEPTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SKILL SET To succeed today, packaging professionals must arm themselves with comunication and other non-technical skills . . . . . . . 16 VISIONARY: DELL Te computer giant is working to ensure future success by investing in sustainability, and its people.. . . . . . . . . 18 SPC SUSTAINABILITY Sustainability’s ugly stepchildren . . . . 20

28

INDUSTRY INSIGHTS Is EPR recycling’s savior? . . . . . . . . . . 54

best practices COVER STORY Co-packer Aerofil harnesses the power of its employee’s knowledge base to help fuel continuous improvement . . . 22 FLEX TIME A new, larger building is facilitating GSC Packaging’s goal to grow while maintaining high quality standards . . . . . . . . . . . . 28 BAGGING BOOST Grain Millers has revitalized its whole-grain packaging operation, boosting efficiency by a reported 40 percent . . . 34

16 34

UPPER CLASS Te “Downton Abbey” estate modernizes with a new automated horse-oats packaging line . . . . . . . . . . . . . . . . . . . . 36 SPEED RACER Adding a high-speed tablet filling line is helping this pharmaceutical co-packer grow its business and capabilities . . . . . 38 SALAD DAYS Installing advanced x-ray inspection is enabling this dressing and condiments company to extend its success. . . . . . . . 40 PURCHASING POWER Risk management redux . . . . . . . . . . 41

new technology LASER SHOW With new laser technology, brand owners have access to a whole new realm of decorating possibilities . . . . . . . . . . . . 42 NEW PRODUCTS: EQUIPMENT. . . . . . . . . . . . . . . . . . . . . 44

22 51

42

NEW PRODUCTS: MATERIALS . . . . . . . . . . . . . . . . . . . . . 48 PROMISING PATENTS Closure releases aroma; more. . . . . . . 51

departments ONLINE . . . . . . . . . . . . . . . . . 6

VIEWPOINT. . . . . . . . . . . . 11

DIALOGUE . . . . . . . . . . . . . . 8

MARKETPLACE . . . . . . . 52

STAFF . . . . . . . . . . . . . . . . . . 10

NEWSMAKERS . . . . . . . . 53

COVER PHOTO BY JENNIFER FIELD

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6

APRIL 2013 www.PackagingDigest.com

online

Read these bonus articles at packagingdigest.com

Training explains British Retail Consortium global standard for food packaging

Natural Products Assn. calls for national standard on GMO labeling So consumers can make educated decisions about the foods they eat, the nation’s largest association for natural products joins the growing movement for labeling products with genetically modified organisms: “People have a right to know what’s in their food.” www.packagingdigest.com/StdGMOlabeling

PACK EXPO launches packaging automation resource Te Center for Trends & Technology: Improving Production through Innovation (sponsored by Rockwell Automation and its PartnerNetwork Program) will debut at PACK EXPO Las Vegas 2013. It is designed to be a gathering spot for attendees interested in learning about new technologies. www.packagingdigest.com/PackExpoAutomate

Whole Foods Market commits to full GMO transparency Te retailer has announced it is requiring all products in its U.S. and Canadian stores to be labeled by 2018 to indicate genetically modified organism content. www.packagingdigest.com/ WholeFoods

UL DQS is offering two-day training classes on British Retail Consortium; the next will be at the UL University facility in suburban Chicago on May 7-8. www.packagingdigest.com/GlobalStandard

New Belgium Brewing joins ranks of EPR supporters Te Colorado craft brewer has pledged its faith in extended producer responsibility with the help of Recycling Reinvented. www.packagingdigest.com/NewBelgium

Manufacturing report offers good news for packaging industry A market report indicates activity in the manufacturing sector expanded in February for the third consecutive month, and the overall economy grew for the 45th consecutive month. www.packagingdigest.com/GoodNews

SEEING THESE ARTICLES FOR THE FIR ST TIME? Sign up for Packaging Digest’s Daily Packaging News e-newsletter to receive news as it happens. Keep up to date with our quick-scan headlines—the best source for what’s happening in packaging, delivered directly to your email inbox each business day. Go to www.packagingdigest.com/Daily

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8

APRIL 2013 www.PackagingDigest.com

dialogue LinkedIn poll: Sustainable priorities This month’s LinkedIn poll indicates that more packaging professionals consider sustainability a priority than an afterthought. Doreen Monteleone, director of EHS and special projects for the Flexographic Technical Assn. and board member of the Sustainable Green Printing Partnership (www.sgppartnership.org) weighed in on prioritization of sustainability: “It will vary with the philosphy of the executives within the company and the pressures of the clients. However, I have found that more than 72 percent of flexographic printers make reference to their environmental/ sustainability initiatives on their websites so it definitely is important to the industry. The Sustainable Green Printing Partnership was created by the printing industry to offer a mechanism for printers to validate their sustainabilty programs. Green washing is out there!”

Which of the following best describes your packaging company's sustainability philosophy? 66%

It is a top priority in all areas 14%

Important only if clients bring it up

15%

Important only if it also can cut costs

5%

Sustainability is not a priority

0

10

20

30

40

50

60

70

Barbara Fowler, Smithers Pira (@ BarbaraRFowler): “#packaging protects far more resources than it uses #sustpack13”

“What a great idea from a consumer and environmental standpoint. I expect the food industry to be slow on the uptake as getting all of the ketchup out of the bottle will reduce the number of bottles of ketchup sold to consumers.”

“Love LOVE Love this! Cannot tell you how many bottles of wine had to be tossed because I didn’t finish them in time, and the number of wines I passed on trying just because of this! I really do have just 1 glass if I’m having it at home.” Arlene Wynn on “Fine wine in a 187-mL glass tube”

Ben Wadler, restaurant purchasing director, on “LiquiGlide gives foods the slip to reduce waste”

“I agree that protective packaging can play a crucial role during shipping and consumer delight upon delivery and can result customer loyalty and repeat purchases.”

“Admirable goal to get the stuff out of the oceans. I do not believe it can ever be a cost effective approach. You would have to cover too much area to pick up several tons of plastic, I would think. It will be very interesting to see a status report after one year of operation.”

Than Nguyen, Protective Packaging, on “Getting in line with online shopping”

Robert Esse, Humidipak/Boveda, on “Project reclaims plastic packaging from oceans”

Process Expo (@ProcessExpo): “Tere are no secrets to success. It’s the result of preparation, hard work & learning from failure -Colin Powell #quote | RT @FoodBevSustain”

Join the packaging community discussions at Packaging Digest’s LinkedIn group at www.linkedin.com, on Twitter at www.twitter.com/packagingdigest or by commenting on a PD article online at www.packagingdigest.com

PMMI (@PMMIorg): “Tanks for the RTs and mentions this week! We’re really starting to rev up the social media engines for #PACKEXPO this year, so stay tuned!”

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10

APRIL 2013 www.PackagingDigest.com

staff Executive Editor Lisa McTigue Pierce 630-990-7384 lisa.pierce@ubm.com

Technical Editor Rick Lingle 630-990-2364 rick.lingle@ubm.com

Senior Editor Jenni Spinner 630-990-7385 jenni.spinner@ubm.com

Plant Operations Editor Jack Mans 630-990-4208 jack.mans@ubm.com

Editorial Advisory Board Editorial Office: 1200 Jorie Blvd., Suite 230 Oak Brook, IL 60523 630-990-7384 e-mail: lisa.pierce@ubm.com

Corporate Headquarters: 2901 28th St., Suite 100 Santa Monica, CA 90405 310-445-4200 www.ubmcanon.com

Art/Production/Marketing

Executive Officers

Lead Art Director Marco Aguilera

Chief Executive Officer Sally Shankland

Production Director Jeff Tade

Vice-President/Executive Director Stephen Corrick

Production Manager Brian Wu

Sr. Vice President, Events Division Mark Snell

Production Coordinator Saravanan Somasundaram

Vice President, Operations Roger Burg

Marketing Manager Mary Williams Director of Circulation Sandra Martin Circulation Manager Xavier Contaoi

Brand DirectorPackaging Steve Everly 610-705-8705 steve.everly@ubm.com

Associate Art Director Jennifer Field 310-445-4248 jenny.field@ubm.com

Oliver Campbell Director Procurement, Packaging, Dell Kim Carswell Senior Manager Packaging, Target Scott Hemink Senior R&D Manager for International Technical Services, General Mills Joe Hotchkiss Director, Michigan State University, School of Packaging and Center for Packaging Innovation and Sustainability Joe Keller Section Head Packaging Development Global Packaging Sustainability, Te Procter & Gamble Co. Denise Lefebvre VP, Global Beverage Packaging, PepsiCo Peter Macauley Director, Global Packaging & Sustainability, Abbott Laboratories Michael Okoroafor VP-Packaging R&D/ Innovation, H.J. Heinz Ron Sasine Senior Director of Packaging, Private Brands, Walmart

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viewpoint

www.PackagingDigest.com APRIL 2013

11

The anywhere, anytime challenge Te next day, though, as I was making the return trip, I A busy month of traveling and conversations at various lamented that there was no easy way to eat one of their industry events got me thinking about some opportunities salads while I was driving. for packaging: It doesn’t matter that the product itself isn’t conducive • Online shopping will continue to grow. Are your to eating on the go. For a split second, I was thinking like primary packages designed for direct home delivery? Can a consumer and blamed the packaging for not meeting my they survive the sometimes brutal small-parcel environment wants. Portable packaging isn’t anything new but there’s and still make a positive impression on consumers when still room for improvement. they arrive? If they are built solely with the protectionDo you know all the ways consumers are using your in-numbers pallet-load supply chain in mind, you might products today and where? Is your package functional be missing an chance to optimize primary and secondary for all those occasions? You might find some insight packaging structures together. into the need for über-functional packaging at www. I started thinking about that because of this big theonehandedworld.blogspot.com. news—“Amazon gears up for private label”—from the • I brought up the idea of making a product/ folks at the Private Label Manufacturers Assn. They write: package easy to open/use with just one hand at a new “How long will it be before Amazon becomes a factor in LISA MCTIGUE PIERCE online community sponsored by DuPont—www. private label? Maybe not as long as you think. The giant Executive Editor medicalpackaginginnovation.com—with a comment online retailer has been running classified ads to hire a lisa.pierce@ubm.com on the 3/18/13 blog post titled “Can You Do It in the Director, Global Product Development, Private Brands.” Dark?” Author Adele Graham-King relays a story about not giving her You can bet that, once Amazon begins to develop products, its packaging young daughter her inhaler during the night because she didn’t want to designers will consider the delivery method as they make their material turn on the light and possibly end up waking the whole house. She asks, and structural choices. For example… “What makes a medical device so intuitive that we can use it anywhere • I stopped at Wendy’s for lunch during a drive from my hometown at any time? How many [caregivers] don’t medicate correctly due to Chicago to Cincinnati, where I was giving a presentation at the EPS inconvenience, technical difficulty, situation, or environment?” Expo 2013. I love this fast-food chain and was happy to see that they Can we use your package in the dark or at the park? On a train or in the improved the packaging to make the burger easier to eat in the car—there’s rain? Here, there or everywhere? a paperboard tray now that is easy to hold and collects any droppings.

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TRENDS // APRIL 2013 www.PackagingDigest.com

packaging concepts Lotions shows can-do attitude with spray package Studies show that while most women in the U.S. have lotions in their homes, many don’t use it because it takes too long to apply and absorb, creating a speed bump in their morning routine. That’s where Vaseline has jumped in with its new Spray & Go Moisturizer. The product comes in a can with continuous spray capability, applying and absorbing in seconds. In addition to the specialized formulation, the product facilitates more convenient use through two packaging elements: • The external structure consists of a twist-lock actuator that is easy to press and avoids spills, and a contoured aluminium can that fts nicely in the hand. • The internal structure uses bag-on-valve technology for 360-degree non-aerosol spray delivery, using only compressed air.

The cans deliver a targeted spray (approximately the width of a user’s wrist) that spreads easily and evenly, and it absorbs readily with a few quick rubs. “This breakthrough moisturizer will help more women incorporate lotion into their morning routines, and will drive category growth in an area that has not seen innovation in more than fve years,” says Dawn Hedgepeth, U.S. skin director for brand owner Unilever. The bag-on-valve mechanism and actuator are supplied by Aptar Beauty and Home (www.aptar.com), and the aluminium can (which is printed via dry offset) is manufactured by Envases Del Plata S.A. (www.envasesdelplata.com). The three varieties (Total Moisture, Aloe Fresh and Cocoa Radiant, available in 6.5-oz cans) hit retailers across America in March.

Mintel Market Snapshot Blister packs innovate with feminine appeal Consumer healthcare is dominated by a small number of pack types: Bottles for liquids, tubes and sachets for crèmes, jars and blister packs for tablets. In many cases, brands will remain within these pack types, sticking to generic shapes and pack designs, to communicate to the consumer the “scientifc” and “pharmaceutical” nature of the product. However, as consumers become increasingly comfortable with self-medication, and brand owners innovate to appeal to new consumers and fnd new use occasions, packaging that moves outside of these norms could offer a simple strategy for differentiation. One potential target audience is the female consumer, particularly for supplements. According to Mintel research, in the U.S. women are more likely to trust vitamin and dietary supplements and, as a result, also are more likely to take them. For example, when offered the statement “I believe that vitamins and other nutrients really make a difference,” 65 percent of female respondents agreed, compared to only 58 percent of men. Similarly 51 percent of women asked by Mintel had taken mineral supplements in the past 12 months, compared to only 35 percent of men. Is there an opportunity to create packaging that reaches out to this consumer group? In

South Africa, one company has done just that with an innovative design change to the standard blister pack in a board carton combination. Kenza Health has created a striking pack for Femolene Mylife Adult (below left), a pack of 28 hormone supplement capsules for women. Each of four blister packs have the blisters arranged in a circle, disrupting the consumer expectation and providing an attractive appearance that mimics a fower. These blisters are held in a litho-printed paper booklet such that each page contains the blister and capsules for one week, with in-depth product information about that weekly course of supplements. This simple presentation could help compliance by making it immediately clear to the user how far they are through the supplement course as each “fower” has petals holding seven tablets, making each blister appropriate for a single week. The overall design softens the image of a product that could come across as clinical and uncaring. Another interesting blister innovation is offered by Nhât Nhât in Vietnam (above). In this pack of Detoxifying Tablets for Women, the

base of the pack (rather than showing the individual blisters that hold the tablets) is covered over with a single larger blister to give a simple smooth surface. This helps to simplify the presentation of the pack and creates a second billboarding space that could be used for brand or product information. Inspiration for healthcare can come from other categories. For example, in China, Orion Xylitol 3+ gum retail in a 56g tub (at right). To reduce noise created when the tub is shaken, the base of the tub can be moved to compress the gum dragees and stop them from moving about. For those women who take supplements to work or to the gym, such a pack could help to keep their use more discrete. From the same category, Wrigley’s Eclipse in the US feature a blister pack where one blister has been replaced with a small groove so that the consumer can pull the blister from a board sleeve with a nail (below). This provides ease of access to the product in a compact and portable pack. In 2012, only 5 percent of global vitamin and dietary supplement innovation was targeted at the female demographic. Therefore, it seems there is an opportunity for products that target the health needs of this group. With many existing packs simply relying on adding an image of a healthy woman on the front of the pack, those brands that can leverage packaging to better ft into the lifestyle of this group will clearly gain a competitive advantage. —Benjamin Punchard, senior global packaging analyst, Mintel

www.mintel.com/gnpd magenta cyan yellow black

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www.PackagingDigest.com APRIL 2013 // TRENDS

13

Makeover of the month

Premium frozen treat brand launches cool new packaging

Whisky bottle takes a shot at heritage

Talenti Gelato & Sorbetto, the company behind the world’s best-selling packaged gelato, has freshened up the brand with new packaging that modernizes the look and the feel of the product, and it also has served up four additions to its stable of favors. The company’s new logo and typeface are geared to support the brand’s simplicity and playfulness. The “smiling spoon” logo and “happier spoons” tagline are aimed to further remind consumers of the product’s fun, quality and natural ingredients. The clear containers, which show off the tantalizing frozen before concoctions inside, are made of PET by Talenti’s packaging partner; the screw-on lids are constructed of HDPE.

Tennessee has a long-standing love affair with white whisky. Short Mountain Distillery hearkens back to that era by employing a traditional distilling process using local stone milled grain and Tennessee spring water to create a sour mash moonshine. The process, and the packaging, salutes Short Mountain Moonshine’s status as the modern-day heir apparent to “white lightning.” The bottle, created by TricorBraun Design and Engineering (www. tricorbraundesign.com) has a 1930s feel. Unique to the design is an indentation in the bottle’s shoulder into which a commemorative, seasonal medallion is placed. Other embellishments include a hand-drawn paper label. It uses a T-top wood and cork closure. The spirit is sold in 750mL, individually designed bottles made with custom-grade fint glass. The 105-proof moonshine won a Gold Medal in the 2012 Intl. Review of Spirits Awards From the Beverage Testing Institute.

after In addition to the packaging updates, the company has introduced four new favors: Alphonso Mango, Argentine Caramel, Southern Butter Pecan and German Chocolate Cake. All of the company’s favor varieties can be found in freezer cases at retailers nationwide and through a number of websites.

Flexible pack helps deer-friendly product attract humans Antler King’s Red Zone seed mixes offer hunters and nature enthusiasts a way to attract deer to their properties by growing a variety of plants that tantalize the critters. The company, with a newly redesigned package, is hoping to attract more two-legged creatures (namely, consumers) as well. The Titanium multilayer fexible packaging structure from partner Flair Flexible Packaging (www.fairpackaging.com) is intended to better showcase the seed mix’s properties, and its ability to boost body weight and rack size of white-tail deer, on display in farm supply retailers. The multilayer material blocks moisture transfer, which protects the integrity of the seed, and accepts multi-color reverse rotogravure printing. In addition to helping decrease order turnaround time and increasing billboard, the new bag features a seethrough window that showcases the product. “The window is important to help explain what is inside. It really engages the customer, which is what you want at a point of purchase,” says Antler King founder Todd Stittleburg. The product can be purchased at a variety of farm and hunting supply stores, and on the company’s website (www.antlerking.com).

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Craft beer launches in juicy new cans Winner of a silver medal at the 2011 Great American Beer Festival competition, Mr. Pineapple (the brainchild of SanTanBrewing Co.), is a traditional German wheat ale with a twist: natural pineapple juice is added to give it a sweet, refreshing taste. The libation originally was brewed for the company’s annual Luau celebration during the summer months in Arizona. To facilitate consumption at outdoor venues (which frequently frown upon breakable bottles) the company has launched in 12-oz aluminium cans from Rexam (www.rexam.com).

“We are excited to offer our customers the opportunity to take our perfect summer seasonal brew with them on their outdoor adventures,” says Anthony Canecchia, SanTan Brewing Co. owner and head brewmaster. “By teaming with Rexam, we are able to meet the growing demand for our products across Arizona and beyond in the most recycled beverage package.” In addition to helping increase the beer’s portability, the opaque cans help preserve the brew’s favor by blocking light, reduce transport weight compared to glass bottles and help increase recycling rate. The seasonal brew launched in select Arizona retailers at the end of March 2013.

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What can an

AMPOULE deliver? Protection of formulations from environmental exposure Hermetically sealed glass ampoule in a butyrate tube protects from oxygen

Cardboard sleeve protects swab and when reversed protects user Assorted polyolefin swabs and porous polyethylene swab tips for topical application

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TRENDS // APRIL 2013 www.PackagingDigest.com

packaging concepts Unique beverage looks on sunny side with cartons Sunrich Naturals showcased its SoL line of sunfowerbased shelf-stable beverages at the Natural Products Industry Expo West in March. The beverages are the frst products to pour into Tetra Pak’s (www.tetrapak. com) Tetra Brik Aseptic Edge cartons. The containers are intended to combine product protection, shelf appeal and sustainability for brand owners. The Tetra Brik Aseptic Edge features a sloping top, intended to make it easier for consumers to access, grasp and open the ridged cap; plus a wider opening that makes it easier to pour. A new look, improved functionality, lower cost and better environmental profle make the carton suitable for shelf-stable. “The new Tetra Brik Aseptic Edge packaging is ideal for SoL and all of our nondairy beverages,” says Tina Nelson vp sales and marketing for the company. “It offers superior preservation of the fresh taste and nutritional content of the product in addition to prolonged shelf life.” Three favors of the SoL beverage (Original, Unsweetened and Vanilla) are available.

Lip gloss hits shelves in striking new tube With beauty product shelves becoming increasingly crowded, brand owners are looking to create packages that help their products stand out and appeal to consumers. The team at OEKAbeauty (www.oekabeauty.com) has lent a hand to cosmetics giant Rimmel London by providing a striking new package for its Apocalips lip gloss. The new product comes in a package with a black molded top and a transparent body. The bottle is only partially coated in the upper region. The fnish ends with a course; the decoration fts well with the transparent PET lip gloss packaging because it combines product visibility (which lets beauty-minded shoppers see the precise color of the gloss inside) with an elegant package look. The new Apocalips gloss is available at department stores and specialty retailers nationwide.

Bottle shows off natural beauty Helen Herber, a personal care product company based in Europe, recently launched a range of shower gels that are intended to deliver clean, beautiful skin without the use of harsh, harmful chemicals. To create packaging that communicates the line’s natural, beautifying properties, the company turned to M&H Plastics (www.mhplastics.com). Helen Herber consulted with the packaging team and decided upon the 250-mL Tall Square PET bottle, part of M&H’s stock container line. They topped it off with a black gloss pump. The self-adhesive label uses highquality photography that depicts the main ingredient of the product inside (varieties include Rose, Melon, Sweet Plum, Coffee and Cornfower).

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TRENDS // APRIL 2013 www.PackagingDigest.com

Tackling the ‘soft skills’ gap Non-technical skills like communication emerge as MUST-HAVES FOR PACKAGING PROFESSIONALS.

Kate Bertrand Connolly, Contributing Writer

“If somebody is mentioning Dell packaging pretty much anywhere in the world, our social media team will alert me to that.” — Oliver Campbell, director of procurement for packaging and packaging engineering, Dell packaging pretty much anywhere in the world, our social media team will alert me to that. I usually know within several hours and can respond if necessary,” Campbell says. He adds that knowing what consumers, bloggers and thought leaders are saying about Dell packaging

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“does influence our thinking as we construct our strategic material roadmaps around packaging and what we’re going to do in the future.”

Interpersonal skills On the other hand, too much reliance on electronic communication can cause its own problems. Lee Longstreth, director-engineering at TricorBraun, says he’s frustrated by the e-heavy communication style he sees in some new hires. In such cases, lack of interpersonal skills may be the underlying weakness. “Te only way you are successful, and you really make an impact for yourself and your company, is to be able to build relationships,” Longstreth says. “Te problem I see today is that it’s all so electronic. …You can’t build a relationship electronically.” With media such as Twitter, texting, instant messaging and even email, “it’s all very short. People don’t get a feel for what you’re saying or what you really mean,” he explains. “Tere’s no inflection to your voice, there’s no facial expression to give them an idea of what you’re getting at, and it’s just brutal.” Longstreth advises engineers who are stuck in the e-media rut to meet in person with colleagues and collaborators—or at least pick up the phone—more frequently. Tese habits serve the double purpose of resolving issues and honing interpersonal skills. “I’m talking about being able to walk out of

your office [and] down the hall into somebody else’s office, sit down and resolve a problem,” he says. “How many times do we have a problem with the person two offices down and instead of talking to them, we send them an email?”

A way with language Multilingualism, figuratively and literally, is another increasingly important communication skill. “Te big complaint I hear a lot from leaders of organizations

“Packaging people are too technical. They don’t speak the business language.” — Brian Wagner, vp, consulting services, Packaging Technology Integrated Solutions (PTIS) is that their packaging people are too technical. Tey don’t speak the business language,” says Brian Wagner, vp, consulting services, Packaging Technology Integrated Solutions (PTIS). He adds, “You have to be multilingual in your own company. Tere are truly different languages.

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Any packaging engineer who wants to get and keep a job obviously needs good technical skills. But globalization, evolving business models and increased visibility for packaging as a discipline have made communication-based skills like social media, relationship-building and selling almost as important. “It’s no longer enough to be versed in traditional packaging. Te industry is changing. Society is changing, as well,” says Oliver Campbell, director of procurement for packaging and packaging engineering at Dell. Te drivers range from global supply chains to demand for greener packaging. Managing global supply chains requires cultural sensitivity, which “inherently involves communication,” Campbell says. And with more companies producing annual social-responsibility reports, packaging professionals need to be able to communicate what they do to a non-technical audience. But, Campbell says, “I’d say the biggest [skills] gap is probably on social media. Te reason I say that is because relatively few—although the numbers are growing—really take advantage of it.” Dell’s packaging team is highly attuned to social media, with the company’s Social Media Command Center in Austin, TX, tracking what’s being said. “If somebody is mentioning Dell

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www.PackagingDigest.com APRIL 2013 // TRENDS

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At Hammer Packaging,

“If you’re a talented engineer, and you speak English and Chinese or even another language, like German or French, you become more valuable to us.” — Sean Murphy, chief creative officer at Hong Kong-based YFYJupiter Marketing speaks a language that manufacturing doesn’t understand and vice versa.” In fact, packaging professionals are in a position to learn myriad business languages, including those of design, marketing and finance, because they interact with so many different functions within their companies. Being fluent in languages used in different regions is becoming more useful, as well. “For our Asian-based engineers and designers, basic English skills are needed to help communicate with our international customers. And for our foreign engineers and designers working in Asia, I would suggest learning some Chinese,” says Sean Murphy, chief creative officer at Hong Kong-based YFYJupiter. He adds, “If you’re a talented engineer, and you speak English and Chinese or even another language, like German or French, you become more valuable to us because so many of our clients in Asia come from all around the world. Tese language skills will really bump up your resume with us.”

Selling it Adaptability is another skill that’s becoming more necessary. Like businesspeople in other professions, packaging professionals “need to adjust and be more adaptable to this rapidly changing global marketplace,” says Pete Macauley, director, global packaging and sustainability, Abbott Laboratories. Macauley further notes the value of skills like collaboration, persuasion and negotiation, all of which have a strong communications component. Packaging professionals have always collaborated with others in their own companies, but now they are collaborating much more with other organizations. “I sit in more meetings today with my peer competitors than I probably did in my first 15 or 20 years in the industry. You have to have that collaborative approach,” Macauley says. Also essential is “the ability to sell your ideas,” he adds. “As packaging teams, we always said we want a seat at the table—we need to be more recognized. Well, you look around industry today, and there are more vp-level packaging people than ever before, so we [have] that recognition. Now we’ve got to be able

to sell it. Now we’ve got to deliver on the concepts.” In addition, negotiation skills are good to have. As with selling, negotiation requires careful communication and the ability to craft win-win solutions.

Getting schooled So where’s a packaging professional to go to develop these skills? Tose on the executive track may decide to earn an MBA degree. Others may go the adult-education route, taking classes in person or online. Many colleges and universities offer relevant undergraduate and graduate-level classes through their continuing-ed programs. Stanford University’s Continuing Studies course catalog includes topics like “Persuasive Face-to-Face Business Communication,” “Coaching Skills for Leaders and Managers” and “Negotiation Mastery: Achieving Outstanding Results and Relationships.” Consultants and industry groups also provide professional-development training. Packaging Technology Integrated Solutions, for example, offers a workshop called “Championing and Selling Packaging.” And companies like Abbott offer in-house training, including cultural-sensitivity classes to prepare packaging professionals for projects in

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“I sit in more meetings today with my peer competitors than I probably did in my first 15 or 20 years in the industry. You have to have that collaborative approach.” — Pete Macauley, director, global packaging and sustainability, Abbott Laboratories distant lands or with far-flung team members. Finally, for social media, how-to videos are readily available online (just Google “social media tutorials”). But they may not be necessary. “Te beauty of something like Twitter is it’s actually very simple. Most people who get on there and start playing with it will grasp it,” says Eben Bayer, CEO of Ecovative. “You don’t need to be an expert. You just need to show up.” Ecovative, 518-273-3753 www.mushroompackaging.com Packaging Technology Integrated Solutions, 800-875-0912, www.ptisglobal.com TricorBraun, 800-325-7782 www.tricorbraun.com YFYJupiter, 415-409-2540, www.yfyjupiter.com

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VISIONARY: DELL

Think like champions EMPOWERING PACKAGING ENGINEERS TO MAKE A DIFFERENCE, combined with the continued development of and investment in sustainable materials, ensures a bright future. Lisa McTigue Pierce, Executive Editor Dell’s revolutionary packaging innovations—such as bamboo and mushroom packaging—make it easier for customers to be “green”, enhance the brand experience and promote a healthier supply chain. By building an innovation pipeline, Dell has become a world leader in sustainable packaging, reducing its packaging material use by more than 20 million pounds, saving more than $18 million and contributing to a top-five placing in Newsweek’s U.S. Green Rankings for the past four years. Oliver Campbell, director of procurement for packaging and packaging engineering at Dell, shares his inspiration and vision for the future. Q: What is the most pressing problem in packaging today and why? A: Creativity, and the ability to synthesize

Bold steps Exploring alternative renewable materials for packaging, such as bamboo and mushrooms, nets Dell top spots in various “green” lists, attention in the press and the respect of eco-conscious consumers. 2007 — Dell introduces the Multipack server packaging option, which eliminates up to half of the packaging materials. Up to four 1U rack height servers or 10 blade servers can be delivered in a single

Michael Braungart who have been ideas to create innovative advantage. my inspiration. “Cradle to Cradle’s” Packaging is currently undergoing contrast of “doing good” rather than rapid transformation in three major just “doing less bad” deeply influenced areas: One, customers are demanding my thinking when developing bamboo greener packaging; two, governments and mushroom packaging. Te book worldwide are doing the same through also served as a cultural marker that increased regulation; and, three, the world is changing; it said, “It’s OK investment dollars are flowing into to think this way, and this is where new technologies. When coupled with the next profitable opportunities lie.” a projected 1 billion increase in global I have a signed first edition copy that population—which is like adding I treasure. another India or China—in 12 short Oliver Campbell years, those who succeed will innovate Q: What are some of the most exciting packaging to provide cost-competitive packaging that supports projects im which you’ve been involved? an empowering future that people are demanding. A: Te projects we work on just seem to get better and better, so stay tuned! Te industry now has Q: How do you motivate your team in more capability and openness to pursue our ideas. packaging R&D? A: I coach my team to think like champions—to But definitely the best moment was when I told my engineers we were going to make mushroom take the smart risks. Nearly everyone has a special packaging. Tey looked at me like I was crazy. I told project. Not all projects pan out, but they are all them they would make history, and they did. interesting. It works because it’s more about the team than the individual. We help each other, Q: Where is the industry headed? share the credit and believe in making a difference. A: Te future of packaging looks bright. Maybe it’s corny, but it’s amazing how powerful this Investment capital continues to move into the type of culture can be. development of sustainable materials. I think it has to for the reasons outlined above. We know the Q: Who has influenced you the most leaders in this sector, and it has been phenomenal in packaging and how? to see their growth. A: Hands down, it’s Bill McDonough and

box with an integrated pallet. Customers ordering delivery of multiple products at one time can take advantage of this highly efficient delivery option. Collateral materials can be reduced by up to 75 percent, too: Only one set of product manuals and CDs is included in each box, further reducing paper use and material waste.

2010 — At No. 1, Dell tops Newsweek’s list of America’s Greenest Companies.

2008 — Dell launches its “three Cs” packaging strategy, which focuses on the cube (packaging volume), content (what it’s made of) and curbside recyclability of its packaging materials. The goal is to save more than $8 million and eliminate approximately 20 million pounds of packaging material by 2012.

Since 2008, the company has increased the amount of recycled content in its packaging to approximately 32 percent.

2009 — Dell begins shipping its Dell Inspiron Mini 10 and Mini 10v netbooks with cushions made from bamboo (below), a highly renewable material that serves as an alternative to foams often used in packaging. The global “green” enterprise IT study released by Strategic Oxygen and Cohn & Wolfe reveals Dell as the No. 1 green technology brand.

Dell’s bamboo packaging is certified “compostable” in municipal and industrial aerobic composting facilities, receiving D-6400 certification from the American Society for Testing and Materials (ASTM).

2011 — After testing cushioning made from a new “rapid renewable” material— mushrooms (above, right)—Dell says it is ready to use the EcoCradle mushroombased packaging from Ecovative (www. mushroompackaging.com) commercially in a pilot with its PowerEdge R710 servers to help reach its waste reduction goal. Dell’s 3Cs strategy earns the 3R Packaging Merit Award from Singapore’s National Environment Agency. Dell ranks No. 8 on Interbrand’s 2011 Best Global Green Brands list.

2012 — Dell announces that it has eliminated more than 20 million pounds of packaging material since 2008. It exceeds its goals by reducing the volume of its packaging more than 12 percent, increasing the amount of recycled and renewable content up to 40 percent and ensuring that up to 75 percent of its packaging is recyclable or compostable at curbside. Dell appears again on Interbrand’s Best Global Green Brands list, moving up to No. 7. The Green Supply Chain CHaINA award by the Global Supply Chain Council, Asia’s leading professional organization in supply chain management, acknowledges Dell for greening its supply chain with bamboo packaging.

Thanks to Muller Martini Packaging Technology (see ad on opposite page) for sponsoring this article about Dell, as part of our continuing Visionary series.

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TRENDS // APRIL 2013 www.PackagingDigest.com

sustainability Embracing the ugly stepchildren of sustainability You have probably never heard of a package that is advertised for its superior low acidification potential. It’s similarly doubtful that many corporate sustainability goals include a reduction of eutrophication. And it’s all but certain that a packaging decision has never been made based on an estimate of ionizing radiation. Tese kinds of indicators are what I like to call the “ugly stepchildren” of sustainability—we know that maybe they ought to receive our attention, but they end up not getting much of it. Te reality is that experts can continue to identify a plethora of important sustainability indicators, but they can’t make companies use them. Te choice to use certain indicators lies with the packaging decision makers, who have varying goals and may or may not be the sustainability experts. One challenge lies in the large and growing number of environmental indicators, and the fact that environmental considerations are only one of several considerations used in decision-making alongside things like cost, availability and marketability. Weighing the merits of several considerations creates the desire for simplified information. Cost is often boiled down to one number. Availability can be as

simple as a yes or no. Marketability, however, is a bit more of an interesting consideration, and perhaps it could serve as a model for determining environmental preferability. To determine marketability, complex information from consumer testing, focus groups, insights and educated guesses may be all distilled into one feeling of whether or not a package will do well in the marketplace. Environmental preferability should follow a similar route—a complex set of indicators used to inform one judgment: whether or not the package will be sufficiently benign to the environment over its life cycle. Te trend in determining environmental preferability, though, is to use a sparse set of indicators rather than a complex one. Recyclability seems to be a commonly used indicator (though the idea of recyclability in itself can be rather complex). It’s not uncommon for a single metric to be the only contributor used in determining environmental preferability. As for the ugly stepchildren, they remain on the outside looking in. If a package does happen to be preferable in, say, SOx and NOx emissions, then that information might make its way into marketing materials and be used as justification for the superiority of the package. But we’re a long way from realizing a

supply chain where a unified set of numerous indicators are always used in every decision. At the root of the issue lie the perceptions of consumers on sustainability considerations. Te trickle-up effect from consumers is often indirect and convoluted, but any profit-seeking enterprise has a prime directive to provide a product that is desired by consumers. Unfortunately for our ugly stepchildren, consumers haven’t heard about the importance of ionizing radiation and eutrophication potential either, and it’s unlikely that they can all become the next incarnation of concern over global warming. If consumers concern themselves with the environmental attributes of packaging, it’s likely that they too will simplify the situation. More often than not, that simplification results in a perception of waste generation. To a consumer, less packaging is good, recyclable packaging is better—and that’s often the extent of the consideration. Consumers cannot be expected to understand every aspect of sustainability as it applies to packaging. Te torch must be passed to industry if a holistic set of environmental indicators is ever to be used in supply chain decision-making. If this is to happen, the embracers of the ugly stepchildren must light the way.

Author Adam Gendell is a project manager at GreenBlue’s Sustainable Packaging Coalition. For additional information about the Sustainable Packaging Coalition, visit www.sustainablepackaging.org.

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BEST PRACTICES // APRIL 2013 www.PackagingDigest.com

Lean efficiency A cculture ulture ooff ttotal otal eemployee mployee eempowerment mpowerment aatt ccontract ontract ppacker acker AAerofi erofil drives drives continuous continuous iimprovement mpro ement eevery er dday. a

pays dividends

Jack Mans, Plant Operations Editor

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PHOTO PHOT O BY JEN JENNIFE NIFER NIFE RF FIELD L LD

Aerofi l Technology Inc. (ATI) began its operations in Sullivan, MO, in the fall of 1988 with two small aerosol lines and less than 50,000 sq ft of space. Since then, ATI has greatly expanded and now serves clients around the world. Its capabilities, customer base and facility size have grown exponentially during the past 25 years. Today, ATI is a Lean contract packager with a continuous-improvement culture with approximately 350 full-time employees and 16 production lines in a 400,000-sq-ft facility. In 2007, ATI’s ownership group (privately held) knew that, to remain competitive in today’s fierce global economy it had to differentiate itself from its many competitors by being able to create a true value-added culture in which the entire supply chain would benefit. Robert Dunaway, CEO/owner, convinced his partners that ATI’s adopting the philosophies and practices of the Toyota Production System (TPS) was vital to the company’s long term success and has never looked back. “At ATI, the Aerofil Business System is no longer just another initiative, but a way of life and the culture of our entire workforce,” says Dunaway. At the outset of its Lean journey, the company immediately dedicated four of its top managers full time to both learn and implement the many learnings and processes of TPS that are now commonplace across the company today. Like anyone about to embark on a journey, they started by creating what is referred to as a Value Stream Map that documented their manufacturing processes and information flow from receipt of raw materials through the shipment of the finished goods to their customers. It was from here that other foundational tools such as 6S, Standard Work, One-Piece Flow and Pull Systems rapidly evolved. “Lean has had an immediate and dramatic impact on the entire workforce and culture since Day 1,” says Pat Bergin, president. At the core of the learning, ATI focused on what it considers its most valuable resource. “Our most valuable and precious asset is not our equipment, it’s not how many units we produced in a given day—it’s our employees,” says Bergin. Lean unleashed and empowered the organization’s workforce from the CEO on down. It engaged every single employee throughout the entire enterprise, driving continuous improvement on a daily basis, according to Bergin. In the spring of 2009, ATI subdivided the company into smaller, more manageable business units, also known as Value Streams, with their own individual Profit & Loss. ATI identified that it wasn’t doing as well as originally thought in its dry and granular business and decided to exit that category completely. It immediately began looking at the latest high-tech/high-speed liquid bottling line available in the marketplace. Te new line, which started in October 2012, runs 15 different bottles with seven different closures, including trigger closures.

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Joe Sonderman (left) and Greg Wilke explain features of the Spic and Span bottle.

In designing the high speed line, ATI first established the operational requirements for each piece of equipment on the new line and then used another Lean tool known as 3P (Production, Preparation, Process), which required seven different layouts at the outset of the project. Once the equipment was selected, the 3P Team literally placed full-size corrugated cutouts of each piece of equipment on the floor to determine the most suitable line layout. “Tis let us get a good idea of how the equipment would fit in the room, and how accessible it would be for the operators,” says Greg Wilke, who was the project manager for the installation and is now the production leader during start-up for the new line. Te result is an efficient high-speed packaging line that is operated by only three people. “Flexibility is one of our strengths, so the new line needed to be capable of running different bottle styles and closures,” says Joe Sonderman, svp of operations. “Changeover was a paramount

concern, because we have to get in and get out of different products in a timely manner.” A major change that was instituted for the new line was that processing and packaging are in the same room, though they are in separately defined areas. “We have always located processing and packaging in separate rooms, but this new arrangement allows close interaction and effective communication between blending operators and line operators,” says Sonderman.

Dedicated line integration As the planning for the new line progressed, systems integrator Advanced Packaging Integration became a key contributor. “We were initially contacted to bid on the robotic palletizer,” says John Vaninger, vp-operations, “but as we got more involved in the project, ATI realized that we could do a lot more for them than the robotic palletizer.” Advanced Packaging Integration provided the systems integration, supplying all of the conveyors and supplying the controls integration.

Changepart storage protects and delivers With the multitude of containers that are run on the new line and more that will be added, storing and keeping track of the changeparts for all of the equipment loomed as a significant challenge. Ingeniously, ATI installed a Shuttle XP500 vertical storage unit with 38 shelves from Kardex Remstar LLC to store all of its changeparts. Horizontal shelves are arranged vertically along the front and back of the unit. When the item on a shelf is required, the shelf is moved onto a belt system that transports it down the center of the unit to the opening at the front, where the item is automatically presented to the operator. The Shuttle XP is a fully automated system. When an item is first placed into the unit, the operator identifies the tray number on the control panel and the system remembers the location. To retrieve an item, the operator enters the item name, and the system automatically retrieves it. The plant uses carts to move the changeparts between the storage facility and the equipment on the packaging line.

An automated vertical storage unit, with 38 shelves, stores all of the changeparts for the new line. To retrieve an item, the operator enters the item name into the HMI, and the system automatically delivers the appropriate tray to the delivery space. “The Kardex system has worked out very well for us,” says production leader Greg Wilke. “It doesn’t take up much floor space for the amount of storage it provides, and it allows us to easily keep track of all of the changeparts. Also, it eliminates any damage that might occur if the parts were sitting out on racks.”

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Monobloc filler/capper includes a 30-head mass flow filler and a 12-head capper. The filler incorporates Coriolis technology that achieves +/-1g fill accuracy.

“ATI had a definite idea of what they wanted in the new line,” says Vaninger. Tey wanted a U-shaped layout with the operators in the center. Because they are a contract packager and have to be able to run a variety of packages, they wanted the line to be as flexible as possible and require minimum changeover time. Among Advanced Packaging Integration’s tasks was to integrate the entire packaging line and the development of the controls. “We integrated all of the machines into one main processor and common HMI, which monitors the status of each machine and displays the status of each machine, as well as the OEE (Overall Equipment Effectiveness), on the 60-inch overhead LCD scoreboard,” says Vaninger. Each machine has its own dedicated controls and HMI, but these are also integrated into the main system. Advanced Packaging Integration designed and built all of the conveyors along with required line devices that monitor bottle movement throughout the system. All of the bottle conveyors are equipped with quick-change guide rails to reduce changeover time, and all case conveyors are powered by 24-volt DC motors to minimize noise and energy costs. Multiple vision systems were installed throughout the packaging line to ensure product quality at each stage of the filling and packaging. Tese are included at the exit of the unscrambler to ensure the bottles are oriented properly, at the exit of the labeler to ensure that no labels are missing and that labels are properly oriented, after filling and capping to ensure proper filling level and that caps are in place and are not cocked and after the case packer to ensure that cases are filled. Cognex supplied the cameras, and the controls are AllenBradley from Rockwell Automation to provide a common platform.

Running 22-oz Spic and Span bottles During Packaging Digest’s visit, the line was running a 22-oz Spic and Span bottle with a handle and a trigger closure at a rate of 150 bottles/min. To start this operation, PET bottles are loaded into the floor hopper of a Posimat Posiflex 30-VA bottle unscrambler. Te bottles are lifted to an overhead Continued on page 24

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hopper on a cleated conveyor. Te 24-pocket unscrambler has two bowls that rotate in different directions to achieve proper bottle orientation. Te bottles leaving the unscrambler are conveyed on a vacuum conveyor to eliminate tipping. “A major reason that we selected the Posimat unscrambler is because the changeover from one bottle to another is so quick. Once the new bottle is programmed, it takes a push of the button on the HMI and toolless changeover of the orienter in minutes to perform the changeover,” says Sonderman. Te bottles travel to a Pago Model 520 non-

stop pressure-sensitive labeler that applies both front and back labels as well as wraparound labels. Sonderman says, “We label before filling, because there is less product waste if we have to discard a bottle because of a bad label.” Te Model 520 labeler was sold to Aerofil by DTM Packaging LLC, but American Fuji Seal Inc. has since purchased Pago. DTM is still the distributor for the labeler in the U.S. Te labeler features four complete label stations arranged for non-stop configuration to apply the front and back labels. When a roll of

labels runs out, the system automatically switches label stations on the same side of the machine, allowing production to continue uninterrupted during label roll changes. Te operator slides out the label head requiring a new label roll, makes the change and then slides the head back into position, ready to operate. Sensors detect the bottles entering the machine and adjust the speed automatically. A wheel and chain alignment system separates and aligns the bottles for optimum positioning without the need for changeparts. An upper bottle hold-down belt holds the bottles in place during the labeling process. Tis belt is equipped with an adjustable air bladder that compensates for slight differences in bottle height. Te main conveyor and holddown belt are all servo driven and change speeds

“We label before filling, because there is less product waste if we have to discard a bottle because of a bad label.” — Joe Sonderman, ATI’s svp of ops

The pressure-sensitive labeler features four complete label stations arranged to apply front and back labels without stopping for label changes.

The versatile case packer efficiently handles glass, plastic, cans and paperboard in both round and non-round configurations with containers of various sizes. It also handles a variety of secondary packaging container formats, including RSC cases, trays and display trays

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synchronously with the label applicators when the line speed is varied or when changing from one bottle to another. Te labeler achieves a label placement accuracy of +/-2mm. A Cognex camera inspects bottles as they exit to ensure proper label application. If an improperly labeled bottle is detected, it is ejected by an air blast. If three bad bottles in a row are detected, the machine shuts down and triggers an alarm.

Mono-block filler/capper From the labeler, the bottles are conveyed to a Pneumatic Scale Angelus (PSA) mono-block filler/ capper that includes a 30-head mass flow filler and a 12-head capper. Te filler incorporates Coriolis technology from Micro Motion USA that achieves +/-1g fill accuracy. To meet ATI’s explosion-proof requirement, the mono-block system is rated as intrinsically safe. Product from the blending tanks in the adjacent processing area is pumped to the hold tank installed next to the filler. Level and pressure control in the hold tank maintains a constant level in the tank to maximize fill accuracy. Te product is then pumped to the 30 fill heads, each of which has its own supply tube, enabling each meter to act independently. Te nozzles are designed for laminar flow to minimize splashing and aeration. Each nozzle is equipped with a diaphragm valve that features soft stop/start capabilities that allow the flow profile into the bottle to be adjusted to accommodate difficult items, such as foamy or high- or-low viscosity products. Te Micro Motion system automatically tracks product viscosity and temperature and will sound an alarm if they are out of spec. Te system, which includes a no-bottle/no-fill feature, tracks the fill of each Continued on page 26

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“Here again, flexibility was essential,” says Sonderman. “Tis capper allows us to efficiently run every kind of closure we have on the market with minimal changeover requirements. Pneumatic Scale Angelus’s solution for not only applying triggers and pumps but also a variety of caps on the same platform was a key reason they were selected.”

Integrated controls

The robotic palletizer HMI allows an operator to change over the palletizer in seconds, without changeparts. The custom controls package allows new product patterns to be both added and adjusted via the HMI without the need of a PC.

Te filler/capper is controlled from a single operator station. Te PLC-based controls architecture is configured with simple recipe-driven parameters that track and display the weight, temperature and density for each bottle filled. A user-friendly touchscreen interface allows each filling head to be monitored, sampled and adjusted. And because each mass-flow meter houses its own control package, each meter can be adjusted independently. Product recipes can be created and edited, and rejection parameters for out-of-spec containers can be set as well. Real-time and historical shift data can be viewed on-screen and printed. And the programmable logic controlbased technology makes system diagnosis and servicing easier. se Te touchscreen also simplifies capper adjustments. Te touchscreen interface allows ad ooperator control of all capper functions and displays diagnostics. Optional recipe height d adjustment offers instant, push-button container ad height changeover. A Cognex system at the exit of the capper looks for cocked caps or missing caps or no quills, and rejects those bottles. QC personnel collect samples from all heads once an hour to ensure that there are no undetected problems.

Versatile case packer

The wrapper features patented No-Thread powered pre-stretch technology in which the system essentially threads itself without operator intervention, and which stretches the film to twice or more its stationary length as it is being wound around the pallet to reduce film usage.

bottle and will reject the bottle after it leaves the fill is low. capper if the fill low Te filled bottles travel through a transfer starwheel into the 12-head capper that was chosen by ATI because it can run all types of closures, including trigger and pump caps as well as plug and screw caps. Trigger caps can be a challenge, and a sensor on the capper detects the opening on the bottle and a V-block system helps guide the quills into the bottle. Te capper fully tightens the cap

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to a preset torque using magnetic torque control, eliminating the need for a retorquer. retorquer In response to ATI’s diverse packaging requirements, PSA also supplied two integrated sorters to supply triggers, pumps, press-on and screw-on closures. Quick SKU changeovers are efficiently accomplished with PSA’s Zepf Mark II, No-Tool container handling parts in conjunction with a recipe driven, motorized turret-height adjustment feature.

Te line at ATI is arranged in a U-shape, so bottles leaving the capper make a right turn and then travel along an accumulation conveyor before making another right turn to travel through the downstream equipment. Tey travel through a PB inkjet printer from Hitachi America Ltd. that applies a lot code on the back side of bottles below the label. Bottles continue through an Enercon Industries Corp. Super Seal induction sealer. Next the bottles enter a Hartness Intl. Inc. Model 835 case packer. As with all of the equipment, flexibility was paramount with quick and simple tool-less changeover. Te Model 835 efficiently handles glass, plastic, cans and paperboard in both h rround and non-round configurations with containers oof various sizes. It also handles a variety of secondary packaging formats including RSC cases, trays and p display trays. d Bottles enter the case packer single file before a swinging gate diverts them into lanes. Te unit was running the Spic and Span bottles in four lanes for 12-pack cases, but it can run up to six lanes, which ATI uses to pack 18-bottle cases. It can also pack multiple cases simultaneously for high-speed requirements. Te packer features a patented “air transfer” system that provides low-pressure container handling that offers gentle conveyance and

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packaging of lightweight and unconventionally shaped containers. ATI installed a Model 330 adhesive case erector/bottom sealer from A-B-C Packaging Machine Corp. to erect the cases for the packer. Te continuous-motion unit features PLC electronics with touchscreen controls for operation, documentation and diagnostics. A Cognex camera

“Our employees are the ‘real experts’ who guide us in our continuousimprovement processes.” — Pat Bergin, president, ATI looks down into the finished cases leaving the case packer to ensure that no bottles are missing, after which an A-B-C Packaging Machine top sealer tapes the cases shut. Te cases travel past a ProSeries printer from Foxjet, an ITW Co., that prints a lot code and other information on the cases, and the cases then travel up a Ryson Intl. Inc. spiral conveyor to an overhead conveyor that transports them to the warehouse. Tere the cases are palletized with an IRB 660 robot from ABB Inc. that is programmed by Advanced Packaging Integration. Te palletizer HMI allows an operator to change over the palletizer in seconds, requiring no changeparts to

MATERIAL MASTER ™

switch to any of ATI’s many products. Advanced Packaging Integration’s custom controls package allows new product patterns to be both added and adjusted via the HMI without the need of a PC. Te pallets are conveyed to a Wulftec Intl. Model WCRT175 stretch wrapper, where an arm rotates around the stationary pallet and applies the film. Te arm starts at the bottom, rises to the top and then goes back down to the bottom of the pallet, so there is a double layer of film applied. Te wrapper features Wulftec’s patented No-Tread powered pre-stretch technology in which the system essentially threads itself without operator intervention. It stretches the film to twice or more its stationary length as its being wound to reduce film usage. Te wrapped pallet is then conveyed past a Model 250 print-and-apply labeler from ID Technology, div. of Pro Mach, that applies a corner-wrap label.

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ABB Inc., 248-391-9000, www.abb.com A-B-C Packaging Machine Corp., 727-937-5144, www.abcpackaging.com Advanced Packaging Integration, 314-993-3400 www.advancedpack.com Aerofil Technology Inc., 573-468-1644 www.aerofil.com Cognex Machine Vision Systems, 508-650-3000 www.cognex.com DTM Packaging LLC, 781-749-1866 www.dtmpackaging.com Enercon Industries Corp., 262-255-6070 www.enerconind.com Foxjet, an ITW Co., 800-369-5384, www.foxjet.com Hartness Intl. Inc., 800-845-8791, www.hartness.com Hitachi America Ltd., 704-494-3008 www.hitachi-america.us ID Technology, div. of Pro Mach, 817-626-7779 www.idtechnology.com Kardex Remstar LLC, 800-639-5805 www.kardexremstar.com Micro Motion Inc., 303-530-8400 www2.emersonprocess.com Pneumatic Scale Corp., 330-923-0491 www.barry-wehmillerco.com Posimat, 305-477-2029, www.posimat.com Rockwell Automation, 414-382-2000 www.rockwellautomation.com Ryson Intl. Inc., 757-898-1530 www.ryson.com Wulftec Intl., 877-985-3832, www.wulftec.com

The future As ATI looks to its future, Lean is clearly the dominating driving force for the company’s culture. “It is our way of life,” says Bergin. “We are steadfast in our convictions that it’s our employees that are the ‘real experts’ who guide us in our continuous-improvement processes daily. Tey were involved from the very beginning of the highspeed liquid line from design, to development, to the FAT [factory acceptance test] to the final implementation and are the true keys to ATI’s longstanding success.”

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A ‘suite’ spot for flex packs GSC Packaging’s move into a new 100,000-sq-ft facility with 16 separate packaging suites that IMPROVE QUALITY CONTROL positions the contract packager for continued growth in stick packs, pouches and bags for powdered and other dry products. Rick Lingle, Technical Editor

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At the center of the quality-protecting product and package flow are the 16 side-by-side packaging suites. Entered through a plastic curtain, each suite is subdivided into primary and secondary packaging operations and offer positive air flow and state-of-the-art dust collection for the largely powdery products.

stick pack vertical FFS packaging lines, as well as various semi-automatic, large-format automatic, secondary packaging, shrink wrapping, banding and cartoning, kitting and point-of-purchase display packaging. Using these systems, GSC Packaging packages dry food-grade powders and particulates for products including nutritional and protein supplements, drink mixes, dry cereals, hot chocolate mix and cheese powders. In addition to powdered products, it also packages croutons, soup mixes and rice. Starting in early 2013, it is packaging stuffing for the first time, for a nationally recognized celebrity brand. Tis month [April] it was planning to package granola for the first time, corresponding

to the startup of two custom-dedicated lines to package the granola into single-serve packages. Te products are primarily sold through retail rather than foodservice channels. Tese dry foodstuffs are packaged into three primary package formats, all of which are flexibles: stick packs, stand-up pouches and bags that range in size from a 2x2-inch sugar-packet size sachet to a large-format, one-kilo bag 18 inches tall x 12 inches wide. Te secondary packaging operations beyond the wall are a mix of semi-automatic and manual operations. Shapiro is a proponent of flexible packaging. “We hear all the time about reduced packaging for Continued on page 30

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For CEO Bob Shapiro, the recent move of GSC Packaging into a new 100,000-sq-ft facility in Atlanta fulfills a long-held vision: To conduct packaging production the way it should be done from a quality-optimized, material-flow perspective. Te facility features a state-of-theart layout and design, the latest air-handling technology, lot-code tracking, real-time computerized inventory control, dust control and air-conditioned storage. Te plant has a centrally located quality lab and an on-site maintenance shop. Additionally, there are data ports in the manufacturing areas so that personnel can input production information in real-time online. But what’s at the focal point of Shapiro’s vision—and literally the center of the building’s layout—are 16 parallel packaging suites isolated from each other and from the rest of the plant. Each room is equipped with positive air pressure and subdivided by a cement wall into primary and secondary packaging operations. Personnel enter the front of each suite through a barrier of thick plastic curtains. While the packaging functions and machinery are segregated, so too are the upstream workers separated from the downstream. “Segregation was not feasible in the previous plant, but it’s something that I always wanted,” says Shapiro. “Essentially what we’ve done is removed much of the product contamination risk. Plant personnel are the main source of contamination in any food plant and with this approach we’ve minimized that risk.” Due to the packaging of nutraceuticals and dietary supplements, the plant adheres to 21CFR111 guidelines that are a higher standard than for food processing for all products. “Tat drives everything here,” Shapiro points out (see “Adhering to a higher standard” on p.30). In one example, batches approved for packaging are secured within a locked fence in the warehouse. One of the 16 suites is currently empty, but the others have been earmarked for on-going or shortterm projects. “We can quickly set up each suite and take them down per-project or we can dedicate rooms indefinitely without interfering with other operations,” says Shapiro. Typically 12 of the suites are actively packaging at any given time over the plant’s six days weekly, two shifts of operation. Within the suites, the operations boast 15 packaging production lines comprising seven horizontal form/fill/seal (FFS) lines, three six-lane

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Several years later in 2008 he bought a second Viking Masek system; GSC Packaging’s newest Viking Masek Model ST560 stickpack machine, built with the latest automation controls including servo drives, was being commissioned during our Q1 2013 visit. It can produce six stick-pack styles. Te stick-pack machines run at 50 cycles/min, and with a 6-up system the output is 300 packs/ min. Product netweights are from 2 to 10 grams. Recently, one line produced 180,000 sticks on one shift, Shapiro boasts. “Te Viking Maseks are extremely A half dozen of the plant’s HFFS systems such as this one were well-made, just beautiful machines refurbished with new components at a cost of $10,000 each. With a that have been refined over the faster ROI versus new, the upgrades enhance the machines’ functionality years,” states Shapiro. “When we as well as “curb appeal” for visitors in keeping with the new facility. bought our second line, it just made sense to buy another one because, sustainability and for environmental friendliness— beyond their reliability, the operators’ familiarity and flexible packaging is extremely conducive to allowed them to operate either line. Tat familiarity decreasing the amount of packaging needed to was also a big plus for our maintenance staff where package a product. Retailers like Walmart/Sam’s standardizing also permits us to maintain a reduced Club continue to push companies to reduce the number of spare parts. Tat has worked out well for amount of packaging. For example, a conversion us. When it came time to buy our third machine, I from a bag-in-box to a stand-up pouch with a went right back to Viking Masek. Te people there zipper eliminates 30 percent of the packaging are nice and their technical support is tremendous.” material. Tese flexible formats we offer are highly In one example, Shapiro made a call at noon sustainable and on-trend.” for a critical problem and the technician from the Te company remains as flexible as its company’s Minnesota headquarters arrived at the packaging. “Tat large-format bag was something Atlanta plant by 7 p.m. that same day. we didn’t do a year ago,” says Shapiro. “We went Shapiro claims that stick packs are the least from producing zero of those to about a million a flexible of the packaging it makes due to the fact month now. If someone came to us and said ‘this is that, though the package length is adjustable, the a format and volume I’m interested in,’ we’ll take a stick packs have a fixed width of 22 millimeters. look at it.” However, they can be produced with a pour-spout Picking—and sticking with—a winner seal and with a tear notch. Shapiro feels stick packs continue to have staying Products arrive preblended in 50-lb bags, 500power. “We still view stick packs as one of our big kilo bulk sacks and everything in between. GSC opportunities for growth,” he emphasizes. “Tere Packaging prefers to use flexible screw conveyors are few companies with our capability in the U.S. from Flexicon to make the product transfer from and none in the southeast. I receive one or two bulk packages to its packaging machines. Due to inquiries a day on stick packs.” the powdery nature of many of the products, the screw conveyors are paired with the plant’s stateof-the-art dust control from Donaldson Torit. “We have an enormous system for collecting dust throughout the plant for environmental and product quality reasons,” notes Shapiro. Rather than following food processing guidelines, Sticks packs have become one of the most GSC Packaging adheres to the more stringent popular packages the company produces. Tat’s pharmaceutical-level standards for all products. little surprise to Shapiro, who had such confidence Examples include: in the potential of the format that he bought • A formal internal audit program is supplemented by the company’s first stick-pack machine about six monthly unannounced audits by GSC’s QA staff; years ago without having a single customer. “I • Card-access security systems and surveillance considered the trend of such an efficient, handy cameras throughout the facility control personnel access format and thought it would be successful and to manufacturing areas and provide 24/7 inspection of all lucked out,” says Shapiro. products and processes; Obviously, it was more foresight than mere luck. • Electronic inventory management system relies on Te VFFS maker, Viking Masek, had been the scanning of printed bar codes to ensure thorough recommended by a consultant. “It ran well and we ingredient identification, as well as forward and had success with it,” he says of the first machine. backward traceability; “It’s the only machine I’ve ever had that was • Sanitation and Good Manufacturing Practices (GMP) uncrated on a Monday and running product at are augmented by validation of cleaning processes production speeds on Tursday. Tat’s uncommon through lab testing of product samples. for a major piece of equipment.”

On rebuilding equipment vs new GSC Packaging CEO Bob Shapiro knows a lot about the concept and reality of refurbishing something old to make it new again. He’s done it not only for more than a half-dozen packaging machines, he’s had it done to the very building in which all this machinery resides, whereby most of the interior has been gutted and rebuilt from the ground up with new systems and walls installed. We asked him more about his lessons learned from the pouching machinery upgrades that were done over the past six months: “To me, rebuilding is a good solution. The capital expenditure is lower so the return-on-investment is quicker. You give existing and familiar equipment a new life and bring it up to the standards of new equipment. We have had a very positive experience considering cost, timing and recommissioning of the equipment. Feedback from our customers has been overwhelmingly positive as well since the equipment looks great and functions at or above original OEM specifications.”

“Dazzling” improvements in HFFS Most of the HFFS machines are from KHS Bartelt, though GSC Packaging also operates other makes as well. He purchased his first KHS machine in 1999 and has added several more since. “Tey really own this market,” he says of the decision. Te most recent addition was a used RPM (rotary pouch machine) Model 950 KHS Bartelt started up in early 2012 that produces pouches with widths from 4 to 9.5 (hence the model designation) inches and from 4 to 15 inches high and with a 4-inch gusset for standing upright. Te machine was rebuilt by KHS with upgraded electronics and new photoelectric sensors. Shapiro likes that the Model 950 maintains positive control of the pouches using two clamps rather than one while they are transported through the machine. “You can drop a large dose and it maintains a solid grip, which then helps produce a good seal,” Continued on page 32

Adhering to a higher standard

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Ingredients kept under lock and key limit access to help raise the company’s food safety and quality standards from food processing level to those of higher pharmaceutical-level compliance.

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he points out. According to KHS, it can accept up to a 5-lb fill and is rated at 65 cycles/min with up to two fill heads. Tese larger packs are mainly protein supplements with multiday servings for 10-, 20- or 30day portions. Other products packed into the large format include stuffing mixes and other foodservice items. Shapiro liked the refurbishment so much he decided to do it for all seven

of the HFFS machines, timed around the relocation. Te motivation for the machinery makeover was as much for looks as performance. “Tis is a bright, shiny new plant and I wanted the equipment to be bright, shiny and like new,” says Shapiro. “We want visitors to be dazzled by the facility, the people and the equipment. While our sanitation crew is second to none, there’s only so much you can do with

older equipment.” Coordinated by his special projects manager and done before and during the move, each machine was stripped down to the frame, which was then sand-blasted, prepped and repainted. All drive motors were replaced and all wear parts were evaluated and replaced as needed by an outside contractor. As the machines were reassembled, current model parts were used exclusively.

YUPO AND VASKA CASE STUDY ®

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A CLEAR, BRAND-FORWARD COLLABORATION IN PACKAGING DESIGN Where brand and packaging innovation meet, exciting new possibilities emerge. Take the recent expansion of Vaska, a leader in natural fabric care that developed a retail product line to complement its institutional laundry care products. The intended launch of Vaska’s new concentrate formulas in 2011 was developed to showcase the unique fluid qualities and clear properties of the detergents. As innovators in the market, Vaska sought out unique packaging design that would let Vaska’s qualities shine through. During that same time frame, Vaska’s bottle molder, Silgan Plastics (silganplastics.com), was also working on innovative new bottle shapes with Yupo Corporation America. Yupo, world leader in In-Mold Label (IML) substrates, had recently expanded its IML product line to include a new, clear substrate to accommodate more options for designs and shapes of blow-molded bottles.

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and for the product to be completely visible through the translucent Vaska bottles. YUPOUltraClear substrate looked just as clear, bold and transparent on Vaska’s lavender bottles as their translucent white bottles. Historically, designers were limited to using a white label that was print matched to the color of the resin. This process, on today’s clear and translucent bottle options, would result in loss of visibility of the product. By promoting product visibility, YUPOUltraClear IML continues to forge the way for brands to showcase their products and truly stand out on retailers’ shelves.

It took about two weeks per machine at a cost of $10,000 each. For Shapiro, that extra work and investment at an already crazy-busy time was worth it. “Te machines look brand new,” he says. “It worked out great.” (See “On rebuilding equipment vs new” on p.30.)

Flexibility in materials and purpose GSC Packaging’s film selection— driven by product and customer needs—is based on moisture- and oxygen-barrier requirements as well as graphics needs. Te majority of the films used are metallized. Because he is not a films expert, Shapiro says he collaborates with several film manufacturers. “I become the focal point and bring all the parties together,” Shapiro explains. “I work with some film companies and folding carton companies and with suppliers of other packaging components. We provide a turnkey solution. We’re not necessarily the expert, but we partner with experts.” One of those expert resources is The Lithotype Co., which for many years has provided the company with rollstock film for

A contract packaging perspective Shapiro has a long history in contract packaging from his early days with Georgia Spice Co., a predecessor company of GSC Packaging. He offers his perspective on the business environment: “Over the last decade people have been reticent to invest in plant and equipment. With the current economic environment, it’s become even more difficult and somewhat risky for especially big companies to be making these investments. That’s particularly true in start-up products or products that might have a limited life span. The trend we’ve seen is that there’s been an increased interest in contract manufacturing and contract packaging. “We see a lot of opportunity with companies that don’t want to make their own capital expenditure investments or that want to concentrate on marketing rather than focus on running a manufacturing plant. We become that manufacturing plant and we just see opportunity after opportunity coming through because of that—a trend I expect to continue.”

For more information or to check out our video showcasing YUPOUltraClear IML, visit yupousa.com/clear or vaskahome.com.

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SYNTHETIC PAPER do it on yupo

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is Printed Specialties in Carrollton, GA. Te vendor provides GSC Packaging primarily with offsetprinted solid bleached sulfate (SBS) cartons in the 15 to 18 pt range for carton counts from 10 to 200. Te print may include specialty metallic inks. “Tey do a tremendous job for us,” adds Shapiro. He says that customers often provide their own qualified suppliers:

“We’re happy to work with any supplier.” Tey are also open to work with just about any customer as well. While the company is 100 percent devoted to flexibles, GSC Packaging is open to non-flexibles, too. “We are a contract packer,” reminds Shapiro. “I tell prospects there’s nothing I like more than buying machines. If someone wanted to package into rigid

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containers, we’d consider it. While we’re exclusively flexible packaging, that’s as of today.” Some time ago Shapiro realized that companies that call on contract packagers want an extension of their own packaging operations—they don’t they want to hear about any limitations. Remaining flexible will remain fundamental to GSC Packaging’s continued success.

GSC Packaging views stick packs as one of the company’s big opportunities for growth.

PHOTO CREDIT: DAEMONPICTURES.COM

stick packs and other products. “Lithotype is extremely capable across many different formats,” says Shapiro. “Tey have wide- and narrow-web presses to do jobs both large and small.” Te vendor provides four basic film structures using various combinations of polyester, metallized low-density polyethylene, paper and foil. For example, a typical HFFS film is paper/LDPE/foil/LDPE. A common stick-pack structure is polyester/LDPE/foil/LDPE. Stick packs are offset-printed in as many as eight colors, though six is typical. A new, fifth film structure introduced in February 2013 that is currently being evaluated by GSC Packaging consists of an outer layer of cellophane to replace the LDPE for stick packs. According to a Lithotype manager, the resultant EZ Tear material is an improvement over tear notches and laser score opening because the material can be easily opened at any point. Another key film supplier is Chromatic Label, based in Irvine, CA. “We’ve worked very successfully with them,” says Shapiro. Shapiro’s go-to company for folding cartons, which he prefers to source locally due to shipping costs, Chromatic Label, 949-475-2300 www.chromaticlabels.com Donaldson Torit, 952-887-3131 www.donaldson.com Flexicon Corp., 610-814-2400 www.flexicon.com GSC Packaging, 404-505-9925 www.gscpackaging.com KHS Bartelt, 941-359-4000 www.khs.com The Lithotype Co., 800-871-8973 www.lithotype.com Printed Specialties, 770-832-1341 www.printedspecialties.com Viking Masek Global Packaging Technologies, 920-564-5051 www.vikingmasek.com

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Filling with minimal labor, maximum output At Grain Millers, PACKAGING PRODUCTION GETS A 40 PERCENT BOOST by upgrading to a new automated filling system.

and, finally, place it on a pallet. “It was a tedious and extremely tiring process,” Selby says. “It really took expertise to properly run the manual machine, and it was extremely labor intensive work.” Te physical strain left operators fatigued, often with sore arms and backs. In addition, the system required two or three operators at any given time. In a typical workday, operators would rotate out and take frequent breaks to keep fatigue at a minimum. Tat created another problem. Te constant pauses and downtime meant inefficient production and lower bag filling rates. Te Grain Millers team knew it needed to find a solution, one that would increase production efficiency by decreasing labor requirements. Te company’s research led to the Topline, a machine that seemed like the ideal solution. Even so, Grain

Top of the line

Te fully automated system accomplishes the entire bagging process from product weighing, to filling and finally bag closure. “It’s really a remarkable system,” Selby says. “One of our biggest challenges had been finding operators who could run the labor-intensive system, both from the skill level required and the physical demand. When we saw Edited by Lisa McTigue Pierce, Executive Editor how easy the Topline system was to operate, we were pretty much sold.” Te Topline weighs the product, fills the bags, seals the filled bags and, best of all for Grain Millers, Tere’s tired and there’s down for the count. requires only one operator to oversee the process and Eugene, Oregon-based grain processor Grain stack empty bags into the automatic bag placer. Millers Inc. was both before changing bagging Product flows into the machine through a machines. Today, with a new machine on its floor hopper system. Once inside, the Topline takes an and workers who no longer have to break their empty bag from a preassembled bundle, fills it to its backs to get the bagging job done, Grain Millers specified weight and then ends the process with the increased its production by about 40 percent. densification and sealing of each bag. From there, an optional robotic system Grain to table takes the bag from the Topline machine Grain Millers has been packaging and places it on the pallet for shipping. conventional organic whole grain Te system works quickly and requires products for more than 30 years. Tese minimal manual labor by the operator. grains are used in baked goods, breads, To further ease operation and cereals and a range of other products increase efficiency, Haver also equipped served around the world. Grain Millers’ Topline with its Haver Getting the grains from raw MEC weighing control system, which commodity to finished product is a acts as the machine’s brain. Haver long process, one that involves several engineers programmed the MEC with steps before packaging. From flake weight and specifications of every grain rollers and dryers to vibratory trays the company bags. Whenever a product and bucket elevators, Grain Millers or bag size is switched out during a relies on several machines to come shift, the operator simply enters the together and create a smooth, cohesive new product ID number and the process. “We operate a closed-loop machine automatically adjusts to the system,” says Tony Selby, plant specified product. manager at Grain Millers. “Basically, it Te MEC ensures the Topline is means we’re able to connect each piece filling each bag to the exact weight of machinery together so we don’t specified for each product. Te system interrupt the flow and disrupt the The filler takes an empty bag from a preassembled bundle, fills it to its specified works by controlling a gate that allows progression of steps.” weight and ends the process with densification and sealing of each bag. material to flow into a netweigher. Once Each machine is important, but the the netweigher is filled to the designated weight, key to the entire Grain Millers system is in the final Millers explored all its options. “It seemed like we the gate closes. Flaps from the netweigher open to step—packaging. Grain Millers now accomplishes just lucked out finding the Topline, so we didn’t a filling spout and the grain flows into the bag. If this key step with the Topline bagging system from stop there,” Selby says. “We communicated our the netweigher is inaccurate, the MEC will pause the Behn + Bates brand of Haver Filling Systems. needs to several manufacturers and asked them production until operators address the problem—an to let us know how their bagging machines could meet them. At the end of the day, we couldn’t find a issue Grain Millers has yet to encounter. Fatigue and frustration “Grain Millers processes so many different types system that fit what we were looking for better than Before Grain Millers had an automatic filling of products throughout the day, so this has been system, its people were shouldering all the weight in the Topline.” an incredible time saver,” Selby says. “It’s the most Selby and his team were also attracted to a manual bagging system. Te strain was beginning consistent scale I’ve ever seen in my life. If you need a Haver Filling Systems because of its extensive to show, not only in the workforce but also in 50.1-lb bag, you are getting a 50.1-lb bag every time.” knowledge and experience. Haver has been the company’s bottom line. Te manual system Haver worked side by side with Grain Millers, not developing technology for greater production required operators to move bags that weighed only in equipping the Topline with the MEC, but anywhere from 25 to 50 pounds, weigh each bag to efficiency and ease of operation for more than also customizing the entire machine to fit the existing 125 years. ensure accuracy, take the bag through heat sealing

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Since incorporating the automated bagging system, Grain Millers has seen an increase in production rates from four to five tons an hour to six to seven tons an hour.

feed conveyors and hopper system. “Te entire transitional process went very well,” Selby says. “A guide from Haver came in, installed the machine and trained us. He went through basic operation and maintenance, as well as recommended spare parts to keep on hand.” Since the transition, Grain Millers has seen a decrease in downtime and increases in production and

maintenance to ensure all the parts are working properly, rollers are oiled, those types of things,” Selby says. “But with the Topline, we do it simply as preventive maintenance to make sure the machine continues to run smoothly.” In addition to weekly maintenance checks, the control panel also “supervises” the machine’s operation to ensure everything is running

“It’s the most consistent scale I’ve ever seen in my life. If you need a 50.1-lb bag, you are getting a 50.1-lb bag every time.” — Tony Selby, plant manager, Grain Millers accuracy. Rather than two to three operators doing hard labor, now only one is required to simply oversee the operation. Grain Millers has been using those workers in other areas of the facility for other tasks, which has made the company even more efficient and productive. Production rates have gone from four to five tons an hour to six to seven tons an hour. Production rates are up to approximately 54,000 tons per year, about 40 percent higher than the 38,000 tons Grain Millers was processing annually prior to getting the automated filling system. At the same time, weekly maintenance time has gone down significantly, from six hours a week to only two. “We like to do weekly

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smoothly and prevents potential maintenance issues. If a part isn’t working properly, the control software sends a signal to the bagger to pause until the issue has been addressed. Operators can check on the issue immediately, before the entire system is potentially thrown off balance and significant downtime results. “Te Haver system really seems to do it all. We couldn’t be happier with our decision,” Selby says. “We’re working the same hours, but we’re able to produce two to three tons more every hour. It’s really made a difference in our operation.”

Haver Filling Systems, 888-964-1837 www.haverusa.com

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Small investment nets big bagging efficiencies A packaging line upgrade for horse oats makes a DRAMATIC IMPROVEMENT IN OUTPUT without extra labor at the “Downton Abbey” estate. Edited by Lisa McTigue Pierce, Executive Editor In the popular British drama “Downton Abbey,” the fictional character Matthew Crawley undertakes to modernize the estate and make it more efficient and sustainable. A modernizing improvement has occurred on the estate on real life: A bagging line at Highclere Castle Horse Feed Ltd., situated on the estate of the “Downton Abbey” drama, has been upgraded by U.K.-based Pacepacker Services to transform a partly manual system into an automated line that now bags 1,500 tons of horse oats each year. Spiroflow Systems is the exclusive distributor of Pacepacker solutions in the United States and Latin America. To minimize the manufacturer’s outlay, Pacepacker seamlessly integrated its Total Bag Control (TBC) bag closing system with the line’s existing machines to provide a turnkey system, giving the manufacturer greater flexibility to handle different bag sizes. As a result the upgraded line has not only eliminated the need for manual labor, but more importantly enabled Highclere Castle to fulfill increased customer demand for oats.

which meant that we could not achieve consistent well-presented packs. As a result, oat wastage was high. Pacepacker Services was recommended to us by wordof-mouth and they immediately suggested their Total Bag Control System as a solution. It would stabilize the bags throughout the sealing process and therefore provide a neat consistent seal.” Ian Merchant, now Pacepacker brand manager for Spiroflow Systems, comments: “It’s the perception of many manufacturers that automating an existing line will be expensive. Pacepacker’s TBC, as with all of our systems, has been designed with features that make it easy to integrate. It works in tandem with existing

The problem Te 3,000 tons of oats processed annually by Highclere Castle Horse Feeds are used as a staple ingredient within horse food. Te harvested oats are clipped, polished, cleaned and graded with the small and broken ones kept for the Estate sheep flock. Te oats can then be bruised or rolled to customer requirement. Half of the oats are delivered in bulk direct to racehorse trainers or collected by feed companies. One feed company puts the “Superior” graded oats into its racing mixtures and exports to seven different countries. Te remaining 1,500 tons, and some wheat and barley, are bagged for various customers from farm shops to polo teams. Quoted as being the “Formula One fuel for racehorses,” the oats are in demand from some of the top U.K. trainers, making them the second celebrated fare to hail from the 5,000-acre Highclere Estate. Over time the original manual line—which weighed, bagged and sealed the oats—was gradually automated to reduce handling and increase throughput. Initially, a weigher, bag presenter and palletizing robot were installed. However, it was the final part of the chain—the bag closing system—that was “letting the side down,” explains farm estate manager James Phillips. “Our old stitching machine drastically hindered our output potential,” Phillips says. “Once the bags were filled and dropped onto the moving conveyor, there was nothing to stabilize them during the stitching process,

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“By automating the bagging and stitching line, we are now able to exploit the potential of our robotic palletizer.” — Lord Carnarvon, owner of Highclere Castle production equipment supplied by other leading manufacturers—as found by Highclere Castle. To achieve a fully automated system, we simply upgraded their existing line to keep project costs to a minimum.”

The solution Programmed with interlocking signals, the TBC is fed from the existing bag presenter and then, with motorized grip arms, holds the bag firmly in place while it is filled from the existing weigher above. Pacepacker programmed the TBC to work in complete unison with the weigher to ensure that the bag filling cycle is as efficient and fast as possible to maximize throughput. Pacepacker replaced the original conveyor system with a TBC system that prepares the bag top while on

the bag clamp, it then transfers the bag to the stitching unit using grip arms and a belt feeder that move in perfect timing with the conveyors sitting underneath. A 90-deg motorized Bag Kicker was also installed, complimenting the line by depositing the upright, sealed, conveyed bag to a flat configuration ready for palletizing. Historically, the line required manual adjustment to deal with multiple bag sizes, which differed depending on each customer’s requirements. Pacepacker’s solution, the TBC, enables the system to be changed over to different sizes and types of bags quickly with only the minimal amount of adjustments required. Quite often the only change required is to raise or lower the conveyors. Once the TBC was established within Highclere’s production line, its problems with waste and pack presentation were completely eliminated. Te full line is now running at six tons of oats per hour. One operator is now able to wrap the pallets, restock the bag presenter and keep an eye on the bagging line operation. By gradually automating its production line, Highclere Castle Horse Feed Ltd. has been able to fulfill its sales potential and is now selling oats on a global scale. “Installation of Pacepacker’s bag closing system has helped us to fully automate our line and we are delighted to report that it has revolutionized the way we pack,” concludes Phillips. Lord Carnarvon, owner of Highclere Castle, says, “I fully endorse the efficiency of the system. By automating the bagging and stitching line, we are now able to exploit the potential of our robotic palletizer. Highclere Castle Horse Feeds has continued to invest in production efficiency and quality of the process and the Pacepacker system has allowed us to considerably increase our sales throughput without the need for extra labor.” Spiroflow Systems Inc., 704-246-0900 www.spiroflowsystems.com

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Pharma bottling line adds flexibility

With the addition of a high-speed tablet filling line—along with a “brite stock” model—Praxis Packaging Solutions is expanding and IMPROVING ITS CONTRACT CAPABILITIES. David Vaczek, Contributing Writer Praxis Packaging Solutions is adding the final touches to its first primary fill equipment line for providing vertically integrated packaging services for over-the-counter (OTC) and prescription pharmaceutical customers. Designed to work flexibly with Praxis’s secondary packaging capability, the high-speed tablet filling line supports compliant, efficient filling and packaging of a multitude of stock-keeping units (SKUs), as well as high-volume projects. For housing the line, the contract packager added on 45,000 sq ft to its already 130,000 sq ft of cGMP space at its Grand Rapids, MI, facility. “We have had a great deal of interest from our current customer base to expand to the next step in contract packaging—primary tablet filling—and new potential clients have expressed interest in this expansion,” says Scott Hanmer, vp of sales, Praxis Packaging. “With these new capabilities, we can confidently sit down with a variety of customers to meet their needs.” Te line is designed for straight-through production or for supporting the “brite stock” model, which is typically used in food canning operations. High-volume jobs run in one pass from bulk product to labeled finished goods. Changeparts

Praxis’ primary fill line features a Fowler Products retourque station (Model CA-8 360).

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are available for a array of bottle sizes. Alternately, primary filling and secondary labeling may be occurring simultaneously on different products. Te inventoried brite stock is packed off as needed in response to fluctuating demand across SKUs with different retail labels or for different countries. “We have engineered the line to be able to do filling and a different label simultaneously, and still maintain segregation and control from a quality and compliance standpoint,” says Scott Wells, project lead consultant, PharmaAgility Consulting Group. Contracted by Praxis for the project, PharmaAgility drew on its network of consultants with expertise in quality, compliance, engineering, and operations, who also helped with training and recruiting, Hanmer says.

Simultaneous filling and labeling PharmaAgility sourced the line from a big pharma company, reengineering it to Praxis’s requirements. Filling on the primary side of the line can be independent of the secondary operations. “It is an innovative design that gives Praxis the most flexibility to offer to their client base. Tey can be filling on one side of the line, and labeling a different product on the other side of the line, and still be fully compliant,” Wells adds. In the packaging-to-demand scenario, Praxis can respond more quickly to demand variations from seasonal OTCs or new product launches. “It gives our customers many more options in our traditional core competency of secondary packaging,” Hanmer says. PharmaAgility’s line revamp includes serialization capabilities that expand Praxis’s ability to help manufacturers meet pending serialization requirements. Te line features a Weiler highspeed labeler with integrated Videojet printer and e-pedigree-capable Systech Sentri vision system.

“Praxis will be able to offer a contract solution to companies facing the large investment hurdle of implementing serialization. We have tied in the different vendors in a holistic solution, to make it as cost neutral as possible through process improvement and waste reduction,” Wells says. According to Wells, this has been the most rapid implementation his company has been a part of. Praxis made decisions quickly. Equipment was specified and purchased at the end of August 2012 and delivered Sept. 11. Qualification started immediately after the commissioning was complete. Te line was in a product-validation-ready state by December. Because this is the first time Praxis was handling open product in its facility, PharmaAgility put quality systems in place so it sits on a solid foundation of quality. “With FDA and European Medicines Agency (EMA) compliance, Praxis can ensure to authorities and its clients it is producing conforming product,” Wells says. Te primary line features an Omega Design unscrambler, and an Aylward Model 725DL counter-filler. Te filler counts the fill by sensing the breaks in a beam that is present over the primary fill chute for each fill unit. Bottles are inspected as they are indexed 25 at a time, with underfilled or overfilled bottles auto-rejected; passed bottles are then further inspected at an OCS checkweigher. Te capping station was upgraded with a KapsAll Packaging Systems GC-8 capper supporting both screw and snap caps used in pharma applications. Bottles then move to an Enercon induction sealer, and on to a Fowler Products retourquer (Model CA-8 360). A CEIA metal detector is available.

Coding for control Te primary line through the retourque station is separated from downstream secondary operations by a cGMP-compliant wall for accountability and control. In straight-through production, filled bottles pass through a transitive separation wall to the Weiler labeler (Model PRL-1500L-S10) for label application and variable printing with a Videojet thermal print system. Multiple cameras check for label content, placement, orientation and quality. Bottles destined for brite stock are coded for identification after the retourquer with a portable Videojet UV printer, before conveyance off the line to storage. Te UV code is checked when the bottles are brought back for secondary labeling to ensure the right product is getting the right product label. Te warehoused-stocked unlabeled bottles are pulled into the labeling operation based on customer

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A growing trend in the pharma space, the brite stock model can be more efficient when multiple products and pack-outs create multiple changeovers and downtime. Upstream primary line performance is not impacted by downstream labeling starts and stops for label changes, increasing equipment uptime. Primary and secondary lines can run more efficiently, as the primary filling process can typically be run faster than the downstream labeling process, Wells says.

Fine tuning A Kaps-all Packaging Systems GC-8 capper is upgraded to support both screw and snap-on caps for pharma applications.

demand. Te process provides a quicker turnaround time with orders filled more closely to the order date. “We can issue the brite stock to any of a number of our secondary packaging lines located in our 100,000 sq ft adjacent space for labeling, inserts, stretch cards and cartoning. Te labeling of the brite stock is married up with the secondary pack equipment. Te flexibility that PharmaAgility group has engineered into the line for us is spectacular,” Hanmer says. Traditional lines in batch production mode producing multiple SKUs each in a different trade dress present “unrewarded complexity—the additional changeovers take away time, add cost and reduce your efficiency as you increase the amount of variation put into the system,” Wells says.

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PharmaAgility redesigned a line that was centrally controlled to one where component stations are individually controlled, mostly using Allen Bradley Panel View Plus HMIs. Te primary line equipment is synchronizable to enable an efficient product flow through the entire line for different speeds and pack-out configurations. Variable speed drivers on each machine are sequenced—generally to the rate of the filler—to avoid overloading or starving equipment stations. Quality and control solutions include automated and manual in-process checks, and a product control and segregation system for cGMP-compliant accountability and control. “We wanted this to be a world-class quality system for meeting FDA requirements and customers’ expectations,” Wells says. Will the new setup offer the capacity required as more customers come looking for more services under one roof? “We can easily expand. Te facility is outfitted

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to be able to accept multiple lines when the need arises. If demand comes in that exceeds the capability of the one filler, it is engineered to be scalable. We are prepared to accept a second or third line,” Hanmer says. David Vaczek is senior editor of Pharmaceutical & Medical Packaging News, a sister media brand of Packaging Digest. Allen Bradley, div. of Rockwell Automation 414-382-2000, www.ab.com Aylward Enterprises, 252-633-5757 www.aylward-usa.com CEIA, +39 0575 4181, www.ceia.net Enercon, 630-864-3600, www.enercon.com Fowler Products Co., 877-549-3301 www.fowlerproducts.com Kaps-All Packaging Systems Machinery, 631-727-0300, www.kapsall.com OCS Checkweighers, 678-344-8300 www.ocs-cw.com Omega Design, 800-346-0191 www.omegadesign.com PharmAgility Consulting Group LLC, 877-751-1301 www.pharmagilty.com Praxis Packaging Solutions, 616-827-8525www.praxispackaging.com Systech Intl., 800-847-7123, www.systech-tips.com Videojet Technologies, 800-843-3610 www.videojet.com Weiler Labeling Systems, 856- 273-3377 www.weilerls.com

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Dressing for success Advanced x-ray inspection helps Ken’s Foods ensure all products MEET HIGH STANDARDS. Edited by Jenni Spinner, Senior Editor Ken’s Foods produces and packages more than 400 varieties of dressings, sauces, marinades and condiments for retail and foodservice. Its three U.S. plants (in Marlborough, MA; McDonough, GA; and Las Vegas) run 24/7, with two shifts working production non-stop. Its clients include some of the world’s biggest retailers, including Walmart. Te family owned and operated company has a laser focus on quality; all products must meet tough customer and consumer standards, and succeed in a highly competitive, increasingly global marketplace. To support this mission, Ken’s Foods partnered with Eagle Product Inspection to include advanced x-ray inspection systems on its line. “Eagle’s x-ray systems have ensured that we have increased contaminant detection capabilities and product savings. Our quality control department also uses the x-ray systems as a critical control point in its verification tools to assist in complying with Hazard Analysis and Critical Control Points (HACCP) guidelines and Safe Quality Food (SQF) protocols” commented Jeff Murzycki, corporate project engineer, Ken’s Foods. After 9/11, the Food and Drug Administration advised food manufacturers to use tamper-resistant seals. At that time, Ken’s Foods started investigating x-ray technology. It implemented tamper-resistant seals before they were mandated, aware that these seals’ foil linings could cause problems for its existing metal detection equipment. Senior management executives at Ken’s Foods saw benefit in investigating a foreign-body detection system that worked with the tamperresistant seals, and that reduced product loss experienced with current methods. At the time, Ken’s Foods used pipeline metal detectors, designed for installation in food production environments with a need to inspect liquid, paste and slurry

Products from Ken’s Foods include dressing and condiments found in Walmart and other retail stores.

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products for contaminants as they travel through process pipelines. It can inspect a variety of food products and detect all metal contaminants, including ferrous, non-ferrous and stainless steel. Pipeline systems are pressurized, making it difficult to add test contaminants to the mixture. Test contaminants are used for system verification as a part of the HACCP program, commonly implemented by manufacturers at all stages of food production and preparation processes including inspection, packaging and distribution. Te HACCP management program supports food safety initiatives by analyzing and controlling biological, chemical and physical hazards. When pipeline systems reject product due to contamination, a reject valve opens to remove the contaminant with a significant amount of product from the production flow, resulting in product loss. To boost contaminant control and reduce loss, the company turned to x-ray inspection technology. After evaluating multiple vendors, Ken’s Foods selected Eagle Product Inspection. Tese x-ray inspection systems evaluate in-process and finished products for contaminants such as metal, glass, stone and bone, while also having the ability to check mass and evaluate compartmentalized fill level. Eagle was chosen based on three main factors: performance, reliability and the quality of service. Ken’s Foods since has purchased 15 x-ray inspection systems consisting of nine Eagle Tall units, three Eagle Pack 720 units and three Eagle Tall PRO XS units. Te line can inspect products at high speeds, in jars, bottles or on composite lines, and upright and odd-shaped containers typically used for salad dressing and sauces. Te blind spots previously occurring at the bottom of such vessels now also can be inspected. Te Eagle Tall units examine the gallon and the half-gallon plastic jugs of salad dressing, produced for foodservice, seeking foreign body contamination. Te systems are set up so that when contaminated products are detected, a pusharm reject expels the product from the line into a rejection bin where products can be evaluated and disposed. Te Eagle Pack 720 is used for inspection of small case sizes and multi-lane applications, permitting inspection of multiple lanes of the same or dissimilar products, or use one lane for production and the other for rework. Te Eagle Tall PRO XS’s tall, slim design lets it easily fit into a smaller surface area than most machines, saving space on Ken’s Foods’ product inspection line. Te system can concurrently perform a range of in-line quality checks, such as verifying component presence and absence, as well as fill level and measuring headspace to alert Ken’s Foods to over- or under-fulfillment. Tat helps the company avoid waste and ensure customers receive what they paid for. Te machine also has the added benefit of being able to inspect gallon bottles and 12-oz containers at up to 200 per minute.

The compact Eagle Tall Pro XS x-ray inspection unit can fit into limited floorspace.

Te Eagle Pack 720 evaluates cases of salad dressing packaged in single-serve cups with foil lids. X-ray technology can look through packaging material to the product within to detect foreign body contamination and can simultaneously evaluate compartment and or total container weight. It can inspect six 12x18-inch cases per minute, each with 200 2-oz single-serve cups. Since installation of the inspection equipment, Ken’s Foods has seen increased line efficiency, reduction in wasted product and additional confidence that it is delivering the highest quality products to the market. According to Murzycki, “Using an Eagle x-ray system has helped increase our yield. We used to reject half a gallon of product during the inspection process. Now we reject just one container, which means we are throwing away considerably less product.” Murzycki also says visiting customers are impressed by the new equipment. Te Eagle systems have online remote diagnostics to allow Eagle’s service department to dial into the system via modem to troubleshoot, saving downtime on the line and the expense of an onsite service visit. “Because Eagle provides remote monitoring, an engineer can dial into the machine to carry out any maintenance which has eliminated 50 to 60 percent of our service calls,” says Murzycki. “Te reliability of the machines ensures that we can save time, money and increase our efficiency. On the rare occasions that we need a service engineer onsite, a member of the Eagle maintenance team is onsite within 24 hours, which is crucial for us to minimizing downtime.” Eagle Product Inspection, 877-379-1670 www.eaglepi.com

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INSTANT

How to implement a risk management program

Mitigation

Contingency

Remediation

Supply Risk

Supplier of unique material (true "sole" source) facing insolvency

Increase safety stock; shorten payment terms

Secure remaining stock; abbreviate qualifcation protocol

Develop alternate source; vertically integrate

Cost Risk

In an earlier column, we discussed a framework for risk identiďŹ cation. With the understanding that risk lies at the intersection of vulnerability (speciďŹ c points of weakness in the supply chain) and exposure (ďŹ nancial or production impact of supply chain failure), let’s turn to establishing a disciplined Risk Management Program. In the construct of Risk Management, the terms Mitigation, Contingency Planning and Remediation are often used interchangeably but each are quite distinct. Mitigation refers speciďŹ cally to proactive eorts to reduce the likelihood/impact of a supply disruption. It is proactive, yet tactical in nature and usually consists of traditional supply management techniques, such as increased safety stock. Contingency Planning is an action plan to address supply disruptions if/when they occur to minimize time to operational recovery. A well-deďŹ ned plan should address speciďŹ c identiďŹ ed risks, while being broad enough to provide coverage for any disruption. Supply options often include alternative sources, abbreviated qualiďŹ cation protocols and temporary reformulation or repackaging of ďŹ nished product. Remediation, as deďŹ ned in the dictionary, is “Te act or process of correcting a fault or deďŹ ciency.â€? Often considered analogous to mitigation, the distinction should be made clear: Mitigation attempts to reduce the potential eects of risk,

Forecasts show key commodity to be increasingly volatile

Forward buy; set defned contractual price adjustments

Increase price to retail

Use hedging instruments; reformulate fnished good(s)

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Reputation Risk

Advanced Antivibration Components (AAC) Uncertainty if "confict material" supply chain is Dodd-Frank compliant

Identify and pre-quality compliant alternatives

Secure temporary supply via compliant distributor

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Qualify new source or bring incumbent into compliance

while remediation aims to either remove the underlying source of risk or to shift the burden to another entity. Where mitigation eorts may be implemented quickly, remediation may take months to implement, require discrete budgets and be subject to approval from senior management committees. Let’s review some common risks and how each term applies (the graphic above shows examples as well as potential risk management approaches): 1. Cost risks: Treaten cost stability; impact ability to produce ďŹ nished goods proďŹ tably; commonly associated with commodity items that contribute signiďŹ cantly to cost-of-goods. 2. Supply risks: Potential to disrupt the ow of goods, either at the source or throughout the supply chain; may be ďŹ nancial in nature (supplier insolvency), but aect assurance of supply; threaten a ďŹ rm’s ability to produce, regardless of proďŹ tability. 3. Reputation risks: May not threaten cost or supply, but can negatively aect market share or brand perception; are ampliďŹ ed by social media; include irresponsible supplier behavior, non-compliance, counterfeit goods or changing public perception (such as the use of high-fructose corn syrup in processed foods). Now that we’ve identiďŹ ed supply chain risks and implemented a robust Risk Management Program, our next challenge is to mobilize corporate resources toward reducing total supply chain risk. Brian Halpin is category management tower lead at Procurian (www.procurian.com), the leading specialist in comprehensive procurement solutions. The company’s built-out Specialized Procurement Infrastructure integrates with businesses to optimize spending and deliver real savings that equal a margin point or more.

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A laser focus on packaging Lasers now provide brand owners with DISTINCTIVE DESIGN OPPORTUNITIES through finessing the texture and finish of polymer and glass containers. Rick Lingle, Technical Editor Used for heavy industrial applications and long a favorite of science fiction writers and movie makers over the past decades, Light Amplification by Stimulated Emission of Radiation (laser) technology is carving out a niche in micromachining molds and in post-molding decoration to alter the look and feel of containers. One of the companies at the forefront of this underutilized package design tool is R&D/Leverage, which unveiled its new Laser Processing capability at Pack Expo 2012 as the company’s latest addition to its “idea to mold” holistic approach to package creation around structural brand development and mold manufacturing. Adam Nelson, the company’s laser business manager, reports a “tremendous amount of interest” in the technology at the show. Tat interest was split among a visitor base of converters and of brand owners, the latter of whom see the benefit of lasers in creating iconic textures for custom containers. According to Nelson, consumer packaged goods makers can benefit from custom, machine-based textures, structures and surface treatments that go far beyond milling and that have an added ecofriendly appeal. “Our Laser Processing is a truly repeatable process that delivers visual and tactile qualities and grabs consumers at the point of sale,” Nelson says. “Our experience tells us that the tactile aspect of a package is as important as the visual cues—the package has to look and feel good in the consumer’s hand. “Without using chemicals or complex, timeconsuming mechanical processes, we can now customize organic and non-organic textures to perfectly match the brand requirements of a product,” he continues. “Our micro-machining laser-defined texture can machine metal to 0.0005

R&D/LEVERAGE

Laser technology is carving out a niche in micro-machining molds (shown) and in post-molding decorating to alter the look and feel of containers.

of an inch—eight times smaller than the human hair—and do it as much as five times faster and six times as efficiently as conventional tooling.” Examples of organic textures include customdesigned rain drops, wood grain, leather-look, pebble patterns, even fingerprints. Non-organic textures might include geometric shapes, herringbone patterns, plaids and more. “We can literally create a texture from an image

BEAUTÉ PRESTIGE INTL.

Lasers add a touch of class to glass

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In addition to the unique details that lasers can add to a range of products to lift even commodities such as soft drinks, Solev in France uses lasers to take aim at the company’s specialty markets in high-end products such as perfumes, cosmetics and spirits. Used for bottle decoration in markets where branding and appearances are of paramount importance, laser cutting has been raised to an art form since 2010. One recent example from Solev is for JPG “Classique” X Collection, Eau de Parfum in 50- and 100-mL glass containers supplied by Solev parent company Pochet du Courval. The bottles were further decorated by Solev including the sharp laser cut of the “dress” portion of the bottle that is highlighted with a special ultra-deep black varnish. JPG is a brand of Beauté Prestige Intl. Precise laser cutting was used to dress up this glass bottle of high-end perfume.

of an organic and, for example, generate a maple leaf design with veins for a syrup package,” Nelson says. In other words, lasers can do for package design what high definition has done for television. Te technology is applicable to any plasticmolded product whether for a medical, personal care, food or beverage application. Other vendors offer post-mold laser-decorating techniques to customize plastic or glass containers (see “Lasers add a touch of class to glass” at left). “Te idea of widening the design space for brand owners is very exciting as they are constantly pushing their packaging to help differentiate the product in the market,” states Nelson. “Te idea is to focus on both the conscious and unconscious needs of the end user. We have found that a visual look through variation of texture is as important as the more traditional idea of uniqueness through shape only. We also believe the tactile feel gives the user a positive experience that they unconsciously desire, but generally have a hard time directly communicating.” Te company says that the laser-enhanced design details can be functional for the package as well, for example a unique grip on a container handle that really engages the consumer.

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Widen the design space Te laser is used not to create a mold, but to supplement, enhance and otherwise add intricate detail features to the mold. “We still use conventional machining technologies for creation of the large cavities, but have found that the laser offers us flexibility in manufacturing,” Nelson tells Packaging Digest. “We create the blow-mold cavity on a milling machine and then use the laser for processing of micro cavities, texture patterns or other features. We are generally five to seven times faster with the laser than traditional mold tools such as Electrical Discharge Machining (EDM) and more like 10 to 12 times more cost effective because there are no additional electrodes, manufacture of electrodes or other supplies that are needed for conventional machining.”

Lasers can do for package design what high definition has done for television. According to Nelson, R&D/Leverage uses 100-watt YAG (yttrium aluminum garnet) lasers that are fitted to a machine platform with 5-axis positioning capability that allows them to create complex geometric shapes used for blow-mold or injection mold cavities. In an interview in November with

Other apps for lasers in and on packaging Lasers have been around for years in packaging. One of the more common applications have been the online laser coding of production data onto packages or labels as a permanent alternative to inkjet or other coding methods. Another application upstream of packaging production includes the laser-cutting of complex designs into folding cartons. Lasers are also used in film converting to yield value-added packaging. Examples include perforated or scored flexible substrates for easy-opening features or to create breathable films used in modified atmosphere packaging or for self-venting of microwavable products.

PlasticsToday (see www.packagingdigest.com/ptlaser), Nelson said that the new laser equipment available to moldmakers today has made laser reproducible and brought a technology into manufacturing that can greatly increase efficiency in time and cost when texturing is required for a mold. “It’s easier to bring in this equipment and train people in its use, and provide valueadd through customization of textures” said Nelson. “While there’s always the art work that’s required to do this, the 3D software package allows us to take a picture of anything and translate that to a 3D surface and apply it to any portion of the mold. It opens up the design capability and allows the ultimate in

For breathability and venting, lasers are claimed to have advantages over the mechanical alternatives such as controlled depth; consistent, clean holes with sealed edges; adjustable perforating patterns; and others. One vendor in the digital laser converting equipment market is LasX Industries Inc., which at Pack Expo 2012 announced a partnership with pouch-making machinery supplier Totani America Inc., to develop equipment solutions that deliver in-line laser scoring and pouching capabilities to the package converting marketplace. LasX also maintains a toll division that provides contracted laser services for materials.

customization of molded parts.” Nelson informs PD that the biggest hurdle is educating potential customers—or their customers—on what the technology can do so that options are considered during the creative and design phase. LasX Industries Inc., 651-407-0011 www.lasx.com Pochet du Courval, 973- 942-4923 www.verreries-pochet.fr R&D/Leverage, 816-525-0353 www.rdleverage.com Totani America Inc., 920-632-7319 www.tontaniamerica.com

Mondi. Nordenia included.

From now on every Mondi solution includes the expertise, innovation and high-quality of Nordenia. FOR YOUR SUCCESS.

SOLUTIONS. FOR YOUR SUCCESS.

www.mondigroup.com/consumerpackaging

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Putting All Your Eggs in Our 3PL Basket

NEW TECHNOLOGY // APRIL 2013 www.PackagingDigest.com

new productsequipment Encoders The TRDA-2E series of light-duty encoders have 0.25-inch stainless steel solid shafts that offer revolutions of 100 to 2,500 pulses per revolution. The encoders are ftted with a 2-m cable with tinned ends, and are available with 12-24 VDC open-collector or 5VDC line-driver outputs. The new TRDA-20 series medium-duty encoders have a

is a Good Investment Order off our menu of dependable integrated services: WAREHOUSING • 1.6 million sq. ft. of total space • Approved Organic/AIB/CCOF/IFOAM CONTRACT PACKAGING (CA Only) • Clear film; Pre-printed film • In-store shippers; Bags/cartons • Club store packs; Gift packs • Private Labeling TRANSPORTATION • Coast-to-coast; DCs in CA, WI, NJ • LTL/TL; Intermodal; Railroad/Boxcar

Cartoning machine The MA352 cartoning 0.375-inch stainless steel solid shaft, and offer the same benefts as the TRDA-2E, but are available with a 5-30 VDC totem pole or 5VDC line-driver outputs. The TRDA-25 series medium-duty encoder is ftted with a military-style connector and has a 2.5in round fange.

machine comes with two 3-axis robots with vacuum pick-up heads for a fexible infeed system. The frst robot picks up fat trays fed from magazines, erects and places them directly in the bucket chain of the cartoner in continuous motion, while the second robot picks up syringes, and turns them 90 degress to position them horizontally inside formed trays.

AutomationDirect, 800-633-0405 www.automationdirect.com

Marchesini Group, +39 051 6518711 www.marchesini.com

We service customers across a variety of industries and offer secure online, real time access to inventory, receipt and shipment information. Our flexibility across the board will help:

Robotic case erector The new TaskMate robotic case erector/loader is integrated with a turnkey serialization solution and bottle tracking system for serialization and aggregation. The system allows pharmaceutical and medical device manufacturers to automate the case packaging process. It can also provide unit sterilization and track-and-trace technology for all products being case packed. The system integrates a FANUC LR Mate 200iC/5L multi-axis robot with an end-of-arm tooling to create a compact system.

Reduce shipment lead time Reduce inventories Improve inventory turns

Point A To Point Be Sure From

ESS Technologies Inc., 540-961-5716 www.esstechnologies.com

Ultra-compact unscrambler Scan Code

for more information

wbwarehousing.com/3pl • Northern CA 800-541-3319 • Wisconsin 877-922-9473 • New Jersey 800-858-3739 An affiliate of Kreilkamp Trucking Inc.

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The NEHCP-32 offers a small footprint and is suitable for production operations that have limited space. Designed for high efficiency and output, they system can process up to 300 containers per minute, depending on the container. It has a low-profle design that allows for easy container loading, operation and maintenance. It integrates into existing flling, capping and decorating equipment, and a fully integrated bulk supply hopper elevator delivers a steady stream of containers to the orienting bowl. Suitable for pharmaceutical, personal care products and nutriceuticals, it features an optional ionized air rinser and is available using all FDA-approved components.

New England Machinery, 941-755-5550 www.neminc.com

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Industrial PC The new PC 910 combines the newest third-generation Intel Core i technology with the new QM77 Express chipset to provide a high level of industrial computer performance. Users can mix and match CPU performance with different-sized main units as needed, and all aspects of the PC infrastructure have been streamlined for maximum computing performance and optimal data throughput. The machine has a serial ATA-based CFast card to replace the CompactFlash, and it comes with various interface options.

B&R Industrial Automation Corp., 770-772-0400 www.br-automation.com

Materials mixing This new integrated mixing system is designed specifcally for fully automated introduction, transfer, mixing and blending of multiple sluggish materials, It produces homogenous blends so that downstream production scrap is almost eliminated. The machine features a lift-and-seal gaylord discharge system with a dusttight, custom discharge hood that introduces material to the transfer bin. An integrated agitator and vacuum pump transfer system supply material to the high-volume material mixer. It also features a 16-inch diameter auger to mix material in a 17-inch diameter 10-gauge mix tube, and in-feed scoop blades at the base of the mixing auger, with broadthrow dispersion paddles at the top of the mixing auger. The system offers centralized system control, communication, monitoring and reporting to a single UL-listed HMI.

National Bulk Equipment Inc., 616-399-2220 www.nbe-inc.com

Strapping machines The automatic N-3400 and N-3400A model strapping machines incorporate new technology and design. The Direct Access Technology allows operators and maintenance personnel to access the strap path without any tools for easy cleaning and maintenance. The machines use 24 VDC direct drive servo motors, eliminating the need for belts, clutches and solenoids. The strap feed and tension system eliminates wearing rubber rollers and minimizes strap dusting in the strapping head. Machines can handle 5-, 6-, 9- and 12-mm plastic strapping.

Dynaric, 800-526-0827 www.dynaric.com

The Answer to all of your small character coding questions With so many small character coding options available today, you might have a hard time determining exactly what you need. ID Technology has the experience and expertise to work with you to develop a solution that’s best for your operations. Working with a complete line of Inkjet and Laser coders, as well as parts and supplies, IDT can help tailor a custom solution that not only optimizes your production performance but reduces your operating costs. And with service and support like no one else, ID Technology is your go-to small character coding resource. To get the answers to all of your small character coding questions call an ID Technology Specialist at 1-888-438-3242, email us at info@idtechnology.com or visit www.IDTechnology.com

ID TECHNOLOGY

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1.888.438.3242

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WWW.IDTECHNOLOGY.COM

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NEW TECHNOLOGY // APRIL 2013 www.PackagingDigest.com

new productsequipment Integrated motion control The new SmartServo line of products is a fully

Enclosure washdown

developed motion control extension of OCS, and connect with OCS over CANopen, with all confguration, programming, tuning and real-time commands routed over the network. The line features high-speed performance, and offers more than twice the processing speeds to boost system performance, the company says. It enhances real-time information for improved productivity and is suitable for applications such as sorting, flling, labelling, packaging, blending and batching. It works with all servo motor types including Brushless DC and DC Brush motors, and supports several feedback methods, including encoder and resolver.

This new enclosed washdown system is an internal product for non-product contact areas of the fller. The machine sanitizes everything inside the guarding, including the inside of the guarding walls, with the exception of sensitive capper areas. The sanitizer runs down the inside of the enclosure and fows to the base of the fller where it is captured and sent to the drain, making it simple to clean enclosures at the touch of a button. A similar system for the capper and changeparts

Horner Automation Group, 371-916-4274, www.heapg.com

Great ideas become great products. Great products deserve great packaging. xpedx is packaging expertise® DESIGN | ENGINEERING | MATERIALS | EQUIPMEN T | WORK FLOW | LOGISTICS

features three separate spray nozzles that focus only on the changeparts and capper area.

Fogg Filler, 616-786-FOGG www.foggfller.com

Sanitary box dumper The

When Thelma’s Treats of Des Moines, Iowa, and their agency, Saturday Mfg., turned to xpedx to help perfect their recipe for a unique delivery box to house their fresh, hot cookies – the results were simply delicious. UÊPackage design and substrate sourcing for structural integrity, sustainability, and efficiency UÊPrototyping, mock-ups, testing and refinement UÊProduction sourcing

Tip-Tite sanitary box dumper forms a dust-tight seal between the container and the equipment, tips the container and discharges bulk material at controlled rates. Suitable for dumping bulk foods, pharmaceuticals and contaminationsensitive chemicals from boxes weighing up to 2,500 lbs, the container platform is raised by dual hydraulic cylinders, creating a dust-tight seal between the top edge of a box and the underside of a discharge hood. The dumper is constructed of stainless steel with continuous welds ground and polished to sanitary standards. Other sanitary features include capped threads, sloped-top control enclosures, guarding standoff brackets and FDA-approved epoxy paint on hydraulic cylinders.

Flexicon, 888-353-9426 www.fexicon.com E-mail us at packaging@xpedx.com

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xpedx, a business of International Paper © 2013

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Package prep for testing The new RACK-6 conditioning system was developed for use with the OX-TRAN Model 2/61, which measures oxygen transmission rates for as many as six rigid or fexible packages simultaneously. The RACK-6 offers uses a separate six-cell conditioning unit, bringing packages to equilibrium offline before moving them to the OX-TRAN for fnal test results. Using container transfer units allows individual package transfer from the conditioning unit to the testing unit, and each RACK-6 hosts six units. A total of 12 units come with the RACK-6 system. Mocon, 763-493-6370 www.mocon.com

X-ray inspection The PowerChek Plus x-ray inspection system was designed to meet product contamination inspection needs of volume producers of bulk and packaged food products. The system uses Allen Bradley controls for reliable performance and optional AMI and 3-A elevated sanitary specifcations are also available. The system can be fully customized for a specifc production line and needs. It uses low-energy x-ray technology to detect and reject contaminants including metal, stone, glass and bone. The machine features a 15-inch full-color touchscreen user interface for simple operating.

Pouch sealing The FPA-4500 was

Mettler Toledo, 80 0-447-4439 www.mt.com

Rinco Ultrasonics, 203-744-4500 www.rinco-usa.com

designed for sealing pouches with up to 4.5 sq inch of seal area. The FPA-4500S was created for use in duplex and triplex applications where a narrow profle is required. The entire FPA series of ultrasonic sealing systems are designed to replace existing heat sealing equipment on liquid flled pouch form/fll/seal machinery or pre-made pouch systems. The system produces seals anywhere from 2 to 25 mm, and the series’ actuators are designed specifcally for the packaging industry as a drop-in retroft to convert heat sealing stations to ultrasonics.

All the options. All the specs. At your fingertips. Download our free App for iPadÂŽ from the App StoreSM and see how PakTech products take major brands and processors to the top of the market. Visit us on the web at paktech-opi.com

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Apple, the Apple logo and iPad are trademarks of Apple Inc., registered in the U.S. and other countries. App Store is a service mark of Apple Inc.

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new productsmaterials

Barrier tray This new biodegradable barrier tray allows retailers to move away from CPET and aluminum throughout ready-meal retail. The sustainable solution, the company says, is ovenable and microwavable. It reportedly has been tested successfully for durability, wet strength and effectiveness in cooking. KCC Packaging, +44 1489 895 234 www.k-c-c.co.uk

High-performance ink Black Ink 3401 is a keotone-free ink that does not contain MEK or acetone; it is said to be suitable for a variety of coding applications for foods, drinks, cosmetics, confectionary products and tobacco. It offers fast drying time of one to three seconds on both porous and non-porous materials, and is resilient to chemical splashes from alkalis, acids, water, alcohol, petrol and cutting fuid. It is capable of heat resistance for 30 minutes up to 300 deg C with no adhesion or color change. Linx Printing

Flexible pouch Pouch-Up now comes in two shapes: one with a single gusset at the base, and one with a gusset at the top and bottom. New formats also have been added, and include 1 and 1.5 L for the double gusset, and 1-, 1.5-, 1.75- and 3-L sizes for the single gusset. The double gusset offers the same benefts as the single, with high-performance flm, and low carbon footprint. Three different flm structures are available depending on customer needs, and the entire surface can be printed.

Technologies Ltd., +44 1489 302128 www.linx.co.uk

Smurft Kappa, +353 1 202 7180 www.smurftkappa.com

Eco-friendly blister ECOmply flm combines biodegradability and product protection stability. It reportedly offers PVC-level functionality without the PVC-level environmental footprint. The formulation breaks down only under favorable anaerobic conditions, and the flm has the same thermoforming parameters as standard PVC flm, meaning no modifcations are needed to existing blister machine equipment. The flm can be used with all common aluminum lid foils or child-resistant (CR) foils with standard sealing parameters. It is available in clear, color and opaque, and in “paper lookalike.”

Bilcare Research Inc., 302-416-0974 www.bilcaresolutions.com

PET bottle The new PowerBlock 3.0 is a 64-oz hot-fll polyethylene terephthalate bottle delivering sustainable advantages. It reportedly eliminates 13.2 percent from the typical 68-g PET bottle. The container also boasts a 38-mm lightweight fnish, compared to a standard 43-mm fnish for the same size bottle. Patent is pending on the bottle’s conical base push up, and a second patent is pending on the rectangular base with strap-like features that are added to create a footed-style base. Amcor, 714-562-6000 www.amcor.com

Dispensing lid The new Dispense Lid doses tablets, capsules or liquids from plastic bottles in a controlled manner. Incorporated into a bottle’s closure, the lid features a liner with a small opening that induction seals to high-density polyethylene, polypropylene and polystyrene bottles. The customized opening feature helps users dispense only the desired number of tablets or capsules, which assists with compliance and minimizes the risk of contamination to remaining product. Constantia Flexibles, +43 1 888 56 40 1000 www.constantia-fexibles.com

Roll foams microZOTE roll foams

Laser scoring The laser scoring process creates

are available in densities from 200 to 400 kg, with small cell sizes, and come in a selection of colors that can be readily laminated to produce striking combinations. The color range can be used in applications such as packaging and as a protection layer for tool boxes, dividers or elsewhere in presentation. The foams are virtually odor free, and are inert and recyclable.

a peel and reclose application for fexible packaging while maintaining the integrity of contents and preserving perishable items. A pressure-sensitive adhesive label combined with the company’s LaserSharp technology creates an easy-open package. The laser scored pattern reportedly works with any shape or size to meet packaging needs. Advantages to this method include consistent score depths and accurate placement of each laser process. This non-contact method is said to guarantee a fnished material free of processing fragments and residue.

Zotefoams plc, +44 20 8664 1643 www.zotefoams.com

LaserSharp FlexPak Services, 651-789-8800 www.fexpakservices.com

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Bubble pads Soft-hold fruit cushioning pads are absorbent bubble pads that combine the cushioning and protective properties of bubble flms with effective absorbency, high permeability and excellent presentation. Safe-hold is available with integrated ethylene absorbing and anti-fungal properties for extending shelf life in all applications. Sirane, +44 1952 230055 www.sirane.com

combines features like holograms, color-shifting security inks and guilloche patterns with voiding effects and LaserSecure, which incorporates special pigments that only become visible via a dedicated hand-held reading device. The combination can be tailored to a manufacturer’s specifc requirements for customized authenticity protection for pharmaceuticals. It also features detachable label parts that, when detached from the substrate, shows the message “peel-off part has been removed” on the bottom label. Other security features embedded in the detachable label part make authentication checks possible even after the label has been attached to a patient’s medical records.

is a 400ml HDPE bottle and comes with a 24/410 neck. Its curved shape provides a distinctive point of difference for stock bottles with a custom appearance. The company offers more than 1,200 standard products plus a full custom molding service for exclusive designs. Virtually every aspect of every product from the company is produced in-house, on site, from concept design, through tool-making, production, artwork and decoration.

Premium paper Superfne MultiLoft is suitable for high-end printed products. The sheets are offered in two formats to print and build ultrathick products. They are approximately 17-pt caliper, Superfne Eggshell 120 cover with the print surface on the top side and cohesive glue on the back side. Two sheets laminated together, post printing, produce a 34-pt stock. Inserts are approximately 17-pt caliper, Superfne Eggshell 120 cover with cohesive glue on both sides of the sheet. One or multiple inserts are laminated together along with a top and bottom printed sheet to produce a thicker product. Two Superfne sheets and one insert produce a 51-pt stock. Two sheets and two inserts produce a 68-pt stock. The paper is available in ultrawhite, white and soft white, in eggshell fnish with i-Tone for consistent toner transfer and adhesion.

Schreiner MediPharm, 845-848-9000 www.schreiner-medipharm.com

M&H Plastics, 540-504-0047 www.mhplastics.com

Mohawk, 518-237-1740 www.mohawkconnects.com

HDPE bottle The new Windjammer bottle Pharma label The new Pharma-Comb label

PVC Tubing Cut Bands Die Cuts Flat Film Labels PETG Film Preforms Rigid Film Roll Stock Tri Bags

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The Choice

For Flexible Packaging Materials For over 20 years, Oaklee International, Inc., a division of Oaklee Industries, has remained a worldwide supplier of flexible packaging materials, including PVC. Whether it is for an automatic application or a manual application, Oaklee is here to handle your requirements. With over 50 years of expertise, our customer service team will give you a quality product, superior service and dependability. Put the Oaklee team to work for you.

Oaklee International, Inc. www.oaklee.com l service@oaklee.com l 800-333-7250

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promising patents Bottle with integrated cap remover A patent filing for inventor Steven Carley relates to an apparatus for removing the twist-off caps of beverage bottles. Te invention is a beverage bottle with a bottle-cap-shaped indent on the bottom surface of the bottle, for placing on the cap of a closed bottle and twisting to open the bottle. Te design is intended to offset the discomfort experienced by consumers opening bottles with twistoff caps. www.packagingdigest.com/ capremover Beverage bottle’s base is molded with an indent to accept a twist-off cap.

Flexible packaging structure with built-in tamper-evidence features A patent filed by Sonoco Development for a flexible packaging structure with a built-in opening and reclosing feature extends the technology to also provide tamper evidence as an integrated part of the package. A flexible packaging laminate formed by an outer structure joined to an inner structure is

scored in both structures to form a flap that is lifted to open the package. A pressure-sensitive adhesive is used to re-adhere the marginal region to an underlying surface of the inner structure adjacent to the opening through the laminate. www.packagingdigest.com/Sonoco

container and closure. Te gelatin capsules are ruptured when the container is opened, thereby releasing the aroma compound and causing a favorable aroma for the consumer. PepsiCo’s gelatinencapsulated aroma Te secondary protective releases when the coating reduces or closure is opened. prevents degradation of the gelatin capsules during product packaging, transport and storage, thereby enhancing their performance. www.packagingdigest.com/PepsiAroma

Heat-shrinkable package and label system Tis patent for Avery Dennison Corp. pertains to a heat-shrinkable packaging system that includes a heat-shrinkable flexible-wall container or wrap and a heat-shrinkable label that can be applied to the container prior to heat shrinking. Te packaging components are matched in shrink characteristics to yield equal shrinkage. In another variation, the shrink characteristics of the components differ. www.packagingdigest.com/ADshrinklabel

Sanitary dispensin g pac kage Te invention relates to flexibles and other packages that have sanitary dispensing features such that the contents remain sanitary or sterile during reuse. Te package generally includes a dispenser that is sealed from environmental contaminants by a feature or portion of the package that is accessed prior to use through a sanitary dispenser that can be inverted and deployed prior to use. A frangible portion is provided with the dispenser. Te dispenser may be resealable in the package and offer a straw for dispensing convenience. www.packagingdigest.com/sanitary

PepsiCo’s releasable, encapsulated aroma Tis filing from PepsiCo is for gelatin capsules that encapsulate a material that includes at least one aroma compound. Te capsule is applied to product packaging, such as food packaging, that has a secondary protective coating at the interface of a

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Package Conveyor Systems by Muller Martini Today’s packaging facilities need to transport product with the highest level of exibility and reliability. • high-speed, gentle pick-up • overheadcon veyerfr ees oor space

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Knives For All Packaging Machines

Blue Grass Metals is an ISO Certified supplier of replacement knives for the Food Processing & Packaging industries. Our knives include: Vacuum packaging, tray formed, tape, circular and straight, piercing, processing blades, bone in-bone out blades, macerator and tenderizer blades etc. We provide most blades from OEM part numbers. Blue Grass Metals, Inc. april@bluegrassmetals.com www.bgmmachineknives.com

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Top Brands Choose YUPOUltraClear™ Vaska’s innovative bottle design takes center stage with YUPOUltraClear as their in-mold label solution. YUPOUltraClear, which resists scratching, fading and flagging, lets your product and bottle be the stars, with its ultra-clear no-label look. Check out our cool video about the project at the link! www.yupousa.com/clear

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newsmakers HAPPENINGS DuPont Packaging Graphics, Xi’an Aerospace-Huayang and other prominent fexographic printing industry associates hosted the opening of the Shanghai CI Flexo Technology & Innovation Demo Center at the MDK Shanghai plant. The demo center is devoted to supporting fexographic printers, tradeshops and brand owners in the China market. A&R Box and Packaging collaborates with Greenpeace USA to enhance ecological conditions throughout its operation and offers a range of ecofriendly products from Oasis Brands.

MOVERS & SHAKERS Serac Inc., the subsidiary of Serac Group for North America, Carol Stream, IL, appoints Acyr Borges as president.

Acyr Borges Serac Inc.

Unilux names Peter Zantop as southern European sales manager based in Barcelona and Advanced Supplies of Wigan as its new distributor in the United Kingdom.

Crown Holdings Inc. promotes Timothy Donahue to president and COO and appoints Thomas Kelly as svp and CFO. Multisorb Technologies appoints Sheri Mahmoudi as business development representative —healthcare packaging Canada. She is based in Toronto, ON, Canada.

Sheri Mahmoudi Multisorb Technologies

Source One Packaging LLC (Hauppauge, NY) appoints Chris Wilbur to director of national accounts. Adept Technology Inc. promotes Glenn Hewson to svp of global marketing.

Bemis Company Inc. elects William Jackson as vp and chief technology officer. Eriez promotes John Blicha to director of corporate communications and Andrew Goldner to senior manager—exports.

Beth Reardon Mohawk

Mohawk names Beth Reardon as district sales manager, national accounts, and John Parsons, Meri Ann Allen and Shannon Greer as new digital specialists.

Exopack Holding Corp. brings executive chairman Jack Knott back as the executive chairman and CEO and names Mike Alger, a member of Exopack’s board of directors and chairman of the audit committee, as CFO.

GROWING & GOING Andrew Goldner Eriez

John Blicha Eriez

Cereplast Inc., a manufacturer of biobased, compostable and sustainable bioplastics, launches Algaeplast Inc., a subsidiary that will focus on development and manufacture of algae-based bioplastics. Tna opens a new regional office in São Paulo, Brazil. Delkor moves its operations to a new 114,000-sq-ft facility in St. Paul, MN. MeadWestvaco Corp. expands its pharmaceutical manufacturing Center of Excellence in Hemer, Germany, at a cost of $7.5 million. The facility is at the core of the company’s pharmaceutical packaging and dispensing systems manufacturing. Menasha Corp. (Neenah, WI) launches a $6 million expansion to upgrade its graphics capabilities and improve its brand management services for

Rondo-Pak, a provider of folding cartons to the Rich Leppert pharmaceutical, Rondo-Pak biotech and medical device industries, promotes Richard Leppert to vp of global business development.

LINPAC Packaging appoints Rajesh Tandon and Amy Bates as new business development managers.

southwest of England.

Rigid Containers Ltd., part of the VPK Group, to open a new 200,000-sq-ft facility in Wellington, Somerset, in the

customers. New equipment acquired includes a high-volume Heidelberg printing press, die cutters, tape applicators and other automated assembly equipment. Sato builds a new plant in Fukushima prefecture, Japan, to increase production of its EcoNano labels—the world’s frst label series able to reduce CO2 emissions released at the point of incineration by about 20 percent.

BUYING & ALLYING Amcor acquires selected printing assets of AGI-Shorewood’s tobacco packaging and specialty folding carton operations for $114.8 million. The acquired business has plants or assets in South Korea, U.A.A, Mexico and China. The acquisition excludes the AGI-Shorewood plant in Smiths Falls, Canada. Fort Dearborn Co. acquires FetterGroup’s paint & coatings label business.

sales staff Sales and Marketing Offices Steve Everly Brand Director-Packaging 610-705-8705 steve.everly@ubm.com AL, DC, DE, FL, MD, PA, SC

INTERNATIONAL REPRESENTATIVES: Europe/Middle East | Doris Luftglass 973-808-9237 doris.luftglass@ubm.com

Russell Thibeault 781-255-2053 Fax: 877-735-6707 russell.thibeault@ubm.com CT, MA, ME, NC, NH, NJ, NY, RI, VA, VT, WV, Canada (East) Steve Slakis 630-990-7429 Fax: 630-990-8894 steve.slakis@ubm.com AK, CA, GA, HI, IA, ID, IL, MN, MO, MT, ND, NE, NV, OR, SD, TX, UT, WA, WI, WY, Canada (West) Peter Manfre 973-808-8942 Fax: 973-808-6557 peter.manfre@ubm.com AR, AZ, CO, IN, KS, KY, LA, MI, MS, NM, OH, OK, TN

China | Sylvia Xiao sylvia@edoomedia.com Japan | Masayuki Harihara mail@yukarimedia.com Taiwan | Robert Yu sales@wwstaiwan.com Mary Williams Marketing Services Manager 630-990-2371 Fax: 630-990-8894 mary.williams@ubm.com REPRINTS Foster Printing Service 866-879-9144 sales@fosterprinting.com

PACKAGING DIGEST® (ISSN 0030-9117) is published monthly, with a special issue in summer, by UBM Canon, 2901 28th St., Suite 100, Santa Monica, CA 90405-2975; 310-445-4200; FAX 310-445-4299. Periodicals postage paid at Los Angeles, California, and at additional mailing offices. SUBSCRIPTIONS—Free to qualifed subscribers as defned on the subscription card. Rates for non-qualifed subscriptions, including all issues: 1 yr. $150, 2 yrs. $250, 3 yrs. $300. Except for special issues where price changes are indicated, single copies are available for $10 USA and $15 foreign. For telephone inquiries regarding subscriptions, call 763-746-2792. CHANGE OF ADDRESS—Notices should be sent promptly to P.O. Box 47461, Plymouth, MN 55447. Please provide old mailing labels as well as new address. Allow two months for change. EDITORIAL CONTRIBUTIONS—Unsolicited manuscripts should be submitted via e-mail to lisa.pierce@ubm.com. Copy will receive every reasonable care; however, the publishers assume no responsibility for safety of artwork, photographs, or manuscripts. NOTICE—Every precaution is taken to ensure accuracy of content; however, the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein. POSTMASTER—Send address changes to PACKAGING DIGEST, P.O. Box 47461, Plymouth, MN 55447. Canada Post: Publications Mail Agreement 40612608. Return undeliverable Canadian addresses to: BlueChip International, P.O. Box 25542, London, ON N6C 6B2. Printed in U.S.A. Copyright 2013 by UBM Canon. All rights reserved. Reproduction in whole or part without written permission is prohibited. Volume 50, No. 4

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industry insights The road to recovery? Demand for recycled-content packaging materials continues to grow in the U.S. But the market and infrastructure for collecting used materials suffers somewhat from various limitations, whether they be financial, logistical or emotional. Recently, there’s been an uptick in conversations around extended producer responsibility programs (voluntary) and/or regulations (mandatory) to help boost recycling rates—which would also help improve the supply of recycled materials. Victor Bell, president of Environmental Packaging Intl. (EPI)— a consultancy specializing in global environmental packaging and product stewardship requirements—talks to Packaging Digest about the current and possible future state of EPR in the U.S. Q: Who is initiating the EPR conversation Victor Bell today in the U.S. and why? A: Te conversation is being led by a number of different interests: 1. Organizations focused on sustainability and balancing corporate economics with the social, health and environmental impacts of consumer products and packaging, like Future 500 and the Product Stewardship Institute; 2. Private industry, like Nestle Waters, whose funding helped establish the non-profit initiative Recycling Reinvented that is committed to increasing recycling rates in the U.S. through EPR; 3. Environmental organizations who view EPR as a way to divert more waste from landfills and waterways as marine debris; and 4. Local cities and towns that are financially strapped

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Company Name

and need money to maintain or expanding their recycling systems. Q: How much of it relates to packaging instead product stewardship? A: I’m only talking about EPR as it relates to packaging and printed paper. In terms of product stewardship, that dialogue is being driven by cities, towns and state governments, who are pushing to get materials like tires, electronics, paint, fluorescent bulbs and mattresses out of the waste stream. EPR for these products is already well-established throughout the U.S. and, for many of them, there’s been good cooperation between industry and government, with some model legislation developed by industry. Q: How do the programs being proposed in the U.S. differ from other countries and why? A: In the U.S., almost all of the EPR programs being proposed include both printed paper and packaging. While that same approach holds true in Canada, in Europe, most programs don’t cover non-packaging printed paper. Other than that difference, the intent of the bills on the table here is the same as the intent of the laws in place globally: to transfer the cost of recycling from cities and towns to private industry which puts the products on the market. What remains to be seen is how costs will be shared. Worldwide, the funding by industry can range from 50 to 100 percent, and this is a big topic of discussion in the U.S. Q: Te goal of many/most EPR programs is to boost recycling rates but not all packaging materials

Page number

Advanced Antivibration Components .................................................................................................................................. 41 Advantage Puck......................................................................................................................................................................................................... 11 All Metric Small Parts ..................................................................................................................................................................................... 51 Alliance Rubber Co. .......................................................................................................................................................................................... 49 AutomationDirect......................................................................................................................................................................................................... 3 Berlin Packaging ...................................................................................................................................................................................................... 55 Bosch Packaging Technology............................................................................................................................................................ 25 Cardinal Packaging Products LLC............................................................................................................................................. 56 Dairy Farmers of America ....................................................................................................................................................................... 20 Domino Amjet Inc................................................................................................................................................................................................... 33 Epson America Inc. .............................................................................................................................................................................................. 37 Fogg Filler Co. ............................................................................................................................................................................................................... 51 Glue Dots International ............................................................................................................................................................................... 41 Hammer Packaging............................................................................................................................................................................................. 17 Hitachi America Power & Industrial Div. ........................................................................................................................... 2 ID Technology ................................................................................................................................................................................................................. 45 Indemax (insert to a select audience)............................................................................................................................... 13 James Alexander Corp. ................................................................................................................................................................................ 14 Klockner Pentaplast ............................................................................................................................................................................................... 6

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are recycled or even have a recycling infrastructure. What then? A: Under global EPR programs, all packaging is subject to fees based on how difficult the materials are to recycle and how valuable the materials are at the end of life. But there aren’t always recycling programs available for all those materials. Tat’s because, sometimes, there’s not economic justification for recycling them since the collection costs are high and there’s no market for the materials. While the fees for these non-recovered materials are normally higher, as the technology to handle them improves and they can be added to the system, their value could increase relative to processing costs—and fees may be reduced. Q: With demand for recycled-content materials high, is EPR the best way to ensure a consistent, quality supply at an affordable cost? Why or why not? A: EPR may not dictate whether a community should have a single stream or multi stream, but it does allow for investment in better education and technology—such as optical sorting, better collection facilities and other infrastructure enhancements that increase the volume and value of the recycled-content materials. Right now, cities and towns don’t have the money to fund these investments; that’s where the private sector could help. Q: What’s the chance that the U.S. will see EPR legislation on a national scale? A: I think it’s unlikely. A number of states are looking at model legislation with similar definitions and other components. But just like in Canada, where there are distinct programs in place in the various provinces, the U.S. Congress has no appetite to pass legislation on a national level. What’s happening right now is on a state-by-state basis. If those programs are enacted, then there could be a move to harmonize them throughout the country at some future date, but at this time, I don’t foresee that happening.

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Kruger Products......................................................................................................................................................................................................... 35 Leibinger..................................................................................................................................................................................................................................... 7 Material Transfer & Storage................................................................................................................................................................. 27 MG America ........................................................................................................................................................................................................................... 8 Microscan ............................................................................................................................................................................................................................. 31 Mondi Packaging AG ......................................................................................................................................................................................... 43 Muller Martini Packaging Technology................................................................................................................................ 19 Oaklee International........................................................................................................................................................................................... 49 Overnight Labels Inc. ....................................................................................................................................................................................... 11 PACK EXPO Las Vegas / PMMI......................................................................................................................................................... 15 Paktech ..................................................................................................................................................................................................................................... 47 PolyOne (Formerly Spartech)............................................................................................................................................................. 29 Primera Technology ................................................................................................................................................................................................ 9 Quick Label Systems ............................................................................................................................................................................................ 5 Source One Packaging LLC................................................................................................................................................................... 39 Unit Pack ................................................................................................................................................................................................................................ 10 WB Warehousing & Logistics............................................................................................................................................................. 44 xpedx............................................................................................................................................................................................................................................. 46 Yupo Corp............................................................................................................................................................................................................................. 32

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Packaging Digest April 2013  

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