Page 1

RELIABLE SHIPPER: Coke bottler co-op saves with reusable bins 22

DOUBLE TAKE: It’s Miller Lite time— again 13

January 2014

AUTHENTICATION: Watermark materializes in flexible packaging 26

Shake it up Dispensing carafe bowls over sugar users 18

Top trends for 2014 14 Barrier to nanotech? 34

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JANUARY 2014 volume 51 no. 1

trends Packaging Concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Elizabeth Arden dispenser; Miller Lite can; Pure Flavor veggie packs; Mintel Market Snapshot Top trends for 2014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Te new year presents opportunities for packaging, if you know where to focus. Hear where leading packaging executives will direct their eforts. SPC Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Why we should eliminate the “B” word from sustainability conversations. Industry Insights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nanotechnology’s promise for food packaging.

best practices Cover Story: How sweet it is . . . . . . . . . . . . . . . . . . . . . . 18 Domino Foods is sitting pretty with an elegant, ergonomic carafe-style container that could make sugar bowls obsolete. Many happy returns of the custom bins. . . . . . . . . . . 22 A Coca-Cola bottling co-op switches from gaylords to reusable, collapsible plastic bins for preforms that raise efciency and hygiene— and cut costs. Te program includes RFID for tracking and robotics.


new technology Authentication technology materializes for fexibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Anti-counterfeiting is the main market focus for Ghost, an integrated watermark for fexible packaging that’s a seamless add-on during converting. Ghost has generated surprising interest from a brand equity aspect, too. New Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Promising Patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Vented can lid; IML label; Leakproof closure; Protective container




Online . . . . . . . . . . . . . . . . . . . 6

Viewpoint. . . . . . . . . . . . . . . 11

Dialogue . . . . . . . . . . . . . . . . . 8

Marketplace . . . . . . . . . . . . 32

Staff . . . . . . . . . . . . . . . . . . . . 10

Newsmakers . . . . . . . . . . . 33

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Read these bonus articles at

What’s the package of the future and why? Tis one packaging format ofers a number of benefts compared to traditional packaging, which could be why many consumer packaged goods companies are considering making a switch

Bottled beverage industry benefits from KNOWLEDGEshare 2013 More than 120 attendees from Europe, the Mediterranean and North Africa discussed the need for sustainability to assure the future of the bottled beverage industry. knowledgeshare

Eco-aware moms wield significant beverage buying power “Product packaging presents an opportunity for beverage manufacturers and retailers to connect with this valuable shopper,” says Erin Reynolds, marketing director at Evergreen Packaging, the company that conducted the study.

E-commerce opportunities abound for CPG companies Consumers are ready and willing to buy more products online but few consumer packaged goods companies have a fully-developed strategy for capitalizing on this channel. Are your packages ready for small-parcel delivery?

America’s manufacturing sector continues its revitalization Te new report “thoroughly and thoughtfully lays out how Congress can make a diference in helping American manufacturers grow” and create good manufacturing jobs, which include packaging production and engineering, for skilled workers.

SEEING THESE ARTICLES FOR THE FIRST 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


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January 2014

dialogue @TeDieline: Dogwood Cofee Co. updated their cofee #packaging with a familiar look but diferent fnishing touches. http://thediel. in/1cS1T8D

“They are used throughout the schools on Long Island. Our district has one in every classroom. Great tool!” — Doreen Monteleone, Ph.D., on “Have you seen or heard of Smart Boards? I saw a demo during a tour of Delkor at the #PMMIAnnual meeting. Most conducive to idea sharing! Fantastic facility overall. Tks JK! pic.twitter. com/dm3oQtgnpk” @DigitalKevin: Kush #Bottles Meet ChildSafe Marijuana #Packaging Req in Colorado Why does this headline bother me? @packfutur: “Beauty products shouldn’t be about the packaging,” Camilla Johnson-Hill TMG10515974/Double-Take-Charlotte-Aitkenand-Camilla-Johnson-Hill.html … O but they are, they are!

@PackagingNerd: 31 Mind-Blowing Examples of Brilliant Packaging Design … via @IAM486 Jim Peters, retired president, J Peters Associates LLC, comments on “Public Pressure and The Packaging Industry”: At its core, packaging IS a social function. It responds to the needs of stakeholders it serves, and those stakeholders include the political process. If you’ve been through enough of these changes in direction, you know that industries adapt. The Tylenol event, child-resistant closures, sustainable package. In my mind, your comments evoke the tone around U.S. bottle deposit laws way back when— critics forecast grocery stores full of dirty bottles and infested with rats craving a lick of soda or beer. Soft drink sales would plummet. Didn’t happen, because of packagers and a distribution chain that found a way to adapt to the social direction (along with politicians who found a source of revenue in unclaimed deposits).

Join the packaging community discussions at Packaging Digest’s LinkedIn group at, on Twitter at or by commenting on a PD article online at

Sustainable packaging certainly embraces the idea of social responsibility, and if plain cigarette packaging is socially responsible by society’s defnition, then we’ll learn to live with that. @neilchawkins: Unilever, P&G, & J&J all exiting mirobeads. #GreatLakes #ecosystem.

“We use these to educate children from preschool to college already!” — Jarno-Petteri Merisalo, on “Have you seen or heard of Smart Boards? I saw a demo during a tour of Delkor at the #PMMIAnnual meeting. Most conducive to idea sharing! Fantastic facility overall. Tks JK! dm3oQtgnpk” @neilchawkins: Unilever, P&G, & J&J all exiting mirobeads. #GreatLakes #ecosystem. @srhyng4761: 3 Tings to Look Out for When Choosing Packaging | SmashBrand #efciency #packaging @LabelmakerVT: How clever packaging design can make your product shine on the shelf via @eskocompany #Packaging #Design

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Editorial Advisory Board

Executive Editor Lisa McTigue Pierce 630-481-1422

Executive Editor Daphne Allen 310-445-4263

Technical Editor Rick Lingle 630-481-1426

Sr Digital Content Editor Kari Embree 630-481-1424

Senior Art Director Vasanth Johnpaul 714-845-0257 x27184 vasanth.johnpaul@mpe.

Editorial Ofce: 1200 Jorie Blvd., Suite 215 Oak Brook, IL 60523 630-481-1422 e-mail:

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


Executive Officers

Lead Art Director Marco Aguilera

Chief Executive Ofcer Sally Shankland

Production Director Jef Tade

EVP/Managing Director Josh Dome

Production Manager Venkatraman Jayaraman

SVP, Medical Portfolio Director Stephen Corrick

Production Coordinator Santhosh Kumar Dorairaj

VP, Design and Manufacturing Portfolio Director Roger Burg

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

Brand DirectorPackaging Steve Everly 610-705-8705

Oliver Campbell Director, Worldwide Procurement, Packaging & Packaging Engineering, Dell Kim Carswell Group Manager, Owned Brands Packaging, Target Scott Hemink Senior R&D Manager for Intl. 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 January 2014


Potentially explosive issues need resolution overview on where we stand today with FDA guidance—and A new year often heralds a furry of resolutions, predictions where we might be headed. and trends. In our Top Trends for 2014 article on p.14, leading 2. Personnel: Baby boomers are reaching retirement age packaging executives at major brand owners talk about costs, at a healthy clip. Te Government Accounting Ofce (GAO) collaboration, competition, sustainability and more. cites 10,000 a day, while others in the blogosphere debunk But two topics our Trends article just touches on could be that “infated” and “politically motivated number” and say quite explosive in 2014: Regulations and Personnel. Here’s why. the real number is closer to 6,800. Either way, a good chunk 1. Regulations: Activity around several packaging-related of the workforce could see a signifcant turnover (not every laws and guidance is heating up, with labeling information Boomer who reaches retirement age will retire). and/or claims often at the forefront. And, with American manufacturing facilities investing in Nutritional Labeling: Te Food and Drug Administration more sophisticated automation to stay cost competitive in the (FDA) plans to update its Nutrition Facts label policies, which global marketplace, the skill level of the workforce is rising will impact nearly all food and beverage products marketed for even as the number of employees is falling. retail sale and promoted in the U.S. According to FoodMinds So in 2014, we’ll be sharing more educational and training LLC, a food and nutrition consulting and communications options with you, whether it be information about formal agency, this sweeping change to update the 20-year-old guidelines Lisa McTigue Pierce programs, such as the Fundamentals of Packaging Technology presents challenges—and opportunities—that food and beverage executive editor courses from the Institute of Packaging Professionals (IoPP), companies will need to quickly understand and mobilize. or learning opportunities at various industry events, such as Track-and-trace/serialization: President Obama signed Te the Learning Labs at WestPack, Feb. 11-13, in Anaheim, CA. Packaging Digest Drug Quality and Security Act (DQSA) into law in November 2013. Tis has put together another dynamic interactive WestPack Insider digital issue, national traceability law pre-empts any tracking regulation of the drug supply which will be sent out in mid-January. Look for it in your in-box soon. It will by individual states and gives pharmaceutical companies more time to build have details about our packaging-related seminars and much more. out a solution for interoperable electronic tracking of serialized product. And rest assured that we’ll continue to cover these hot topics throughout Nanotechnology: Scientifc breakthroughs in nanotech continue, with many the year in print and online. So make sure you also bookmark www. potential innovations in packaging. On p.34, Michael Flanagan, chair of to stay up-to-date. the Food & Beverage Industry Team at Foley & Lardner law frm, gives an

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packaging concepts Elizabeth Arden dispenser ensures a continuous product flow Elizabeth Arden selected Airopack ( as an all-plastic, pressurized dispenser that uses 42 percent less energy and emits 74 percent less CO2 than a typical aerosol can to dispense the new Ceramide Self-Foaming Cleanser formulation. Airopack makes use of compressed air, assuring a continuous flow from start to finish to provide the ultimate consumer experience. Airolux AG, a joint venture between I.P.S. Innovative Packaging Solutions AG and Resilux NV, announced the completion of the first delivery of their Airopack system to prestige beauty company Elizabeth Arden. The patented Airopack technology offers a safe and clean alternative for traditional aerosol-

dispensing systems and is a suitable fit for the enhanced formulation and dispensing requirements at Elizabeth Arden. The Elizabeth Arden Ceramide products are being packaged through the Airopack Full Service Operation. Through this fullservice offering, the dispensers are produced, filled, sleeved and packed to Elizabeth Arden’s high specification standards while guaranteeing an on-time market introduction.

Mintel Market Snapshot Increase in packaging launches points to innovation in the sector New food innovation in the U.S. took an expected decline in 2008 and 2009 in response to the recession. Despite an upturn in 2010, declines swiftly followed in 2011 and 2012, now looking to stabilize in 2013. However, while new food product launches have been faltering, the subset of those launches is that new packaging has been increasing. New product launches that were due to new packaging increased 72 percent from 2007 to 2012, indicating that food packaging innovation has recovered well from the recession. This reflects recognition by food companies that new packaging can bring increased consumer interest to an old product, either through improving the shopper moment or through offering new functionality. Flexible packaging has had the most success in this time period, with resealable bags and resealable stand-up pouches driving usage and product sales. Innovative packaging can offer consumers added value on their food purchases and, at Mintel, we have seen a number of strategies being adopted. For example, packs that help food stay fresh longer or that help consumers get all the product out of the packaging will help reduce food waste and have been used by brands to support consumer perception of value in a food product without price discounting, which can damage brand equity. Enhanced functionality and convenience of food packaging offers consumers more free time or offers a new consumption opportunity—for

example, turning a meal solution into an on-thego snack by repacking into a small resealable pouch. Lastly, improved on-pack labeling and communication via the web and mobile apps is not only allowing consumers to get more information faster but is also helping brands better engage directly with consumers and shoppers. One example of packaging that engages consumers with the brand comes from Austrian ingredient supplier Wiberg ( They have launched a new retail range of herbs and spices in a brushed metal container with an innovative dispensing closure (lower left image). A large hinged flap lifts up and over the top of the container to become a broad “scoop” from which the product can be sprinkled/broadcast. The action of rotating this scoop also activates a smaller flap in the top of the container that aligns with the positioned scoop. The pack has been recognized by the German Packaging awards in 2011 and by the reddot design awards in 2012. This robust pack does at first glance look masculine and perhaps a bit over-engineered for such a simple product. However, this appearance does fit with the brand’s professional look, which uses the color gray and brushed metal effects across its range. The three-piece tin-plate box features two litho printed labels on self-adhesive foil.The closure and scoop are injection molded in polypropylene with a pull-off tamper-evident tab. From China, Baike Beverage has released a dual beverage bottle. The injection stretch blown PET bottle contains an iced black tea in the top and a snow pear juice in the bottom, totaling 485ml. This novel arrangement means that the two beverages are consumed in slightly different ways.

The top compartment is consumed in the normal way directly from the bottle. To access the lower compartment the consumer uncaps a tube that runs down to a middle fitment that separates the two halves and draws out an embedded straw through which the lower beverage can be consumed. Though this is not the most practical design, it is fun for younger consumers. The chambers are split via what appears to be a polypropylene fitment with the plastic straw running through the center. A gravure printed shrink-sleeve label is present, whilst closure is provided by an injection-molded polypropylene screw-on cap. Another fun and unusual example of packaging was created by Thai German Meat in Thailand. This chilli pork product (upper right image) is held in a stitched textile, shaped and printed to resemble a pig. Though this is quite fun it may well have too close an association with cutting open an animal to reach the meat inside for some consumers to be happy with. Outer packaging comprises a plastic sachet, featuring a litho printed label on self-adhesive polypropylene. Butter brand Lurpak has expanded into premium butters with the launch of Lurpak Slow Churned Butter (center image). The product is described as a traditionally crafted butter created in small batches, over several hours, to bring out its full, rich flavour. To differentiate on the shelf and give the product superior positioning, the butter is retailed in an aluminum serving dish, formed of thin aluminium that is robust enough for transport and use long enough to consume the butter. The small batch positioning is supported with a batch number printed onto the outer board sleeve, highlighting again the artisanal nature of the product. Author Benjamin Punchard is global packaging insights director at Mintel ( magenta cyan yellow black

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Miller Lite releases limited-edition Original Lite Can Miller Lite, the beer that launched the light beer category, invites consumers to reach for a piece of brewing history. In January 2014, Miller Lite will release the limited-edition Original Lite Can, an updated version of the iconic packaging that changed the beer industry almost 40 years ago. The Original Lite Can features the familiar images of hops, barley and the words “a fine pilsner beer,” which reinforce the high-quality ingredients and the unique brewing process that consumers have enjoyed for generations. “There was a time when all that existed was heavy beer that weighed you down,” says Elina Vives, marketing director for Miller Lite. “The launch of Miller Lite broke this category convention and offered beer drinkers the best of both worlds: great taste at only 96 calories and 3.2 carbs. Miller Lite is the original light beer and this limited-edition can celebrates that innovation and helps inform consumers of the rich history behind our beer.” In addition to becoming available to consumers in January, the Original Lite Can will appear in the upcoming Paramount Pictures’ release, “Anchorman 2: The Legend Continues.” The news team can be seen enjoying the Original Lite in the film, which was released nationwide in December 2013. The limited-edition Original Lite Can will be available nationwide January through March in 12-, 16- and 24-oz sizes.

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Pure Flavor launches freshened veggie packs Pure Flavor, a leading and innovative greenhouse produce company, has unveiled new packaging and design for its Aurora Bites—mini peppers and Beefsteak Slicer Tomatoes. These new designs adhere to the central design elements that formed the bedrock of the previous design. In the new version, everything from colors to the layout is more dynamic and vibrant. Pure Flavor’s new design packaging is rolling out as early as January 2014. The new and improved Aurora Bites Mini Peppers program features packaging that reduces by 25 percent of plastic usage from industry standard while presenting three different eye- and consumer-catching recipe suggestions. The new package material uses minimal plastic with the ability to strengthen the banner handle to hold/carry large packs, as well as to improve display abilities by providing a premium packaging look and feel.

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TRENDS // January 2014

Top trends for 2014 The new year presents opportunities for packaging, if you know where to focus. Hear where leading packaging executives will direct their efforts. Lisa McTigue Pierce, Executive Editor Meet the new trends; same as the old trends—but with some twists and nuances. Packaging Digest tapped into the mind trust of our editorial advisory board to discover what trends some of them see that will have the most impact on their packaging decisions in the coming year (see “Our expert panelists” on the opposite page). Hear what they have to say about sustainability, collaboration, cost savings, competition, health and wellness, authenticity, diferentiation and communicating to the consumer. Packaging Digest: What market trends are you seeing and how are they impacting packaging? Campbell: In the tech industry, we see more demand for sustainable or green packaging among our customers. Ernst & Young has a recent statistic that the largest category of shareholder proxy activity is for sustainability, at 38 percent, and that is up about three times from several years ago. I’d say that’s a market trend around sustainability—as well as a societal trend that we see in government regulation from Australian packaging regulations and Canada take-backs. Te trend in sustainable packaging is being backed up by investment in research and new factories. Te industry is walking the talk. It makes me feel good about the future. Continued supply chain efciency is another trend within Dell. For packaging, it’s is how can we get smaller packages while maintaining quality and providing a better customer experience. One fnal trend is the programs being structured around 2020 initiatives. Dell just launched our Legacy of Good Initiative. We have 20 diferent 2020 goals focused on the environment, communities, and people. Our zero waste packaging for 2020 is among those. What that means is all Dell packaging by 2020 will be either recyclable or compostable, plus it has to be sustainably sourced. Keller: I’m in hair care now at Procter & Gamble. It’s a fairly fast-paced category. We’re seeing a lot more competition on every level in our businesses. So we’re continuing to look at how to use packaging to diferentiate our products—whether that’s through more sustainable packing options or decoration techniques, those types of things. Where’s the additional competition coming from? Is it local or global? What are the drivers? Keller: Te competition is more new start-up brands. Tey wouldn’t necessarily be global, but

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sometimes they are. Even local, small brands are trying to ofer something new to the consumer. As P&G, we need to continue to show why we are diferent, what do we bring to the consumer— and packaging obviously is a key driver in that because it’s right there at the shelf. So you need to show the value proposition of your products. How is that going to translate on the packaging side? Keller: Our advertising channels have changed vs where they were 10, 15, 20 years ago. That will drive more importance on making sure we stand out on the shelf. It helps to communicate the quality proposition we have to the consumer. It’s pushing us to rely more on the packaging to do that.

“if you can share your strategic views early to inform and infuence your supply chain partner’s direction in their capital investment, it’s huge.” — kim carswell, Group Manager, Owned Brands Packaging, Target Te need to diferentiate still drives a lot of packaging projects. Mike, Heinz recently came out with a new plastic bottle to better diferentiate on the shelf. What can you tell us about it? Okoroafor: Te consumer motivation for redesigning our bottle was twofold: to diferentiate and to provide better ergonomics. Since Heinz came up with upside-down bottle, everybody has copied us. So when you look at the store shelf for ketchup bottles, they look the same. Packaging should be your biggest media. If everybody looks like you, there’s no diferentiation. We wanted to design a plastic bottle that would maintain the iconic impression of the Heinz glass bottle, but ofer better diferentiation on the shelf. Te new bottle is called the thunderbolt design, like the Tunderbolt car that Ford came up with. We also wanted to design a bottle that everybody can hold and squeeze without any difculty. Te new ergonomic design allowed us to reduce the weight of the bottle without sacrifcing the strength. In a

The new iconic Heinz plastic ketchup bottle differentiates on shelf and is easy to use for all ages and hand sizes.

compression test, the top load is actually slightly better than the original one because of this smart design. When it comes to packaging design development, while we address emerging markets outside of this country, we also have to address emerging channels in this country. People who immigrate to the U.S. become an emerging channel. Near Lancaster, PA, one of the biggest restaurants is a Peruvian restaurant. Why is that? A lot of Latino people from Peru are in that area. Which means we have to think about how we’ll deliver the food or the beverage— and your delivery vehicle is your package. What is the implication for packaging because of emerging channels? Is it using a structure that they’re familiar with? Is it graphics? Is it all that? Okoroafor: It is all of that. But the point you make about structure is critical because that way you can make it more afordable. For instance, I can ofer you ketchup in a plastic bottle or, same quality, in a pouch. In the emerging market, like Brazil, they love the pouch. So for them, it doesn’t mean less quality. As long as your shelf life is the same and we try to do that through science. But you also have to think about merchandising. Your package has to do more than just to protect. Tat merchandising means that you have to come up with winning graphics. Carswell: From a retailer perspective, health and wellness is defnitely a trend. And when it comes to packaging, we are continuing to push the envelope in a sustainability space more. We expect to keep doing that because the consumers in the store are looking for that more than they were fve, 10 years ago—and will probably look even more for it in the future. Te things that we’ve done in the past that we know are good for the environment—like less packaging, make it more recyclable, make it recycled content—are understood by consumers. Te things they might start to understand are use of renewable materials and other second-tier improvements to the package design.

Okoroafor: Sustainability is here to stay. Obviously, people don’t want to be asked to pay for sustainability, but it is your key to the consumer’s door. Without that, you’re not entering. Sasine: Where we’re really making a good deal of progress is linking our sustainability eforts farther

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up into our supply chain. We began eight years ago with a great deal of efort around sustainable packaging and made some large commitments and were able to deliver on those earlier this year. (See What we’ve found is we can make similar progress with suppliers of all the products we sell and not just in packaging—by putting out some tools that people can use, particularly our buyers as they make decisions about products. Our sustainability index is now rolled out across all of our categories and buyers are using it as they analyze products. It’s had an interesting impact on us in packaging. It’s creating additional visibility into cost and—by packing and shipping more efciently—how we can drive costs and continue to maintain that sort of customer-focused cost reduction that Wal-Mart is famous for. For us, sustainability has always been an objective and we’ve always strived to connect

“our advertising channels have changed vs where they were 10, 15, 20 years ago. that will drive more importance on making sure we stand out on the shelf.” — Joe keller, Section Head, Packaging Development, Global Packaging Sustainability, The Procter & Gamble Co. sustainability to our ability to deliver everyday low prices. We’re starting to see that come to fruition in a lot more of our categories in a very meaningful way. It’s been an opportunity to do the right thing and cut our costs at the same time. Macauley: I would echo a lot of the same items when we talk about sustainability, but I will take a diferent tact and talk more about healthcare. Tink pharma, think med devices, think nutrition. Healthcare hasn’t had the same kind of sustainability pressure points as the CPG brands. It’s starting to get a much better awareness and push.

We’re seeing sustainability drive more design eforts. A lot of that can simply be, within a hospital setting, how do we increase our ability to recycle? From a packaging designer’s point of view, we are starting to look at how we can help our customers separate the packaging for reuse or for recyclability. A second trend we’ve had for a while is an increased amount of collaboration. Ron pointed to it, as well— going upstream. We are clearly working better across our overall value chain and generating more aligned sustainability metrics, which is still a missing link. Hotchkiss: One of the emerging issues you’re going to hear more about is the role of packaging in food waste. Te issue of how much of a product doesn’t get sold for whatever reason is becoming a day-to-day driver. I use the analogy that packaging is like bridge building. Anybody can design a bridge that absolutely guaranteed will not collapse. Te problem is that no one could aford to use it. A good bridge builder builds a bridge that just barely doesn’t collapse. Tat’s the optimum. And that’s the same thing in packaging, getting the right amount of barrier so the product shelf life is just right. Okoroafor: One of the biggest trends we see is…You have to design for afordability. But afordability doesn’t mean cheap. You have to make sure your packaging is afordable for these consumer demographics: the struggling, the middle class and the afuent. It means you have to rethink how you innovate. You have to innovate for growth and productivity so you can make your product available at the lowest possible cost while you still make your margins. Macauley: As we strive for new innovation, there’s sometimes going to be a cost impact. Do consumers understand that? A missing link is, where is new technology in terms of its lifecycle to provide new solutions? Take biopolymers, for example. Biopolymers have been discussed and are rolling out, but are they at the level where we feel they should be today vs what we thought they were going to be fve years ago? To provide those sustainability solutions—if it’s not a reduction; if it’s more renewable type materials— there’s sometimes going to be a cost impact. Can we pass that on to our consumers or not? Te feedback so far is “not.”

Our expert panelists oliver campbell Director, Worldwide Procurement, Packaging & Packaging Engineering, Dell kim carswell Group Manager, Owned Brands Packaging, Target Joe Hotchkiss Director, Michigan State University, School of Packaging and Center for Packaging Innovation and Sustainability Joe keller Section Head, Packaging Development,

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Global Packaging Sustainability, The Procter & Gamble Co. 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, Wal-Mart


Keller: Tere is more pressure to drive costs out of the system and be especially conscious of capital and making that stretch as far as it can. We only have certain amounts of money. Sometimes we’re going to choose to put it towards packaging or capital and sometimes we’re going to choose to put it in other places. I haven’t seen any major shifts from what I’m seeing on costs other than just the increase in focus on it. Campbell: At Dell, we’re focused on cost reduction primarily through innovation. As a tech company, innovation is part of our DNA and we tap into the resident brainpower in the company to come up with smarter solutions. Te use of the term cost reduction is almost a disservice because if you look at innovation through the lens of value creation, you get to diferent points. Can you do the same thing at lower cost or can you do something better at lower cost, which is an improvement in value for our customers? A great example of where we’re doing something at lower cost but better performance is our new wheat straw packaging. Our supplier just dedicated a $50 million plant in China [in October 2013]. Yes, investments are being made where they’re smart and yield better customer value.

“Healthcare hasn’t had the same kind of sustainability pressure points as the cpg brands. it’s starting to get a much better awareness and push.” — pete Macauley, Director, Global Packaging & Sustainability, Abbott Laboratories Keller: One of the things we’re looking for, too, is what we consider “platform” ways to reduce costs. What we look for from suppliers is, how can we leverage technology across our diferent products and not just in one specifc area? Tat’s something we always look to leverage given the focus on resources with our company and trying to be more efcient with not only our money, but our people. Carswell: If you can share your strategic views early to inform and infuence your supply chain partner’s direction in their capital investment, it’s huge. Maybe certain projects could advance or other ones could be quickly killed. Tat helps with the cost equation vs thinking it’s about the pennies on the unit you’re talking about. Campbell: Tat’s a good point. We tied our wheat straw back into a social trend in China. Tis is what’s made it so compelling. A lot of the air pollution in China is from burning of agricultural waste, such as rice and wheat straw. Now we’re creating an application which creates a market for what was formerly waste. When you do those types Continued on page 16

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TRENDS // January 2014

of things, and it saves money, it becomes much easier to justify the capital investments. Sasine: One of the things Wal-Mart has been spending a good deal of time looking at over the past few months is the revitalization of American manufacturing. As the market for manufactured products and consumer opportunities grows in the

“Local manufacturing in many parts across the u.s. is becoming more competitive. that makes it an important time to consider packaging reinvestment.” — ron sasine, Senior Director of Packaging, Private Brands, Wal-Mart U.S., there’s also going to be an upstream demand for packaging, components and other materials that go into providing that fnished product. A good deal of capital investment opportunity will be tied to that. It’s encouraging more local supply for product as manufacturing comes back into some of our communities. Lots of towns were known for what they made. Tat sort of community-centered

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manufacturing is set for a rebound in the U.S. Tat ties back into cost. Clearly the cost of transportation is a critical part of what’s eventually paid at the checkout by consumers. Te cost of labor in many of these markets around the world is also a part of that component. When all of the pieces get added together, we’re seeing that local manufacturing in many parts across the U.S. is becoming more competitive. Tat makes it an important time to consider packaging reinvestment. Hotchkiss: Cost reduction is always a driver. But people are looking at it much broader because it’s not just the cost of the primary container that you’ve got to focus on. You’ve got to focus on logistics, supply chain, all of the costs that go with distributing products. You’ve got to focus on costs in terms of product loss. You’ve got to focus on costs of your consumers. If you put a cheaper package out there but it drives 10 percent of your consumers away, you haven’t done the company any good at all. Okoroafor: [Going back to trends,] an emerging trend I see is consumer interactivity—using mobile devices to communicate with the consumer. Tat interactivity encompasses everything from personalization to communicating directly, one-onone with the consumer. And packaging becomes your trigger for that virtual communication. Look at the emergence of NFC, near feld communication. You could be walking down the ketchup aisle and a package would tell you “I’m

Dell’s new wheat straw packaging is an example of innovating by improving packaging performance at a lower cost while advancing sustainable initiatives.

now zero calorie” or “Please buy me. I’m on sale.” Te packaging is triggering it because of printed electronics. Goods can interact with mobile devices. I see this trend going into the future for a long time. Watch out for printed electronics. Do you think printed electronics is going to be done at the supplier level, or do you see it as something that brand owners are going to do online, on the fy, to get additional levels of personalization? Okoroafor: Te initial idea of going into printed electronics was so people can deliver it online quick, easy, low cost. Ultimately, I think brand owners will be doing it. Because I want to be able to do personalization as fast as my current mass production. And that is a reality with printed electronics. It’ll be just like printing with your inkjet printer.

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sustainability Why we should eliminate the “B word” from sustainability conversations At frst blush, it certainly sounds like a good word, a warm and fuzzy word. A word that surely belongs hand-in-hand with the many R words we use in sustainability conversations. It’s a word that conveys a sense of closing nature’s loop and returning materials right back into the bosom of mother earth. But the B word—“biodegradable”—has no place in modern sustainability conversations. It’s outdated. Maybe it used to be the holy grail of the quest to make materials more sustainable, but we’ve gotten smarter. We’ve learned. It’s now time for our lexicon to reflect how much we know, and it’s time for us to use our modern understanding of sustainability to have meaningful conversations—conversations that don’t include yesterday’s buzzwords. So, thanks, B word, we’ve learned a lot from talking about you, but it’s time for us to part ways. Te problem with the B word? Its connotation that it’s always a good thing and never a bad thing. Truth be told, it’s not necessarily either. Sometimes it can lend positivity to a sustainability profle, while sometimes it can be a detractor. It’s like if we were to automatically assume superior sustainability for square packages, or transparent packages, or purple packages. Biodegradability is an arbitrary quality that needs to be expanded and explained, not simply touted. First question when you hear the B word: Where is it likely to biodegrade? In a home composting operation? In an industrial composting operation? On the side of the interstate? In a landfll? It’s the same as assessing real estate: location, location, location. Packaging producers can’t know where their packaging is going to end up, so if we’re going to assess what the B word means for a package’s sustainability, we have to assess each and every likely scenario. No matter what we do, a lot of packaging will end up in a landfill where it’s unlikely that biodegradability will do it any good. In the oxygen-deprived enclosure of a landfill, things biodegrade anaerobically, which essentially is a big word meaning they generate a lot of methane as they decompose. Methane, you may have heard, is an extra-potent greenhouse gas. Landfills are the third biggest source of manmade methane emissions to the atmosphere. If trash didn’t have that pesky quality of biodegradability, landfills would be a bit more benign. As litter on the side of the interstate? Tat’s a bit trickier. I doubt anyone can argue that we’d be

better of if litter didn’t biodegrade, but there’s a lot of complexity in judging the answer. Do we want consumers to think that a package is litter-friendly? I would argue that every package needs clear instructions to tell a consumer what they need to do to send a package to its best possible end-of-life scenario. Touting the B word on-package doesn’t do that. Ten of course there’s the issue of time. If something takes 10 years to biodegrade on the side of the interstate (or say, in the ocean), that’s a lot of time for damage to be done. Once again, just using the B word doesn’t tell us the whole story. Ten there’s composting, where biodegradation time can spell the diference between benefcial recovery and more-harm-than-good contamination. A host of other factors (potential plant toxicity of any additives in a package, for instance), matter when it comes to composting. And biodegradability, in its general sense, tells us nothing about whether a package fts in a composting operation. Te concept of compostability is constantly becoming better defned and it’s this C word, not the B word, that tells us if a package has the potential for a benefcial end-of-life scenario involving its decomposition. So yes, a package can be biodegradable and not compostable. A biodegradable package can even detract from the success of a composting operation. Once more, the B word really doesn’t tell the whole story. A sub-topic that rightfully deserves its own article is the idea that we should ever put biodegradability additives in petroleum-based plastics. If you’ve read this far, you probably get it without me going into detail. But suffice it to say that the carbon in petroleum-based plastics was sequestered from the atmosphere millions of years ago and it makes the most sense to keep that carbon bound up in a useful material. If we allow those plastics to biodegrade, we release their carbon content into the atmosphere and we also send the wrong signal to the recyclers who offer the best chance for a sustainable usage of petroleum-based plastics. It’s just another example, though perhaps counterintuitive, where a material is much more useful to us and has a greater potential for sustainability when it doesn’t biodegrade. Again, though, this isn’t to say that biodegradability is automatically bad. For many materials, it can be good. But if it’s good, we should be able to talk about its compostability and use the word that actually carries meaning. If not, you can be hip, be informed, be smart, be modern—and keep the B word out of the sustainability conversation.

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

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BEST PRACTICES // January 2014

How sweet it is

Domino Foods is sitting pretty with AN ELEGANT, ERGONOMIC CARAFE-STYLE CONTAINER that could make sugar bowls obsolete. Kate Bertrand Connolly, Contributing Writer

In 1906, a print ad for Domino Sugar’s 5-lb, sealed boxes of sugar proclaimed: “Imagination could not conceive of a handier and prettier form than is presented in ‘Crystal Domino Sugar.’” Spring forward 108 years, and the same words perfectly describe the new package Domino Foods Inc. has created for its Quick Dissolve Superfne white sugar and Pourable brown sugar. Te sugars are sold under both the Domino and the C&H brand names. Te new carafe-like package launched in the northeastern United States in the fall of 2013 and currently is completing its rollout in the western part of the country. Décor-friendly but also practical, the bottle combines good looks with ease of use. “It was designed to be a very graceful shape— the word we use is ‘willowy,’” says Brian O’Malley, president/CEO of Iselin, N.J.-based Domino Foods. Te company, which markets the Domino and C&H brands, is part of ASR Group.

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Aesthetics were a key concern, because Domino Foods wanted a package that would look good sitting out in the kitchen or dining room. “Because of the shape and the way it looks, it’s table-worthy. It’s a nice departure from the typical sugar bowl that’s sitting on your kitchen table or countertop, and it can spark somebody to say, ‘Wow, I really like the look of that. Where did you get it?’” O’Malley says. Ease of use was the other critical goal of the package design. “Functionally, it was important it ft into the consumer’s hand and allow them to easily open and dispense the sugar onto their food or into drinks without using a spoon,” O’Malley explains. He adds, “We wanted to make sure, because of the size of the product, that it would be very easy to use, for everybody.” Te fll weight of the packages is 12 oz for Quick Dissolve Superfne sugar and 10 oz for Pourable brown sugar. Te bottles are close to 8 inches tall.

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UBM January 2014 // BEST PRACTICES


Better package, better sugar Domino Foods worked with New York-based design frm 4sight Inc. to develop the ergonomic new package, which features a high waist that’s easy to grip for people of all ages and with hands of all sizes. Te disc-type dispensing closure can be operated with one hand. Te category-busting package emerged from insights gained in focus groups, during which consumers brainstormed about packaging formats that would make sugar easier to use and store. “We looked at a variety of diferent things, and these—what we call the ‘vase products’—were the culmination of all of that work,” O’Malley recalls. To add even more value, Domino decided “to take improved sugar products and put them in the improved The customized fller has an integrated package. We thought of it as a weigh scale to ensure accurate weights. way to give the customer a double beneft, basically taking a welldesigned package and putting a better sugar in it.” Te Quick Dissolve Superfne white sugar, which has been on the market for several years as Domino and C&H Superfne Sugar, is granulated. But its granules are smaller and more uniform in size than those in conventional white sugar, so it dissolves more quickly and thoroughly, even in cold drinks. Until now, Superfne Sugar has been packaged in paperboard cartons. As for the Pourable brown sugar, it has been available for many years in the eastern United States as Domino Brownulated Light Brown Sugar. Te product, which is formulated with less moisture than conventional brown sugar to eliminate clumping and hardening, was originally packaged in a carton but in recent years has been available in a resealable stand-up pouch. With the launch of the vase package, this specially formulated brown sugar will be distributed in the western states for the frst time. In that region, it will be sold as C&H Pourable Golden Brown Sugar. In the east, the product will be called Domino Pourable Light Brown Sugar. Domino Foods plans to switch completely to the vase package for its Quick Dissolve Superfne and Pourable brown sugars, nationwide, as the cartons and pouches currently on-shelf sell through.

Do you know which one is leaking?

Anatomy of a package Te new package design includes just three components: a colorless, transparent bottle; a white, opaque closure; and a full-body shrink sleeve. Adhering to its corporate commitment to sustainability, Domino chose recyclable materials for all three components. Te bottle is PET, the closure is polypropylene and the shrink label is PETG. Form and function meld neatly in all parts of the package. Te injection blow-molded bottle, with its oval base and gentle curves, is easy on the eye and the hand. And the closure, viewed from above, looks like an egg, right down to its color and its size. Te pleasingly shaped closure comprises two pieces. Te primary part, which snaps into the top of the bottle, is molded with a triangular aperture for dispensing. Te second piece is a hinged lever that covers the snap-in component. Te product’s logo Sleeve labels are applied to containers (either Domino Sugar or C&H) is after they are flled and capped. Domino Continued on page 20

We do. To many inspection systems, these two containers look identical but to a TapTone system they couldn’t be more different. TapTone inspection systems identify micro-leaks, fll level variations, and visual package defects at full production line speeds. With over

40 years of experience and a long list of patents, we know how to solve your inspection challenges, today and in the future. Talk to a TapTone representative today and fnd out how to ensure that the defective containers on your line never reach your customers.

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BEST PRACTICES // January 2014





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The vase package from Domino Foods is just the latest in a series of packaging innovations for the Domino Sugar and C&H brands. The company sells C&H granulated sugar in a 4-lb gabletop carton, for example, and it sells both brands in a 4-lb plastic canister. The canister has an easy-grip feature and easy-open lid, and its wide diameter makes it simple to scoop out sugar. The color of each canister coordinates with the identifying brand color: yellow for Domino and pink for C&H. Made of polyethylene, the canisters and lids are recyclable. But the company encourages consumers to reuse them, as well, with a web page highlighting

the ways in which the package can be repurposed when the sugar is gone— storing puzzle pieces, making a piggy bank, holding crayons, storing leftovers and more. Domino Foods also has responded to consumers’ requests for easier-to-store packaging by introducing resealablezipper bags and pouches. For the younger set, the company packages a blend of granulated sugar and cinnamon in a fun shaker package. The 3-oz Sugar ‘N Cinnamon Shakers are fgurine-like bottles decorated with cartoon characters. Marketed as collectibles, the shakers help the brand live on after the product is gone.

embossed in the center of the lever for some subtle branding. To dispense the product, the consumer presses a small depression molded into the lever beneath the logo; the lever fips up to reveal the aperture. Pressing on the other end of the lever closes the cap with a satisfying click. Te consumer can hold the bottle, open it, dispense the sugar and reclose it, all with one hand. On unopened packages, the shrink label extends well over the closure, providing a tamper-evident seal that exposes only the logo embossed in the cap. Te label is horizontally perforated at the bottom edge of the closure for easy removal of the tamper-evident portion. The label also is perforated vertically, from top to bottom, for easy removal prior to recycling or, if the consumer prefers, a non-labeled sugar dispenser on the tabletop. Unwilling to let its brand identity disappear with the label though, Domino Foods debosses the Domino Sugar or C&H logo directly into the bottle. The logo appears near the bottom of the bottle, on the widest portion of the package. With the sleeve label in position, containers enter the dry-heat shrink tunnel.

Protect and present

Containers exit the shrink tunnel and are put into cases by hand in counts of six.

Creating a package structure that consumers would feel good about leaving in plain sight was a key part of the project, but product protection was equally important. Moisture barrier was an essential consideration. “Te combination of PET packaging material, coupled with a snap-close feature in the fip top, protects against moisture and provides the consumer a great option for handling and storing their sugars,” says O’Malley. Freshness was another concern. Te closure “provides maximum moisture control and also keeps the product as fresh as possible. Sugar will pick up odors from other things in the cabinet, if you have it sitting next to cofee, for example,” O’Malley explains. “With the cap on, you’re going to have maximum moisture control and freshness capability.”

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Prior to purchase, the shrink label provides a modicum of extra moisture and gas barrier by covering the seam between the bottle and closure. The label’s most important job, however, is branding. The shrink label’s graphic design features swirls of each brand’s signature color—yellow for Domino Sugar and pink for C&H—and highlights the package’s easy-pour feature with text and an arrow. The label material’s clarity and high gloss, together with high-quality flexographic printing, provide a premium look for the products and position the offerings as part of their respective brand families. Two swirling windows on the label provide a clear view of the product inside. “One of the things we really wanted to do was make sure the product showed through. On the brown sugar, you can see that it’s not like a regular brown sugar. Tis is a diferent product. You can see the granules,” O’Malley points out. “And in the case of the pourable white sugar, the Quick Dissolve, the crystals are identifably smaller than what you typically see in a sugar bowl,” he adds. “Tat’s why we wanted to make sure that the products are actually visible. With most sugar, if not all, you really can’t see the product. It’s hidden in the package.”

equipment seats the cap securely in the opening. The filled, capped containers then pass through a metal detector and are conveyed out of the controlled-environment room. From there, the containers are conveyed through a full-body sleever followed by a customized dry-heat shrink tunnel. Finally, the labeled packages are manually packed into

shipping cases, six per case. After distribution and unpacking at the point of purchase, the vases make a pleasantly disruptive statement on-shelf. “We’re hoping the biggest attraction, as consumers walk down the aisle, will be this innovative shape—that it will draw them to the product to take a closer look,”


O’Malley says. “We hope our loyal customers will be attracted to these new products, but also that new customers will be attracted to them and think of us for other items they need, for baking. It’s the halo effect.” 4sight Inc., 212-253-0525

On the flling line Domino Foods uses multiple contract packagers to fll the vase packages. Te brand owner sends its sugar in trucks to the contractpackaging plants, where the product is of-loaded into fexible silos. Each silo can hold up to 53,000 lbs. From there, the sugar is transferred to a controlledenvironment flling room using fexible screw conveyors. Te empty vase containers pass through an inverter/rinser to remove any particulate, and sugar is metered into each container using a customized dual-head fller. Te fller has an integrated weigh scale to ensure correct fll weight. After the containers are filled, a product code is laser-etched into bottom of the package. Then, as the containers exit the filler, a cap is manually placed on top of each container and a customized piece of

See us at WestPack Booth #5146

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BEST PRACTICES // January 2014

The many happy returns of the custom preform bins A Coca-Cola bottling co-op switches from corrugated containers to reUSABLe, coLLApSiBLe pLAStic BinS for preforms that raise effciency and hygiene—and cut costs. The program includes RFID for tracking and robotics. Rick Lingle, Technical Editor Te toughest test for packaging in the supply chain may be time. Tat is certainly true of reusable plastic containers (RPCs), where durability is as important as protection—whether what’s transported is a packaged product or “prepackaging” in the form of PET preforms. It may be more important for the latter: Preform faws like nicks and scufs created during transportation and handling can become magnifed during blow molding. Southeastern Container (SEC), a cooperative of

Bin erecting is done in three SEC facilities using robotics in a process that takes one minute, start to fnish.

16 independent Coca-Cola bottlers in the eastern U.S. serving about 34 states and six Canadian provinces, sought an alternative to bulk “gaylord” corrugated containers used to distribute preforms internally that would maintain integrity through dozens of reuse cycles. Te preforms are used for bottles from 20 oz to 2L in size. SEC collaborated with RPC supplier Orbis to develop a custom bulk bin that was tested and customized in size, structure and value-added features to hold the most preforms in the lightest weight possible. Today, with several years’ time as a known variable, SEC can assess the results for a program launched in 2009 with the Orbis HDMX4845-50 bin that’s 45 x 48 x 50 inches, vs a standard 40 x 48 x 46 inch bin. Te RPC volume is 50 cubic feet, 10 cubic feet more than the gaylords or the equivalent of about 20 percent more preforms, yielding for SEC a net savings when calculating total costs. Te bin ofers four-way forklift entry in the approximately 4-inch tall injection-molded highdensity polypropylene base along with the Coke-red PP sidewalls. A snap-on PP lid seals the bin. At 140 pounds, SEC’s lidded bin weighs 20 to 30 pounds less than the competition’s, according to Orbis, and ofers several unique features:

Customized to SEC’s requirements, the collapsible RPC bin holds 20 percent more preforms than the corrugated bin it replaces and is equipped with RFID on bin and lid.

• ɨe bottom platform features a plastic sheet with integrated dampening springs to deaden the bounce of the initial preforms dumped into the bin to reduce damage; • Recessed latched handles fold out to permit the sidewalls to be lifted and completely removed so the bin components can be thoroughly cleaned, rather than using hinged sides; • Radio-frequency identiëcation (RFID) tags are afxed to every bin and lid.

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USDA Approved Rotary Band Sealer includes bag top trimmer and vacuum scrap removal. Economy model for “lay-flat” packages conserves production floor space.

Medical Pouch Sealer with verification ports for process validation of pressure, speed, and temperature. For lightweight products and smaller pouches.

Portable Sealer with synchronized conveyor. Ideal for candy, confections, and snacks in lightweight or smaller stand-up pouches. Great for start-up companies!

Visit us at WEST PACK Booth 5417 Anaheim Convention Center

February 11-13, 2014 • Anaheim, CA

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UBM January 2014 // BEST PRACTICES

Lidding is automated with robotics that use one tool to smooth out the pile of preforms in the bin (shown) before it changes tooling to apply and secure the lid.

Te closed-loop SEC bin project encompasses three preform injection molding production facilities, eight blow-molding operations and approximately 10 in-line bottling operations throughout the eastern U.S. SEC installed RFID readers and robotic cells at the three preform facilities to re-erect bins returned in fat form; in Asheville, NC, SEC also operates a robotic lid application system. Tere are more than 40,000 bins currently in the system, according to Doug Wehrkamp, SEC president, who was the company’s director of engineering during much of the bin development and implementation process. “Te gaylords were not heavy, but someone had to ‘wrestle’ it from a knocked-down position into an erect form and place it on a pallet—it was not an ergonomically ideal situation,” he says. “We sought the optimum, one-piece collapsible plastic bin that

would retain to the degree possible what we liked about a gaylord—including light weight and a good return ratio—and that conveniently knocked down. We wanted a bin that would better cube out in a trailer, that we could extend the life, was repairable and was modular in the sense that a damaged part could be replaced instead of having to dispose of the whole unit. Finally, we wanted it used in a system we could automate.” Some key highlights: Light weight: When the project started, the bin weight was around 250 pounds. “When it was reduced to around 200 pounds, we still couldn’t make the economics work, but when we got to below 150, we could clearly see that there could be an economic payback,” Wehrkamp says. “Getting that weight down was crucial.” Te weight reduction resulted from various iterations of cross panel designs for the sidewalls and diferent types of lids. Trough the design process, “bellying” was controlled to prevent the bin walls from bowing outward due to the weight of the preforms—even when they are flled and stacked four high. Bowing negatively afects the lid application, whether done manually or robotically. “Stacking allowed us to shrink the footprint of our warehouse storage by 15 percent,” Wehrkamp adds. Good return ratio: Wehrkamp estimates they got about 10 use cycles on a gaylord. SEC sent about 5,000 unusable gaylords yearly into the recycling stream. Each bin makes about 12 to 15 roundtrips


yearly, with SEC’s goal a minimum of 100 to 150 turns over a bin’s lifetime. “We’re about halfway there and we don’t see any signifcant issues or wear with the bins,” Wehrkamp reports. “Tere’s nothing to indicate that we’re not going to be able to achieve that or perhaps as high as near 200 turns.”

The automated erecting systems determine the sequence of folds to erect the bin properly and with automatic confrmation before the bin is released. SEC reports that these robotic systems worked as expected from Day One.

Shrinkage has been minimal. “Te number of bins lost is staying well below one percent,” he adds. “Economically, we’ve been very happy with the returns—it’s met our expectations in all areas.” Efcient knock down: Technically, the bin is made up of several components, including Continued on page 24

See us at WestPack Booth #5239

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removable sidewalls. But according to Wehrkamp, it’s efectively a single-unit bin. After use, the bin is manually collapsed for return. “Te latches are pressed and the four side walls collapse,” says Wehrkamp of the simple process. It can fold in several ways, but due to the programming on the robotic erecting system, the sequence doesn’t matter, he adds. A bin has a collapsed height near

13 inches, which at a 4.8:1 ratio is just short of the 5:1 ratio the gaylords had provided. “It’s not exactly what we’d originally anticipated, but was extremely close, so we consider that successful,” reports Wehrkamp. When it eliminated the gaylords, SEC also eliminated all the corrugated and wood dust associated with those components. It also eliminated a bin liner in the form of

a plastic bag, a corrugated cover sheet and two polyester straps that secured each corrugated bin. “We were able to clean up our operations from a housekeeping perspective,” Wehrkamp points out. “We maintain extremely clean plants, but the amount of dust and contamination that was removed from our plants was a pleasant surprise.” Wehrkamp says the bottling

operations receive the same benefits the blow-molding facilities enjoy: “They’ve got no corrugated or wooden fiber coming into the operation with the bins. With a plastic bin, you’ve got that consistency and repeatability day in and day out, including the exact same footprint that also handles well on our equipment.”

Robotics erect, lid bins Te project also included robotics, which were frst implemented at the Asheville, NC, facility in 20092010 by ProMATIC Automation, a local automation integrator, followed a year later by automating facilities in Bowling Green, OH, and in 2012, in Winchester, VA. All three facilities share a similar bin

RFID tracking SEC felt that RFID was something that it wanted to have from the outset as the only feasible way to track bin usage. “RFID was a quick, relatively inexpensive way to capture the number of turns on a bin-by-bin basis at the erecting robot,” says Wehrkamp. “Otherwise it’s very difficult to track that.” He also felt that the most economic time to do that was at the front end during bin manufacturing. SEC uses a custom tag for bin and lid. The RFID tag, which took some design work according to Wehrkamp, is about 1 inch square and is supplied by Alien Technologies. SEC supplies the RFID tags to Orbis to affix. Every bin and lid is tagged. The three preform facilities use RFID readers-interrogators from Motorola Solutions installed near the automated bin erecting systems. Wehrkamp says that he’d like to leverage more benefits from RFID; at some point, he’d like to track the movement of the bins in and out of the plants from and into the trucks. “As costs for the technology come down, there’s a point where using RFID might become more beneficial than just a simple tracking mechanism we use today,” he explains. “Hopefully, we’ll be able to build a business case to use that technology further in the next few years.” Alien Technologies, 408-782-3900 Motorola Solutions, 847-576-5000

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erecting setup; Asheville also has an automated bin lidding system. “ProMATIC came up with a solution for us that was relatively simple in design and efective,” Wehrkamp relates. “We achieved the automation piece that we’d anticipated to eliminate a source of workplace injuries and moved that labor elsewhere in the plant.” A robotic cell re-erects the collapsed bins. Te fats enter the cell on a roller conveyor, which senses the order in which the bin sides have been folded. Tat data directs an overhead, inverted six-axis Fanuc M16 robot to sequentially open the bin using grippers in the required order. Te system confrms using sensors and air cylinders that the bin has been erected with all sides secure. Te bin then conveys to a separate mechanical system that inverts it and cleans it with ionized air to remove any remaining preforms (to prevent

“We maintain extremely clean plants, but the amount of dust and contamination that was removed from our plants was a pleasant surprise.” — Doug Wehrkamp, SEC president loads of mixed-size preforms) and any particulates. Te bin is reoriented and released from the cell. Te process, which takes about a minute, was one of the positives from the outset. “We were surprised on how well the robotic cell has worked from day one,” Wehrkamp relays. “It grabs the jaws of the latches and very reliably and repeatedly assembles the bins.” In Asheville, a flled bin is lidded by a robotic system also supplied turnkey by ProMATIC. Larger than the erecting robot, the Fanuc M710 uses two kinds of end-of-arm tools that mate to the robot. In rake-like fashion, the frst tool is used to even the level of the preforms, which tend to pile in the middle above the sidewall and may prevent the lid application. Te robot then switches tooling and orients and applies the lid

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using vacuum grippers. Tat process also takes about a minute.

What’s ahead? “Next for us is to complete the automation on the lid application side,” says Wehrkamp, referring to automating that process for the two remaining preform plants. SEC is also looking to automate bag insertion when a vapor-

barrier bag is added manually before flling to protect heat-set preforms. He estimates that about 10 percent of the bins need a barrier bag. While the project has remained locked down for a number of months, Wehrkamp discloses that the fnancial benefts have become clearer over time. “We see a reduction the cost of dunnage on our bottom-line


fnancials,” says Wehrkamp. “From where I sit now, it’s pretty obvious that’s had a dramatic, positive impact.” Fanuc Robotics, 248-377-7000 Orbis Corp., 800-890-7292 ProMATIC Automation, 828-684-1700

PakTech takes major brands and processors to the top of the market. How? Sustainability and efficiency. Our handles are made using clean manufacturing practices and Post-Consumer Recycled (PCR) resin. Being 100% recyclable, they look good, feel good and have an amazing effect on consumer happiness. Plus, operations are streamlined with our state-of-the-art, automated application machinery that fits seamlessly into any production line. The ultimate turnkey solution found in something as simple as a PakTech handle.

Sustainable Handle & Applicator Solutions

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NEW TECHNOLOGY // January 2014

Authentication technology materializes for flexibles Anti-counterfeiting is the main market focus for Ghost, an integrated watermark for flexible packaging that’s a seamless add-on during converting. Ghost has generated surprising interest from a brand equity aspect, too. Rick Lingle, Technical Editor On Sept. 23, 2013, during PACK EXPO, Rollprint Packaging Products launched its Ghost technology as an economical alternative—done seamlessly during flm converting—to create a unique, customizable barrier to packaged product counterfeiting. Rollprint president Dhuanne Dodrill demystifes and updates this intriguing brand protection product, which is available license-free to customers.

How does Ghost work and in what formats can it be implemented? Te process creates an integrated, repeating watermark embedded in the composite fexible packaging material. Te easily visible, overt watermark provides visual confrmation to the user that the products being used are authentic. Te Ghost watermark is created by diferentially cooling the extrudate to generate an optical efect that appears as a watermark. Te key to making it work is to precisely control cooling to create a sharp, distinct image rather than a smeared image. Adding the watermark requires specialized equipment with knowledge of proprietary, advanced technology, coupled with signifcant fnancial investment, making it technically and economically challenging to duplicate. Ghost can be produced as an extrusion coated or extrusion laminated composite and is compatible with a variety of chemistries, including polyethylene, polypropylene and polyester. Sealants can be either peelable or welded and paired with polyester, nylon, foil and other substrates. Te fnal composite material can be used to create packages such as chevron pouches, or package components such as an overwrap or lidding. What options and variations are possible? Tere is a fair amount of fexibility on size. We can produce the Ghost technology on web widths up to 64 inches. Tat means that the largest image size possible is 25 x 64 inches. On the opposite end of the scale, we can create small hairline images— complex line work, and type as small as 4 point remains crisp and legible. Companies have the fexibility to use corporate logos, brand names or other symbologies. Te technology was initially developed for clear structures. However, we quickly learned that

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The Ghost process creates an integrated, repeating watermark embedded in composite fexible packaging materials that provides visual confrmation that the products being used are authentic.

it works equally well with opaque and colored materials, as well as foil composites. What market need does it address? Ghost is an inexpensive approach to brand protection. Because the watermark is added concurrently during normal processing, we can usually add the feature at little or no additional cost. It requires no additional ingredients or additives, and has no impact on the packaging manufacturing process—sealing conditions and speeds remain the same. Tis cannot be said for the majority of anti-counterfeiting techniques. Most other options add signifcant cost and frequently require specialized equipment. Examples include inks only visible under UV light, forensic markers or taggants, and micro printing. Ghost pairs well with these other techniques and can help create a layered approach to brand protection. Can you provide more details about costs? Te watermark is produced during a proprietary diferential cooling process to provide an optical efect without the use of ink or any chemical additives. Te costs associated are for tooling that is required for a custom image. At large volumes, this would translate into a minimal expenditure.

What about the “specialized equipment” that produces the mark? Due to the nature of the product and its intended use, we are unable to discuss the exact process for obvious reasons. Te whole point of this type of technology is to minimize the chance of duplication so we are keeping the specifcs confdential. Te equipment is located in Rollprint’s Addison, IL, facility outside Chicago. How did this technology come about? What was the biggest technical hurdle? Rollprint has a reputation as a packaging development pioneer for medical device and pharma applications. As such, we are always on the lookout for trends, technologies, regulations and such, that are going to drive next-generation packaging structures. Our Ghost technology is a collaboration between marketing and R&D to proactively create an option based on criteria listed in the European Falsifed Medicines Directive. Although the guidelines do not currently apply to medical devices or to the United States, we believe that they might eventually flter down to us. As a result, we wanted to create a technology that customers would fnd benefcial.

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One of the criteria in the directive calls for an “obligatory authenticity feature on the outer package of medicine.” We can envision Ghost technology being used on the sealing web of a blister package, for example. Regarding the technical hurdle during development, one of the issues was reaching a “visibility” balance—trying to fnd that sweet spot between visibility and being too hard to read.

layered approach to addressing counterfeiting and product diversion. For high-risk products, customers are looking at potentially integrating this technology with serialization initiatives and creating a “moving

“Because the design of the watermark can be changed very inexpensively, the design can be updated regularly and tied to a particular lot or range of serial numbers.”

Please comment about the level of interest and market status. Tere has been signifcant interest from medical device and pharmaceutical companies exploring anti-counterfeiting options. Some are looking for an inexpensive option to help protect their brand that does not slow or disrupt their established process fows. Others like the fact that Ghost can easily be coupled with other established techniques—such as forensic markers or taggants, micro-printing and holographic options—creating the recommended

— Dhuanne Dodrill, president, Rollprint target.” Because the design of the watermark can be changed very inexpensively, the design can be updated regularly and tied to a particular lot or range of serial numbers. Tis provides yet another layer of protection and further confounds counterfeiters. However, in addition to those security-oriented applications which were anticipated, we were surprised to discover signifcant interest from companies wishing to use this technology to enhance branding. We’ve received queries from

Tech at a glance Ghost flexible packaging watermark from Rollprint TARGET MARKETS: Medical device, pharmaceuticals and luxury products OTHER POTENTIAL APPLICATIONS: Cosmetic, personal care and household chemicals STATUS: Commercially available LEAD TIME: 6 to 10 weeks, depending on complexity


cosmetic, personal care and even household chemical companies looking for ways to boost brand equity. For example, instead of using a clear flm on a peelof cosmetic application, the Ghost technology can be used to subtly repeat the logo. You could do the same for higher-end personal care products (such as razors and tooth brushes) and household chemical items (such as scent dispensers and bug repellants). Tis additional branding is another reminder that consumers are purchasing authentic items and not lesser-quality duplicates.

How is this layered with Chameleon and what is the status of that sealant technology? Ghost is compatible with Rollprint’s Chameleon proprietary color-changing sealant technology for heat-seal applications. Chameleon was engineered to allow a flm of one color to transfer a peel indicator of a diferent color to provide strong visual indication that a package has been opened. Te objective is to enhance product security and help deter counterfeiting, in a cost-efective manner. Since we launched Chameleon in late 2012, it has generated an unprecedented amount of market interest and feedback—particularly from the medical device segment. Many companies expressed their “pain” regarding hermetic seal authentication. We’ve funneled that feedback back into R&D to create new ways y to address this issue. Rollprint Packaging Products Inc., 630-628-1700

Flexi-Pass only $449! Register by January 17th!

Applying critical concepts and enabling technologies in design, manufacturing, engineering and automation February 11-13, 2014 Anaheim Convention Center | Anaheim, CA

Sponsored by:

Enhance your expo experience this year, like never before An expo allows you to see, touch and experience new innovations and technology. Now, learn how to apply these enabling concepts to your projects and business in the Learning Labs!

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Medical Devices

This educational program is a perfect complement to any visit to Anaheim— \with the option to book just one Learning Lab for $299, or a Flexi-Pass so that \you can come and go as you please, for only $449*! *Early bird rates vaild until January 17th, 2014

Stefan Schmidt, Manager - Plant Development, BMW SuPing Lyu, Senior Principal Scientist, Medtronic Cardiac Rhythm Disease Management

Russ Roberson, Vice President Quality and Regulatory Affairs, GE Healthcare

Jim Hanna, Director, Environmental Impact, Starbucks

Corey Morton, Director of Technology Solutions,, B&R Automation

Matt Alford, Packaging Director Boys Entertainment, Mattel


All part of your show experience:

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Register by show online | Register by phone 310 445-8534

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In association with

The 8th Annual

SUSTAINABILITY Innovative & Sustainable Solutions to Achieve Profit by Packaging

March 5-7, 2014 Renaissance Orlando at SeaWorld, Orlando , FL, USA Proctor & Gamble, Aveda, Williams Sonoma, Zappos and Microsoft are just a few of the major international brands who will be presenting at the 2014 edition of Sustainability in Packaging. You can’t afford to miss it! 4Relevant for every sector of the packaging industry: from paperboard to plastics to flexibles to metals and more, the 2014 agenda offers our most comprehensive look at the sustainable packaging industry ever. 4More end user perspectives than ever before: 2014 Sustainability in Packaging delegates will hear from Herman Miller, Safeway, Tetrapak, Method, Bemis, Pearlfisher, The Coca Cola Company and more. If you want to supply your products to companies like these, book your spot today to find out what they are looking for. 4Other industry insiders highly recommend it: Past attendees say “if you need critical information on how to incorporate more sustainability into your package production, this is the place” (Hewlett Packard); call this “a good opportunity to interact with key packaging stakeholders on sustainability issues” (Solvay) and note that this conference is “very informative from all aspects of the packaging industry.” (J&B Group)

Use code PACK14VIP to save $100 off of your registration! The conference provided great contacts and connections to those with varying experiences in packaging from novice to expert. THE SCOTTS COMPANy The conference is a great way to network with people who are really making impacts on sustainable packaging. PROCTER & GAMBLE A great opportunity to meet and interact with a large variety of suppliers, users and brand owners with a passion for more sustainable solutions. DOW CORNING COMPANy


part of the

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CONFERENCE HIGHLIGHTS Day 1 - Wednesday March 5, 2014 Workshop 1: Delivering Sustainability without Compromising Brand Equity Workshop 2: Data Demands for the 21st Century - A Workshop on Satisfying your Customer’s Requests for Packaging Information Sustainable Packaging Strategies Executive Panel Moderator: Jeff Loth, Senior Manager, Packaging Engineering, MICROSOFT Advancing Sustainability Through Partnerships Len Sauers, VP Global Sustainability, Procter & Gamble

Aveda’s Sustainable Packaging Strategy and our Efforts to Achieve True EPR Dave Rapaport, Vice President, Earth and Community Care, AVEDA Future Focused Design and Environmentality Mike Branson, Founding Managing Partner and CEO, Pearlfisher Getting a Sustainable Packaging Project Started: the Balancing Act of Sustainability vs. Cost and Meeting Supply Chain Needs Chair: Betsy Dorn, Director, USA Consulting, Reclay StewardEdge Getting a Sustainable Packaging Project Started Christina Nicholson, Director- Sustainable Development, WILLIAMS-SONOMA, INC.


Success Stories and Developments in Fiber Packaging and Novel Materials Chair: Lisa Pierce, Executive Editor, PACKAGING DIGEST From Plants to Packaging Neil Darin, Senior Global Innovation Program Manager, HAVI GLOBAL SOLUTIONS Sustainable and Biodegradable Food Grade Packaging Materials based on Natural Chitinnanofibrils Derived by Waste from Fish Industry Dr. Morten Sivertsvik, Research Director, NOFIMA, PROCESSING TECHNOLOGy The Large Scale Mineralization of Paperboard Plastic Coatings: the Next Step in Eco-Technology for Food and other Barrier Sensitive Products Chris Tilton, Chief Technology Officer, SMART PLANET TECHNOLOGIES What Happens with my Packaging at the End of Life? Chair: Alan Blake, Executive Director, PAC NExT

Private Label Supply Chain: Challenges of Program Development Brad Tomm, Sr. Manager of Campus Operations and Sustainability, ZAPPOS FAMILy OF COMPANIES

Design with Intent Tom Carpenter, Director, Sustainability Services, WASTE MANAGEMENT

Going Green for Babies Emily Erickson, R&D and Sustainability Manager, HAPPyFAMILy BRANDS Consumers’ Insights and Systemic Behavior Change as it Relates to Packaging and Sustainability Co-Chairs: Alan Blake, Executive Director, PAC Next and Jeff Loth, Senior Manager, Packaging Engineering, MICROSOFT Packaging and the Environment: The Consumer Perspective Matthew Salem, Account Director, PERCEPTION RESEARCH SERVICES

Reusable Packaging in Retail Daniel Block, Senior Packaging Engineer -R&D, Consumer Brands, Safeway Reducing the Carbon of the Drink in your Hand – What does it Mean? Jeffrey Meyers, Manager Sustainable Packaging, The Coca Cola Company

Emerging Trends in Technologies for Smart Packaging, 3D Printing and Returnable Packaging Chair: Saskia van Gendt, Captain Planet, METHOD The Ever Changing World of Returnable Packaging at Herman Miller Cindy Doman, Packaging Engineer, HERMAN MILLER Sustainability through Intelligent Packaging Scott White, Chief Executive Officer, PRAGMATIC PRINTING LIMITED 3D Design for Sustainable Product Development and User Experience in Parallel Kate Ertmann, President, ANIMATION DyNAMICS Marine Debris Case Studies and Policy: Moving Towards a Solution Chairs: Lisa Pierce, Executive Editor, Packaging Digest and Saskia van Gendt, Captain Planet, METHOD How California is Moving Beyond Cleanups to Address Marine Debris Eben Schwartz, Marine Debris Program Manager, CALIFORNIA COASTAL COMMISSION Ocean Plastic Saskia van Gendt, Captain Planet, METHOD Producer Responsibility Laws Can Help Address Plastic Marine Debris Loading Dr. Allen Hershkowitz, Senior Scientist, NATURAL RESOURCES DEFENSE COUNCIL U.S. Navy: Sailing into new Sustainable Seas Jennifer Thran, NAVSUP Weapon Systems Support, Asset Protection & Pollution Prevention Department, Chair -DOD Sustainable Packaging Materials Workgroup, Program Manager US Navy’s Plastic minimization efforts, US DEPARTMENT OF DEFENSE

How Consumer Insights Drove Package Design: Windows 8 Jeff Loth, Senior Manager, Packaging Engineering, MICROSOFT

Sustainable Materials Management Keith A. Weitz, Environmental Scientist, RTI INTERNATIONAL

CONFERENCE HIGHLIGHTS Day 2 - Thursday March 6, 2014

CONFERENCE HIGHLIGHTS Day 3 - Friday March 7, 2014

Driving Sustainable Innovation Chair: Alan Blake, Executive Director, PAC Next

The Changing Face of EPR Chair: Betsy Dorn, Director, USA Consulting, RECLAy STEWARDEDGE

The Aidpod: An Innovation Filling the Negative Space in Crates and Saving Children in Africa Paul Cowley, Executive Creative Director, pi North America

Operating under EPR: An In-Depth Look at What’s Working and What Isn’t David Clark, Vice President, Safety Environment & Sustainability, Amcor Ltd and Chairman, PLASTIC RECyCLING CORPORATION OF CALIFORNIA

Making Fiber-based Packaging Fun, Smart and Active Fredrik Rosén, Director Market Strategy, INNVENTIA AB

EPR in Transition: Problems and Possibilities Dick Lilly, Business Area Manager for Waste Prevention and Product Stewardship, SEATTLE PUBLIC UTILITIES SOLID WASTE DIVISION

OtterBox Packaging: We’ve Gone to Plaid Josh Caldecourt, Packaging Engineer, OTTERBOx

Implementing Producer Responsibility for Printed Paper and Packaging (PPP) Allen Langdon, Managing Director, MULTI-MATERIAL BRITISH COLUMBIA

The Full Effect: A Case Study of Using Innovation for Social Change Heather Cutter, VP Innovation, PLUM ORGANICS

Sustainable Packaging Sourcing Chair: Betsy Dorn, Director, USA Consulting, RECLAy STEWARDEDGE

Key Sustainability and Innovation Trends around Flexible Packaging for Better End of Life Scenarios (10 min mini-sessions) Chair: Laura Rowell, Global Sustainable Packaging Manager – Consumer Packaging, SONOCO PACKAGING Introduction to the Session including Recent Trends in Flexible Packaging John Baumann, CEO, AMPAC PACKAGING Flexible Packaging and Resource Recovery Pete Hunderup, Resource Recovery Consultant, FLExIBLE PACKAGING ASSOCIATION A Review of Recent Market Trends Influencing Packaging Sal Pellingra, Director of Innovation, AMPAC PACKAGING Enhancing the Sustainability of Products Through Flexible Packaging Innovations Wayne Wegner, Director of Sustainability, BEMIS Flexible Film Packaging and Its Implications to Diversion Programs Mike Birett, Director, CONTINUOUS IMPROVEMENT FUND Flexible Packaging: Recycling and Alternative Solutions Susan Robinson, Federal Public Affairs Director, WASTE MANAGEMENT

What Makes a Sustainability Standard Credible? Nicolas Viart, Head of Sustainability, BONSUCRO Driving Certified Supply – the Tetra Pak Way Elisabeth Comere, Director, Environment & Government Affairs, TETRA PAK Field to Market: How and Why and Where it has Gotten to Through Focused and Sustained Supply Chain and Stakeholder Engagement Sarah Alexander, VP Programs, THE KEySTONE CENTER KEyNOTE: Solving Solid Waste Challenges by Working Both Ends of the Spectrum: Designing for Recovery of Waste Resources Jill Boughton, President & CEO, W2WORTH INNOVATIONS KEyNOTE: Towards the Circular Economy April Crow, Global Sustainability Director, Packaging at THE COCA-COLA COMPANy magenta cyan yellow black

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NEW TECHNOLOGY // January 2014

new productsequipment Vision guiding technology Integrated Vision is a smart camera system that uses 2D vision guidance to track products more accurately, improve supply chain management, improve quality, troubleshoot challenging lines and processes, and significantly expand the use of robotic automation. The system features sophisticated imaging technologies such as the PatMax algorithm for advanced part location, resulting in robust inspection, defect detection, guidance, alignment and measurement, all critical to ensuring that manufactured products meet the highest possible quality standards. The smart camera offers the widest range of built-in communication protocols that interface directly with the robot, according to the company, helping complete programming and set-up in approximately 25 percent of the traditional time. ABB Robotics, +41 (0)43 317 7111

Integrated conveyor Integrated conveyor solutions for coding/ marking applications allow for precise alignment with coding systems to deliver the best printing results possible. The conveyors fit industrial applications with powder coated/anodized aluminum and powder coated steel construction, and can achieve speeds of up to 200 fpm. Solutions with printhead, photocell and encoder mounts are available. adjustable guides help improve efficiency for operations with variable case sizes. all guide rail brackets, encoder mounts and printhead mounting plates clamp onto the side and limit operator intervention to help mitigate errors. The conveyor height is adjustable from 24 to 36 inches. Videojet, 800-843-3610

Industrial Inkjet Printing for the Packaging Industry

Custom solutions for unique printing applications X X X X X

Fast setups and changeovers Speeds from 14" per sec. & faster Store hundreds of jobs Full color - CMYK plus White Custom feeders, pretreatment, inspection options available

HMI/OEE dashboard software Point of View is software for developing SCaDa, HMI and OEE/ Dashboard projects that can be deployed anywhere. Designed for most Windows supported platforms, Point of View projects can either run locally on a development workstation or be downloaded to a remote workstation to operate using Point of View runtime software. a project tag database manages all runtime data, and configurable drivers communicate in real time with programmable logic controllers, remote I/O devices and other data acquisition equipment. animated HMI screens and OEE dashboards give plant personnel a graphical view of the process. Integrated modules include alarms, events, trends, recipes, reports, scriptable logic, schedulers, a security system and a complete database interface. Point of View software supports three types of remote application viewers and is available in three software packages: Development, runtime and Complete.

AutomationDirect, 800-633-0405

On-line gas analyzer The MaP Check 3 Vacuum now offers process control and traceability data to help support the latest food safety protocols. The gas analyzer is suitable for a variety of modified-gas food packaging applications, including meat, poultry, fish and baked goods. It continuously measures gas content of the packages before they are sealed. as the packaging machine is running, MaP Check 3 Vacuum takes a gas sample directly from the sealing die and gives an average reading of the residual oxygen, and optional carbon dioxide, for every cycle. If the gas levels approach the preset limit, MaP Check 3 Vacuum will notify the operator. If the limits are exceeded, the packaging machine will be automatically stopped. The machine has full data logging capabilities, uSB and Ethernet connectivity, and provides on-line process control and quality assurance. Dansensor, +45 57 66 00 88

*Made in USA

Bulk container unloading The process-

Direct to print

Engineered Printing Solutions

201 Tennis Way  East Dorset, Vermont 05253 Visit us at or call 1-800-272-7764

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specific sanitary bulk container dumper is designed and built to the particular sanitary operating processes and practices of the application to ensure optimal compliance contribution (OCC). The construction meets the Food and Drug administration’s cGMP definition for cleanability according to 21CFr110.40, with design features that proactively facilitate thorough cleaning and meet or reduce target cleaning times. This sanitary container dumper, required to run 24/7, is made of 6-in x 4-in x 5/16-in structural framework, and has a lift carriage capacity in excess of 2,500-lb per 135-degree rotation. Hermetically sealed connectors and components are protected from corrosion and high temperature. u.S. and IEC/ISO compliant controls enable simple integration to the facility’s SCaDa system.

National Bulk Equipment Inc., 616-399-2220

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promising patents A-B InBev’s vented can lid improves pouring

IML label adds oxygen barrier to retortable containers

Anheuser-Busch InBev has fled a patent that relates to improvements in a double-opening system for beverage cans. Specifcally, the patent describes methods for two openings in the lid of a beverage container or can: a primary or pour

Te invention addresses the need for new in-mold labeled (IML) containers that have good oxygen barrier properties and that can be retorted. Te processes involve setting into a mold a multilayer label having an oxygen barrier layer and injecting a melted resin suitable for forming a container. Te process forms a container with an oxygen barrier layer; it is optimized when the multilayer label has at least one oxygen-absorbing resin layer containing ethylene-vinyl alcohol copolymer, has an oxygen absorbent and the container is retortable.

A closure with a 3D seal prevents leaks opening for the liquid and a secondary vent opening to allow air into the can while liquid is fowing from the primary opening. Key aspects include a lid, a pour panel defned by a pour score in the lid and a vent panel defned by a vent score in the lid.

In this update, inventor/CEO Aron James Clarkson of the Star One Group in the U.K. discloses the latest status concerning a patent-pending closure that prevents leaks for chemical containers and other package types that relies on a form-ftting seal. He claims that the larger, 3D surface area of the seal becomes far more efective than for a normal container and closure.

Protective container displays light-sensitive products Transparent containers such as bottles and jars have a coating that reduces light transmission through the container and ofer a viewing area or window to make the product and its actual color visible to a consumer or purchaser. Te containers are useful for protecting photo-sensitive products while allowing the color of those products to be displayed to the user. It is claimed to be especially applicable in protecting light-sensitive or light-curable products, including cosmetics, from the efects of environmental light exposure during storage or while merchandised.

Optimize Your Packaging February 11–13, 2014

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June 10–12, 2014

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Javits Convention Center New York, NY

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October 29–30, 2014

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Standard classifcations are: Machinery & Materials; Contract Packaging; Career Opportunities. Other more specifc classifcations may be requested. 2014 rates are $325.00 net per column inch (1 time frequency), $310.00 net per column inch (3 time frequency), $295.00 net per column inch (6 time frequency), $285.00 net per column inch (12 time frequency). Add $30.00 net per column inch for second color. Colors available are: Standard Red, Blue, Green, Yellow and Magenta. All rates are non-commissionable. Blind Boxes are available for a $25.00 fee. Deadlines: 5th of the month preceding issue. Please send all materials, insertion orders to:

PACKAGING DIGEST 2901 28th St., Ste. 100, Santa Monica, CA 90405 • Fax: (310) 362-8808 Attn: Steve Everly at 610/705-8705 Email:


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newsmakers MOVERS & SHAKERS Axium Foods, a privatelabel snack manufacturer, announce its new Packaging Manager, Victor Rodriguez.

Victor Rodriguez

Sonia Jackson Axium Foods Myles joins the Board of Directors at The MATLET Group. Avure Technologies appoints Jeff Williams, an executive with a long career in the global food and beverage industry, as CEO of the HPP Equipment and Services Div.

PolyOne Corp. has begun production of a new facility in Turkey. The new location offers a specially designed layout for customer meetings, training and collaboration, as well as state-ofthe-art manufacturing. Mettler Toledo joins the Organization for Machine Automation and Control (OMAC) and the Mettler Toledo Product Inspection Div. will participate in OMAC’s Packaging Workgroup (OPW).

BUYING & ALLYING Sonia Jackson Myles The MATLET Group

Pro Mach has acquired André Zalkin, a worldwide leader in capping equipment. Zalkin operations, facilities and its management team will remain in France. Federal Mfg., powered by Pro Mach, says that M.G. Newell, one of the leading sanitary-process-equipment distributors in the U.S., is now a full service Federal Mfg. distributor.

Bunting Magnetics Co. names Rod Henricks director of sales.


The Klöckner Pentaplast Group delivers its ffth consecutive year of growth and increases proftability. Net sales increased by 2 percent.

Jeff Williams Avure Technologies

& GOING H.B. Fuller Co. is investing in a Packaging Center of Excellence in North America to address customers packaging adhesives needs Rod Henricks Bunting across a range Magnetics Co. of applications, substrates and environmental conditions. Crown Holdings Inc. announces the opening and commercialization of its metal beverage can manufacturing facilities in Da Nang, Vietnam, and Sihanoukville, Cambodia.

Adept Technology Inc. has announced a partnership agreement with Harpak-ULMA Packaging LLC, naming it a primary and secondary food packaging partner. Amcor has entered into an asset purchase agreement with Constar Intl. Holdings LLC to acquire certain of its U.S. business assets. Michelman establishes a joint venture with Maruyoshi Chemical Co., a specialty waterborne polyolefn emulsions manufacturer, based in Gifu, Japan. Mason Wells has closed on the acquisition of the rigid medical packaging business from Sealed Air Corp. The business will be owned by Nelipak Corp. and operate under the name of Nelipak Healthcare Packaging.

Scholle Corp. and Innovative Packaging Network (IPN) have agreed to combine their businesses to form a new diverse performance packaging company, employing more than 2,000 people globally. Barry-Wehmiller has acquired Arcil SA, a Paris-based supplier of packaging technology for the fresh dairy and food industry. The purchase expands the frm’s packaging platform to six separate operating companies. Sercos Intl., supplier of the Sercos automation bus, announces that Festo Corp., Hauppauge, NY, has joined Sercos N.A., the North American promotional alliance for the Sercos interface, as an associate member.

ACHIEVEMENTS Smurft Kappa was awarded top prize for Bio Strategy of the Year and

Mill Manager of the Year at the PPI Awards ceremony which took place in December in Dubai. MeadWestvaco Corp., a global leader in packaging and dispensing solutions, is celebrating the 50th anniversary of its Barcelona manufacturing plant. Tetra Pak announces that fve more of its packages have been certifed by the Swedish Rheumatism Assn. (SRA) for their ease of use. Sonoco launches a new, responsive corporate website that provides better access to visitors on tablets and mobile phones. Ball Corp. receives Can of the Year honors for three packaging innovations at the 2013 Canmaker Summit, held recently in Edinburgh, Scotland.

sales staff Sales and Marketing Offices Steve Everly Brand Director-Packaging 610-705-8705 AL, AR, AZ, CO, DC, DE, FL, IN, KS, KY, LA, MD, MI, MS, NM, OH, OK, PA, SC, TN

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Mary Williams Marketing Services Manager 630-481-1421 Fax: 630-481-1499

China | Sylvia Xiao

Taiwan | Robert Yu

REPRINTS Wrights 877-652-5295

PACKAGING DIGEST® (ISSN 0030-9117) is published monthly, except for a combined Nov/Dec issue, 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 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. Printed in U.S.A. Copyright 2014 by UBM Canon. All rights reserved. Reproduction in whole or part without written permission is prohibited. Volume 51, No. 1

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TRENDS // january 2014

industry insights Nanotechnology’s promise for food packaging Te barrier benefts of nanotechnology for food packaging are understood but the regulatory landscape is still uncertain. Michael Flanagan, chair of the Food & Beverage Industry Team at national law frm Foley & Lardner, clears up where we stand today.

G.R.A.S. So a full market review and approval on a case-by-case basis will likely be warranted. Te primary challenge will be to take the safety studies traditionally required for food and food contact materials and validate them for nano-scale materials. But that’s a challenge research scientists and regulators are working to overcome.

What’s the U.S. regulatory situation Michael Flanagan regarding nanotechnology in food Why hasn’t this been solved yet? packaging? Flanagan: I’m not suggesting that signifcant Flanagan: Several U.S. federal agencies play a role progress hasn’t been made, and that a case can’t be in regulating the use of nanotechnology. But the made through these tools about the safety of nano Food and Drug Administration is the principle materials in food packaging. I believe that it can. Te agency overseeing its regulation in food packaging. challenge is tied in part to the standards that have to FDA’s clearest statement on the subject remains be met from a regulatory approval standpoint. the draft guidance it issued in April 2012. At its core, the guidance recommends a prior safety assessment Who is driving the discussion about of products involving nanotechnology using tests that nanotechnology regulation and why? have been validated for nano-scale materials. Because Flanagan: FDA and other federal agencies have the of their size, nano materials can have diferent obligation to regulate and maintain safety in these chemical, physical or biological properties than areas, and they’re obviously playing a signifcant their conventionally sized counterpart materials. role. But other stakeholders—including nonprofts And, because of the newness of the technology, and citizen groups, industry representatives there may not be a consensus for a determination and research scientists—are making signifcant that a product is generally recognized as safe,

contributions to, if not driving this discussion. In many cases, industry trade groups and individual companies desire more certainty so they can make decisions about the development and marketing of products. And it’s the scientists’ ongoing research and each new demonstrated application for nanotechnology that’s fueling the questions surrounding regulations. Tis pressures regulators, who attempt to keep pace with the rapidly advancing technological process. How can or does nanotechnology impact food packaging production? Flanagan: Anticipated or potential impacts include preserving food and gaining longer self-life through the use of nano materials in packaging. Nanotechnology may enable consumers to more efectively gage the freshness of food. It could improve our ability to track and trace products, increase green packaging through the use of nano materials and even enhanced food safety through incorporating nano materials in food handling equipment and food packaging. It’s incredible the scientifc breakthroughs and the level of innovation in the packaging area and the potential benefts it could have for companies and consumers. Tat doesn’t mean that all these applications will be here in the next year. But pressure will be placed on companies and on regulators to complete risk assessments to, if possible, pave the way for these innovations.

ad index Company Name

Page number

Company Name

Page number

Company Name

Page number

All Packaging Machinery .......................22

Paxton Products, an ITW Company ..........17

PAD Print Machinery of Vermont .............30

AutomationDirect ...................................3

J.W. Winco Inc......................................19

PakTech ..............................................25

Bivans Corp. ..........................................6

James Alexander Corp. ..........................13

Dairy Farmers of America ......................10

Kliklok-Woodman ...................................1

Global Vision Inc. ....................................6

Klockner Pentaplast ................................8

Groninger USA L.L.C. .............................11

Leibinger ...............................................7

Harpak-ULMA Packaging LLC .................24

Markem-Imaje .......................................9

HLP Klearfold .......................................21

Messe Dusseldorf NA ............................20

Teledyne Taptone .................................19

InkJet Inc. .............................................5

Overnight Labels Inc. ............................11

Triangle Packaging Machinery Co............36

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Primera Technology Inc............................2 Sleeve Seal .........................................23 Smithers Pira .................................. 28-29 Source One Packaging LLC ....................16

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Packaging digest January 2014  
Packaging digest January 2014  

Packaging News