Packaging World January 2023

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As consumers seek more sustainable products and packages, direct-toconsumer and consumer packaged goods companies in a range of industries—household cleaning, personal care, and luxury goods, among them— develop reusable packaging systems that can be re lled at home.

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Buzz-Worthy Spray Closures Go Viral for Tropicana Campaign

In a social media campaign targeting TikTok, Instagram, and Facebook in uencers who are pushing the tongue-in-cheek #ThePerfectMimosa trend, Tropicana scored big-time buzz.

54 COVER STORY/SPECIAL REPORT Re ll-at-Home Packaging Takes Off Across Categories

Beginning with innovative at-home re ll solutions from Direct-to-Consumer startups, reusable/ re llable packaging has found its way into retail, in markets that include household cleaning, personal and oral care, lawn care, and luxury brands, to name a few.

92 AUTOMATION

Robotic Automation Doubles Capacity for Dot’s Pretzels

With no perceivable impediment to its growth other than capacity, Dot’s Pretzels, now a Hershey Co. brand, opened a new facility with a special focus on robotic packaging automation.

104

Smart Packaging Provides a Glimpse of the Ongoing Industrial Revolution

The AIPIA World Congress proves that smart packaging holds great promise for a host of near-universal brand objectives, including traceability, recyclability, consumer engagement, food waste reduction, and better supply chain logistics. Can tech suppliers in this sector band together to create ecosystems that deliver total solutions to brands?

CONTENT

Matt Reynolds Chief Editor Anne Marie Mohan Senior Editor @PackagingTrends Iris Zavala Managing Editor Sean Riley Senior News Director Pat Reynolds, Sterling Anthony, Eric F. Greenberg, Ben Miyares Contributing Editors David Bacho Creative Director

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Wendy Sawtell Vice President, Sales wsawtell@pmmimediagroup.com

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Paper Pack Pragmatism

We’ve been keeping an eye on a localized spate of big confectionery brands in Australia swapping out traditional mixed-plastic flow-wrap film for what they say is curbside recyclable paper-based material. Mars Wrigley Australia’s new pack film format (more on page 16) consists of 86% sustainably sourced FSC-certified paper, plus a thin (enough) plastic liner as a barrier layer. Not to be outdone, Nestlé Oceania’s KitKat is trialing a paper-based material (pwgo.to/7873) using an on-pack QR code to invite consumer feedback on disposal habits for the curbside recyclable pack. These recent announcements follow similar Nestlé and Mars Wrigley paperbased confectionery pack rollouts in Europe over the past few years.

Are you sensing a trend? So is Bob Lilienfeld, a packaging consultant and executive director of SPRING (Sustainable Packaging Research, Information, and Networking Group), an online community of experienced, science- and fact-based packaging professionals pushing for a more circular, sustainable packaging future.

Lilienfeld posted the Mars Australia article on his popular LinkedIn page, predictably garnering a flurry of follower reaction ranging from praise to consternation. Seeing this activity unfolding online, I asked Lilienfeld about it. For his part, he’s taking an interested, but even-keeled approach.

“I’m a skeptic,” he told me. “Before I say ‘hey, this is a great move,’ tell me what the greenhouse gas savings are. Let’s see whether it actually improves—not the recyclability per se—but the actual collection, and then the actual conversion of these wrappers back into new materials … In my ideal world, the switch to this substrate would reduce the greenhouse gas generation over its entire lifecycle, versus having that package made out of plastic. And that’s whether or not the plastic is recycled.”

Variables that factor into this ideal-world preference are numerous, making a life cycle analysis (LCA) a complex endeavor (much less two LCAs to compare the new paper pack with the legacy plastic film). But Lilienfeld looks to two primary considerations. First is the LCA information “from cradle to cupboard; or more appropriately for a candy bar that’s immediately consumed, from cradle to conversion,” he says, possibly coining a new phrase. That involves everything from extracting materials from the earth—either as trees for paper or fossil fuels for plastic—to the actual conversion of the material into a printed roll of candy bar wrapper film.

Assuming differences between packaging, supply chain, and consumption variables of the two pack formats are negligible, the next consideration is disposal of the pack after the candy bar has been eaten. “What happens if it goes into a landfill?” he asks. “You can claim all the recyclability you want here, but a significant amount of these are going to landfill … And even if they do go into a recycling bin, is the paper material recovered and converted into a new material? Is the plastic liner removed? Used as waste to energy? There are a lot of possibilities, but from the point of diversion forward, what does the environmental profile look like for the plastic format versus this package?”

A couple of other notable observations Lilienfeld shared got me looking at the several paper-based candy bar packaging projects in a new light. For one, on-pack brand presence is reduced on the paperbased Mars bars. “Only a company like Mars, which has incredible brand equity, could actually pull something like that off,” he says. In a way that a newcomer to a crowded, vibrantly colored candy aisle couldn’t, Mars has the luxury of being able to sacrifice some on-pack branding space in favor of building a family of products (Mars, Snickers, and Milky Way) that all signal “sustainability” to consumers via a natural, kraft paper appearance.

Also, candy has a unique quality that it perhaps only shares with beer and spirits—food waste is negligible and doesn’t come into play in an LCA. As long as the candy bars aren’t sitting for months in inventory outside of temperature exclusion ranges, they move fast off of shelves, and are quickly and entirely consumed, often before the consumer even gets home.

And given candy bars’ quick and on-the-go consumption quality, I wonder if waste disposal becomes more a function of available recycling receptacles? If I’m buying a Snickers bar in a recyclable flow wrapper, it’s never making it to my home curbside recycling bin since it’s not making it home with me to begin with.

I’m with Bob. It’s interesting to follow these big brand decisions, but let’s wait and see. PW

mreynolds@pmmimediagroup.com

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Coca-Cola’s ‘Recycled Records’ Highlights

Music Sampling & Recycling’s Shared Values

The Coca-Cola Company teamed up with two legendary names in music sampling, Mark Ronson and Madlib, to bring a bold musical experiment to life with the launch of “Recycled Records.”

“A great sample doesn’t have to come from other music, it just has to make you move. Your ear is your greatest asset when it comes to nding unique sounds and chopping them together,” says beatmaker and rapper Madlib. “The thud of a plastic bottle going through a recycling facility is, in its own way, a piece of art. Being able to take sounds so different from what I’ve used in the past and ip it into a whole new format is a great example of the versatility of sound— and clear plastic. Now fans of The Coca-Cola Company will get the opportunity to listen to my tracks and make some dope sounds of their own.”

To learn more, fans can look to acclaimed artist and female rap pioneer MC Lyte, who narrates a documentary-style short lm that draws a clear connection between the heritage and spirit of music sampling and the closed-loop recycling process. The company says this lm, lled with rich soundscapes, imaginative beats, and riveting visuals, showcases the creative process behind Recycled Records including extensive sound recordings at recycling facilities nationwide and a fascinating glimpse into the studios of Mark Ronson and Madlib.

The campaign introduces an original EP made up of the sounds taken from the bottle-to-bottle recycling process, alongside a versatile sound library and engaging short lm. Not only will fans be able to listen to these uniquely made tracks, but they’ll also have the ability to re-mix the very same sound library used by the two musical legends into innovative compositions of their own through an interactive digital beat machine.

Creative masters Mark Ronson and Madlib chopped, looped, and distorted recycled sounds, vocals, and ambient noises into an imaginative collection of six one-of-a-kind tracks to celebrate Sprite, Fresca, and Seagram’s transition from green to clear packaging. From the percussion of a forklift beeping to the tonal beat of a conveyor belt to the hi-hat of air blown into a plastic bottle, the EP brings to life the magic of multiple reuses.

“Sound sampling is constantly regenerating. Sampling is what my heroes did, and it’s now become an integral part of my own work,” says Grammy award-winning producer and sampling master Mark Ronson. “The creative process is lled with happy accidents...creators will nd, you play with this beat pack a million ways and no composition will be the same. Now it’s time for the fans to recycle the sounds of recycling itself. After all, some of the most inspiring sounds we can use in music creation are from our everyday lives.”

A sound sample is to music as clear plastic is to recycling. The process of music sampling is ongoing; an old sound is used in a new track, which is ipped again into a newer track, and so on. When green plastic is recycled, it is usually turned into single-use items that do not get recycled again—so, it was time for a moment of clarity, the company says. Now Sprite, Fresca and Seagram’s clear plastic bottles increase the likelihood of them being remade into new bottles many times.

“The Coca-Cola Company is thrilled to have teamed up with Mark Ronson and to celebrate our portfolio’s transition from green to clear. This sonic partnership is part of The Coca-Cola Company’s broader World Without Waste goals,” says Kurt Ritter, VP and general manager of sustainability, North America at Coca-Cola. “We’re excited about the switch because it increases the amount of high-quality, food-grade recycled plastic available in the marketplace and ultimately allows our brands to use more recycled plastic in their packaging.”

Consumers can watch the lm and take the Recycled Records beat machine for a spin to create their own musical compositions at greentoclear. com. —Matt Reynolds

Getting Started with Sustainable Packaging

Looking for information on how to get started with sustainable packaging? This Packaging World primer provides an overview on what sustainable packaging is, what’s driving the push for more sustainable packaging, and how to reduce the environmental impact of packaging. It also includes links to resources. Download this free PDF today at pwgo.to/7345

Pantone Color of the Year 2023 Celebrates the Natural World, Verve for Life

A vast departure from 2022’s soothing blue and violet Veri Peri Color of the Year, Pantone’s choice for Color of the Year 2023, Viva Magenta 18-750, “vibrates with vim and vigor,” says the brand. Explains Pantone, Viva Magenta is a shade rooted in nature—more speci cally, it originates from a beetle found in tropical and sub-tropical environments—descending from the red family, and expressive of a new signal of strength. “Viva Magenta is brave and fearless, a pulsating color whose exuberance promotes a joyous and optimistic celebration, writing a new narrative,” Pantone says.

Expanding on the nature of Viva Magenta, the brand states that it is powerful and empowering, an animated red that revels in pure joy, encouraging experimentation and self-expression without restraint, an electrifying and a boundless shade that is manifesting as a stand-out statement. “PANTONE 18-1750 Viva Magenta welcomes anyone and everyone with the same verve for life and rebellious spirit,” it says. “It is a color that is audacious, full of wit, and inclusive of all.”

Furthermore, Viva Magenta is described as a nuanced, crimson-red tone that presents a balance between warm and cool; it is a hybrid color, one that comfortably straddles the physical and virtual in our multi-dimensional world. “It is assertive, but not aggressive, a carmine red that does not boldly dominate but instead takes a ‘ st in a velvet glove’ approach,” says Pantone. “Exuding dynamism, PANTONE 18-1750 Viva Magenta is a transformative red tone capable of driving design to create a more positive future.”

Viva Magenta is the 24th color in Pantone’s Color of the Year series, which was rst launched in 1999 by the Pantone Color Institute. The Color of the Year is described as being “one moment in time” that provides strategic direction for the world of trend and design. It is a culmination of institute’s year-round work forecasting trends, based on all aspects of society, including fashion, marketing, social media, and politics, and developing color palettes for its clients.

In explaining the reasoning behind its choice of Viva Magenta for 2023, Pantone says, “As we balance our digital and physical lives, we continue to grow our appreciation for the natural world. The Color of the Year 2023 acknowledges our gravitational pull towards natural colors as movements swell around climate change, sustainability, and land protection.”

In this year’s Color of the Year selection process, Pantone says it observed a heightened appreciation and awareness of nature represented by countless lifestyle trends. “We’re incorporating more living things into our homes, such as plants, orals, living walls, and restorative outdoor spaces,” it notes. “We’re nding newfound enjoyment in travel, sports, and outdoor recreation after pausing these activities during the pandemic. We’re more careful to protect our bodies as a result of the public health crises—we look to apply and ingest trusted, life-giving ingredients. All of these lifestyle trends speak to the heartiness of natural forces.”

Viva Magenta’s organic origins hail from the cochineal beetle, an insect that produces carmine dye, which, according to Pantone,

is one of the most precious, strongest, and brightest of the natural dye family. As a result, the company says that “the red tone of Viva Magenta connects us to original matter, imbibing us with a primordial signal of strength.”

“The Color of the Year 2023 merges the richness, warmth, and strength of natural matters with the rich, open horizons of the digital world,” says Pantone. “The result is a shade of red that expands our horizons of authenticity. The metaverse creates new opportunities for us to express ourselves, and the raw fortitude of Viva Magenta inspires us to do so with con dence and bravery.”

Along with Pantone’s designation of the Color of the Year, it provides a number of tools for designers in fashion, beauty, home and interiors, graphic arts, and packaging and plastics that provide direction on how to effectively incorporate the color into their designs and to what end. For those designing packaging and plastics, Pantone says that brands wanting to appear animated and passionate can use Viva Magenta to elicit a strong consumer reaction. “Because reds are advancing colors, they draw the eye and muscle out the colors surrounding them,” it says. “Whether consumers are scrolling on their phones or browsing the aisles, tapping into the Color of the Year 2023 will ensure you stand out.” —Anne Marie Mohan

Clemson Announces Fall 2022 Packaging Science Award Winners

From Clemson University comes news about two Fall 2022 awards. Rebekah Pereira was named the Robert Testin Outstanding Packaging Science Senior Award winner, and Sophie Owen was the Packaging World Outstanding Packaging Science Senior nominee.

Clemson University Robert Testin Outstanding Senior in Packaging Science winner for Fall 2022

Rebekah Pereira, a Packaging Science major with an emphasis in materials, graduated December 2022 from Clemson University Honors College. Throughout her years at Clemson, she has become very involved in the Packaging program. As a sophomore, she attended PACK EXPO, where she found a great interest in this major. From there she participated in her rst coop at Unilever during the spring of her sophomore year, returning a year later to complete a second rotation. She was Vice President of the Packaging Science Club for an entire year and participated in the nationwide 48HR Repack Student Packaging Design Competition, where her team won rst place. During her nal year, she has been working at The Sonoco Institute of Packaging Design and Graphics as an intern and has participated in a Creative Inquiry Undergraduate Research project designing football photo displays for recruits. Pereira says she hopes to continue her Clemson legacy well beyond these accomplishments.

Packaging World

Outstanding Packaging Science

Senior winner for Fall 2022

Sophie Owen graduated in December of 2022 with a bachelor’s in Packaging Science, an emphasis in Food and Healthcare Packaging, and a minor in Sustainability. In 2020, she completed her cooperative education requirement with Arthrex and gained invaluable experience in medical device manufacturing and regulatory practices. During her time at Clemson, Owen was part of the team that submitted and won a bid for a PMMI PACK EXPO booth, which focused on sustainable packaging alternatives, research, and initiatives. Additionally, Owen took part in creating and presenting packaging for the FRESH 2022 Food, Packaging & Sustainability Summit. She says she is extremely grateful for all the opportunities that the Packaging Science faculty at Clemson have given her and will cherish these experiences for a lifetime. —Matt Reynolds

PACK EXPO Southeast Debuts Spring 2025 in Atlanta

PACK EXPO Southeast will debut spring 2025 in Atlanta (March 10-12; Georgia World Congress Center) bringing packaging and processing machinery, materials, and technology all under one roof to a growing manufacturing corridor.

The newest show in the PACK EXPO portfolio, produced by PMMI, will offer solutions for over 40 vertical markets to address the packaging and processing needs of southeast manufacturers.

“This show represents a big opportunity to bring the industry together in a region of the country that is not currently served by a trade show focused on packaging and processing,” says Jim Pittas, president and CEO, PMMI. “PACK EXPO Southeast in Atlanta is the perfect location to focus on targeted opportunities in this robust market, which is home to some of the top manufacturing industries in the region.”

Located within driving distance of key manufacturing cities and a mere two-hour ight from 80 percent of the U.S. population, PACK EXPO Southeast will harness all the power of the PACK EXPO portfolio of trade shows, directed at the robust southeast market.

“PACK EXPO Southeast 2025 will provide a prime opportunity for exhibitors to reach a new, untapped customerbase in this region,” says Laura Thompson, vice president, PMMI. “And attendees will have the chance to experience new kinds of machinery, materials, and other innovations live and in-person, while forging critical relationships with their peers and suppliers.”

As PACK EXPO East does for the northeast market, PACK EXPO Southeast will laser focus and target the southeast market and offer a depth and breadth of exhibits not provided by any other events in the region.

Exhibitor booth sales for PACK EXPO Southeast 2025 start in September 2023. Attendee registration will open during PACK EXPO International 2024. Request information and learn more at packexposoutheast.com —Sean Riley

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Walkers Multipacks Get Paper Cartons; Stretch Film Made with Nanotechnology

PepsiCo has announced that it has invested approximately $18 million in new sustainable food packaging innovations for its Walkers UK potato chip snack brand. The new packaging, part of the company’s PepsiCo Positive (pep+) sustainability strategy, is expected to remove 250 million tons of virgin plastic across the brand’s supply chain annually.

As part of the move, the outer plastic packaging on millions of Walkers 22- and 24-bag multipacks will be replaced with a new paperboard carton design. After a successful trial with Tesco, the new and improved multipack outer packaging launched on shelves in all major supermarkets in the U.K. following the October announcement.

Alongside the new packaging design, Walkers has invested in a new pallet stretch lm. The lm, from a proprietary supplier, is produced using nanotechnology, which puts tiny air bubbles into the lm to reduce the amount of plastic used while retaining the same strength and stretch needed to protect the snacks as they travel to stores across the country. The use of this new technology will lead to a 40% reduction in virgin plastic year on year, compared to the previous lm. Reducing the amount of fossil

fuel-based virgin plastic in the shrink wrap will also reduce the company’s annual carbon emissions by 465 metric tonnes.

Says Simon Devaney, sustainable packaging director, PepsiCo UK & Ireland, “We are constantly exploring new scalable solutions, and this investment marks an important step forward, delivering a huge reduction in virgin plastic across some of our best-selling ranges, while also helping to tackle our carbon footprint.

“Reducing virgin plastic across our supply chain is a key part of our commitment to creating a world where packaging never becomes waste.” —Anne Marie Mohan

Erewhon, the Los Angeles premium organic grocer, announced a partnership with Cove, a California-based material innovation company, making it the rst retailer of Cove’s fully biodegradable water bottles.

“Erewhon has celebrated the amazing bene ts of naturally grown foods and the importance of preserving the earth for more than 50 years

and continues to lead the way in conscious consumption today,” says Vito Antoci, executive vice president of Erewhon Markets. “When we were introduced to Cove, we were incredibly excited to be part of this innovative and potentially world-changing moment for CPG—the world’s rst fully biodegradable water bottle is something we are very proud to be launching at Erewhon.”

The company says that Cove bottles are plastic-free, biodegradable, renewable, non-toxic, and compostable. They are made with polyhydroxyalkanoate (PHA) a sustainably sourced, naturally occurring biopolymer.

PHA is produced and consumed by microorganisms that occur all over the world, including soil-inhabiting and marine microorganisms. It biodegrades in all natural environments–fresh water, soil, and marine environments–and breaks down without producing any toxic waste. It is broadly biodegradable at a rate comparable to cellulose, the building block of plant life and the primary component of paper, the company says.

“Cove entering retail is a signi cant milestone for the company and it was important for us to nd a mission-aligned retail partner to debut Cove. We’ve found that in Erewhon and are excited to take a big step forward in our mission to create a sustainable material world,” says Alex Totterman, founder and CEO of Cove.

The water bottles, named the Plastic-Free Innovation of The Year in 2019 by Dieline, will be available at Erewhon stores throughout Los Angeles, as well as online at cove.co. Cove says it will announce new retail partners in coming months as they scale up manufacturing at their production facility in Los Angeles. —Matt Reynolds

Mars Wrigley to Switch to Paper-Based Packaging in Australia

Article rst appeared in Australia’s PKN Packaging News on Nov. 28, 2022. Coverage courtesy of Lindy Hughson, Managing Editor & Publisher.

Mars Wrigley Australia’s move to paper-based wrappers for its chocolate bar lines marks a world- rst for the company and is in line with the growing global trend for brands to switch from single-use plastics and adopt ber-based packaging materials that it says are curbside recyclable.

The company will roll out the new paper-based packaging for its Mars Bar, Snickers, and Milky Way chocolate bar lines nationally from April next year, with plans for its full chocolate bar portfolio to transition.

The packaging, made from sustainably sourced FSC-certi ed paper, was developed and trialed at Mars Wrigley’s manufacturing site in Ballarat, Australia. The Ballarat-based R&D team leading this project is pioneering paper-based sustainable packaging solutions for the Mars Wrigley

tained, seals and inks for labelling. While the packaging features a very thin plastic barrier, it remains able to be recycled via curbside recycling as validated by APCO’s PREP tool.”

Hutton con rmed Mars Wrigley is currently working on the second iteration of this packaging, which will remove the thin plastic barrier, and this will be available by the end of 2023.

“The transition to paper-based packaging for our locally made chocolate bars marks a signi cant milestone in our sustainability journey,” says Andrew Leakey, general manager of Mars Wrigley Australia. “Mars’ ongoing investment in local R&D has allowed us to be agile and create solutions that have a positive impact on our environment, meet our stringent quality and food safety standards but are also convenient for our consumers to recycle via curbside recycling.”

Leakey says ensuring consumers had easy access to recycle the new packaging was “crucially important” to the company.

“As one of the largest snacks and treats manufacturers in Australia, Mars has a responsibility to reduce our environmental footprint right across our business, including packaging. The launch of our new paper-based packaging is a signi cant step for us towards our local and global packaging targets.”

The step by Mars has been welcomed by Australian Packaging Covenant Organisation (APCO) CEO Chris Foley, who said Mars Wrigley’s new packaging was a prime example of innovation within the food industry to meet packaging targets.

“Mars Wrigley’s switch to paper-based packaging sets an “excellent example to all businesses in Australia of the critical role innovative packaging formats that are more readily recyclable play in meeting the 2025 National Packaging Targets,” Foley says.

The packaging will incorporate the Australasian Recycling Label (ARL) to provide clear instructions to consumers on how to recycle.

Once the Australian-made chocolate bar portfolio is fully transitioned to paper-based packaging, Mars Wrigley says it is set to eliminate more than 360 tonnes [397 tons] of plastic from its value chain. This, the company says, will contribute to its aim of creating a circular economy and achieving the 2025 National Packaging Targets.

business globally. The plan is for the technology, learnings, and insights developed and deployed locally in Australia to be shared and implemented in other Mars Wrigley markets across the globe.

The packaging material is manufactured locally by Amcor. Chris Hutton, R&D director, told PKN, “As this is a world- rst for Mars Wrigley, we didn’t have a playbook or a road map to follow, so our local R&D team worked really closely with Amcor Australia and New Zealand to come up with a solution that maintained the quality and freshness of our product, whilst working ef ciently with our machinery and technology in the factory.

“They have been an incredible partner to work with and they’ve played a pivotal role in getting to where we are today.”

PKN asked about the composition of the paper material, and how it was achieving the requisite barrier properties, to which Hutton responded, “Our paper-based packaging is made up of 86 percent paper, a thin plastic barrier to ensure the quality and freshness of the product is main-

Mars Wrigley’s transition to FSC-certi ed paper materials for its wrappers is a move applauded by CEO of FSC Australia and New Zealand, Melanie Robertson, who says it “sends an essential message about the importance of choosing forest-friendly alternatives to single-use plastics”.

“FSC ANZ is proud to partner with Mars Wrigley and congratulates them on this demonstration of support for the responsible management of the world’s forests.”

As part of the company’s commitment to its $1B Sustainable in a Generation plan, Mars Wrigley says it is “committed both in Australia and globally to supporting and creating a circular economy where packaging never becomes waste.”

Mars Wrigley’s new paper-based packaging will be available on 47and 64-g Mars Bars, 44- and 64-g Snickers, and 45-g Milky Way at all leading supermarkets and convenience stores in Australia beginning in April 2023. PW

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Hazelnut Growers of Oregon (HGO) is relaunching its Oregon Orchard CPG brand with what it says is striking new packaging for its baking, snacking, and chocolate-covered hazelnuts. The rebrand aims to elevate consumer awareness of hazelnuts as a delicious, healthy, and sustainable alternative to almonds and other popular nuts. The updated brand also introduces Hazel the Health Nut, an adventurous mascot that embodies the philosophy of the Lifestyles of Health and Sustainability (LOHAS) customer.

“This campaign is colorful and fun, but it serves a serious purpose: to expand people’s perception of hazelnuts beyond their role as a avor added to sweets or coffee. They’re a delicious, healthful snack on their own, and a versatile ingredient in baking and cooking,” says Dan Herdon, Vice President of Sales and Marketing.

The exographically printed pouches are produced and converted by Sierra Packaging & Converting in Reno, Nevada.

The new pouch uses the same PVDC and EVOH structure as the legacy pouch. The polyester (PVDC) uses an additive formula to increase the barrier. The EVOH is a polyethylene with an additive formula to further increase the barriers, with a higher barrier that PVDC, the company says. The duplex structure means the recyclability pro le is #7.

The pouch does have a new element, a window that’s designed “to give consumers a view of the hazelnuts and chocolate-covered hazelnuts so they can see the quality of our products,” a spokesperson told Packaging World. The company also worked with Blue Collar Agency of Hood River, Oregon, to update the design and branding.

“The redesign will bring attention to Oregon Orchard Hazlenuts and highlight the health bene ts and avor that each variety brings,” the spokesperson continued. “Hazel the Healthnut brings a new, fun and vibrant element to Oregon Orchard and its customers.”

Nut enthusiasts in the Twin Cities area of Minnesota will be among the rst to encounter the rebranded Oregon Orchard products at the prominent regional grocery chain, Lunds & Byerlys. Over 99% of U.S. hazelnuts are grown in Oregon thanks to the perfect blend of rain, sun, and wind, and Midwesterners will get the rst pick of this Paci c Northwest staple as part of the national relaunch of the Oregon Orchard brand.

To drive consumer awareness of Oregon Orchard products and availability, HGO is supporting retailers with a co-branded social media push that directly connects nut shoppers to a store near them. —Matt Reynolds

Popcorn Maker Deploys PFAS-Free Microwave Bag

Berkeley, Calif.-based Connect Snacks has an interesting backstory. The purveyor of whole grain popcorn was launched by eco-friendly fertilizer startup Pivot Bio to connect consumers with those farmers who are growing food with synthetic-free nitrogen fertilizers. Following the successful launch of its popcorn kernel product in October 2021, Connect Snacks turned its attention to developing a microwavable popcorn option. Given its better-for-the-planet mission, however, it knew it needed to nd a packaging solution that was more sustainable than the per-and poly uoroalkyl (PFAS)-lined popcorn bags currently on the market.

The drawback to PFAS compounds, which have a tendency to leach into the product, is that they are classi ed as “forever chemicals,” designated as such because they break down very slowly, accumulating both in the environment and in the human body. One report from the U.S. Centers for Disease Control and Prevention’s (CDC) National Health and Nutrition Examination Survey (NHANES) found PFAS in the blood of 97% of Americans. Interestingly, a 2019 study found that people who regularly eat microwavable popcorn have signi cantly higher blood PFAS levels; for those who consume it daily, their levels were up to 63% higher than average.

Bioaccumulation of these compounds can seriously impact an individual’s health. A recent CDC review outlined a host of negative health effects associated with PFAS exposure, including cancer, liver damage, decreased fertility, and increased risk of asthma and thyroid disease.

Removing the PFAS lining from popcorn packaging is not easy though, and alternative options also typically carry with them a higher price tag— up to three times higher, in fact, according to Temme. To address the challenge, Connect Snacks used several strategies. “We solved it by using the highest quality popcorn that’s also sustainably grown using no chemical nitrogen fertilizer,” he shares. “We also ask consumers to add their own oil to their popcorn rather than including it in the bag, and we invested in a lot of research and development to create delicious avors from natural ingredients that wouldn’t stick to the bag.”

While information on the exact material used for Connect Snacks’ microwavable popcorn bag as well as on the material supplier is proprietary, Temme does share that the bags are made from “FDA-approved, greaseresistant PFAS-free papers that were engineered for microwave popcorn packaging.”

PFAS is a man-made class of plastic chemical compounds commonly used in microwavable popcorn bags. It is also used in packaging such as cardboard takeout containers, pizza boxes, fast food packaging, and pet food bags. PFAS is added to microwavable bags to keep the oil that pops the corn from soaking out and to prevent the bag from burning.

Connect Snacks CEO Karsten Temme notes that the PFAS liner provides two other functions as well. “First, it seals in a metal susceptor, which improves heating to pop the kernels. And second, it helps seasoning not stick to the bag,” he explains.

Of the importance of developing such a bag, Temme cites how ubiquitous plastic-coated packaging is in the lives of consumers, adding that it’s also often hidden. “Coffee cups, sandwich wrappers, and paper takeout containers often have a plastic liner,” he says. “We want to do our part by removing the plastic coating in our microwave popcorn—and this means no more microwaving your popcorn in plastic, too.”

Connect Snacks’ Better for You Microwavable Popcorn was introduced in October 2022 and is available on the brand’s website as well as on Amazon in four avor varieties packaged in 3-ct cartons. —Anne Marie Mohan

Vibratory Feeders

With 100% more capacity (45 tph) and twice the available tray size/mass than our next largest feeder, Eriez high capacity 76 Series Electromagnetic Vibratory Feeders are designed for packaging applications with high head loads or needing exceptionally long overhang.

•Handles high head loads

•Exceptionally long overhang

•Up to 45 tph

•High speed and high deflection drives

Cal Poly awarded 2022 Mark C. Garvey Scholarship

The PMMI Foundation, in cooperation with the Garvey Corporation, has selected Cal Poly as the recipient of this year’s $5,000 Mark C. Garvey Scholarship. PMMI, The Association for Packaging and Processing Technologies, provides nancial support for packaging and processing education at colleges, universities, and technical schools throughout the United States and Canada through the PMMI Foundation.

The student selected to receive the scholarship, Jayna Regehr, is a junior studying Industrial Technology and Packaging. Jayna has a GPA above 3.0 and is currently studying as part of a co-op education program with Annie’s Kitchen. She is actively involved in club activities, serves as a faculty research assistant, and recently attended the PACK EXPO International trade show in Chicago.

“The Garvey family is pleased to award the 2022 Mark C. Garvey Scholarship to Jayna Regehr at Cal Poly. Garvey Corporation has had the honor to hire Cal Poly graduates in the past and looks forward to supporting the program in the future. Cal Poly does an outstanding job preparing students for a future in the packaging industry. Congratulations Jayna,” says Jake Garvey, director of OEM sales, Garvey Corporation.

PMMI established the Mark C. Garvey scholarship to honor

the memory of Mark Garvey, former president and CEO of the Garvey Corporation, past chairman of PMMI, and longtime supporter of packaging education. Each fall, the Garvey family selects one PMMI Education Partner to receive this scholarship based on a commitment to excellence in the packaging industry. The school chooses a student to accept the award based on GPA, major, commitment to the packaging industry, extracurricular involvement, and nancial need.

The PMMI Foundation provides over $200,000 annually in scholarships to students attending PMMI Education Partner schools. These scholarships underscore PMMI’s commitment to the future of the packaging and processing industry.

For more information on the PMMI Foundation, visit pmmi. org/foundation. —Matt Reynolds

BY THE NUMBERS

1.9B lb+

The amount of post-consumer PET collected in 2021 in the U.S. for recycling—the largest amount ever, according to NAPCOR—increasing PET recycling rates in the U.S. from 27.1% in 2020 to 28.6%

“As 2022 heads to its close, we’ve seen a return to normal that isn’t quite as normal as we had wished. There’s increased economic pressure on an already stretched global supply chain, increased focus on the foodservice packaging industry from a legislative and regulatory policy perspective, and movement and growth in both the foodservice segments drawing consumers and the ways in which they choose to have their foodservice delivered—or not.”

–Natha Dempsey, president of the Foodservice Packaging Industry (FPI), in a press release from the association, “Supply Chain Disruptions and In ation Continue to Impact Foodservice Packaging Industry”

“Between 2018 and 2020, the weight of our e-commerce in our sales nearly doubled from seven to 13%. Now, in 2022, in the post-COVID era, we see a certain slowdown of that growth, but we still continue to see that growth come in, and we are above 15% for the rst nine months of the year.”

29The number of Direct-to-Consumer companies Unilever has purchased since 2015, including Dollar Shave Club and Paula’s Choice

84%

The reduction in beverage container litter in states with bottle deposits; such laws have also been shown to increase recycling rates in states that have them versus those that don’t

–Bernard Meunier, executive vice president and head of strategic business units and marketing and sales at Nestlé, in an article from FoodNavigator-usa.com, “Nestlé aggressively pursues online sales, predicting a ‘rebound’ in e-commerce, rise of ‘channel-less commerce’”

“Digitalisation underpins automation, unlocking the potential of eCommerce and improves business operations based on data analysis. It is essential in the short term, with the looming recession, and it makes improving ef ciencies increasingly important. In the longterm, digitised packaging businesses will become more nancially and operationally attractive to customers as they will be able to produce material more cheaply and with eCommerce capabilities.”

–Rory Gopsill, associate analyst for Global Data, in an article from Inside Packaging magazine, “The trends shaping packaging in 2023”

6.3M MT

The amount of metric tonnes of global bioplastics production predicted by 2027, up from 2.23M MT in 2022, according to the European Bioplastics (EUBP) association

“Premium-priced products are at risk of being left on shelves, as consumers switch to private label/cheaper brand alternatives. This has clear implications for change on packaging design and costs. GlobalData forecasts that larger packs sizes, 3,001 to 5,000 g/mL, will grow in volume at a rate of 4.3% per year to 2025, outpacing that of smaller pack sizes. However, smaller pack sizes are still expected to continue to dominate the consumer packaging market overall. Longer term, rise of both shrink ation and larger pack sizes will lead to further polarization of packaging sizes in many product categories, with the standard medium-sized pack hit hardest.”

–Ramsey Baghdadi, consumer analyst at GlobalData, in a press release from the organization, “Medium-sized packaging hit hardest by in ation as customers turn to bulk buying or premiumization to get more bang for their buck, says GlobalData”

Inkjet

After Pandemic-Related Innovation Pauses, Active Packaging’s Back on Track

Packaging World sat down with Andrew Manly, managing director of AIPIA, at the AIPIA World Congress in Amsterdam, the Netherlands in November 2022. He helped to catch us up with all things active and intelligent packaging and gave us a valuable lens through which to view its recent growth.

Packaging World:

First, explain to our readers what AIPIA is and who you serve?

Andrew Manly:

AIPIA is the Active & Intelligent Packaging Industry Association. It was founded just over 10 years ago by a chap called Eef de Ferrante and myself. The aim is to make AIPIA a network hub, an information hub, and a meeting place for the smart packaging sector; those who are interested in it, and those who want to use it. A lot of companies entering the smart packaging space are not necessarily coming from a strong packaging background, so they need to know and understand the ways of the packaging industry, which is where I come in. We’ve created a website, which is really a place where people can gain information about those people who are active in this industry. Also, we run a regular newsletter which brings you up to date with some of the latest trends and activities from members, from brand owners, and from NGOs, anything and anyone that’s of interest.

From that, we extended our role into running live activities, which translates itself into the Congress you’re attending here in Amsterdam. It is a meeting place, a networking hub for the industry to talk to those companies, particularly brand owners who are interested in these technologies and who want to really start to adopt and implement the

smart packaging ideas into their daily packaging use. And that covers both active packaging—which is basically shelf extension and product safety—through to the sexier stuff, which is connected packaging. That can run from supply chain management, traceability, authentication, provenance, or anti-counterfeit, right through to the stuff that one of our regular exhibitors at the Congress showed you on the last session of the first day, which is how augmented reality can add a completely different dimension to your product, and entertain and engage consumers in completely new ways.

Read more details about the speci c technologies and systems debuted at the AIPIA World Congress on page 104.

Those are certainly top trends in packaging, but what specific technologies constitute active and intelligent packaging today? Obviously, technologies like RFID, NFC, QR codes, traceability, functionality, and all kinds of stuff around those, are where we’re at. And that’s a fast-moving and fast-developing sector. Particularly, we’re used to handle the digitization of packaging. And that includes not just the consumer-facing stuff, like the stuff [a consumer] can scan [on a smartphone], but also all of the background activity, the background software and search engines and data management and processing hubs that are so valuable, offering insights to the consumer in one way, and equally valuable to the product owners and the brand owners in the other.

A major takeaway from the brands I’m hearing from here at the AIPIA World Congress is that there are all sorts of interesting active and intelligent packaging capabilities available. But the challenge comes in knitting them together, often from several different suppliers and providers, with several different interfaces, into a practical, end-to-end product. Has this been your experience? There are lots of different technologies there, but one of the keys to opening and unlocking the usefulness of smart packaging is to combine technologies to provide a complete solution. And that’s one of the areas that AIPIA is working on, helping our members work together to offer the brands and the products a complete idea, rather than bits of ideas that need to be tted together.

We learned very quickly that a lot of [active and intelligent packaging suppliers] were going to brand owners and saying, “Well, look, hey, we got this wonderful capability.” To which the brands responded, “Yeah, it’s interesting, but how on earth do we use it in a real-life environment?”

One of the things that we had to really do is educate backwards, explaining that you can’t just take an RFID tag and tell a CPG that it does this, this, and this. You’ve got to have the complete background, the software programming, and the sustainability issues, which now are quite an important part. It’s a moving target, also, because elements like sustainability have come on the scene. Which probably 10 years ago, whilst it was important, it wasn’t really something we related to.

What did you expect to see at this World Congress?

We had a board meeting just before the event, and we picked out three pillars that seem to be key elements. One is recycling, one is food waste, and one is supply chain management. And we felt those are the three areas we need to be focusing on, as an industry. But one of the other elements that came out of that discussion—and was

from presenting at the Congress was from a company called Complete Inspection Systems, who is an American company and they’re doing really deep-dive QR codes. They can be quite dif cult [secure] in terms of anti-counterfeiting, so that your own U.S. Defense Department can use them. But also, they can have up to four functions in one code. You’re not just getting the normal barcode functions, you’re also getting consumer engagement, you’re getting deep security, and traceability just off a QR code. And the beauty of that is that you don’t always have to download an app to use a QR code.

But even with this increased amount of adoption, the fact is that a lot of [consumers] don’t really understand what’s on the pack when they see an RFID tag or a QR code, because nobody’s telling them what’s there to use, or how to use it.

I’ve seen loads of bottles of wine with RFID tags in my local supermarket, but nobody knows that they’re there because nobody’s telling people that they’re there. And they’re not exactly huge and easy to see, because you don’t want big RFID tags on small bottles of wine. Adoption is happening, but education is a big issue, and we are scratching our heads a little bit about that at the moment. And we will continue to work with other stakeholders, and it is something that we all are going to have to work on together to get the maximum benefit.

echoed in a lot of the presentations that we saw—is that we need to get the consumer a lot more on board with the technology. They need to understand it. And that is in-part our role, but we can only do so much. It needs the retailers and the brand owners to buy in to the technology, and not just in terms of using it, but in explaining to consumers the bene ts of it.

We’ve read that QR code adoption received a big boost among consumers since the outset of the pandemic, since touch-free ordering and menu access became prevalent. Was that evident at the event?

I think one of the things that was the great bene t to the industry, from a perverse point of view, in the COVID-19 pandemic was that people got used to remote shopping, scanning at restaurants, and non-contact access like the QR codes. And the QR code development has been quite exponential. There are a lot more people using more QR coding with more attributes to it. One of the guys who was out sick

Another effect of the pandemic was that there were fewer events over the past three years. Given this longer than usual time interval between major events (AIPIA World Congress is typically annual), have any trends become easier to spot, or maybe have accelerated since 2019? Did anything surprise you? We’re getting much more of a feel that there’s a lot more interest from the brand owners now. They’re much more focused on it. Digitalization is a key issue and I’ve just literally today read a report from one of the big research and analytics companies that’s saying in some respects, they can see digitalization in packaging becoming as important or even more important that sustainability in the current circumstances.

Visit pwgo.to/7826 to read about the digitalization report from GlobalData that Manly references above.

Whether they’re right or wrong, the fact that they’re even thinking about it that way shows how much the concept of digitization, smart packaging, and its use are getting further up the food chain.

Things like RFID are becoming a lot more ubiquitous, and not just in the apparel sector. We’re seeing a lot more uptake, and we are getting feedback from those companies who make them that there’s a lot more uptake, because obviously prices of the tags have come down and what they can do has improved. And you’ve got some big players, like Avery Dennison and others, who are really pushing the technology out so that you can now have, for example, RFID tags that

can sit on metal and remain readable. Whereas, maybe five years ago, that was not a very distinct possibility. And they’re also much better in things like wet environments and other advances.

Does Moore’s Law apply here, where the technology improves and price goes down over time, as the hardware becomes more ubiquitous?

One of the inhibitors to using tagging or electronic antenna was that they had batteries, which contain some kind of conductive metal. We are now having companies like Wiliot, and they were here at the Congress, who have a battery-free tag which is much more feature driven. But it us also a lot easier to apply, is a lot more sustainable, and because it doesn’t contain [as much or any] metal, it is not as expensive to produce.

Looking back to 2019, one of the key differences [between then and now] is that is that [suppliers] have continued to develop the technology so that they’re more cost efficient and more cost effective. Because one of the walls that we have had to overcome—and there are still a few walls left—is a lot of brands like to use these technologies for campaigns or for particular product promotions, things like that. But using them in a general rollout was not as common as we would hope or expected to be. And that is partly due, we think, to the disruption caused by COVID-19. But we are now seeing the other side of it. In America for instance, Walmart is now mandating a lot of its suppliers to use RFID or codes on whole range of SKUs, which is encouraging. But we don’t see that rolling out yet to other big retailers in the way that we hope it will. But then, like all small industries, we all hope to go faster than we actually manage to do.

What did you see that’s new in traceability or track & trace?

You’ve got scanning technologies like the one that Systech uses, which is clever because it doesn’t require any amendments to the landscape of your packaging. [What the scanners are] picking up is differences—tiny, tiny differences—in the print register on each pack, and it can therefore use it as a unique identi er. Because they’ve developed in the software as well, they’ve also added in a lot more with product identi cation, and not just the traceability aspects. But even going into the [consumer] engagement side, you can say that as well. This is one of the things that I think Haleon and GSK liked about the Securikett [which they chose as a winner of a supplier challenge, more on page 106]. One of the reasons Securikett came out on top in the challenge was because they have both the hardware and the software elements in which they’re fairly well-developed, so only one provider of a solution instead of several. Another exhibitor, Kezzler, also has done a lot of work in traceability.

You already mentioned that sustainability, while important, wasn’t center of the bullseye for active and intelligent packaging as recently as five or six years ago. But that’s clearly changed. You mentioned recycling as a pillar, how and why is that?

It’s very important, and the Holy Grail 2.0 project [active and intelligent sorting of plastics at MRFs in Denmark, Germany, and France] has really developed very fast. They’re almost beyond the pilot stage with it now. They ran a pilot at the beginning of this year with Henkel, and now they’re going to be doing some more with it. At the Congress, there was another presentation from a company called FiliGrade Sustainable Watermarks, with the brand CurveCode, which embeds readable information about the plastic into the pack itself [so materials recovery facilities can scan and sort more easily]. But the nice thing about projects like Holy Grail is that they’re consortiums that span right across the value chain. They’re not just the smart and active packaging industry technologies who are trying to convince

people like Proctor and Gamble or Henkel to use these things. Also, we’re getting into reuse as well as recycle, and there are smart technologies like RFID in a company called 1Less. They’re doing an RFID-tagged set of cutlery, containers, cups, and saucers, that can be used in big venues [like sports or music, or in catering situations]. The consumer uses them, then puts them into a smart bin [trash can] and they’re automatically sent for washing and cleaning and reuse. But the good thing about them is that you can put any trash in the smart bin, and it will sort them out. The consumer doesn’t really have to think about separating.

Another sustainability-related pillar of yours was food waste prevention. What do you see happening there?

Angela Morgan from Aptar was here, talking about active packaging and food waste prevention. And it’s such a big thing now—I’m sure there are more active packaging products out there than we are aware of because it’s one of those that I call an invisible technology.

You don’t know whether your plastic film on your snack wrapper has had a treatment on it unless you’re told. Provided again we can make the retailers understand both the consumer benefit and the cost benefit, I think that we’ll see a lot more active and monitoring devices on packs at item level, rather than at batch level. On your supermarket shelves, you might see some of these color changing labels getting going, stuff like that, because food prices are going through the roof. And people are becoming a lot more cost conscious and therefore, that should translate into better management of the food that you buy.

That’s where you get into nifty areas like dynamic pricing, correct?

There are a few dynamic pricing models out there. I’m not going so far as to say that everyone’s going to end up with an intelligent refrigerator. There are fridges like that already that will tell you when to use your products, but they’re probably quite expensive. And people don’t just change fridges every day because there’s a new feature. But in stores you’ll see active and compliance packaging. There was a lot of talk, if you recall, of GS1 rolling out coding and traceability standards,

and there’s better promotion of the bene ts of it now. That’s thanks to GS1 being a world network, and there’s a lot of people working with them now. A lot of drive comes from regulation, and I can only see regulation getting heavier rather than lighter in the next few years. I’m not talking about sustainable packaging. I’m talking about food regulation and food safety, and active and intelligent packaging can help there. So, those things are good for our industry.

Coming out of this latest AIPIA World Congress, where are you seeing active and intelligent packaging gaining the most traction?

In the early days, we thought that the things that would really excite the brands would be anti-counterfeiting and traceability, market diversion, avoidance, and all that. Actually, the thing that they really bit on was consumer engagement. It’s making a much closer relationship with their clients, with their consumers. And I don’t see that going away at all. Marks & Spencer had to cancel, but their contribution to the Congress was roughly going to be about consumer engagement aspects of active and intelligent packaging. And that was the thing that they as a retailer were interested in; in engaging their consumers more closely. We sort of went to the background elements of smart packaging a bit during COVID thing because other things, like safety, security, and traceability seemed to become more the focus. But now you’re getting a bit more relaxed again. We’re going to get more consumer engagement features, I think. —Matt Reynolds

By Eric F. Greenberg, Attorney-at-law

Other Shoe Finally Drops on Cosmetics Regulation

In late December, the U.S. Congress passed, and President Biden signed, a big federal spending bill that included signi cant new changes to the laws applicable to cosmetics products. The new law places new requirements on cosmetics packagers, and gives FDA new powers over them. It’s a massive strengthening of FDA oversight over these products, and is the culmination of years of efforts by advocates for more FDA power, who asserted that FDA’s limited powers had resulted in safety issues.

Cosmetics companies will, starting December 29 of 2023, be required to register their facilities with FDA, and list with FDA the products they make (and update the list each year) including a list of their ingredients. They’ll also have to keep on hand records substantiating the safety of the ingredients they use in their cosmetic products, and report adverse reactions to its products. FDA gains new power to suspend a company’s facility registration if it thinks a product made there could be a danger to health, and can order a company to recall a product if it thinks there’s a “reasonable probability” that it’s adulterated and might be a danger to health and the manufacturer refuses to recall it. The new law calls on FDA to develop Good Manufacturing Practices regulations for cosmetics as well, and take steps to address asbestos in talc and PFAS in cosmetics.

Also, state and local governments are preempted by the new law from imposing other requisites relating to topics including those mentioned above, though they will maintain some powers over cosmetics, such as the ability to restrict some uses of specific ingredients.

The law’s definition of a “cosmetic” stays the same as it has been for decades:

The term “cosmetic” means (1) articles intended to be rubbed, poured, sprinkled, or sprayed on, introduced into, or otherwise applied to the human body or any part thereof for cleansing, beautifying, promoting attractiveness, or altering the appearance, and (2) articles intended for use as a component of any such articles; except that such term shall not include soap.

What you see here is a definition that incorporates one of the core concepts in FDA law, namely the packager’s or manufacturer’s intended use of a product.

What you also see here is that cosmetics’ intended use is all about making superficial changes to the body, not, for example, changing its structure. So, cosmetics include “skin moisturizers, perfumes, lipsticks, fingernail polishes, eye and facial makeup, cleansing shampoos, permanent waves, hair colors, and deodorants,” says FDA.

As noted, cosmetic products don’t need FDA approval before being marketed (except for the color additives in them), and the companies marketing the cosmetic can choose the ingredients they use, but have been responsible for assuring they are safe and must avoid the relatively small number of ingredients that are forbidden or restricted by FDA. It’s long been the rule that, as long as the ingredient and the cosmetic it’s in are “safe under labeled or customary conditions of use,” the product is “properly labeled,” and using the ingredient “does not otherwise cause the cosmetic to be adulterated or misbranded,” FDA says, the ingredient can be used.

Now, the packager will need to have proof of ingredients’ safety. What’s more, cosmetics labels had long needed to list the product’s ingredients on packages for retail customers, and also needed to include any material facts that would make use of the product safe, such as directions and relevant warning or caution statements, in addition to the common label elements for consumer products, which are a statement of identity, a statement of the net quantity of contents, and the name and place of business of the manufacturer, packer, or distributor. Now, companies will need to submit their ingredient lists to FDA each year.

Over my years practicing food and drug law, I have often found myself saying something to the effect that, of all the product types FDA regulates, it had the lightest touch on cosmetics packagers. It was a reflection primarily of FDA’s relatively limited legal powers over cosmetics, as opposed to drugs, foods, medical devices, biological products, animal foods and drugs, radiation-emitting articles, and tobacco.

And I sometimes wondered if saying that gave the false impression that cosmetics weren’t regulated at all, the same way too many people mistakenly think dietary supplements are not regulated simply because individual dietary supplement products aren’t specifically approved by FDA before they go to market. The reality is that supplement makers must, for example, follow Good Manufacturing Practices, comport with a range of labeling requirements and restrictions, and face important procedural steps when they decide to make “structure or function” label claims. That sure doesn’t seem ‘not regulated’ to me.

And in some ways, it was the same with cosmetics. For many years, cosmetics have been regulated in a variety of ways, even though individual products didn’t have to get FDA approval. The new law still doesn’t require premarket approval, but it sure does add lots of new requirements, such as those mentioned above. So, I think I will get out of the habit of using the expression “light touch” when describing FDA regulation of cosmetics. PW

Eric Greenberg can be reached at greenberg@efg-law.com. Or visit his rm’s website at www.ericfgreenbergpc.com.

By Sterling Anthony, CPP, Contributing Editor

The Importance of Pallet Patterns

Palletization provides ef ciencies and economies by treating multiple boxes of product as a unit load rather than individually. Those bene ts are inherent and self-presenting. Optimizing palletization, however, requires knowledge-based decision making. Optimization must include considering how many boxes are put onto a pallet and how they are arranged on the pallet. Such is the essence of pallet patterns.

Optimization differs from maximization. The latter seeks to achieve the most from a given variable. The former seeks to achieve the best trade-offs among multiple variables. Optimized pallet patterns balance requirements for density, stability, and strength. Those requirements must be consistent with product characteristics, but also with the limitations imposed by material handling equipment, transportation conveyances, and storage conditions.

Citing transportation as an example, pallet patterns influence cube utilization, and therefore, impact the number of conveyances needed and their fuel and emissions. So as with everything related to packaging, pallet patterns have a sustainability component.

By its nature, a palletized load is of a size and weight that makes it a hazard to nearby personnel, if the load were structurally compromised. A load should remain intact until disassembled. Any prior event in which it comes apart can result in injury. Even in the absence of injury, there is the potential for damage to the goods. When damage renders goods unsellable, all the expended labor, time, and resources will have been squandered. But pallet patterns should not be the sole means for achieving load integrity. Auxiliary means, such as slip sheets, corner boards, straps, and stretch wrap play a role.

configurations. Typically, an interlocking pattern will result in fewer boxes per pallet.

Regardless of the chosen pallet pattern, there are fundamentals to be followed. One is to make sure that the pallet is of adequate design and construction. Another is to cover fully the surface area of the pallet, while avoiding overhang and its associated problems. Still another is to make sure that boxes are arranged such that bar codes and RFID tags are readable.

As packaging levels go, palletization is tertiary, distinguishable from primary which contains the product, and from secondary (the boxes). There are two approaches to integrating the levels.

The first and most common approach starts with the design of the primary package. Afterwards, a case-count is designated. Lastly, a pallet pattern is chosen. The approach is fraught with elements of default.

Optimizing palletization requires knowledge-based decision making. Optimization must include considering how many boxes are put onto a pallet and how they are arranged on the pallet. Such is the essence of pallet patterns.

With the second approach, the design of the primary package and of the secondary package are done to best utilize the dimensions of the pallet. Such does not mean that marketingrelated concerns have to be sacrificed, just that they be satisfied within certain constraints regarding size and shape. Case counts—often arbitrarily a dozen or multiple thereof—instead, are designated to accommodate case dimensions that complement pallet dimensions. This approach requires a series of mathematical calculations that can be tedious, if done longhand.

Decades ago, there were charts, displaying dozens of pallet patterns, each assigned a number. The charts had two slide-rule type scales, one for locating box length, one for locating box width. When the scales were aligned, a number(s) would show in a window.

Knowing what’s at stake does not make the choice of pallet pattern any easier. The choices are numerous, but they all fall under two aptly named categories: columnar and interlocking. A columnar pattern resembles stacked blocks. An interlocking resembles laid bricks. As might be suspected, each has its strengths and weaknesses, making the choice application-specific.

A columnar pattern provides strength, particularly against compression. That’s because the corners (the strongest part) of a stacked box is aligned with the corners of the box below. On the debit side, columnar patterns are more subject to toppling, a vulnerability that increases as stack height increases.

An interlocking pattern provides stability, due to the hold-down effect that a superimposed layer has on the layer below. Rotation of the layers results in a variety of iterations, in pinwheels and other

These days, there are software programs that integrate the three levels of packaging. The software takes imputed data and then cranks out dimensions for the primary package and for the secondary package, suitable with the dimensions of the pallet. Such software can be used for a new design project and for a redesign project.

Ultimately, any chosen pallet pattern has to be assembled. Manual assembly is plagued by imprecision, along with worker fatigue. There comes a threshold of scale at which automation makes sense. There is a variety of conventional palletizers. What’s gaining increasing popularity, however, are palletizers that utilize robotics. The challenge is to invest in equipment that’s sufficiently versatile and programmable to accommodate the range of pallet patterns used by an organization. But whether pallet pattern assembly is manual or automated, it is a vital component of end-of-the-line operations. PW

Packaging Policy Update and 2023 Outlook

by the quickening pace of packaging legislation and what it means for your company? In this annual Q&A, AMERIPEN Executive Director Dan Felton and the association’s principal lobbyist, Andy Hackman of Serlin Haley, break down current state and federal policy and what to expect in the coming year.

Packaging World:

The trend of more states enacting Extended Producer Responsibility [EPR] laws continued in 2022. Can you tell us more about that and what packaging companies can expect regarding implementation of those laws? Will there be more laws enacted in 2023?

Dan Felton:

Following Oregon and Maine in 2021, California and Colorado enacted their own packaging producer responsibility laws in 2022. Like their predecessors, packaging producers in these two new laws are generally de ned as brand owners rst, followed by brand/trademark licensees or owners, and then importers of covered packaging into the states. Packaging producers will start paying into all these new systems over the next three to four years—Colorado and Oregon in mid-2025, Maine in late 2026, and California in early 2027.

Oregon is moving the quickest with implementation, with a committee, council, and workgroup already discussing and formulating various components of the new law for rules to be proposed and implemented thereafter. Maine began an 18-month stakeholder engagement process in December to gather information that will inform their rulemaking, while Colorado seated its program advisory board in December. California will get underway with its implementation processes by seating its advisory board in mid2023. Just as they were with the legislative process leading up to the enactment of these new laws, brand owners and packaging companies are strongly encouraged to also get involved in the implementation and rulemaking for these new packaging producer responsibility laws, as there is still ample opportunity to influence the development of these new programs.

Andy Hackman:

In 2022, we saw 40 bills across 18 states addressing packaging producer responsibility in some way. We anticipate that trend will continue in 2023, especially considering the impact of the 2022 elections, and we will probably have even more proposed bills in more states and perhaps one or two more states enacting something into law.

AMERIPEN is already, and will continue to be, deeply involved in the discussions and negotiations in these states to help shape the best possible outcomes for packaging companies.

With four state packaging producer responsibility laws that are not alike, is there any possibility a federal bill gets enacted?

Hackman:

The Break Free from Plastic Pollution Act [BFPPA] and the CLEAN Future Act from the last session of Congress both included packaging producer responsibility language, and it’s likely that one or both bills will be reintroduced into the new Congress in 2023. BFPPA, in many respects an “anti-plastic” bill, included language to establish a national packaging producer responsibility program. CLEAN, a broader climate change action bill, carried many provisions from BFPPA, including language to establish a taskforce to study the possibility of a national packaging producer responsibility program. It’s unclear how much traction either of these bills, including their packaging producer responsibility language, might gain in 2023 given the partisan split in Congress and more pressing legislative priorities. However, discussions continue to grow in Congress, and in the long-term, there is potential for some legislation to pass if the politics align.

Overwhelmed

Andy Hackman

Dan Felton

Felton:

AMERIPEN continues to believe there is merit in the packaging industry engaging at the federal level or across multiple states at the regional level on packaging producer responsibility to avoid a patchwork of onerous state laws with different requirements placed upon packaging companies and owners. This is even more so with enactment of the new laws in 2022 in California and Colorado that were not aligned with each other or the previously enacted laws in Maine and Oregon.

Might we see traction on any other packaging and recycling issues at the federal level in 2023?

Hackman:

In 2022, AMERIPEN supported the Recycling Infrastructure and Accessibility Act [S.3743/H.R.8183] and the Recycling and Composting Accountability Act [S.3742 /H.R.8059]. The Recycling Infrastructure and Accessibility Act would provide grants for projects to make recycling programs more accessible to rural and disadvantaged communities. The Recycling and Composting Accountability Act would require the development of data to provide the U.S. Environmental Protection Agency [EPA] the resources that will help inform real and actionable composting and recycling policy with improved collection and access to reporting and data across current and emerging recovery and recycling materials and technologies.

While these two bills were not enacted in 2022, AMERIPEN hopes they will be reintroduced in Congress in 2023 and ultimately enacted to further improve and innovate the current packaging recovery infrastructure in the U.S., including for systems that can recover compostable packaging.

Felton:

AMERIPEN also hopes to see additional traction in 2023 on implementation of the EPA’s National Recycling Strategy that began in 2022 to expand data collection, standardize recycling de nitions, and advance end-market development for recycled materials. Finally, AMERIPEN is optimistic there may be some consideration of federal uniformity around the issue of recyclable, compostable, and reusable labeling for packaging following enactment of rather onerous legislation in California in 2021 that will restrict recycling messaging on packaging beginning in 2025.

With other states actively considering similar legislation, AMERIPEN believes the EPA and the U.S. Federal Trade Commission [FTC], which may soon begin a formal review of its Green Guides, are good forums for efforts to establish national definitions and a labeling language so we can avoid multiple state-specific labeling standards, which we believe will result in increased consumer confusion and additional packaging material going to landfill. It appears there will be ample additional opportunities for packaging companies to engage at the federal level this year on packaging policy for recycling, recyclability labeling, increased recovery, and end-market development.

Recycled content continued to be a big issue in 2022, including proposed legislative mandates. What’s happening there, and how should packaging companies be planning for this?

Hackman:

Following Washington State’s relatively broad recycled-content mandate law in 2021, which includes plastic beverage containers, household and personal care products, and trash bags, New Jersey went even further in early 2022, enacting a new recycled-content mandate law covering rigid plastic containers, glass containers, paper and plastic carryout bags, and plastic trash bags.

In November, the New Jersey Department of Environmental Protection [DEP] began a stakeholder engagement process that should continue well into 2023 and offers an excellent opportunity for packaging companies to help shape pending rulemaking around this new law. Washington State considered legislation to expand its 2021 recycled-content mandate law to additional forms and types of plastic containers, but that bill language failed to advance. AMERIPEN expects to see some form of that language introduced again in 2023, along with several other states likely to consider recycled-content mandates as standalone legislation or wrapped into packaging producer responsibility proposals.

Felton:

There were a handful of other state legislatures that considered recycled-content mandates in 2022, including an onerous proposal in California that would have mandated recycled content speci cally for thermoform containers. It was ultimately vetoed by Governor Gavin Newsom who recognized that enacting such a proposal right on the heels of the state’s new packaging producer law that contains recycledcontent language didn’t make a whole lot of sense.

AMERIPEN released a study in 2021 that looked at packaging goals

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for recycled content versus available supply and capacity. At that time, we identified a shortfall for all plastic resins except for high-density polyethylene. Now add in more state mandates and more companies increasing their post-consumer recycled content goals, and that pressure is anticipated to increase. This could add significant pressure and additional complexity on smaller converters and brands, further exacerbated by the slow pace of U.S. Food & Drug [FDA] approvals for food-contact recycled content. Packaging World readers are encouraged to join AMERIPEN in discussions in 2023 to help shape legislative and regulatory outcomes that are achievable and reasonable and that recognize that “one size” doesn’t always fit all.

AMERIPEN has been working with PMMI on a packaging trends study. Can you tell us more about this and why it matters to AMERIPEN?

Felton:

AMERIPEN has been collaborating with PMMI – The Association for Packaging and Processing Technologies to learn more about the trajectory of packaging design over the next 10 years and the factors that will drive cutting-edge innovation. Through a survey and a series of focus groups and workshops, we heard from more than 400 Consumer Packaged Goods brands, converters, raw material suppliers, and operation equipment manufacturers, and we were able to identify which materials and packaging formats are on the rise or in decline. Their input also helped isolate when and where packaging substitutions might occur and offered insights into the dynamics fueling such decisions. Working with peers and stakeholders, we then explored the potential implications of these packaging shifts on public policy and our recovery systems.

The study, which should be released this month, indicates that public policy is not fully aligned with the projected growth of some packaging materials (i.e., compostables and flexibles) and the need for more recycled content and that proactive public policy should look beyond just design for recycling and toward more recycling infrastructure and innovation. We believe this forward-looking perspective will help advance necessary dialogue to ensure recycling investments through packaging producer responsibility or federal or state funding initiatives to address recycling infrastructure are directed toward the future needs of the system and not just to support the system as it’s designed today.

Any other packaging policy considerations you think our readers should know about as 2023 begins?

Hackman:

There was an increased focus on toxics in packaging in 2022, with ongoing interest from policymakers in certain chemicals, like PFAS and phthalates, either in or used to manufacture packaging and other products. This trend is expected to continue in 2023. There was also an increased focus on advanced, aka chemical, recycling in 2022 that will likely continue during 2023 at least within the context of packaging producer responsibility and recycled-content discussions. Finally, there is a growing policy discussion about the potential for additional deposit return systems, aka bottle bills, in the U.S. as some material sectors see that as a path forward to increasing the use of PCR content while some environmental organizations want beverage containers to be covered by this policy rather than packaging producer responsibility. This may result in more traction for bottle bill proposals at the state level, as well the potential for some more pressure at the federal level for a national bottle bill.

Felton:

Overall, AMERIPEN believes 2023 will be one of our most active years for packaging policy ever. We encourage PW readers to get involved with their trade associations, state chapters, and chambers, and/or AMERIPEN to ensure their voices are heard. —Anne Marie Mohan

AMERIPEN, a material-neutral trade association for the packaging industry, is focused on the intersection of packaging policy and the environment and educates the industry on the value of packaging.

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Buzz-Worthy Spray Closures Go Viral for Tropicana Campaign

In a social media campaign targeting TikTok, Instagram, and Facebook influencers who are pushing the tongue-in-cheek #ThePerfectMimosa trend, Tropicana scored big-time buzz.

Rapid prototyping In uencer campaign

By Matt Reynolds, Chief Editor

In 99 out of 100 cases, packaging’s primary deliverable to a big brand is to safely transport a product through the supply chain—intact and without spoilage—to a consumer. That’s not to diminish packaging’s secondary jobs, like conveying product information or engaging consumers while on the shelf. But at its core, packaging is a practical endeavor.

But occasionally, packaging vaults into the limelight by playing a starring role in splashier CPG goals, like buzz marketing. Such was the case with a November 2022 Tropicana (Tropicana Brands Group) campaign that seized on a recent TikTok, Twitter, and Instagram trend led by in uencers in the mixology space, among both professional bartenders and their brunching in-home weekend warrior counterparts. In this trend, mimosas, which traditionally are half Champagne, half orange juice, are made using diminishingly small amounts of orange juice, or “just a hint of OJ” as one in uencer in the hash-tagged #ThePerfectMi-

mosa Twitter feed said. The tongue-in-cheek joke at work behind the scenes is for the mixologist, with a wink and a nod, to be heavy on the boozy portion of beverage, and light on the non-alcoholic portion.

Instead of a ham- sted pour of OJ into the Champagne- lled ute, these social media in uencers apply the OJ in just a few drops or a mist. To achieve this effect, home mixologists and in uencers use their own bottles to “apply” the OJ—some with spray closures, others with liquid droppers, likely repurposed from other standard CPG product packages, like body mist spray bottles or cosmetics droppers.

But the trend gave the notably creative Tropicana team, who isn’t new to buzz-worthy campaigns, some big ideas.

“Tropicana introduced the Tropicana Mimosa Maker to celebrate the beloved brunch beverage and offer mimosa lovers a fresh, rst-ofits-kind way to enjoy their perfect mimosa at their next gathering,” a

Tropicana capitalized on the #ThePerfectMimosa social media trend with this in uencer-targeted, packaging-centric campaign.

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Tropicana spokesperson tells Packaging World. “Mimosas are undoubtedly a brunch classic. As long as brunch lovers have enjoyed the adult beverage, they’ve had an opinion about the ‘perfect’ OJ-to-bubbly ratio. In fact, in the last year alone, more than 1.6 million videos were created sharing #ThePerfectMimosa. As an iconic breakfast brand that celebrates the brightness that even a single sip of orange juice brings, Tropicana recognizes there may never be a one-size- ts-all approach

to the perfect mimosa. What they do know for sure is that the perfect mimosa includes Tropicana orange juice.”

The company turned to packaging design, prototyping, and testing agency Fuseneo to create a spray closure with a trigger that would be compatible with Tropicana’s existing 12-oz bottle and threaded screw cap. Notably, the project wasn’t designed to roll out to market at scale. Instead, a small scale run of trigger sprayers were sent, in kit form, to so-

An example of #ThePerfectMimosa in uencer trend, as it appeared on Twitter. In this case a single squeeze of orange, only a few drops, is added to a full glass of Champagne.

cial media in uencers. Each Tropicana Mimosa Maker kit includes a 12-oz bottle of Tropicana Pure Premium Original orange juice, two Champagne utes, two iconic Tropicana red and white striped straws, and a Tropicana Mimosa Maker screw top that was developed through the company’s partnership with Fuseneo.

“There’s been a trend amongst brands to create buzz-worthy social experiments and get content to be promoted in uencers, creating this kind of natural, organic public discussion,” Fuseneo’s Brent Lindberg

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We wanted to ensure the design of the Tropicana Mimosa Maker was uniquely ownable to Tropicana, so we pulled inspiration fromTropicana’s branding and colors, and included nods to the brand’s iconic red and white striped straw and signature offering – OJ.

setting  out to create a whole production tool, and production molds around triggers, and they’re very complicated. The, the initial stage of the project was really about nding out what was the right way to allow

consumers to dial-in and dose for themselves, to create that variable experience.

“We explored everything from droppers to puffers to triggers to see what would best give consumers this kind of an experience. Triggers and sprayers were really the impetus from the beginning, but we had to try and gure out if we were even going to consider them. How do you create a new trigger within these kinds of timelines and project constraints? But it made too much sense, so that was the chosen direction. After a couple rounds of iteration and concepting, we locked-in on this on this direction, where we would be able to source an in-market, food-safe trigger that was certi ed for food contact and would allow consumers to adjust the experience as they wanted. Taking off the existing external housing of this in-market trigger and sprayer, we were then creating new housing components— kind of snap-on style pieces. Those pieces don’t have any food-contact surfaces themselves. We ultimately applied that trigger and housing to the existing Tropicana Pure Premium threaded closure, to act as its base. So it works with any off-the-shelf 12-oz Tropicana bottle, with the in-market closure that’s already on the bottle today, since that closure

The full set, sent to in uencers, includes a 12-oz can of OJ, two iconic red and white straws, two Champagne utes, and a new trigger spray bottle cap and closure that allows personalized dosing.

The Tropicana campaign was so catchy that it caught the eye of several local news casts. Check out one segment from channel 12 news in Arizona.

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is actually the base of our trigger closure.”

Fuseneo sourced the existing food-contact trigger apparatus through a broker, but the supplier wasn’t speci ed. As Lindberg and his team went through this process of ideation, considerations on how to form and assemble the trigger spray closures were top of mind. The design agency had to weigh numerous different potential processes to rst see what would work, then see what would work well and work quickly.

At rst, everything was designed and prototyped via 3D printing process, as stands to reason. If they only needed a handful of spray triggers for show and not function, then 3D printing, plus spot painting, would have been the chosen method. And of course, had they needed millions of triggers for a full-scale product rollout, then cutting a steel mold for injection molding would have been the preferred method. But the scale was somewhere in between, in the hundreds, with the need for real, functional triggers that could be used at home or in commercial settings, like bars.

“The process that we wound up using to create the real, branded trigger closures was casting, using urethanes and silicone molds,” Lindberg says. “That’s the that’s the process that we landed on because it’s one we use when we only need a limited number of pieces, we need them very quickly, we need them to have high detail, we need them to be a solid color. Also, we didn’t want to deal with painting these parts because we were worried about scuf ng or paint coming off in a commercial bar setting. Making them out of a solid material that was a consistent color was really a driver for going this direction. And then, lower-cost tooling and parts was another reason. Rather than cutting steel and injecting plastic, you can get those plastic properties and everything from two-part urethanes using silicone tools. Casting can serve this middle space, where we’re looking to create a medium number of prototypes that have similar properties to production parts.”

Results

So how did the campaign turn out? How did consumers and in uencers react?

“People are excited about getting their hands on the Tropicana Mimosa Maker, as seen on Tropicana’s Instagram, with comments like, ‘Very very smart move! Way to read the room [orange emoticon],’ and media have been loving it, too. Mario Lopez is a fan, calling the Tropicana Mimosa Maker ‘awesome’ in an Access Hollywood segment and it seemed to help change the mind of one Barstool Sports editor who shared, ‘I’m not a mimosa person per se [...] but now that I can choose how much OJ to put in there it ips my mind a bit,’” the Tropicana spokesperson told PW.

It sounds like a success—and orange you glad that packaging gets to play this kind of starring role for creative CPG buzz campaigns? PW

Refill-at-Home Packaging Takes Off Across Categories

Beginning with innovative at-home refill solutions from Direct-to-Consumer startups, reusable/refillable packaging has found its way into retail, in markets that include household cleaning, personal and oral care, lawn care, and luxury brands, to name a few.

Re llable/reusable packaging Material reduction Four models of reuse

By Anne Marie Mohan, Senior Editor

Reduce, Reuse, Recycle. This mantra has become the rallying cry for organizations throughout the packaging supply chain—including suppliers, retailers, brand owners, NGOs, and government organizations, among others—when developing strategies around more sustain able packaging. But few may realize that the phrase is more than a catchy slogan: It represents the non-hazardous materials and waste management hierarchy developed by the U.S. Environ mental Protection Agency.

According to the EPA, the most preferred method for the preven tion of waste for non-hazardous materials is Source Reduction and Reuse. This is followed by Recycling/Composting, after which is Energy Recovery. At the bottom of EPA’s inverted pyramid is the least preferred method, Treatment & Disposal—essentially land lling.

Back in the early 2000s, when Consumer Packaged Goods companies began looking at their packaging with an eye toward making it more environmentally friendly, reduction was the easiest change to imple ment. Innumerable tons of material were taken out of the waste stream through efforts such as eliminating the secondary packaging for products such as bottled OTC medications and shaving millimeters off cartons and bags, resulting in big wins for major brands selling millions of products annually. In one “out of the box” example, General Mills actually reen gineered the physical properties of the noodles within its Betty Crocker Hamburger Helper meal to enable the design of a smaller carton size.

However, once that low-hanging fruit had been picked and CPGs became more adept at rightsizing their packaging, recycling became the next major area of focus, with reuse almost entirely disregarded. “And while recycling is still important, it’s nowhere near enough,” advises a new white paper, “The New Reuse Economy,” from Upstream, a nonpro t committed to nding solutions to move communities from single use to reuse. “Somewhere along the line, we forgot that the rst two R’s—reduce and reuse—are way more important for the environment than recycling.

“While ‘lightweighting’ packaging for source reduction has gained some attention, brands, NGOs, and government of cials have spent

most of their time, energy, and resources focused on recycling because frankly, it’s the easiest,” adds the white paper. “This ‘recycling- rst’ approach has been the standard largely because it doesn’t threaten the one-way, throwaway, disposable paradigm that governs current practices and supply chains.”

Rethinking reusable packaging

When the Ellen MacArthur Foundation published “Reuse – Rethinking Packaging,” in mid-2019, as part of its vision for a circular economy for plastics, it brought the topic of reusable packaging to the fore. The report outlines the nancial and environmental opportunities related to reusable packaging and the major bene ts of reuse versus single use.

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According to the report, globally, replacing just 20% of single-use plastic packaging with reusable alternatives offers an opportunity worth at least $10 billion. It also notes that reuse is a fundamental part of the solution to eliminating plastic pollution. “Through the New Plastics Economy Global Commitment, over 350 organizations [as of press time, that number is now 500 plus] have signed up to the vision of building a circular economy for plastics, explicitly acknowledging that we cannot simply recycle our way out of this issue, and that rethinking how we bring products to people without relying on disposable packaging is a crucial part of the solution,” the report reads.

In fact, one of the key progress metrics of the Global Commitment is that the signatories will ensure that by 2025, 100% of their packaging will be reusable, recyclable, or compostable. Not surprisingly, given the ambitious scope of this metric, EMF’s recent 2022 progress report shows that the signatories will most likely not reach these goals by 2025 (see pwgo.to/7850). When it comes to reusable packaging, the report actually indicates negative progress, with a slight decline in 2021 to an average of 1.2%, from 1.5% in 2019.

Yet, there is reason for optimism. Studies show there is a healthy appetite for reusable packaging among consumers. According to a survey of more than 1,100 consumers on sustainable packaging conducted by consumer insights platform Suzy, the word respondents associate most with sustainable packaging is “reusable.” “Recycle” is fth on the list, after “environment,” “friendly,” and “package.” It also reported that the number-one thing consumers want personal care brands to do to be more sustainable is to offer a re ll program for products. Furthermore, 84% said they would be willing to swap their current personal care products for ones that are more sustainable, particularly for products like shampoo, conditioner, body wash, and body lotion.

And, noted the survey, consumers are putting their money where their mouth is: Forty-four percent of respondents said they try to use reusable products and packaging instead of single-use plastic to be more sustainable, and 49% of consumers said they prioritize rellable/reusable packaging when they shop.

Market data from consultancy Smithers also provides reason for optimism around the future of reusable packaging, even if growth is expected to be rather modest. In a recent report, “The Future of Re llable and Reusable Packaging to 2027,” Smithers notes that global sales of re llable and reusable packaging in 2017 amounted to $35.1 billion and grew at an average annual rate of 3.4% to $40.1 billion in 2021. It also projected sales for 2022 of $42 billion, forecast to grow 5% annually during 2022 to 2027 to $53.5 billion.

move consumers away from a single-use, disposable system to a reusable one, CPGs must ensure the switch is as easy as possible by making the reusable packaging as simple to use as disposable packaging. Another challenge, speci c to those systems where the reusable packaging is returned to the brand owner, is the need to develop a reverse logistics infrastructure, as well as a process of cleaning and sanitizing the used packaging. Another challenge is the perceived higher price of products in reusable packaging, despite the fact that the cost of the product decreases every time the re llable package is used.

Four models of reuse

Challenges aside, according to EMF’s seminal reuse report, re llable/ reusable packaging offers a number of bene ts for both brands and consumers. Reads the report, “Reuse presents an innovation opportunity to change the way we think about packaging from something that’s simply as inexpensive and light as possible to viewing it as a high-value asset that can deliver signi cant bene ts to users and businesses.”

In its report, “Reuse – Rethinking Packaging,” the Ellen MacArthur Foundation identi ed four models of re llable/reusable packaging.

Additionally, the report indicates that re llable and reusable packaging sales accounted for an estimated 4% of global packaging sales in 2021; in 2027, re llable and reusable packaging sales are forecast to reach 4.2% of global packaging sales.

The moderate pace of growth most likely re ects the many challenges involved with implementing a successful re ll/reuse program, not the least of which is the shift in consumer behavior that’s required. To

Among the advantages enumerated, the report notes that reuse can cut packaging and transportation costs, as re lls can be supplied in a more compact form; it can adapt to individual needs, since users can customize their experience, as in the case of mix-and-match avors or personalized packaging; and it can build brand loyalty through deposit and reward schemes. Reuse can also improve the user experience. Given that CPGs can invest more money in a package that will be reused

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multiple times versus a single-use disposable one, the functionality and aesthetics of the package can be signi cantly improved.

Another advantage of reuse, according to EMF, is that economies of scale for distribution and logistics can be achieved through sharing reusable packaging across brands, sectors, or wider networks. The last bene t cited by the report is the ability for reusable systems to gather intelligence. Says the report, “Information on user preferences and system performance can be gathered by incorporating digital technologies such as RFID tags, sensors, and GPS tracking into the reusable packaging system.”

The bene ts that apply, however, depend on the model of reuse employed. In its report, EMF establishes four reuse systems, each one of which differs in terms of packaging ownership and the requirement for the user to leave home to re ll or return the packaging. One model is Re ll on the go, whereby users re ll their reusable container away from home, such as through an in-store dispensing system. In Return from home, the reusable packaging is picked up from the user’s home by a pick-up/return logistics service. The third model is Return on the go. In this system, users return the packaging to a store or a drop-off point, such as a deposit return machine or mailbox.

The last model—and the one that will be explored in detail in the balance of this article—is Re ll at home. In a Re ll-at-home system, users re ll their reusable container at home, for example with re lls delivered through a subscription service or purchased at retail. Some of the earliest examples of the new breed of Re ll-at-home products came from the e-commerce sector, particularly for products such as household cleaning, laundry, and personal care.

Blueland was among the early adopters of re llable/reusable packaging, offering a Re ll-at-home system for household cleaning products.

D2C brands pioneer re llable/reusable packaging

One early example of a Re ll-at-home system is from direct-to-consumer company Blueland, which launched a subscription service several years ago with three household cleaning products and a foaming hand soap (see pwgo.to/7851). Blueland’s system comprises a counterworthy, reusable bottle made of either a shatter-resistant copolyester for the cleaning products or a glass bottle for hand soap, paired with concentrated product formulas in the form of a tablet. To create the product, users simply add the tablet to water in the reusable bottle. For the consumer’s rst order, they receive the bottle and a number of re lls; thereafter, they receive only the re ll tablets.

Another, similar system is one from D2C household cleaning products company Truman’s (see pwgo.to/7852). In 2019, the company introduced four concentrated cleaning products, for kitchen, bath, glass, and oors, packaged in re ll cartridges that are loaded into a durable, reusable PET spray bottle lled with water.

Both Blueland and Truman’s illustrate how Re ll-at-home systems can both eliminate packaging waste, with the re lls using just a fraction of the packaging materials required for a traditional ready-to-use bottle (RTU), as well as reduce the costs and emissions related to transport. According to Truman’s, one full truckload of its re ll cartridges is equivalent to 30 truckloads of RTU spray bottles.

In the area of personal care products, in mid-2019 subscriptionbased D2C company Wild unveiled a reusable packaging platform for its natural deodorant product that includes an eye-catching, anodized aluminum re ll case and deodorant re ll sticks wrapped in a rst-of-its

kind bamboo-pulp package, making the system plastic-free, as well (see pwgo.to/7853).

While small, startup subscription-based D2C companies may have dominated the Re ll-at-home landscape initially, major CPG brands have quickly followed suit, introducing new re llable/reusable packaging for some of the world’s most well-known products. Among the rst was Unilever, with re llable/reusable packaging for its Dove deodorant, introduced in early 2021 (see pwgo.to/7854). The system comprises a sleek, stainless-steel case and compact re lls.

In early 2021, Unilever followed that launch with a reusable system for its Dove body wash products that includes a reusable bottle, made from either 100% recycled high-density polyethylene or aluminum, and a petite, HDPE bottle holding a liquid concentrate (see pwgo.to/7855).

Currently, the most common product types using Re ll-at-home systems are those that require water, which can easily be added by the consumer and make small re lls possible. These include household cleaning, personal care, and beverage products. But other product categories are also joining that list. Among them are cosmetics, spirits, and lawn and garden products, to name just some, each with their own speci c requirements and challenges, as well as their own, customized solutions.

SC Johnson, Reckitt Benckiser get in the game

As noted, one of the rst categories to embrace Re ll-at-home systems was the household cleaning products market, beginning with small and specialized D2C companies and expanding to include major CPG brands offering their products at retail. One recent introduction is from multibillion-dollar global company SC Johnson.

In February 2022, the multinational producer of household consumer and professional products introduced Dissolve Concentrated Pods for its Windex Glass Cleaner, Windex Multisurface Cleaner, Scrubbing Bubbles Bathroom Cleaner, and fantastik Kitchen Cleaner. The

aptly-named Dissolve system includes dissolvable pods, or sachets, that hold 0.28 oz of cleaner concentrate and a custom-designed, reusable and recyclable PET spray bottle. To create the cleaner, users drop the pod into the empty bottle, ll the container up to its shoulder with warm water, twist on the spray dispenser, and shake the bottle to dissolve the pod. Each sachet of concentrate yields 26 oz of cleaner.

While Dissolve is new, SC Johnson’s efforts in Re ll-at-home systems are not. In 2011, it introduced a liquid concentrate for Windex Glass Cleaner in a 2.9-oz plastic bottle, followed by Scrubbing Bubbles Bathroom Cleaner and fantastik Kitchen Cleaner re lls in the same packaging. The concentrates, which are still available, are said to use 78% less plastic versus a standard 26-oz bottle with trigger spray.

According to SC Johnson Chief Communications Of cer Alan VanderMolen, when the company introduced its rst Windex concentrate more than a decade ago, it wanted to provide consumers with an option that offered both cost savings and environmental bene ts. “But plastic waste wasn’t top of mind enough for consumers, and the product never gained much traction,” he says. “Since then, consumer expectations for action from corporations are increasingly higher. At SC Johnson, we have several teams, from RD&E [Research, Development & Engineering] to Procurement and Sustainability, that work to push us even further and provide consumers with an array of product options.”

Despite the increasing demand from consumers for more sustainable options, however, VanderMolen believes there’s a “chasm” between what they know about re llable options and what their expectations are in terms of purchasing more sustainable options. “That’s where we see an opportunity,” he says. “Dissolve is easy to use, is accessible at major retailers such as Target and Amazon, and reduces plastic waste by 94%” compared with a 23-oz or larger same-branded spray bottle.

When it comes to re llable/reusable packaging, VanderMolen conrms that consumers are de nitely engaged. In a survey conducted by

In mid-2019, D2C brand Wild introduced a re llable deodorant case, with re lls wrapped in a bamboo pulp material.

SC Johnson, it found that 91% of respondents were supportive of hearing about new re ll options; 64% agreed that “reducing the amount of plastic used in products and packaging will have the most impact on our ability to achieve a waste-free environment”; 70% agreed that “developing concentrated re lls for popular cleaning brands like Windex, Scrubbing Bubbles, Pledge, and fantastik so consumers can keep and reuse triggers while recycling the bottle” has an impact on creating a more sustainable world; and 61% agreed that SC Johnson promoting the use of re llable bottles to increase consumer reuse of plastic products is important to leading the charge in sustainability.

“However,” notes VanderMolen, “less than half of consumers said they knew about our re ll options. That’s our challenge—increasing awareness and enabling consumers with more options.”

In selecting products for the Dissolve Re ll-at-home system, VanderMolen explains that SC Johnson chose Windex, Scrubbing Bubbles, and fantastik because they are iconic brands that offer the resources for SC Johnson to pilot the concept across its larger product lines. “Since these brands have a heavy U.S. focus, we’re starting here,” he says, “but we are evaluating where we can incorporate Dissolve around the world.” He adds that the company is also looking at ways it can further develop the concept across other brands.

Dissolve products are available in a starter pack for $5.69; re lls are available in a three-count pack for $6.59. The starter kit includes one reusable bottle and one re ll pod in a exible pouch that are sold together in a paperboard carton. The re lls are packaged in a side-gusset stand-up paperboard package.

Another well-known household cleaning brand now offering a rellable/reusable packaging option for one of its products is Lysol from Reckitt Benckiser, with its new Smart Trigger + Re ll system. In this case, the liquid concentrate is packaged in a plastic cartridge that is inserted, still sealed, into the neck of a custom-designed PET bottle. The trigger spray is then added to the bottle, with the dip tube fed through a hole that runs the length of the cartridge. When the dispenser is tightened onto the neck of the bottle, the concentrate is released into the container. The solution is similar, if not the same, as the one used by Truman’s, introduced by the D2C household cleaning company in 2019.

The Lysol bottle, which has been designed to be reused up to 25 times, is a signi cant departure from the brand’s standard opaque HDPE spray container. The custom container sports a bulbous, bowling pinstyle shape as opposed to Lysol’s traditional angular design and is made from a clear PET. A clear plastic label decorates most of the bottle, with an area at the top providing visibility to the cartridge once it’s inserted. A vertical perforation on the back of the label bears the words “Unzip,” prompting the consumer to remove the label before recycling the bottle. The plastic concentrate cartridge measures approximately 1 in. in dia and 3.5 in. in length. It also bears a brightly colored Lysol-branded label.

The re ll cartridge holds 0.195 oz of concentrate and, when added to water in the reusable bottle, produces 25 oz of cleaner. According to Lysol, this results in 75% less plastic versus Lysol Lemon All Purpose Cleaner in a 32-oz bottle. Lysol’s Smart Multi-Purpose Cleaner is available in two scents: Citrus Breeze and Fresh Waterfall. Starter kits, in a 100% recycled-content, recyclable paperboard box, include the bottle, trigger spray, and one cartridge. Re lls are sold in two-count blister packs with a die-cut peg hole. related video on the Lysol Smart Trigger + Re ll system at pwgo.to/7856.

SC Johnson’s Dissolve system includes dissolvable pod concentrates and a reusable PET spray bottle.

Similar to Truman’s re ll system, Lysol uses cartridges to hold its cleaner concentrates, with one 0.195-oz cartridge producing 25 oz of cleaner.

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Thrive’s Own-Brand Cleaner Uses Pouched Concentrates

Not to be outdone by their big brand competitors, D2C companies continue to launch innovative, design-forward refill/ reuse systems for household cleaning products. Among them is Thrive Market, a membership-driven e-retailer that curates a range of healthy, affordable, and sustainable products that include food and beverage, health and beauty, baby, and pet products, among others. Described as “Costco meets Whole Foods,” Thrive has more than 6,000 products from which to choose, including 600-plus of its own-brand offerings.

In March 2022, it launched Rosey by Thrive Market, a 28-SKU line of planetfriendly household cleaning essentials. Representing Thrive’s first foray into reusable packaging, the line includes three liquid cleaning concentrates in flexible pouches that can be used with three beautifully designed, minimally branded reusable glass bottles.

According to Christine McNerney, senior director of Home, Health + Beauty for the e-retailer, Thrive launched Rosey to meet the all-time-high demand for household cleaning products, driven by the pandemic, the back-to-school season, “and everything in-between,” she says. “Consumers are looking for highperforming, high-quality, and affordable home cleaning goods: enter, Rosey. The new line features a refillable, reusable cleaning system and squeezes in two 16-ounce bottles worth of cleaner in one four-ounce pouch [the formula is 8x concentrated].”

Like a number of other brands that have moved to or have launched in reusable packaging, Rosey’s formula is equally eco-conscious. “We have a rigorous set of standards spanning ingredient portfolio, materials, and formats, and Rosey adheres to the highest echelon of standards, allowing our members to clean their homes more safely and sustainably versus traditional household cleaners,” McNerney explains. Rosey’s affordable price point also makes “clean” cleaning accessible to all of Thrive’s members, she adds.

bottles—or vessels, as Thrive refers to them—feature a glass body, a non-slip, protective silicone boot colored yellow, blue, or green and subtly engraved with the Rosey logo, a plastic trigger spray made from recycled material, and a bamboo neck. According to McNerney, the bottle can be used “forever.”

Given the range of reusable packaging options for household cleaners available on the market today, McNerney

Thrive Market’s new Rosey line of household cleaning products includes three re ll/ reuse option, pairing concentrate in a exible pouch with counter-worthy, reusable glass bottles.

Products in the refillable/reusable line include an AllPurpose Cleaner in a Fresh Lemon scent, a Tub & Tile Cleaner in a Peppermint Scent, and an unscented Glass & Mirror Cleaner, with the concentrates packaged in a flexible film stand-up pouch with a dispensing spout and a reclosable, screw-on cap. The complementary reusable, dishwater-safe

says that with Rosey, Thrive wanted to closely mirror a format that consumers are familiar with, i.e., liquids. “We know converting from a conventional, familiar option to a sustainable alternative can be challenging for the consumer,” she says. “Our team’s shift to a refillable liquid pouch required a smaller behavior shift to introduce this sustainable option to a broader member base.”

All Rosey products, including the reusable bottles and refill concentrates, are sold on the Thrive Market site. The Refillat-home products are available as standalone items—at press time, priced at $9.99 per 16-oz bottle and $4.99 for a 4-oz refill—or bundled together for $12.99. PW

A ‘re llable universe,’ starting with lip balm, for above & beyond

The second category making the early plunge into re llable/reusable systems is personal care, with most offerings coming from D2C and a recent spate of new products showing up on retail shelves as well. Currently, one of the more unique e-commerce-only personal care products on the market is a reusable lip-balm system from above & beyond (a&b), an Integro Innovations Ltd. brand. On a broader scale, a&b says it’s on a journey to turn people’s homes into a lifetime-use, re llable universe, while eliminating single-use plastic.

“Our single-use mentality with daily products is killing the planet,” says a&b co-founder Bryn Walbrook. “Unless we all want to move to Mars with Elon Musk, we will need to treat the earth much better.”

Why did a&b decide to begin its journey with lip balm? Says messaging on the company’s cheeky website, “OK, so single-use lip balms probably aren’t the main problem keeping Attenborough up at night. But hundreds of millions of them are tossed into land ll every year. And given the choice between a lip balm that kills the planet a bit and one that doesn’t kill it at all … well, we know what we’d pick.”

code that allows consumers to reorder product via their smartphone. The case comes in a choice of four metallic colors: Volcanic Pink, Earth Metal, Desert Gold, and Autumn Blossom.

According to Walbrook, a&b studied a variety of structures and designs before deciding on the aluminum case. “The hardest compromise was balancing design with optimal eco-credentials,” he says. “Why create something beautiful if it destroys the planet? Equally, why create an optimal environmental product that no one buys? One alternative we explored was paper. This turned out to be structurally weak and damaged the performance and quality of the product. So we binned [recycled] it. We needed to create something beautiful that worked well—hence aluminum.

“Aluminum is known as the green metal for a reason. In nitely recyclable, with almost all aluminum ever produced still in use today! We love our bioplastic alternative [the re ll pack is made from a bio-based material], but aluminum has become part of the fabric of the brand and identity. Aluminum is built to last, and we wanted to create a product that re ected the resilience and power of this material. However, this does increase costs and asks our audience to pay a small premium. The next product launch will be an affordable alternative that maintains the beauty and design, while challenging existing brands to do better.”

A re llable/reusable lipbalm packaging system from above & beyond includes a metallic, dome-shaped case and product re lls packaged in bio-based material.

The lip-balm re ll is also dome-shaped and can be easily slotted in and out of the base. To create the re ll packaging, a&b worked with bio-based packaging supplier Sulapac. Recalls Andy Hill, director and co-founder of Integro Innovations, a&b approached Sulapac in late 2019 about developing a bioplastic re ll pack after having run some trials with other suppliers without success.

Shares Sulapac Sales Manager Miranda Sutton, among the requirements given to Sulapac for the packaging were that it needed to be processable with existing machinery and a prototype mold, compatible with hot- lling the cosmetic formulation, and truly sustainable, with the scienti c background to prove it.

Providing more insight into the decision, Walbrook shares that a&b had both a deodorant and a lip balm ready to ship when it elected to focus on the latter. “We opted for lip balms as there were no ecoalternatives to mainstream, plastic-abundant lip care,” he says. “Rather than cannibalize our eco-system in deodorant and other categories in beauty, we pursued lip balm to create a new standard in the category. The rest will come.”

The reusable element of the system is an aluminum case designed in-house. The container features a tactile, dome-shaped, screw-on lid and a base with a smooth nish, printed with the a&b logo and a QR

Elaborates Hill, the packaging also had to use the minimum amount of material possible, with the least processing possible, in a simple construct using few parts, aiming always for simplicity. “It also needed to be attractive and intuitive to the consumer, as well as interesting and perhaps unexpected. Very importantly, at the end of its useful life, it needed to be able to quickly return to nature, never to become an environmental pollutant, whether its disposal was thoughtful and responsible or thoughtless and irresponsible,” he adds.

The resulting packaging is a biocomposite made of wood from industrial side streams and plant-based binders that biodegrades without leaving toxic substances or permanent microplastics behind. The material is 100% bio-based, certi ed according to ASTM D6866, is industrially compostable, tested according to EN 13432/ASTM D6400, and is certi-

ed by the Biodegradable Products Institute (BPI). “Sulapac is safe for people, animals, and the planet,” Sutton con rms. “Naturally occurring microorganisms can digest it.”

“Sulapac’s material offers many of the bene ts of oil-derived plastics, but with none of the downsides,” says Hill. “Going with Sulapac has allowed us to create attractive and very functional packaging that is very strong and durable, even with thinner-wall sections. This allows us both to keep the material usage low, while the thin walls aid the speed of decomposition at the end of life.”

The bio-based re ll pack is injection-molded and comprises three parts: a dome lid, a circular body/collar, and a thin disc base, all of which connect with a simple interference t. Explains Hill, “The re ll is bottom- lled into the dome lid, which is attached to the body/collar. After cooling, the base is applied to keep the product clean.”

To use the re ll, the consumer inserts the three-part package into the base of the reusable container. The container base is re tted, and then the domed re ll cap is removed for recycling, after which the product is ready to use. “It’s very possible to use the re ll by itself without the reusable container, and although that was a consideration of the design, it was not the intention,” Hill adds.

Regarding the environmental impact of the reusable lip-balm system versus a traditional single-use lip-balm package, Walbrook says it depends on the behavior of the individual consumer. “The QR code [on the base of the reusable container] will eventually allow each user to access the a&b platform and monitor their waste and reduction,” he explains. “At the moment, that is an expensive task, and so it’s taken secondary precedent.”

At press time, the lip balm is available only through a&b’s website and only in the U.K., although Walbrook says the company will be launching a product in the U.S. in 2023 through an exclusive brand partnership. The product is sold in a variety of combinations of cases and re-

ll counts, with the re lls offered in four varieties, and can be purchased on a subscription basis for a reduced price or on a one-off basis.

Says Walbrook, the response from consumers since the lip-balm system was introduced in April of 2021—more speci cally, on World Earth Day—has been overwhelmingly positive. “Those who have one, love it,” he says. “Once our audience learns more about the product and brand—the QR code, the mission, etc.—the appeal and resonance of our brand grows and encourages the lifetime-use behavior of our product. We’ve been collating the feedback from our users from our rst year, and we have an exciting launch incoming to re ect this.” related video at pwgo.to/7857

D2C brand Myro makes ‘waste reducing’ deodorant system

As a (previously noted) survey from consumer insights platform Suzy reveals, consumers are quite open to purchasing personal care products in re llable/reusable packaging. When the 1,100+ consumers surveyed were asked which personal care products they would be willing to use if it came in reusable packaging, 73% said shower gel, 61% conditioner, 60% body wash/shower gel, 56% body lotion, and 52% deodorant. Out of 15 categories listed, only 15% said, “None of the above.”

When asked what steps they would like to see personal care products take to be more sustainable, 52% of respondents said they’d like to see them offer re ll programs, 49% said they’d like them to offer package recycling programs, 48% want plastic-free packaging, 44% want brands to create more natural products, and 44% would like to see fewer synthetic ingredients.

One D2C brand, Myro, “the plastic-neutral body care brand that makes the three R’s a breeze,” is right in that sweet spot, with re llable/reusable solutions for deodorant and body wash products that are made with non-toxic, natural ingredients. Since its launch in 2018, the company has sold more than 1 million units and has collectively saved the equivalent of 30 metric tons of plastic waste—“that’s like removing 1 million plastic straws or 3 million plastic bags out of land lls,” says Greg Laptevsky, Myro’s founder and chief executive of cer.

Of the origins of Myro, Laptevsky shares that his previous role in marketing for meal kit company Plate, which used compostable packaging in its kits, is what inspired him to launch Myro. “As a startup, it was all hands on deck, and one of my tasks was customer interviews, late night kitchen cooking sessions, etc.,” he says. “It was in those informal research conversations that I learned about this deep-seeded interest across a broad consumer base to reduce their waste footprint. Interestingly enough, people often wondered out loud why there wasn’t a waste reduction solution for their beauty and personal care items the same way meal kits were for the food space.

Myro’s deodorant re ll pod is said to use 50% less plastic than traditional deodorant sticks.

“This prompted me to think about my own personal care routine and woke me up to the amount of one-time, throwaway stuff we buy at our household. I hadn’t thought about it before, but when I did, I was sort of shocked that I simply accepted one-time bottle and throwaway overpackaging as normal for years and years. So I set out to test whether we can take the most obscure, boring, low-consideration everyday

item like deodorant and turn it on its head by making it reusable and waste-reducing and actually sell enough of this crazy product to make a meaningful dent in waste reduction. If we could do it with deodorant, we could do it with any other product.”

Launched in late 2018, Myro’s plant-powered, gender-neutral deodorant includes a reusable and recyclable “made-for-keeps” PP plastic

Myro’s Tubed Gel Concentrate for Body Wash Creates a ‘Magic Moment’

With learnings in hand from the launch of its first refillable/ reusable product, in 2022 Myro added another Refill-at-home product to its portfolio: a line of body wash products made with essential oils and 100% natural fragrances that are vegan, cruelty-free, and sulfate-free. The refillable/reusable system consists of a durable, PETG bottle with pump dispenser— “Made for keeps, not the landfill”—coupled with body wash concentrate in a 1.5-oz squeezable aluminum tube.

One of the features household cleaning products and personal care products have in common that has made them such an appropriate fit for Refill-at-home systems is that many use water, something consumers can easily add at home. However, while it seems like an easy switch for brand owners—supply the concentrate, and let consumers mix it themselves— Myro CEO Greg Laptevsky shares that formulating a concentrate for a product that can be prepared at home is anything but. “You’re constantly balancing three things, and it feels like you’re playing a never-ending whacka-mole game,” he says. “You solve for one product by creating an unintended consequence somewhere else.”

The three considerations, he explains, are the concentrate-state product profile—how much you’re diluting, its temperature profile, its packaging compatibility, etc.; the diluted-state product profile—consistency viscosity of final product, skin feel, skin benefits, lathering experience, consistent scent experience, etc.; and dilution—how easy it is to mix, how it works with 13 different types of tap water profiles around the country, its viscosity and recyclability profile, etc. “And that’s before you get into production trials,” Laptevsky says. “Then you go back to the drawing board and do this again with a different set of problems to solve.”

But solve them Myro did, creating a gel-like concentrate in

three scents—Chill Wave (cucumber, jasmine, and spearmint), Pillow Talk (violet leaf, ylang ylang, and wild amyris), and Solar Flare (orange, juniper, and sunflower)—that are said to be ultra-moisturizing and silky smooth. The concentrates come in a 100% aluminum tube from a supplier based in Spain. “The tube feels very squeezable without feeling forced, which was an important solve for the viscosity profile of the product and the overall dilution experience,” Laptevsky says. “When you see it, you immediately want to squeeze it. We’ve seen this time and time again in consumer research and now live with the body wash debut.”

Myro offers its body wash concentrate in an aluminum tube, perfect for squeezing, with a reusable bottle designed with aesthetics in mind.

As with the company’s reusable deodorant case, the dishwashersafe body wash bottle was designed to be gender-neutral and beautiful enough to keep. The container has a transparent body with a ribbed design that echoes the design of the deodorant case. The screw-on cap incorporates a pump dispenser, whereby product is dispensed by pushing down on a button on the top of the cap. The container is sold with a paperboard band around it that contains marketing messages and instructions for use. When the band is removed, the only branding on the container is the Myro logo on the side of the cap. As for durability, Laptevsky shares that the only part of the bottle that has a lifespan is its pump, which research has shown can be reused for approximately 10 years.

The body wash is available through the same online and retail outlets as Myro’s line of deodorants and is priced from $18.75 to $25 for the starter kit (containing the bottle and one refill tube) and approximately $15 for a refill.

Of the launch of the body wash line, Laptevsky says it’s been extremely positive. “A lot of people are referencing a ‘magic moment’ of turning tap water into body wash—all waste-free.” PW

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case with rounded edges and a ribbed surface coupled with re ll sticks housed in a recyclable HDPE tube. Both packages were designed inhouse, with the containers sourced from China. Although the packaging is patented, Laptevsky provides a high-level description of the design of the components: “The minimalistic re ll pod containing the deodorant bulk is inserted into the deodorant case and gets locked in using a simple cylindrical snap feature. The same cylindrical snap feature also holds the case cap in place.” He adds that each re ll pod uses 50% less plastic than traditional deodorant sticks, which drives overall waste reduction over time.

While a couple of the choices around the packaging seem counterintuitive—the use of plastic materials and sourcing from China—there is sound reasoning behind them, including issues such as ease of consumer use, protection of the product, and nancial considerations.

“On the reusable case, we initially landed on the plastic as a primary material due to in-use user experience reasons and travelability,” Laptevsky explains. “We looked into aluminum and tin but kept getting stopped by the TSA every time we ew with prototypes in our carry-on... not a great side effect of a product that’s intended to be traveled with. There are a few other user experience aws with aluminum containers that became obvious during consumer testing, but we’re working on some ideas on how to potentially overcome them.

“On the re ll, we landed on plastic due to the nature of the deodorant formula itself. Our formula is water-based and has been optimized for glide and absence of white streaks during application. Other alternate re ll material types would have been incompatible with the core technology unless we were willing to sacri ce something about the actual deodorant experience. We are constantly pushing the needle on the formula though so I can certainly see opportunities down the road.”

Myro offsets its use of plastic by partnering with an organization out of the Philippines called PCX (Plastic Credit Exchange). PCX eliminates plastic in an amount equivalent to Myro’s usage through its partnership with local communities.

As for the packaging from China—an option that increases greenhouse gas emissions (GHGs) due to the long distance the containers are transported—Laptevsky explains that Myro’s mindset has always been about designing for scale to be impactful. “This practically means that we need to have a margin structure that can compete with the gigantic MOQs [minimum order quantities] of incumbents, so sourcing from China is often an obvious choice. Alternatively, if the margin structure isn’t there, scale—and therefore ultimate plastic reduction impact—is not possible.”

When approaching the design of the packaging, Myro’s in-house team, along with creative direction from boutique agency Deer eld, focused on making the end-use experience as close to the mainstream experience as possible, with the addition of the intuitive re lling feature.

Aesthetically, the team sought to create an object of permanence that’s worth keeping. “Reusable products are, by de nition, objects of permanence,” says Laptevsky. “It turns out that consumers implicitly have a very different standard for objects they intend to keep versus those that are meant to be discarded. We think through every detail from aesthetics to functionality to storage to transport because reusable packaging is more than just about being reused.”

The colors and graphics chosen for Myro’s case and re ll packs are all about conveying optimism. Cases come in a selection of six colors: three soothing pastels and three bold shades. Re ll pods come in com-

pact FSC-certi ed, paperboard cartons, with atmospheric photography on the front that corresponds to the scent inside. The company currently offers nine gender-neutral fragrances and one unscented re ll. Myro’s line of deodorant products is available on its website, as well as on Amazon and Target.com and at Bed, Bath & Beyond and CVS. On its site, the re ll pods are priced at $15, and a starter kit that includes a case and two pods ranges from $18.75 to $25, depending on whether the customer is a subscriber or is making a one-time purchase.

Proverb’s research deems virgin HDPE the best option for its deodorant

In the U.K., another personal care products company that says it struggled with the issue of using plastic for its re llable/reusable packaging system is Proverb. Its conundrum and resulting comprehensive research into alternative packaging materials—among them, paper, aluminum, glass, bioplastics, and recycled plastic—point to how complex implementing a more sustainable packaging solution can be.

Proverb was founded by husband and wife Kirstie and Luke Sherriff, who developed the mission of the company from the perspective of the product rst. Kirstie is a skincare expert who co-founded a beauty school and developed a line of spa products, Pinks Boutique, with Luke. Luke was a professional rugby player. In 2005, he was introduced to the concept of endocrine disruptors within beauty products, including the use of aluminum in deodorants, which blocks sweat ducts and reduces perspiration. According to the Sherriffs this opened the “Pandora’s box” of understanding beauty ingredients and caused them to embark upon a career producing skincare.

In 2019, Proverb crowd-funded its aluminum-free, vegan-friendly deodorant line in a re llable/reusable package, but put the brakes on its of cial launch when COVID-19 hit, turning its attention to the pro-

U.K.-based skincare company Proverb explored all material options before deciding on HDPE for its reusable deodorant case.

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New Format for Lawn-Care Concentrates

As happens many times in the packaging universe, trends in one category can inspire packaging innovation in another, completely different category. Such was the case with ScottsMiracle-Gro, which says it was influenced by the developments in refillable/ reusable packaging in other markets in the design of its new weed and grass killer concentrate pouch.

“There was no individual product on the market that inspired the development of our Ortho GroundClear Super Concentrate flexible refill pouches, but rather a culmination of macro level trends,” explains Keith Miller, senior packaging engineer for The Scotts Miracle-Gro Company. “Our teams stay on top of consumer trends and are continuously exploring sustainability opportunities. There has been increased interest and adoption of reusable and refillable products in other consumer product categories, and we have developed a form that makes concentrate use less intimidating to new consumers in the weed control category while also being a great sustainability benefit for the market.”

Scotts first introduced its Ortho GroundClear Super Weed & Grass Killer in 2020 in a 1-gal container with trigger spray attachment, known as a “comfort wand,” along with a 32-oz concentrate refill in a plastic bottle. In August 2022, it debuted a new concentrate option consisting of a 5-oz flexible pouch. “Concentrates in rigid plastic bottles have been an offering in the weed and insect control categories, but Ortho is leading the category with this flexible form innovation,” says Miller.

Each 5-oz pouch of concentrate makes up to 0.5-gal of finished product when mixed with water. The pouch is a construction of PET/nylon/PE film and is topped with a 20-mm child-resistant cap. According to Scotts, the new packaging reduces waste by up to 90% when compared to a 1-gal refill bottle and provides a smaller on-shelf footprint for retailers. It also requires less storage space in the consumer’s home versus a standard-size bottle.

When asked about the use of a non-recyclable packaging material for the refill package, Miller says that while there are opportunities to build on recyclability and sustainability in the lawn care market, there are limitations given that it’s a regulated category. “We think this is a great first step to begin to change consumer habits and lead the way when it comes to reducing plastic use in a category that has been so reliant on single-use plastics historically,” he says.

One of the obstacles to the adoption of refillable/reusable systems that Miller says Scotts worked hard to address was consumer ease of use. “Not feeling comfortable or not knowing how to mix or use refillable products is a barrier that the team put a lot of effort into eliminating for consumers,” he says. “This new product form minimizes the guesswork and mess that consumers deal with when mixing concentrate products.

The new 5-oz Ortho GroundClear Super Concentrate re ll pouch was designed to make it easy for consumers to mix their own product for 0.5-gal of weed and grass killer.

It’s really simple—one five-fluid-ounce pouch makes one half-gallon of finished product. We do the measuring for the consumer.”

Scotts’ hope for the refill product is that consumers will use their existing Ortho bottles and tank sprayers with the concentrate. The containers and comfort wands designed for the Scotts Ortho brand are said to be extremely durable and built to last over multiple uses. For those consumers who don’t already have a tank sprayer, Scotts offers an online option for the product that includes an empty 0.5-gal reusable bottle.

For the Ortho GroundClear product sold online, Scotts has further minimized packaging waste by designing a SIOC (ships in own container) configuration, which eliminates the need for a box within a box.

When considering options for filling the new pouch format, Miller says Scotts explored the use of a contract packager, but concerns over product contamination limited its search, with most partners requiring a capital investment from Scotts in order to isolate its products. After a “make-versus-buy” analysis, the company chose to invest in a fully automated rotary pouch-filling machine, which Miller says allows Scotts to have more control over production to meet launch timing and expand offerings as needed.

The Ortho GroundClear Super Concentrate flexible pouch refill is available in more than 850 stores around the country, as well as online on sites that include Amazon and ScottsMiracle-Gro. A two-pack of the concentrate is priced at $18.49. PW

related video at pwgo.to/7859

duction of hand sanitizer. As a result, the of cial launch of the product was in spring 2022. Says Kirstie Sherriff, “This was the rst [re llable/reusable deodorant] to market in the U.K., whatever our competitors say!”

The reusable element of the Proverb deodorant system is a sleek and stylish HDPE case in a choice of grey, yellow, or white. Says Proverb, “They are smooth to the touch, never dent, and are happy rolling around in your gym and travel bag. They are suitable to put in the dishwasher and on average will save you adding eight to 12 deodorant cases a year to plastic land ll.”

The elephant in the room, however, is this eco-conscious company’s use of plastic. “We have made natural and organic skincare since 2007, and the right packaging choice for this is a huge part,” says Kirstie Sherriff. “We are well practiced at it and have used many [material] options in our ranges… . Clearly, we started this journey believing the case would never be plastic, we went straight to carboard tubes. However,

we are also academics and research everything to the hilt, and if you are really willing to take the time and learn, then it is never simple. All the marketing of ‘deodorant cases made entirely from plants’ or aluminum being better for the world is frankly just that—marketing.”

In researching paper as a packaging option, Proverb found that paperboard deodorant tubes are hard for the consumer to use—“a bit like putting a Calippo ice lolly [a frozen dessert in a push-up tube] under your armpit, the deodorant just keeps falling back down,” says Kirstie Sherriff. In addition, to achieve the right functionality, the packaging would require layers of paperboard and lm, which would end up making the tube non-recyclable.

Having used aluminum for their Pinks Boutique spa products in the early days, the Sherriffs say they had seen how packaging made from the material can get dented and scratched, unless a plastic liner is added, which makes the package dif cult to recycle. Kirstie Sherriff

Listerine Advances More Sustainable Oral Care Packaging

Less common in the Refill-at-home space are products that are ingested by the consumer, e.g., food and beverage and oral care products. But there are examples in these markets, as well. Not the first, but definitely the most recognizable brand to introduce a refillable/reusable packaging system in the oral care market is Listerine mouthwash from Johnson & Johnson Consumer Healthcare.

New Listerine concentrate re lls in a 100-mL PET bottle are said to use 60% less plastic when compared to a standard 500-mL bottle of Listerine.

same benefits.

“Listerine is committed to helping people achieve the best oral care in a way that is responsible and more sustainable to help protect our planet,” says Jessica Snell, R&D director of Global Oral Health at J&J. “The Listerine Cool Mint Zero Alcohol Concentrate product was prioritized by Listerine’s scientists and packaging engineers, who worked to ensure that it met our rigorous standards for product safety, quality, and efficacy.”

The packaging system was introduced in July 2022 and includes a reusable, 500-mL Listerine bottle made of PET with a PP closure that J&J says can be used with the concentrate refills for up to two years from purchase if directions are followed properly. Both the reusable bottle and the refill bottle, also made of PET with a PP closure, are widely recyclable.

To tackle the challenge around changing consumer behavior, J&J says it is concentrating on education around product usage. “Our marketing and education for the product focuses on the four steps for diluting the concentrate to help consumers understand the new format,” says Lauren Wexler, head of marketing, Global Oral Care, J&J Consumer Health. “These steps can be accessed via on-pack labeling, product description pages, the concentrate landing page, and Listerine’s social media platforms.”

The four, simple steps are as follows: 1.) Start with an empty and rinsed 500-mL bottle; 2.) Fill with room temperature, drinkable water; 3.) Add one entire bottle of concentrate. Replace cap & shake gently; and 4.) Swish!

Said to be another step toward the brand’s goal of “achieving healthier mouths on a healthier planet,” new Listerine Cool Mint Zero Alcohol Concentrate Refills in a 100mL PET bottle are said to use 60% less plastic when compared to a standard 500-mL bottle of Listerine while providing the

The packaging system was introduced in July 2022 and is available from Amazon.com, Walmart, Rite Aid, Walgreens, and Kroger. Options include a starter pack with a reusable bottle filled with mouthwash together with two concentrate refills or a three-count refill pack. Both options are packaged in a recyclable paperboard carton. PW related video at pwgo.to/7860

adds that research on the impact caused by mining aluminum brings into question whether it’s actually better for the planet than plastic.

Glass, Kirstie Sherriff says, also wasn’t an option for Proverb. “Living a ‘get out what you put in’ ethos likely means travel, an active life, and adventure,” she says. “Carrying glass in your bag isn’t ideal, nor is it when you drop it on your tiled bathroom oor.”

In looking for a “better plastic” option for its product, Proverb also examined bioplastics, but concluded that plastic made from sugarcane isn’t the real solution to the world’s plastic crisis, and its impact on the planet is not any better than that of petroleum-based plastic. “Farming sugarcane in Brazil relies on large plantations, using lots of pesticides and fertilizers that negatively impact soil and biodiversity, as well as signi cant amounts of water,” says Kirstie Sherriff. “Large plantations displace local farmers onto more marginal and vulnerable land. Not to mention, everything then has a carbon footprint starting in Brazil. … We weren’t willing to take the ‘made with sugarcane plants’ band-aid to market to our customers.”

Finally, a look at post-consumer recycled materials revealed that wasn’t an option either. To start with, Proverb could only use from 2% to 30% rHDPE in their package, as using 100% would mean the case wouldn’t be durable enough. The company also wouldn’t be able to produce their case in white, given PCR is multi-plastics mix. And, although they were willing to live with that and while they were able to nd sources of PCR pellets, the challenge became nding a bottle producer willing to pour the material into their multimillion-dollar machines. Says Kirstie Sherriff, “We get that and are still looking for someone who will. If you know them, please send them our way.”

Thus, they settled on a virgin HDPE case—a stock package from a proprietary supplier. Proverb decided to go with a stock package rather than a custom one because the Sherriffs weren’t ready to invest in a custom mold until they knew the market was ready for the product. They also wanted to prove that there was no reason other brands couldn’t produce a re llable option. Lastly, they wanted to wait until a genuine ocean plastic alternative became available.

But the stock package has proven an excellent choice, with consumers who have tried Proverb as well as competitive brands sharing that Proverb’s case is much more robust than those of the competition. “The re ll never falls out due to an internal spindle-and-wheel mechanism, and it is super easy to ll,” says Kirstie Sherriff. “Nothing breaks, nothing wears out. So, while we have now known for a while that the market is absolutely ready and are loving re llable deodorant, we aren’t inclined to change the case now, after market testing.”

The paper that covers the re ll sticks was speci ed by Kirstie Sherriff, who spent a lot of time researching how the company could wrap the naked deodorant and not have it dry up or have the oils in the stick leak through the packaging. The solution, a recyclable paper with the needed barrier, was inspired by a material used in the food industry.

The sticks themselves are molded with a PET wheel—described as looking like a Trivial Pursuit wedge wheel—integrated into the bottom of the stick. To load the re ll into the case, the consumer removes the paper wrap along with a hemp- and linen-based sticker and places the re ll on the top of the open case. The spindle inside the case goes into the center of the wheel located on the bottom of the re ll. The consumer then turns the base of the case to the left, and the re ll retreats down into the case.

Looking for the most sustainable outcome for every part of the product, Proverb also offers consumers the option to receive a prepaid bag from the company in which they can send back the PET wheels from the re lls after use. Proverb loops these materials back into the production cycle, creating a circular system.

According to Kirstie Sherriff, Proverb offers the largest deodorant rell on the market at 70 g, compared with the 40-g re lls available from other brands. This means that on average, its sticks last three months. The deodorants come in three scents plus an unscented option, in different strengths, and with or without sodium bicarbonate/baking soda.

Proverb’s products, which now include a line of body wash sold in a reusable bottle, with re lls in a exible pouch, are available on its website, as well as through a number of its spa partners. As with the other D2C retailers in the re llable/reusable space, the deodorant case and re ll packs are priced according to whether the consumer opts for a subscription or buys a single product.

related video at pwgo.to/7858.

Perfume, spirits brands lessen burden of heavy packaging with re lls

There is another category of Re ll-at-home products where the goal is not only to reduce packaging waste, but also to drastically minimize the weight of packaging being transported and to preserve the customer’s original investment in the brand’s packaging, which in the case of luxury products can be quite signi cant.

A clever dispensing applicator on the aluminum bottle re lls for O.U.i.’s eaux de parfum product ensures product is transferred to the reusable glass package cleanly and easily, without product waste.

O.U.i., “Original Unique Individuel,” is one of seven brands owned by Grupo Boticário, a Brazilian beauty group that distributes its products in 16 countries. The French perfume brand was developed, says the company, with sustainability and health at the forefront. O.U.i. products are 100% vegan and cruelty-free, meaning they do not contain ingredients

of animal origin and have not been tested on animals at any stage of development. O.U.i. is also the rst of Grupo Boticário’s brands to use re llable/reusable packaging, which was part of the brand’s strategy from the outset.

“The decision to include re lls for the brand’s eaux de parfum is to show that it is possible [for consumers] to contribute to the environment while enjoying the everyday pleasures of life and taking care of themselves daily,” says Sabrina Serrato, innovation and product manager at O.U.i. “With re lling, in addition to encouraging the reuse of the original packaging, we were able to signi cantly reduce the weight of the material transported in our operations, reducing the greenhouse gasses involved in these routes.

“In addition to the impact on the environment, re lling brings bene ts to our consumers, who can have access to the same quality as in the original packaging at a better cost.”

O.U.i. is available in 10 fragrances: ve for women and four for men, and one sharable scent. The eaux de parfums [EDPs] come in elegantly crafted glass bottles tted with metal closures, in a 75-mL re llable size and in the Les Petits version, which is a 30-mL bottle. Upon the launch of the brand, it introduced four re ll selections; currently there are seven.

In evaluating packaging systems for the re ll, Serrato shares that O.U.i.’s requirements fell in line with the philosophy of the brand. “One of the main values of O.U.i. is Savoir-Faire, or the ‘know-how’ with excellence and quality, so prized in French culture,” she explains. “And for our re ll line, it couldn’t be different. We wanted to bring to the brand

a package that was practical, aesthetically consistent with the high standard of the rest of the line, and that kept the product in its best condition, to ensure the best experience for our consumers.”

The resulting 75-mL re ll bottle, supplied by Trivium Packaging, is made from aluminum with 10% post-consumer recycled content. Explains Serrato, “Different packages were prospected, but through a survey of consumers, we understood that the aluminum package would be the most appropriate, as it protects the product and maintains the brand’s aesthetics.”

The shape of the bottle also complements the reusable glass bottle from a re ll standpoint, shares William Ferreira-Altea, business manager, Aerosol & Beverage for Trivium Packaging-Brazil. “The aluminum re ll sits nicely on top of the decorative glass vessel to ll easily and cleanly,” he says. “The shape of the bottle is simple and lightweight.”

The re ll container is tted with a Techniplast RT-Twist spout lid system with applicator nozzle for product transfer to the glass bottle. According to Serrato, O.U.i. is the rst perfume brand in Latin America to use the Techniplast license, which is exclusive to Aptar.

To allow for re lling, the glass EDP bottle was designed with a threaded screw-on closure. To prepare the re ll bottle, the consumer rst removes the cap and threads an applicator nozzle, which comes separately with the re ll, onto the aluminum bottle. The consumer then unscrews the valve from the EDP bottle, puts the re ll bottle on top of the reusable bottle, with the nozzle inside the glass bottle, and turns the applicator around the thread on the bottle neck to secure it.

Pepsico Doubles Down on Scaling Up Reusable Packaging Options

On the beverage side, one prime example of a Refill-at-home system is SodaStream, founded in 1903 in the U.K., with the invention of the aerating machine. While the brand stagnated for many decades after its introduction, it was revived in the 2000s, and in 2018, PepsiCo purchased Israel-based SodaStream International Ltd. for more than $3.2 billion.

The SodaStream Sparkling Water Maker is a home carbonation system that includes a machine, a carbon dioxide cylinder, and a plastic bottle designed to be reused for up to three years. PepsiCo also offers a range of bottle options for purchase separately, including glass carafes and dishwasher-safe, on-the-go containers. There are approximately 60 concentrate syrups to choose from, including soft drinks, flavored waters (PepsiCo’s bubly sparkling water brand), and kombucha.

To create a carbonated beverage, consumers insert the CO2 cartridge into the back of the machine, place a bottle filled with water into the front, and push down on a carbonating block to create the carbonation. The consumer then adds the desired concentrate flavor to the sparkling water. They can also mix concentrates for a customized beverage. According to PepsiCo, by using the system, a consumer can save approximately 63 plastic bottles in a month, or 772 in a year.

To further minimize packaging waste, PepsiCo also offers a system whereby consumers can exchange their spent CO2 cylinders for new ones. With each online order, cylinders are shipped in a corrugated box that also contains a preprinted UPS label. Consumers are encouraged to keep the box for use in returning the empty cylinders. Cylinders can also be exchanged in-store. SodaStream then sterilizes, inspects, and refills the cylinders with fresh, dietary-grade CO2.

In early December 2022, PepsiCo announced that it will be pursuing four approaches to reusable packaging to double the percentage of all beverage servings it sells that are delivered through reusable models—from 10% to 20%— by 2030. PepsiCo is an Ellen MacArthur Foundation New Plastics Economy Global Commitment signatory, and its four approaches align with the four models outlined by EMF in its “Reuse – Rethinking Packaging” framework. Says PepsiCo, reuse is one of several critical levers it is using to meet its goals to reduce virgin plastic per serving by 50% by 2030 and to become Net Zero by 2040.

As part of its effort to increase the percentage of its products sold in reusable packaging from 10% to 20% by 2030, PepsiCo has announced it will be expanding its SodaStream sparkling water system business.

The company’s Refill-at-home strategy involves the expansion of its SodaStream business, both at home and in the workplace, through SodaStream Professional. Says PepsiCo, “The widespread international availability of SodaStream and SodaStream Professional, and its continued growth, enables consumers to reinvent how they consume some of the world’s most loved beverage brands and personalize their choices in reusable containers, potentially eliminating the need for more than 200 billion plastic bottles by 2030.”

PepsiCo adds that many of its brands, including Gatorade, Propel, Muscle Milk, and Evolve, are offered as concentrated powders or tablets that allow consumers to customize the drink to their preferences in their own containers—another option for Refill at home. As part of its goal to increase its reusable packaging options, the company says it plans to accelerate growth in its powder and concentrate business.

“Fundamentally transforming the traditional beverage consumption model will require making reusable and refillable options accessible and convenient, at scale, for consumers— and that’s what PepsiCo aims to do,” says Jim Andrew, chief sustainability officer for PepsiCo. “PepsiCo will accelerate our investment in disruptive innovation and advocate for policies that allow us to scale up reusable packaging options, platforms, and programs so that we can offer consumers a wide variety of alternative ways to enjoy their favorite beverages while moving away from reliance on single-use packaging.” PW

The perfume then transfers out of the aluminum bottle and into the perfume bottle. A valve inside the applicator stops the ow of liquid when the bottle is completely lled.

“The goal was to bring this re ll option, but without losing the premium side of the brand and in a way that was easy for the consumer to do at home,” says Serrato. “The aluminum packaging and coupled dosing spout made this all possible. In this way, the consumer can ll their glass bottle, without wasting product.”

Among the advantages of the O.U.i. packaging system, it allows consumers to reuse their original perfume bottle, and its re ll component is made from a highly recyclable material. According to Altea, because of well-established recycling channels, metal packaging has one of the highest recycling rates, with a global average of 60% to 70%. In Brazil, that rate is over 97%.

In addition, the O.U.i. packaging system positively in uences the entire logistics chain, Serrato says. “This makes it possible to reduce the weight of the package by 91%, reducing the greenhouse gasses involved in transport,” she says.

And, costing 44% less than the brand’s 75-mL glass bottle, the re ll is an excellent value for consumers, as well.

Also in Brazil and also involving Trivium as the supplier is another premium brand that has opted for a re llable/reusable system, this one for artisanal gin. According to Trivium, BEG Distilaria, located in the “charming and bucolic district of Joaquim Egídio in Campinas-SP,” was the rst spirits company to develop an aluminum re ll bottle in Brazil.

Founded in 2015, BEG produces all of its products by hand, with every bottle hand numbered and distilled under the “one-shot” distillation method, whereby once the botanicals have been distilled, the resulting spirit is diluted with water, rather than neutral alcohol, in order to reach the ABV required for bottling. “That means that every single drop of our gin is redistilled and comes in contact with all the natural, fresh, and exclusive Brazilian botanicals in the recipe,” says Arthur Flosi, BEG Boutique Distillery’s founding partner and master distiller.

When BEG switched from a standard glass bottle for its gin to a unique mold and branded bottle, the company realized that in an effort to appear more premium, it had added more weight and consequently a bigger carbon footprint to its product. “For the on-trade market [bars and restaurants], that factor [custom packaging] counts little, unless for bottle service, and even more glass was ending up in the trash,” says Flosi. “Day after day, we received various feedback on social media regarding how beautiful our bottle is and how pitiful it was to throw that beauty away. That’s how the idea of launching a sustainable alternative was born.”

with the original glass bottle. According to BEG, the re ll bottle is ninetimes lighter than glass, “meaning less fossil fuel per volume transported.”

“The aluminum bottle from Trivium is perfect,” says Flosi. “It looks great, it feels great, it’s more versatile—aluminum goes where glass can’t—it costs less for our customers, and it’s way more sustainable. In Brazil, 98.4% of all the aluminum packaging is recycled—we have an incredible circular economy around aluminum here.”

One of the considerations in developing the re ll bottle was the selection of a coating for the inside of the container. Nery shares that Trivium is using a special food-grade liner that resists the high content of alcohol to protect the properties of the product and extend its shelf life. Notes Flosi, “We are already at 12 months of real shelf-life testing without any change in avor and/or chemical structure.”

The stock bottle is custom printed using two processes: dry offset printing and heat transfer to allow for different graphics for small orders.

At 48-g, BEG Distilaria’s 500-mL aluminum re ll bottle is nine-times lighter than its glass bottle, greatly reducing GHGs from transport versus the distillery’s custom-molded heavy glass bottle.

While BEG considered a range of alternatives for the re ll bottle, including aseptic cartons, lighter glass bottles, and even aluminum cans, Flosi says that none were up to the quality of the distillery’s gin or felt as premium as the brand’s unique glass bottle. Instead, it chose a 500-mL stock aluminum bottle, which Trivium Packaging-Brazil Coordinator of R&D Marcelo Nery says is produced using an advanced alloy, allowing for a lightweight, 48-g container with a low carbon footprint when compared

The re ll system was launched at retail in Brazil in Q4-21. BEG offers ve different aluminum bottles that correspond to each of the glass bottles it sells in Grupo Pão de Açucar, the biggest retailer in Brazil with a nationwide presence. The cost of the re ll is 33% less than that of the glass bottle. “We wanted an easy math for our customer,” explains Flosi. “Each aluminum bottle has 500 milliliters versus 750 milliliters from glass. The price of the aluminum is 50% cheaper, so the customer would be able to buy one liter of BEG Gin for the same price as 750 milliliters in glass.”

Look to future issues of Packaging World to learn about the other three models of reusable/re llable packaging and how they are being used today. PW

New Reusable/Refillable Packaging Products

Packaging suppliers have taken notice of brand owners’ growing interest in reusable packaging and have begun to offer stock packaging products for refill/reuse systems.

What follows are a selection of these new products.

Bottle, Neck Insert for Concentrated Cleaners

ALPLA Group’s NOW solution for concentrated cleaning solutions consists of two elements. The rst is a recyclable, 80-mL HDPE bottle that, when completely lled with concentrate, weighs just 10 g. According to Aptar, compared with containers for ready-to-use (RTU) products, the NOW container uses 80%-plus fewer materials. The container’s snap lid features a predetermined breaking point, yet is said to seal the bottle safely. The second component is a neck insert for a reusable bottle that allows for an easy press through the predetermined breaking point. To transfer the concentrate, the re ll bottle is plugged head rst onto the cleaner bottle, allowing the concentrate to ow cleanly into the bottle following an audible click. The neck insert remains in the neck of the reusable bottle, while the spray nozzle can be screwed back on without a problem.

ALPLA Group www.alpla.com/en

Refillable Wooden Lipstick Pack

Aptar Beauty + Home and Quadpack have blended their respective expertise in stick mechanisms and wood to create a re llable lipstick package, the Iconic Woodacity. The package uses Aptar’s Iconic non-guided lipstick mechanism, which is said to offer a smooth, constant, and precise rotation over time. The mechanism is compatible with most lling lines, without adjustments. Polyoxymethylene (POM)-free, glue-free, and lubricant-free, the mechanism allows for smooth actuation of the bullet. The lipstick casing, from Quadpack, is made from 100%-certi ed ash wood from sustainably managed forests and features the new and patented Solo Twist system, which features an oval-shaped interior that ensures the cap auto-locks on a quarter turn. The lipstick case is re llable: Consumers simply pull out the used mechanism and snap in the new one. The package also enables users to have various lipstick colors and insert the one they want to use on a given day.

Aptar Beauty + Home www.aptar.com Quadpack www.quadpack.com

Refill System for Solid-Format Bar Products

The HEX hex-shaped, reusable, re llable system (watch video at pwgo.to/7861) for dispensing solid-format re ll bars from DCA can be tailored to t a range of personal care or laundry products. Base-loaded, the system provides a continuous conveyance of product. According to DCA, the consumer simply inserts the re ll into the base and twists to dispense product. A thread cuts itself into the product, driving it forward or backward, with no additional parts required. The conveying device has a two-part drive mechanism that can be made from mono- or high recycled-content material. The hex-shaped re ll also creates an ef cient packing density.

DCA Design International Ltd. www.dca-design.com

New Reusable/Refillable Packaging Products continued

Refillable PP Cosmetic Jar

FASTEN, an IBG (Innovative Beauty Group) company, has introduced the RE ll REuse REpeat re llable cosmetic jar system, designed for cream skincare and makeup products. The package, available in a standard 50-mL cream jar size, is made entirely from recycled polypropylene, and all parts of the package are fully recyclable. The concept comprises a lightweight, open outer jar base combined with an ultra-light, thermoformed re ll cup. The re ll is inserted inside the base with a single click, and can be removed the same way. The reusable jar is said to save up to 80% on material usage and is 70% lighter when compared with conventional 50-mL jars. The re ll units are designed to be stackable and can be produced in different colors to distinguish between creams. The package also uses debossing rather than ink, and elephant grass is used in the paperboard carton that houses the jar.

FASTEN, an IBG company https://fasten.nl/

Refillable, Mono-material Cosmetics Jar

New to Quadpack’s Regula family of jars and airless products is the Regula Re ll Jar, a re llable, recyclable PET jar that can be combined with a PP inner re ll jar. Designed for prestige cosmetic products, the 50-mL outer jar features a thick wall and a premium, glass-like aesthetic. The inner jar is designed for compatibility with most skincare formulas and is made to be easily heat-sealed. Both components can be quickly separated by hand, due to a gap in the outer jar speci cally designed to enable easy removal. The re ll is just as easy to insert, the company says, with the inner jar making a “click” sound when closed. The jar’s double-walled cap is also made from PP, which means all of the package’s components are recyclable.

Quadpack www.quadpack.com

Refillable, Wooden Cosmetics Jar

The P-Re ll from Pujolasos comprises a wooden jar for cosmetics made from PEFC (Programme for the Endorsement of Forest Certi cation)- and FSC (Forest Stewardship Council)-certi ed wood with a removable and recyclable plastic interior. The jar can be customized to any style and can be combined with one of two caps: the Woon or Woodle. The patented, threaded Woon cap is made from 100% PEFC- and FSC-certi ed wood and is glue-free. The Woodle, also patented, is a recyclable cap made from natural, PEFC- and FSC-certi ed wood that includes a recyclable inner plastic liner that can be easily separated for recycling.

Pujolasos www.pujolasos.com

Recyclable Packaging for Liquid Soap Refills

Mondi and Thimonnier have launched a new recyclable, monomaterial berlingot sachet for liquid soap re lls that is said to reduce the use of plastic by more than 75% compared to rigid plastic bottles. The sachet is made from coextruded PE and is designed to replace multilayer, non-recyclable PVC re ll containers. According to Mondi, the sachet has an unusual and eye-catching shape that differentiates the packaging, while its durable and leakproof structure allows the consumer to smell the product inside— particularly useful for the liquid soaps it is designed to protect.

Mondi Group www.mondigroup.com Thimonnier www.thimonnier.com

OEM APPLICATION NOTE

Robotic Automation Doubles Capacity for Dot’s Pretzels

With no perceivable impediment to its growth other than capacity, Dot’s Pretzels, now a Hershey Co. brand, opened a new facility with a special focus on robotic packaging automation.

WHAT YOU’LL LEARN

By Matt Reynolds, Chief Editor

Known for its bold, distinctive seasoning, Dot’s Homestyle Pretzels is the third-largest pretzel brand in terms of sales volume in the United States. That’s quite an accomplishment for a company founded in 2012, operating in a mature product segment, that didn’t gain national distribution until the middle of 2019, with much of that initially through hardware stores.

Founder Dorothy (Dot) Henke and her team have managed the growth carefully, expanding from early roots as a home business, to successively opening plants in Dot’s hometown of Velva, N.D., her winter home in Goodyear, Ariz., and then an eastern leaning, geographically equidistant plant in Lenexa, Kan.

Despite the steady expansion in production capacity, Dot’s strained to meet the rapidly growing demand, even with each plant predominantly operating 24/7 production schedules.

A new model for fourth production facility

With no perceivable impediment to its growth other than capacity, as plans developed for a fourth production facility Dot’s management decided to make a signi cant investment in automation.

The 186,000-sq-ft., state-of the-art facility opened in November 2020 in Logistics Park Kansas City in Edgerton, Kan. It features automated product preparation, handling, and packaging from beginning to end, and like other Dot’s plants, it operates a 24/7 production schedule with some downtime every other weekend for cleaning and maintenance.

“Our prosperity over the last few years allowed us to gather the resources needed to pursue automation, which we believe to be the natural progression in keeping the company on an aggressive growth trajectory,” says Kent Schmidtberger, Dot’s project manager at the Edgerton location.

Custom multi-purpose EOAT PLC control logic

ABB FlexPicker delta robots ll the POP display cases (above). VMRA makes machine and operator safety a top priority and so deploys the GuardLogix Safety CPU to monitor all safety devices and ensure machine safety meets or exceeds SIL2/PLd safety requirements (top right).

“I came from plants that were heavily automated, so I know the bene ts. Not only are we able to produce more pretzels, but we do so with greater consistency. Plus we have the added exibility to expand our product lines down the road.”

Dot’s turned to Oostburg, Wis.-based packaging solutions provider Viking Masek to design, specify, and install the automated packaging systems in the facility. The packaging systems include a bucket eleva-

tor that transports nished product to several weigh stations, then on to bag sealers, metal detectors, checkweighers, vertical bag llers, case packers, and ultimately a case palletizing station.

Dot’s twisted pretzel sticks come in eight package sizes ranging from 0.5 to 32 oz, and in three avors: Original, Southwest, and Honey Mustard. The most popular retail 16-oz size is available in both standard and point-of-purchase display cases.

INNOVATION

With the most variation to the product coming in the case con guration, to design and install the case packing and palletizing processes, the most exible portions of the overall packaging line, Viking Masek and automation system integrator IAS Inc. came together to form Viking Masek Robotics & Automation (VMRA). The strategic partnership combined the expertise, experience, and resources of both companies to provide cutting-edge packaging solutions that automate the entire packaging process from bagging to palletizing and beyond.

Two delta robot case packing lines

“The biggest challenge for VMRA in designing the case packing systems was to accommodate the various size packages, and facilitate both the stand up and lay at pouch case con gurations,” says Schmidtberger. “They basically had to accomplish, through robotic automation, the packing of all the SKUs that we manually process at our other facilities.”

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VMRA designed two parallel case packing lines, one with three ABB IRB 360 FlexPicker delta robots for the 0.5-, 1.0-, 1.5- and 2.5-oz bags, and one with two identical FlexPickers for the 5.0-, 16.0-, 24.0- and 32.0-oz bags. The 6-kg payload delta robots pick the packages off a conveyor and place them in the various case con gurations utilizing differing designs of vacuum-based end-of-arm tools (EOAT).

The three smaller size SKUs are vertical form lled pillow bags with heat seals on each end. The three-robot case packing line is optimized for maximum throughput, with automatic changeover functions to ac-

commodate the differing pick-and-place requirements for each size. The smaller bags are typically destined for convenience stores, vending machines, and airline hospitality commissaries.

The changeover from one SKU to another is handled by a few button presses at the machine HMI. Once the new recipe is accepted, the machine automatically adjusts the physical and program parameters to handle the next SKU. All this is accomplished in a matter of minutes.

When 16-oz bags come down the line to be packed in the POP cases, the robots pick them up and lay them at into a dumper bin to the side of the conveyor, adjacent to the case. When the bin is lled with the appropriate case quantity, it automatically tilts and dumps the bags into the case in an upright orientation. The bags are thusly positioned for display when the front case cutout is removed on the retail oor. The standard, non-POP cases bound for distribution centers or locations where product is stocked on shelves are packed at directly into non-display cases. This extra bit of automation provides the exibility to pack multiple 16-oz case con gurations on the same line.

The large bag line also integrates automatic changeover functions, as well a tool changer that seamlessly alternates between two different

Check out a brief video on the new Dot’s facility, including robotic case packing and palletizing operations.

EOATs depending on the product size being packed. When switching between bulk packing to display-ready packing, operators are instructed by the machine to perform a manual change that positions the display packing automation in a ready position. This process is tool-less and veri ed by sensors on the machine to ensure it has been done correctly.

VMRA worked with the Dot’s production team to optimize the vacuum tools for the project. The geometry of the tool, suction cup design, and robot programming have all been carefully engineered for maximum performance and lifespan.

One palletizing robot simultaneously serves both lines

The case packing lines end adjacent to a single ABB IRB 660 palletizing robot that, with a 3.15-m reach, is able to reach cases from the end of both conveyors, alternately picking cases from each conveyor to simultaneously build a separate pallet for each product SKU.

The palletizing EOAT is a vacuum-based foam area gripper designed by VMRA speci cally to meet the needs of the application. With a single tool, the palletizing robot is able to accommodate single- and multi-product picks to maintain optimal throughput.

The palletizing EOAT is a vacuum-based foam area gripper designed by VMRA speci cally to meet the needs of the application. With a single

tool, the palletizing robot is able to accommodate single- and multiproduct picks to maintain optimal throughput. Completed pallets are transferred to a main exit conveyor, stretch wrapped and sent to the warehouse to be staged for shipping.

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Programming software optimizes system design

VMRA utilized RobotStudio, ABB’s of ine simulation and programming software, to assist in designing the robotic lines.

Using PickMaster for the case packing lines and the Palletizing PowerPac for the palletizing system, two application-speci c add-ins to RobotStudio, VMRA was able to experiment with highly realistic simulations of automation systems featuring various robot model and layout combina-

tions in the progression of reaching the optimal design for each line.

In addition to helping identify the relative positioning of each robot based on their footprint, reach, and payload, the software is able to select and position all other line components, such as conveyors and other xtures needed to perform the various line processes. As a system simulation is developed, RobotStudio can identify any potential bottlenecks and calculate accurate space requirements and cycle time metrics that the system concept would deliver if actually installed on the plant oor.

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“RobotStudio is a great program that allows us to simulate real world system con guration scenarios ofine, which saves a lot of time throughout the system design and commissioning processes,” says Dave Raschke, the VMRA project manager who worked closely on the Dot’s project. “In essence, we were able to experiment with complete and accurate system design variations through risk-free trial and error until the ideal system was designed.”

Custom PLC design, seamless integration with robot controllers

VMRA also wrote the PLC program for the packaging and palletizing lines. The system is designed to be modular. Each case packer/palletizer machine uses an Allen-Bradley GuardLogix PLC with custom logic to integrate with the higher level customer systems for analytics.

Dot’s Homestyle Pretzels is the third-largest pretzel brand in terms of sales volume in the United States. The Hershey Company acquired Dot’s for $1.2 billion in December 2021.

platform is to act as the ‘machine master’ and control the major automation functions of each machine such as running conveyors, indexing boxes, and dumping product. VMRA makes machine and operator safety a top priority and so deploys the GuardLogix Safety CPU to moni-

tor all safety devices and ensure machine safety meets or exceeds SIL2/ PLd safety requirements.

In parallel to this, the ABB IRC5 (palletizing robot) and ABB IRC5 Compact (case packing FlexPicker robots) controllers handle all motion and application speci c code pertaining to each robot. Coupling the Allen-Bradley PLCs with the ABB IRC5 family of controllers allows for seamless integration between each robot and its corresponding PLC master. This enables the two systems to exchange information via the Ethernet/IP and Ethernet/IP CIP Safety protocols, simplifying the machine control code and overall machine topology signi cantly.

Steadily increasing performance

The performance measures have been very good, with the Edgerton facility processing more pretzels each successive quarter it has been in operation, an increasing productivity output that is approaching double that of any other Dot’s plant.

The project has also fostered other positive results among the participants.

In May 2021 Viking Masek and IAS established a strategic partnership, resulting in IAS changing its name to Viking Masek Robotics & Automation (VMRA). The new entity has the ability to design and build fully automated production and packaging lines from raw product to a shrink wrapped pallet.

In an unrelated, yet highly publicized transaction, The Hershey Company acquired Dot’s for $1.2 billion in December 2021. PW

Smart Packaging Provides a Glimpse of the Ongoing Industrial Revolution

The AIPIA World Congress proves that smart packaging holds great promise for a host of near-universal brand objectives, including traceability, recyclability, consumer engagement, food waste reduction, and better supply chain logistics. Can tech suppliers in this sector band together to create ecosystems that deliver total solutions to brands?

By Matt Reynolds, Chief Editor

Packaging World was in attendance for the rst live AIPIA World Congress since 2019. Given the longer-than-usual three-year interval between installments of a typically annual event (thanks, pandemic), we expected to see some pronounced vaults forward in the technology. We weren’t disappointed.

While the world was mired in the pandemic, creators and suppliers in the active and intelligent packaging space kept pushing the envelope on technologies. This has kept many of them roughly following Moore’s Law, with quality and capabilities improving, and costs dropping. For instance, we’re seeing a shift away from the need for expensive, material-heavy batteries for RFID functions. Williot’s light, battery-free Pixels, for instance, need only ambient energy, propagating in space through radio frequency waves, to power them. Also, the stalwart QR code, which was a basic building block technology of active and intelligent packaging three years ago, emerged in 2022 capable of carrying multiple loads at once in ways it couldn’t before, including consumer engagement, insight gathering for brands, traceability, security for all, and achieving that pleasing GTIN “beep” at a checkout counter (more on page 124).

AIPIA World Congress in Amsterdam was convened in person for the rst time since 2019, and given the long interval since we last visited, the technology and had advanced considerably.

But smart packaging adoption undoubtedly experienced pandemicrelated delays. While the suppliers kept moving the ball down the eld technologically, brands and CPGs had to shift their focus away from R&D and toward more practical realities—like simply keeping production

facilities procuring, producing, packaging, and meeting orders. Brand packagers reading Packaging World know that precious little packaging line space could be spared for R&D or new product testing; you were struggling just to keep up. While brand owners did the hard work of navigating the pandemic, many active and intelligent technologies that seemed to be just on the cusp of scalable adoption in 2019 were shelved for a few years.

Digitization of analog packaging Brand and consumer bene ts

WHAT YOU’LL LEARN

The

But there were some silver linings in the interim that lead AIPIA delegates to believe active and intelligent packaging is primed to come roaring back. For one, many of the underlying supply chain inef ciencies that the pandemic revealed could have been far better managed with active and intelligent packaging. Having navigated their own pandemic supply chains, brands see this now more clearly than ever. Consider all the supply chain ef ciencies afforded by digital printing, digital watermarks, digital twins, and sensors reading those marks. Brands now know they could be following individual packs through the chain, collecting actionable data, and responding to it in real time.

Flip to page 262 for more on active and intelligent packaging as it applies both to supply chains and to consumer experience, embodied in Sealed Air’s Prismiq offering, as reported from PACK EXPO International.

Another result of the pandemic is that consumers became better acquainted with QR codes in bars and restaurants when traditional menus were deemed unhygienic. Apple rst cleared the way by making QR codes readable to the native camera in iPhones in 2017. The pandemic accelerated adoption, and by the Super Bowl in 2022, we saw a QR code dancing enticingly on the TV screen in an unimaginably expensive 30-second commercial spot. No brand or messaging was revealed, just a 2D barcode. Did you scan it? Did one of your friends at the Super Bowl party?

Despite setbacks based on a pandemic pause in R&D, AIPIA Director Andrew Manly says, “We’re getting much more of a feel that there’s a lot more interest from the brand owners now. They’re much more focused on it. Digitization is becoming the key issue.”

Flip to page 26 to read the entire interview with Manly.

Bottom line? Most of the technologies and connected packaging capabilities being discussed at AIPIA are inevitable, and our industry will be a major vector in implementing them. Speaker Anita Etrati of consultancy Accenture posed this question, “What does an industrial revolution feel like?” answering, “Just like this, like this moment, right now; it doesn’t feel momentous until we see it in the rearview mirror.”

What remains to be seen is the relative speed and ease of scaling active, intelligent, connected packaging in the global economy.

Brands Seek ‘Pre-connected’ Solution Among Disparate Providers

A coordination challenge currently vexes many leading-edge suppliers seeking to get brands on board with their smart packaging tech. Most end-to-end active or intelligent packaging solutions require several layers of disparate technologies and capabilities, and they may involve a network of software providers, hardware suppliers, and Application Programming Interfaces (APIs) to accomplish. That means layers of suppliers working together—an ecosystem that isn’t yet fully formed. There is some consolidation occurring in the industry that may alleviate this disconnect over time—for instance the recent sale of EVRYTHNG to Digimarc—but it remains a sore spot for brands. This dynamic was evident in the Active & Intelligent Packaging Challenge. But rst, more on the challenge itself.

Long a xture of this event, the AIPIA Packaging Challenge gives technology suppliers the opportunity to pitch their smart packaging solutions to a major brand owner in a “lightning round” of tailored presentations, each only three minutes.

Challenging these suppliers was a duo of consumer health giants: brand owner Haleon, a new primarily OTC entity holding brands such as Sensodyne, Aquafresh, Advil, Thera u, and Centrum, and brand owner GSK, from whom Haleon was spun off (demerged) in early 2022. At the show, Haleon’s Alex Orchard and GSK’s Anu Gadhiraju viewed product pitches from nearly a dozen active and intelligent solutions providers to see if there were any ts between technology and brand.

It’s worth rst mentioning that Haleon recently made a splash on the smart packaging front, teaming with Microsoft to launch an enhanced version of its Seeing AI app, which it says will advance inclusivity and improve accessibility. This new collaboration aims to help people who are

Recent innovations in smart packaging demonstrated at the AIPIA World Congress include Wiliot’s battery-free IoT pixels (RFID), that power themselves by harvesting ambient radio waves.

Tom Quinten (left) with anti-counterfeiting specialist Ennoventure receives recognition from Alex Orchard with home health brand owner Haleon. Orchard suggests smart packaging providers present entire ‘pre-connected’ ecosystems, rather than disparate, piecemeal parts of a total active or intelligent packaging solution.

blind, have low vision, or have dif culty reading packaging labels due to low literacy. On World Sight Day in October, just before the AIPIA World Congress, Haleon launched its Always Read the Label campaign, hoping consumers will be able to access more detailed labeling information directly from Haleon by scanning the product barcode and using the app. In short, Haleon is no stranger to this space.

In advance of the event, the Haleon/GSK duo instructed technology providers that it was seeking a “trusted, circular, inclusive solution with an advanced UX (user experience).” More plainly, the request was for safety, security, sustainability, accessibility, and consumer engagement features. Ticking all ve boxes would be a stretch for any single smart packaging solution provider, which brings into sharp relief the coordination problem between brand owners and the many disparate packaging tech companies that seek to supply them.

Brand owner Haleon, which judged smart packaging pitches in the Active & Intelligent Packaging Challenge, recently teamed with Microsoft to launch an enhanced version of the software giant’s Seeing AI app to improve accessibility for people with limited sight.

notion of it taking a village [to get smart packaging adoption off the ground], and we talk a lot about ecosystems, but [in the real world], many of the pitches are still happening where everyone has individual solutions. I think it’s very, very powerful if you are pre-connecting as an ecosystem of solution providers and instead come into a pitch with that pre-connected vision and set of solutions that are more integrated, as far as facing the brand owners. Some brand owners do have resources internally, where they can start to sort that out, but many times they don’t. So, it’s much more powerful if we can see your value chain and know who the other players are that are needed to make an integrated proposal. And then for you to bring that pre-connected, integrated proposal to the table. That would be quite powerful in the future.”

Another misstep smart packaging tech suppliers make in pitching to brand owners is getting ahead of themselves. They know their own products so well, and have so deeply thought about their potential, that they are prone to think several steps down the road, pitching a nal solution or “endgame” without describing what it might take to make it happen. Orchard invoked Maslow’s hierarchy of needs as a pyramidshaped model to help tech suppliers approaching a pitch—you need to cover the basics, the structure, and the roadmap, before you promise a complete solution.

“You really need to help us understand what you believe are those foundation stones, the value-add, and [only] then the endgame and the aggregate effect of the topic you’re bringing to the table. We need to see the direction of travel, so we can make the endgame come alive, and then can we build the stepping stones towards that. You must understand that with some of these topics, some of the brand-owning companies are very early stages. We need to understand how to learn to walk before we run, before we y,” Orchard advised.

Food Waste Prevention

Suppliers presented their cases, pitching digital temperature indicators to avoid temperature exclusions, individualized interactive experiences that could boost adherence, reusable packaging systems that are sustainable and engaging, QR-adorned tamper-evident labels for safety, and more. It came down to three winners: Ennoventure (anti-counterfeit solutions), Securikett (cloud platform for non-transferable, paperbased, tamper-evident labels), and AlmaScience (paper- and bio-based electronics), that will continue their conversations with Haleon. Why did the new brand owner select these three companies? The winners had demonstrated the fullest end-to-end solutions, the most complete ecosystems, with clear paths to implementation.

Alex Orchard at Haleon had this to say at the awards soiree after the winners were announced: “Someone this morning brought up the

According to Angela Morgan, PhD, from Atpar, 931 million metric tons of food are wasted per year globally, with 570 million metric tons at the household level and 361 between foodservice and retail. For obvious reasons, food waste is a burden to waste management, and it aggravates food insecurities. About $400 billion is lost to food waste before products even reach the market each year, or about 14% of all food produced. This wasted food is also a lost humanitarian opportunity. According to Morgan, 690 million people are hungry, and 3 billion cannot afford a healthy diet. On the environmental front, “food lost in waste, if it were its own country, would be the third largest source of greenhouse gasses behind China and the United States,” Morgan said.

We can agree that food waste is a problem. What can active and intelligent packaging do to help? She mapped out a representative set of options for AIPIA delegates.

Antimicrobial Active Packaging—One technology that offers an array of solutions to help cut down on food waste is antimicrobial packaging. Aptar’s InvisiShield is a three-phase polymer that uses chlorine dioxide to protect produce from pathogens. The technology is integrated into sealed packaging with “channels in it that will release in a controlled way that chlorine dioxide gas into that headspace of the pack in order to extend the shelf life, reduce food waste, and make the product safer,” Morgan said.

The Antipack from Handary is a commercial lm that uses a coating of nisin to inhibit mold growth on solid food products, like cheeses. Another mold inhibitor from SoFresh uses ethyl pyruvate. “It can either be spray coated inside a bag or extruded, and it inhibits mold in bread,” Morgan said.

The UltraZap XtendaPak from Novipax extends the shelf life of produce by using carbon dioxide. The product is placed inside the package to wick juice away and generate carbon dioxide to inhibit microorganism growth. This product is also focused on produce and comes in the form of a sachet.

Also available from ParxMaterials (formerly ParxPlasics) “is a multilayer structure where in their sealant layer they have a non-leaching metal,” Morgan said. This is used in the poultry space to prevent crosscontamination of bacteria.

its own place in active packaging, while sometimes intermixing with other categories. One example is Copptech, which uses nanoparticles including copper to produce antimicrobial textiles. Another is Danaflex-Nano, which makes a exible pack with a rigid top that uses silicate nanoplates to extend shelf life. In doing so, it’s also reducing the volume of preservatives that must be used.

“It’s lighter weight and fully recyclable, and it can be thermally processed [retorted] and reheated in the microwave, so it is shelf stable,” Morgan said.

The European Union is funding a project to continue advancing the use of nanotechnology in packaging. The three-year NanoPack project aims to develop antimicrobial packaging solutions for perishable foods based on natural nanomaterials. Again, the aim here is to extend shelf life of food to reduce food waste.

Indicators Built Into Packaging—Indicators are a wide-ranging category with several key functions depending on the product, from time temperature indicators (TTIs) to gas sensors. Morgan said RipeSense is an example of a gas sensing indicator. She cited its use with pear packaging, where it “indicated the crispness, when you should actually be consuming that pear for it to be at its optimal crispness.” A newer technology in this space is pH indicators. Using a milk application as an example, Morgan said this technology can indicate lactic acid bacteria production, “and so it will change color from pink to purple when the milk is starting to sour.”

The MonitorMark from 3M is one example in the realm of TTIs. This indicator monitors the product’s exposure to a range of temperatures over set times, with an adhesive backing for application to secondary packaging. Varcode digitizes TTIs with the Smart Tag app. Users can scan a barcode-based temperature tracker using their phone, and track the temperature changes over time via the app.

Edible Coatings—Edible coatings are applied directly to the product using spraying, dipping, or brushing, and “you really wouldn’t know that the coating’s there,” said Morgan. “It’s protecting, but it’s really invisible to the consumer.”

For gas barrier protection, polysaccharides stemming from seaweed or the chitosan layer on insects are an ideal solution, said Morgan. Protein coatings derived from corn, soy, or wheat also make great oxygen barriers, she added. And nally, the hydrophobic nature of lipids makes for an effective moisture barrier. Brands can use a blend of these methods to create an optimal edible coating for speci c products.

Akorn Tech is one example of a protein coating that uses a “corn coating with other plant-based ingredients” to preserve produce, Morgan said. Also on the market is Apeel, which uses the acids from natural peels and stems for produce protection.

Active Packaging with Nanotechnology—Nanotechnology holds

Exhibiting at AIPIA was Mysteria Colorum (MyCol), whose TTI labels feature symbols printed in inks that remain invisible when at room temperature and only appear when outside of either a low or high exclusion temperature. These inks are irreversible, so they continue to indicate that the product was outside of the exclusion temperature range, even when it is back within the preferred temperature parameters. On the low side of the equation (Low Temperature Irreversible Thermochromic Labels), the threshold can be customized from freezing through chill to room temperatures up to 50°C. On the high side (High Temperature Irreversible Thermochromic Labels), the threshold can be customized from 50° to 200°C.

Scavenging Technologies–Oxygen scavenging is an established active packaging category that already has several innovative examples in use. Carlsberg’s ZerO2 cap is a scavenging technology placed in the liner of the beer brewer’s bottle caps that prevents “skunking” in beer. The liner actively absorbs oxygen to prevent beer from spoiling. Fruit Brite by Hazel Technologies uses ethylene in its scavenging, making it ideal for produce that is climacteric, or ripens quickly after harvesting.

SavrPak is a moisture scavenging sachet that prevents soggy food. “That one became really popular during the pandemic because people were ordering a lot of food that was ready to eat, from restaurants,”

Angela Morgan, PhD, of Aptar lays out a wide swath of active and intelligent technologies, from several different categories, that can have a positive impact on global food waste.

said Morgan. Another sachet-style smart packaging addition is the Multisorb oxygen scavenger.

Perhaps one of the rst options ever to appear in this category is a moisture scavenging capability that’s injection molded into the pack itself. This tech has been around for 30 years stemming from Mars/M&M’s desire to remove dissolved moisture from inside packaging. Aptar’s CSP Technologies is an example of a supplier in this space.

Finally, there’s a coating option, more speci cally a dual coating for

oxygen

and moisture, Ageless by Mistubishi

Smart Labels and Inks Avery Dennison’s Freshmarx is a dissolvable label solution targeting foodservice that includes a full suite of back-of-house data management and printing applications, like general TTI functions in its smart label capacity. But then, these labels completely dissolve in the presence of water (when a tray is being washed, for instance), so they leave no residue that could house bacteria or microbes and don’t clog the sinks.

Marley Spoon Meal Kits Guarantee Freshness with Sensors

Marley Spoon is a meal kit subscription service that says it makes it easy to cook delicious meals at home by sending tasty recipes and fresh ingredients directly to your doorstep. Among popular heavyweight competitors like Blue Apron and Hello Fresh, Marley Spoon differentiates itself with celebrity Martha Stewart, who provides recipes and her name to the brand. “With Martha Stewart as your guide, chef-quality cooking is simple,” according to the company website.

But in general, a meal kit company’s freshness promise can be tough since they usually rely on third-party delivery

Europe. “Evigence’s Freshness Management System uses sensors that track time and temperature exposure over the course of the meal kits’ shipping journey, from packing to the customer’s doorstep. [End-consumer] customers scan the sensor upon receipt of the meal kit to confirm freshness, giving confidence that the ingredients inside have been properly refrigerated during transit and are safe to consume. Marley Spoon leverages aggregate freshness data gathered through scans to ensure compliance with their rigorous quality standards and enable continuous improvement in logistics operations.”

Consumers are invited to scan the sensor upon receipt of the meal kit to con rm freshness, giving con dence that the ingredients inside have been properly refrigerated during transit and are safe to consume, all the while feeding valuable supply chain data back to the brand owner.

companies. There’s a data void and blind spot during transit that can leave a brand with little visibility into their products’ freshness when it arrives on doorsteps. There’s always the problem of ingredients suffering temperature abuse in transit. Not to mention, here in the states, this emerging meal kit market is increasingly falling under FDA scrutiny and regulation.

That’s why the company sought help in the freshness assurance department from Evigence Sensors, whose Evigence Freshness Monitoring system integrates sensors and analytics to measure and optimize food’s shelf life.

“Marley Spoon recently rolled out our Freshness Management System to ensure the freshness of meal kit ingredients when they arrive to customers’ homes,” said Evigence’s Danny Hacohen, head of business development,

Program objectives were threefold. First, it aimed to ensure freshness of ingredients upon delivery to consumers’ homes. Next, it sought to enable continuous improvement in logistics operations. By repeating those first two practices, the company expects to achieve its third objective: to increase customer confidence and brand loyalty.

Execution of the plan entailed placing a sensor-laden postcard into the packaging. The brightly colored postcard invites consumers to scan the sensors to confirm freshness for themselves. And who wouldn’t check? Marley Spoon then tracks this data and uses alerts and reporting to correct trouble spots.

The results of the project speak for themselves, with 54% increased confidence in quality and freshness among consumers, 52% improved trust in the brand, and 85% of respondents claiming they’d like to see the program continued. PW

SmartLabel, which comes from industry but is now operated by the Consumer Brands Association, allows consumers in retail settings to scan a QR to access more product information (ingredients, nutrition, recycling pro le, etc.) than could ever t onto a label. There’s also a post-retail, online component, so a consumer doesn’t have to have the pack in hand to use it.

Finally, straddling the on-pack indicator and smart ink categories are colormetric time indicators used on CO2 gas- ush packages. There are many iterations of these stickers that use smart ink to indicate freshness to consumers. This isn’t overall shelf life, rather it’s use life once the consumer starts using it, since “upon opening is actually when it activates,” Morgan said. “And it will have that color change based on the time temperature that it sees. And that can actually be calibrated to the food product itself.”

Smart Packaging Takes Sustainable Turn

Food waste clearly impacts sustainability, and that’s why it has always been a key element of active and intelligent packaging. But in the three years since the last AIPIA World Congress, perhaps the biggest sustainability developments in active and intelligent packaging have come by way of digital product passports (DPP).

Proposed EU regulation, called Ecodesign for Sustainable Products Regulation (ESPR), is driving brands toward the DPP model, where manufacturing and the packaging’s plastic resin information travels with each and every individual product through the supply chain and is easily readable by sensors at a material recovery facility (MRF) for sortation. Europe leads the U.S. in digitization of products for better end-of-life sortation and improved reuse circularity. Reasons for that are varied, but in general, it’s a mix of greater political will behind sustainability, alongside more practical, scarcity-related motivations.

“The basic reason is, of course, to slow climate change, but also, we are lacking in resources, especially in the region of Europe,” said Jan Merckx, sustainability lead, GS1 Netherlands. Circular economies that better recover materials at end-of-life help ll the resource void. “The EU made up this plan and identify the most critical areas they should work on. These are electronics and batteries, textiles, construction, packaging and plastics, and food and water. These are high materialconsumption categories, so that’s where they’re starting.”

About $400 billion is lost to food waste before products even reach the market each year, or about 14% of all food produced.

RFID and NFC Tags—Another category that’s been growing in food waste reduction circles is RFID and NFC tags. Price once was a factor here, but prices are coming down over time, and for more expensive product, the functionality can outweigh the cost.

WaveSafe from Avery Dennison comprises specially designed RFIDs for item-level tagging of chilled and frozen packaged foods, avoiding arcing or excessive heating “that could burn consumers” when being prepared in a microwave.

DipoleRFID, designed for drinks, vegetables, and meat, provides allaround traceability. “If there were to be a pathogen outbreak, they’d be able to quickly recall that product,” Morgan said. “It’s also communicating shelf life and constantly measuring the headspace around the product.”

Finally, there’s the ultra-splashy Ovie Smartware system. This inhome, consumer-aimed smart labeling system “is helping the consumers know what product is going to expire, it might recommend some menus that they shouldn’t be using in order to manage their inventory better and reduce the food waste at the household level,” Morgan said.

After all, when it comes to food waste, she reminded AIPIA World Congress attendees, most of it comes at the household level, not foodservice and retail, which have optimized their operations to avoid it.

Under the packaging subset, called the Packaging & Packaging Waste Regulation (P&PWR), the EU’s goal is that all packaging on the EU market will be reusable or recyclable by 2030. A revision to this proposal, released shortly after AIPIA on Nov. 30 that’s meant to further harmonize regulations among different EU regions, muddied the waters on what would be required, by whom, and by when. But the basic DPP technologies underpinning the future state of a European circular economy remain.

Eventually, DPP will consist of a structured collection of product-related data with a prede ned scope, agreed data ownership, and access rights conveyed through a unique identi er. It’s believed that this will be operated in a decentralized system, linked with the European Dataspace for Smart Circular Applications (EDSCA). The scope of the data will encompass information related to sustainability, circularity, and value retention for reuse, remanufacturing, and recycling.

So, why should Americans care? “What’s happening in Europe is important because Europe is a big market,” says Frits van den Bos, manager innovatie, GS1. “All these regulations, in the end, also apply for everything that’s being imported into Europe, and anything manufactured here.”

“What’s underneath the DPP will be the license to be on the European market in the future,” Merckx adds, comparing the rising tide to a tsunami, slowly gathering strength but eventually becoming overwhelming. “It will start slowly and gradually, product line by product line, product category by category, but it will arrive over the next decade.”

Leaders in the DPP space at the show included Avery Dennison, Kezzler, and Digimarc. Also present, Reath from the U.K. uses DPP for reusable/re llable packaging models for retailers like Marks & Spencer and brands like Bower Collective (see sidebar on page 116).

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Bower Collective Uses Digital Passport System for Reuse/Re

Bower Collective is an e-commerce business that specializes in home care and home cleaning products. Reuse and refill are central to the mission at Bower and the company’s goal to eliminate household plastic waste.

When consumers place an order with Bower, a filled, reusable pouch is mailed to them. Upon receipt, they empty the product into their durable home spray bottle (or other container appropriate to the cleaning product) and then flat pack the pouches and pop them into a prepaid mailer to send them back to Bower to be cleaned and refilled for the next customer.

Flip to page 54 for an exhaustive report on what’s new in the reusable, re llable packaging market, speci cally the re ll-at home model described here.

The system uses the concept of a unique digital passport tracking system, which Bower says it developed in collaboration with Reath. “Each pouch has a unique digital ID, so we know exactly which batch of product is in each pouch at any given moment in time,” says the company.

engagement once they’ve scanned the QR with a smartphone. For Bower, logistics and performance information is gleaned at each scan, both on the filling lines and upon collection as the empty pouches are mailed back.

“We’re able to use the data we’re collecting on the reverse logistics and the filling times to improve the reuse system to be more commercially competitive with single-use product,” Rogers says.

It also helps Bower to track the reuse cycles, so the consumer can scan the QR code and find out how many times the pack has been used, how much plastic waste has been saved, and how much carbon has been saved, too.

“So, they’re giving the packaging a bit of a story and history,” Rogers added at the World Congress. “Plus, they include service information on how a consumer should actually use the product. The QR can also communicate batch, product, and allergen information to the consumer. We have about a 15% engagement rate with reading the QR codes on the packaging.

And all this [consumer-facing information] is hosted on a brand-owned webpage, and no app is needed to access it. They just scan the QR code, and it takes them to the information.”

An interesting sidenote on Bower’s packaging system: When it was first launched, Bower was taking used pouches and washing them, inside and out, for reuse. The company soon realized that this process was neither environmentally nor economically scalable. So, Bower sought to design away the need to wash the pouch interior and still deliver products safely. The company arrived at what it calls the BowerPack, which uses the digital passport system. They’ve designed a one-way valve system in the spout that ensures once a consumer has emptied the product into durable dispensers at home, no air or contaminants can get back into the pouch, eliminating the need to clean the inside of the pouch. The consumer simply screws the cap back on and returns the pouch to Bower for quality control and refill.

Reath co-founder Emily Rogers spoke at the AIPIA World Congress and explained to attendees how this works. Reath first tags the reusable packaging. Tags like NFC, RFID, or traditional barcode are available depending on the package and application, but Bower uses QR codes, which are serialized and digitally printed onto the pouches themselves. The QR codes are scanned on the automated filling line, at speed, to input information on the product batch that has gone into each specific pouch.

The QR code serves two masters. On the consumer side, provenance information and directions foster consumer

“The experience of using the pouch is also improved, as there’s less potential for mess and spillage, and we have a beautiful, digitally printed pack that we can use again and again. At the end of the pouch’s usable life, we aggregate for recycling with our specialist U.K. partner,” Bower says on its website.

The company started with a limited-edition, 750-mL trial run of the BowerPack across two of its product lines— Grapefruit Washing Up Liquid and Lavender Laundry Liquid— with the goal to roll out BowerPack across its entire refill range by the end of 2022. PW

Bower Collective uses an on-pack QR code to provide provenance information and directions to foster consumer engagement once scanned with a smartphone in the home. Meanwhile, for Bower, logistics and performance information is gleaned at each scan, both on the lling lines and upon collection as the empty pouches are mailed back, forming a reusable, re llable, circular system.

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Lightweight, Single-Purpose DPP for Sorting, Recycling

Related directly to the collection phase of recycling, CurvCode demonstrated a sorting technology based on a type of DPP with a lower informational load than the multi-pronged offerings, this time a digital watermark consisting of a curving line of dots. In Europe, a lot of high-quality, potentially food-grade PCR (from PET, polyethylene, or high-density polyethylene streams, among others) ends up being “downcycled” into lowerquality, non-food grade plastic. Or worse yet, it’s frequently incinerated. This is due to sortation practices that intermingle high-quality content with lower quality, reducing the quality of each bale. CurvCode seeks to maximize the amount of high-quality material captured for true food-grade to food-grade plastics recycling. The problem it seeks to solve is that on-pack barcodes, or even the new 2D QR codes, can be obscured to sensors; vision systems nd them dif cult to reliably locate and read. This is especially true when a disposed-of package is compacted or still dirty from its product contents.

“This is the reason why we designed a special watermark, and the watermark is either embossed or printed on the pack. Printing can be almost invisible to the consumer. And also, for the embossing, we do as much as possible to make it as invisible as possible… happily, the European Committee has decided that there is new regulation for 2024. And at least 25% of every package should be recycled content, [so CurvCode will help] to get the amount of plastics needed for this purpose,” said Johan Kerver, chief engineering of cer, FiliGrade Sustainable Watermarks b.v. and CurvCode.

The European Committee says by 2024, every package should contain at least 25% recycled content. Systems like CurvCode aim to help sorters and recovery facilities divert valuable, highquality, potentially food-grade PET, PE, and HDPE back into food packaging applications, instead of downcycling or worse, incineration.

He says this new sorting technology delivers a pro t to every stakeholder in the value chain. There’s no need for extra ink for print purposes—the system allows for the ef cient embedding of sorting-key dots into plastics that are easily read, with limited computer power. Using what he calls a straightforward, single-purpose digital watermark technology, Kerver said all value-chain participants can harvest the added

value coming from fast-growing market demand for recycled materials. The system offers three unique features. First, the code is single-purpose; the effective sorting of plastic and ber-based waste is the sole purpose of CurvCode, whose software does not store sensitive brandowner data. Kerver said it’s also low-cost compared to alternative technologies, plus it’s reliable. The simple and fault-tolerant ICT architecture and the use of standard components (monochrome cameras and LED lighting) requiring minimal PC power ensure reliable operation of CurvCode detection systems in the challenging conditions encountered in waste-handling and sorting facilities.

The business model implies that a brand owner will pay for a license fee, per [metric] ton of plastic, and they may bene t from reduced extended producer responsibility (EPR) commitments. Brand owners and their upstream converter partners only need to embed the codes in molds or in printing les, which Kerver says is easy and low-cost. The sorters and MRFs must only invest in CurvCode reading systems and possibly improved sorting infrastructure to accommodate the system, but the high value of collecting more food-grade PCR should offset that investment.

AR, Consumer Engagement Drive Consumer Insight Feedback Loop

With so many weighty topics like recycling regulations or world hungeraggravating food waste being discussed at the AIPIA World Congress, the consumer engagement piece of smart packaging can sometimes seem lighter fare, more the realm of marketing than of solving global problems. But it’s highly complex in its own right. And the value to brands could be great, because by using Augmented Reality (AR), onpack marketing doesn’t have to be a one-sided conversation. There are

Jan Merckx, sustainability lead, GS1 Netherlands, explains how digitalization, digital twins, and ultimately, a digital product passport, can unlock sustainable packaging streams.

Scan from a Distance, Enlarge Product Information for the Blind

At the show, Zappar debuted a quite different execution of connected packaging alongside the company’s usual AR fare. In June, Zappar unveiled what it calls Zapvision, a new scanning technology. It builds upon a standard QR code to enable scanning from a distance and to deliver relevant and personalized content that adapts to smartphone accessibility settings (for partially sighted or nearly blind people). The scanning tech uses a “D3 QR code” (named D3 for its “dot-dotdash” pattern placed around the corner of a standard QR code). A D3 QR code (patent pending) printed at 15 mm in size on a pack can be detected at over five times the distance (115 cm) of a normal QR code, when scanned through an app featuring Zappar’s free software developement kit (SDK) on a smartphone. The company says brands can easily and affordably implement this D3 QR code on packaging, at scale, without having to create any new code scheme, use up any additional on-pack space, or introduce new printing processes. That means it is easy for brands to implement while also making it easier for partially sighted customers to find their products, either in-store or on the shelf at home, and instantly access the product information they need.

According to Zappar, “There are currently 285 million people in the world with visual impairment and 39 million registered as blind. Two billion people globally wear corrective glasses. For many, the simple task of identifying products on a shelf and accessing relevant product information is a daily challenge. We believe through a simple technology solution we can help make that a problem of the past. Zapvision’s mission is to provide access to relevant product information to everyone as a basic right, regardless of their visual acuity. We want to remove any barriers for brand owners, retailers,

two stakeholders in the AR relationship. You have the consumer, and he or she needs some sort of motivation or incentive to take their phones out of their pockets and scan. The other stakeholder is the business, and they need to extract some commercial value out of it.

Anyone can build a pleasant or informative landing page to take customers to with a scan of an on-pack QR. But that’s a one-way street. Maximizing any investment in this space—connected packaging—should include some form of a consumer insight feedback loop that provides actionable data back to the brand, either on how their product is being consumed or what could be done to improve the product or experience. It should also foster continued interaction and conversation, via drip campaigns, push noti cations, or smart discounting. And all the while, the brand should be gathering more data to better customize the experience to the individual, improve their product, and maximize sales.

“My bold claim is that by 2030 (this is my ctitious number), there’s going to be no such thing as an unconnected pack,” said Martin Stahel, sales director of AR provider Zappar

“I think brands really need to start looking and researching now to understand what it is that a connected pack means for them. They need

Stahel demonstrates Zapvision at

at AIPIA. The system allows a smartphone to read an on-pack QR code at a distance. For a user with sight limitation, more information becomes available on the screen—in large text or with audio—as he or she moves closer to a product on the shelf.

and large corporations to implement this solution on their products, packaging, and signage by providing them with a scalable and cost-effective solution that can benefit the blind and partially sighted community.” PW

to start researching and testing now, so they don’t get left behind on this trend. And a connected pack can mean a whole lot of different things for different people.”

Stahel said he’s passionate about packaging from a marketing sense because it’s an untapped media space for many brands. It sits there in people’s homes, it’s on their kitchen tables, or it’s on their desk at work. But until now, packaging has been an analog proposition in a digital world. Now, it represents an untapped media channel.

“That’s because we as people are all connected,” he said. “And we all own these very powerful devices and have them in our pockets. And unfortunately, the time that we spend connected to these screens is only going up, and love it or loathe it, that smartphone is taking over more and more of our time. But we can harness that for good and deliver value to the consumer—deliver them a service that helps them—but also delivers value back to our brands.”

Don’t just take his word for it. Manolo Arroyo, the global chief marketing of cer of Coca-Cola, said that QR codes are arguably the most unexploited and underleveraged media vehicle that exists out there. He’s rolling out the three-year plan to put QR codes on all Coke’s products. And

his booth

he said even pessimistically, if Coca-Cola only gets a 3% redemption on the 1.9 billion products it creates per day, that really moves the needle. But only, Stahel said, if it can harness the value of that at the other end. Why are these brands on board? Not on a whim. There’s science behind it. Zappar teamed up with a company called Neuro-Insight to test a

couple of hundred people’s subconscious brain responses to AR compared to traditional media, such as print, video, and websites. The results revealed that AR delivered a 95% increase in visual attention compared to TV viewing. AR also delivered a 60% spike in emotional intensity, and because people learn through making emotional connections as well as then learning through doing (including interactive, on screen), it was observed that AR delivered a 70% increase in memory retention.

But to achieve that value, you have to get the consumer to use the technology. A linchpin term Stahel used in describing how brands should deploy AR is “value exchange.”

“More brands are understanding that value exchange,” Stahel said. “What do I need to offer the consumer to get them to pick the phone up and invest their two or three minutes of time in our product? Because, sorry guys, nobody is going to scan just to watch your latest TV ad. We’ve got to give them something more valuable. Something that’s fun, useful, or interesting to them when they’re holding that product. Only then can we give the brand an opportunity to monetize that time.”

Three Things to Do Today to Digitize Your Brand’s Packaging

Anita Etrati, senior manager of consulting and strategy at consultancy Accenture, was giving out gifts well ahead of the holidays at the World Congress in November. She directed attendees toward a free-to-access, 30-page market report titled,“Reinventing packaging: Companies can use packaging—a new contributor to the digital thread—to better engineer and manufacture products.” Accenture and AIPIA collaborated in 2022 to produce and publish the report.

Recognizing that the full report would take some time to digest, Etrati also provided AIPIA attendees with more instant gratification in the form of three quick, actionable steps to drive toward packaging digitization at their brands. This was her advice.

1

Empower the right functions

Provide your product design, engineering, and manufacturing functions with an “innovation mandate” to build digital packaging solutions that not only provide data to consumers about the product, but also pull relevant data from the consumer to improve the quality of the product experience across its lifecycle.

“If you’re not in those departments, connect with them, listen to what they need, help them to break down the silos,” Etrati said.

2Be ready to thread incoming data

Weave a digital thread across functions so that they are ready to share data collected by smart, connected packaging. Establish appropriate governance and collaboration mechanisms to ensure friction-free and responsible distribution of data among functions.

“When you have data in a certain department, how do you communicate it?” she asked. “How does it tie back to other departments, is something like that in place? If not, try to requestion your status quo. It’s okay to question and try to find the right partner in the company to help you to tie it back to the product manufacturer and the manufacturing departments.”

Invest in a flexible and intelligent technology architecture to break data and function silos. The value threaders are already using cloud, AI, and advanced analytics to help functions collaborate and build value with packaging data.

You have to be “thinking from end to end, which creates a feedback loop, which is actually a circle. It’s not just in one direction, it should also come back,” Etrati said. “Look at what kind of technology solutions you have now, a lot of new technologies are available. Start to see how much you rely on a certain technology, and then be open to other technologies that are available.” PW

A real, live interactive experience on a smartphone at the World Congress while Martin Stahel, sales director of augmented reality provider Zappar, presents.

3 Build a technology architecture to start breaking silos

QR Codes’ Next Generation:

GS1 Digital Link

URI

The original barcode is 50 years old and looking forward to retirement. That means something is coming from GS1, the not-for-pro t, international organization developing and maintaining its own standards for barcodes and related identi ers.

number to make sure containers are only exchanged for a deposit once. And at the end of a container’s life, a 2D code can be scanned at material recovery facilities (MRFs) for sorting and proper recycling.

“We also need more information printed on the back in a way that can be automatically read by a machine, without going online to get that extra information,” Archer said. “So within this large list of things we want this QR code to somehow do, consumer engagement is just one item. A new barcode has got to earn its place on the pack, it’s got to do lots of things, not just one thing. Otherwise, you end up with a bag with seven QR codes—on one product in China, we actually counted seven QR codes on one pack.”

That’s where the new standard, GS1 Digital Link URI format for 2D in retail, comes in. It has a few key features. The rst and most important is that it contains the GTIN item, so it scans at register and makes the familiar “beep” noise. Current testing by the University of Memphis shows the 2D barcodes are reading at retail checkout line speeds.

Also important is the consumer interaction piece. “It’s connected to the brand’s own domain name. Remember, some people think QR codes are scary and will take them to the dark web. If your brand name matches the domain name you’re taken to, you’re going to feel more con dent about scanning them,” Archer said. “What that means is, this is done and maintained by the brand, not someone else.”

The QR code is set to replace it, but how can it do everything the exiting barcode does and include more information like serial numbers and expiry dates, be the entry point for consumer interactivity, and importantly, still go “beep” at the checkout thanks to the all-important Global Trade Item Number (GTIN), traditionally housed in the legacy 1D barcode?

Launched in November 2022 at AIPIA was a new standard, called GS1 Digital Link URI format for 2D in retail, that Phil Archer, director, web solutions at GS1, said can do all of the things necessary to earn the real estate it will occupy on your product’s package or label.

So why is the organization that has been promoting the barcode and infusing it into commerce for the last 50 years wanting to get rid of it? Barcodes translate into text or characters, and with some variation by symbology, a traditional linear barcode can hold a certain number of characters, maybe as many as 85 characters. The goal is to replace it with a higher-capacity, 2D code that can accomplish a lot more, serve a lot of different masters, and do so in a lot less space.

It bears repeating that the popular conception of what a QR code does is often limited to the consumer engagement piece, because that’s how we as consumers interact with it. But a 2D code like QR can be used for traceability through the supply chain, or for batch and lot number for inventory control, or to keep data to handle recalls. Serial numbers are important for things like deposit return schemes—you need a serial

It’s important to note here that the new QR standard encodes a single line of text, similar to (but not identical to) a URL, that has a standardized structure, a prede ned order of information. As QR codes only

The GS1 Digital Link URI aims to let a single 2D QR code accomplish the tasks of many.

Phil Archer, director, web solutions at GS1 (lower right) summarizes the rollout of the GS1 Digital Link URI.

German Supermarket METRO Experiments with Dynamic Pricing

METRO, Germany’s largest supermarket, has recently tested dynamic pricing related to expiration dates, and results led it to further implementation.

“When you go to the supermarket and you buy some fresh food, say cheese or ham, and you look at the pack at the front, and the expiry date is tomorrow—what do you do? You put your hand around the back, and you get the one back there that has an expiry date in two-week’s time.

Everyone does that,” Phil Archer said in his presentation on the new GS1 Digital Link 2D URI standard. “What happens to the pack in the front? It goes in the bin [trash], even though it’s perfectly good.”

He pointed to German supermarket chain METRO, which has experimented with dynamic pricing with sustainabilityminded tech provider Wasteless. The program tracks expiry information associated with each serialized product (that could be contained in a 2D barcode) and connects it with price, which decreases as the product gets closer to expiration. And by discounting the items that are approaching their expiry date, METRO incentivizes consumers on price as well as on expiration date. If a consumer wants the full two weeks of inhome shelf life, they will have to pay full price for it.

As products get closer to their expiration date, prices are dropped accordingly, creating an incentive for consumers to purchase near-expiration fresh foods if they intend to consume them soon. German retailer and wholesaler METRO tested the concept with provider Wasteless and is rolling it out over more stores.

emissions. Wasteless’ technology brings optimization to the pricing of perishables, using a proprietary AI-driven markdown engine to set prices automatically.

According to the retailer, while testing this technology, “METRO’s first Food Waste Report documents a 15.3% drop in food waste … between financial years 2017/18 and 2020/21.”

Founded in 2016, Wasteless focuses on reducing greenhouse gas emissions by reducing food waste in retail and wholesale, one of the top-five causes of greenhouse gas

really contain text, this text can be structured in a de ned way, and then a device can recognize that structure and correctly interpret it.

And in a structured line of text, anything can be added to that. “We can add batch numbers, we can add serial numbers, we can add expiry dates, and the structure of that is as precisely de ned as the way we would convey a Wi-Fi con guration, or contact details, or anything else we would encode into a 2D QR. That structure was not made up. Now, you can’t drop in any old URL, it’s not going to work, you have to use that standardized structure.”

The important thing is that by having that information in a de ned structure, it can be extracted without having to go online. And Archer claimed that every major scanner manufacturer in the world, that GS1 is aware of, is building new cameras to recognize the GS1 Digital Link syntax. And software updates help scanners translate DGS Digital Link

METRO announced on its website in May of 2021, “Following extensive testing, Wasteless technology will be seamlessly integrated in wholesale specialist METRO’s point of sale (POS) system. The new pricing system will first go live at selected Makro stores in Poland. A wider rollout of Wasteless’ AI-driven pricing technology is expected throughout METRO’s network of wholesale stores.” PW

barcodes and parse data from those barcodes.

“But we can do better. We can be smart,” Archer added. “We can put a little sort of service in the middle. And then service can respond to speci c requests. What we’re doing is turning that product into an API. So, you can ask for speci c things. Ask a speci c question to get the answer back or get back the data that allows you to present those things to your end user. The standard effectively creates a common API for every identi ed thing.”

Archer hopes that “roundabout 2027,” GS1 can start of cially putting the 1D barcode to pasture. And as a parting piece of wisdom in what’s soon to be a 2D digital barcode world, Archer advised that as the manufacturer of the product containing a QR code, make sure you know exactly what’s in any QR code on your product and make sure you remain in full control. PW

PACK EXPO International 2022 Innovations Report

By PMMI Media Group Editors

Back after four years, PACK EXPO International convened more than 44,000 attendees during its Oct. 23-26 run at Chicago’s McCormick Place, thus surpassing the 2018 event. With 2,200 exhibitors showcasing groundbreaking packaging and processing innovations over 1.2 million net sq ft, PACK EXPO International was the one and only time the entire industry came together last year.

Pharma and Medical Device Innovations

Searching speci cally for PACK EXPO innovations related to pharma and medical devices?

Healthcare Packaging magazine covered it, and you can access it. Visit pwgo.to/7869 to nd our coverage, which will also appear in the next print edition of Healthcare Packaging.

Next up in the PACK EXPO portfolio is EXPO PACK Guadalajara (June 13-15, 2023) followed by PACK EXPO Las Vegas (Sept. 1113, 2023; Las Vegas Convention Center, Las Vegas). Information for the upcoming show can be found at packexpolasvegas.com

“The success of PACK EXPO is a testament to our industry’s continued growth as well as PMMI’s commitment to bringing the industry together to share cutting-edge innovations,” says Jim Pittas, president and CEO, PMMI. “The event showcased countless end-to-end solutions, offering attendees everything they need to compete in a changing marketplace.”

Industry growth translated into buyers coming in signi cant numbers, ready to see the latest packaging materials as well as technology in action. Improving operations, reaching sustainability goals, and checking out new innovations are just a few of the drivers that brought consumer packaged goods (CPG) and life sciences companies to PACK EXPO International. The buzz on the show oor con rmed that exhibitors and attendees from companies of all sizes found a rewarding, and some claim unparalleled, experience at the four-day event.

Answering the need to come together, network and see advances, PACK EXPO International 2022 offered more show features than ever before, bringing value to all market segments.

A record-breaking Packaging and Processing Women’s Leadership Network (PPWLN) breakfast brought together nearly 1,000 professionals to hear Dawn Hudson, former chief marketing of cer at the National Football League and former president and CEO of Pepsi-Cola North America, talk about her experiences in the workforce. The PPWLN event, aimed at advancing the future of women in the packaging and processing industry, was sponsored by: Emerson, ID Technology, Morrison Container Handling Solutions, Plexpack Corp., Septimatech Group Inc., and SMC Corporation of America

Developing the future packaging and processing workforce was a top priority at PACK EXPO International with the largest number of students in attendance in the history of the event. More than 1,500 students attended the show and participated in many opportunities to get them excited about careers in this industry. In addition to the prestigious Future Innovators Robotics Showcase, educational Amazing Packaging Race sponsored by Emerson, and Students

•

• IMA Ilapak

6400 (IMA North America Inc.)

• CueSee Mix/Dual Chambered Device for storage of liquids/powered/lyophilized components (Eurotrol)

• ClipCombo™ (Graphic Packaging International) Visit pwgo.to/7867

PACK the Expo programs, this year six teams faced off in a brand-new machine building PACK Challenge, sponsored by PepsiCo.

With robust education offerings, the focus on developing our industry went beyond students. PACK EXPO International held over 120 education sessions, beginning with the one-day Emerging Brands Summit, making its debut at the show. The education continued throughout the show on various on- oor stages, offering educational sessions such as the Innovation Stage, Processing Innovation Stage, PACK to the Future Stage, The Forum, and Reusable Packaging Learning Center.

Additionally, the PACK EXPO Association Partner Program connected attendees to leading associations from all segments of packaging and processing. This year’s program was the largest in PACK EXPO history with 50 partners.

“We would like to thank PMMI’s Board of Directors, our membership, exhibitors, and all attendees who supported PACK EXPO International and made this show a tremendous success,” says Laura Thompson, VP trade shows, PMMI.

Once again the editors of PMMI Media Group were on the job covering the innovations shown by the exhibitors. Our report begins on the next page, and it’s divided into ve main categories: Machinery, Food Processing & Packaging, Sustainable Packaging, Robotics, and Controls. This report is brought to you by:

Matt Reynolds, Chief Editor, Packaging World

Pat Reynolds, Contributing Editor, Packaging World

Anne Marie Mohan, Senior Editor Packaging World

David Green eld, Director of Content/Editor-in-Chief, Automation World

Stephanie Neil, Editor in Chief, OEM Magazine

Keren Sookne, Director of Editorial Content, Healthcare Packaging

Aaron Hand, Editor-in-Chief, ProFood World

Melissa Griffen, Editor, Contract Manufacturing & Packaging

Casey Flanagan, Editorial Assistant, PMMI Media Group

Joe Derr, Contributing Editor, PMMI Media Group

Michael Costa, Senior Editor, ProFood World

Lilian Robayo Paez, Editor, Mundo PMMI

MACHINERY

Accraply, a BW Packaging company, and the Intelligent Systems team at Barry-Wehmiller have collaborated on a new human machine interface (HMI) for Accraply’s labeling systems that is developed to provide greater insight into labeling operations for increased overall plant productivity.

Designed with ease of operation and training in mind, the SmartLink HMI features video tutorials and on-demand training guides to simplify set up and operation. On-board manuals, drawings, and consumable parts ordering enable the operator to nd information and submit parts orders. Additionally, self-diagnosing software helps educate operators on faults and assists them in troubleshooting.

To improve labeling machine ef ciency, the SmartLink HMI creates preventive maintenance schedules for the operator and maintenance team that display daily, weekly, and monthly tasks. The HMI’s improved analytics dashboards provide information regarding the machine’s availability, performance, and condition to increase operation uptime. The HMI technology has also been designed to accommodate rapid changeovers by storing recipes and providing video changeover guides to assist operators and reduce downtime.

Allowing for greater interface capabilities, the system’s SmartLink interface allows plant management to leverage HMI technology in front of the machine or remotely; remote machine access can be reached through a smart tablet or phone. Accraply also offers machine con guration and a setup audit trail to ensure the product is working correctly as well as remote video assistance from a trained local support team through the customer’s smart device.

just by measuring the bottle. “They don’t need to understand dispense speed or any of that because we understand it, and we write in the code and algorithms to calculate the speeds,” explains BellatRx President and CEO Alan Shuhaibar. “All they need to do is measure the bottle and enter the dimensions.”

A short animation or video also serves as a step-by-step guide in the HMI on how to get the BellatRx labeler up and running. The video is coupled with an LED light strip installed along the length of the machine. When setup is required on a certain assembly, the section of the LED strip in front of that assembly will light up to draw the operator’s attention to that point. The mechanical adjustments include electronic feedback that turns the LED light green when it is in the correct setpoint or red when it is not. On the HMI, the operator cannot progress to the next screen unless all setpoints for that assembly are green.

In the past, the OEM’s expectation was that the operator knew how to set up the machines. But that’s no longer true in many cases. In addition, people expect the same user-friendly interface as an iPhone. “We are trying to take that mindset and put it into the machines. You shouldn’t need a PhD to run a labeler,” Shuhaibar says. a video of the new Notaris labeler in action at the BellatRx PACK EXPO booth at pwgo.to/7782.

Also featuring automated changeover on a labeling machine, thanks to the power of servo technology, was Nita Labeling Systems. VP Sales and Marketing Ken Hubscher showed how quickly and automatically the Nita labeler (3) goes from applying front and back labels on an Fstyle container to applying a full-wrap label on round containers. a PACK EXPO video demonstration at pwgo.to/7783.

Among the Accraply machines currently using the new SmartLink HMI are the Sirius 100 pressure-sensitive labeling system and the Sirius MK6 (1) advanced pharmaceutical-grade labeler.

Elsewhere at PACK EXPO International, BellatRx introduced a new Notaris Plus labeling machine (2) that includes a component that takes the measurements of a bottle. When these are entered into the HMI, a recipe is created automatically that contains all of the conveyors, label dispensing, wrap, and metering wheel speeds necessary. So all of these are automatically set and synchronized without further operator intervention. This gets the operator to 90% of where the setup needs to be

The most notable feature of the EZGUIDE™ system is it does not have any protruding brackets or shafts which could be a major safety hazard. The EZGUIDE™ system does not have any mechanical components which protrude from the sides of the conveyor during adjustment. All the mechanics are done without the need to protrude past the conveyor, keeping everything safe for those walking close by.

Another feature of EZGUIDE™ is it is designed to remain adjustable through curves. That is, the radius of the guides can change as the guide width is increased/decreased in the curve. While there are many traditional guide rail systems which can be made to adjust their width in straight sections, there are very few that can truly be adjustable through a curved portion of conveyor. The reason is because changing the radius of a section is di cult – the guides must bend, and the length of the guide has to increase/ decrease as the radius is changed. The EZGUIDE™ system handles both of those problems with its unique design.

MACHINERY

SUITABLE FOR ECOMMERCE

Weber Packaging Solutions used PACK EXPO International to unveil its latest label printer/applicator, Model 4050, designed with distribution centers and e-commerce operations in mind. Based on a version of a Weber machine created by its engineers in Germany, Model 4050 (4) is engineered to be a modular, variable-height labeling system that is easy to service while using 80% less air than comparable systems.

designed without service parts, Model 4050 is easy to adapt to applications and service, he adds. The only maintenance item—the print engine—can be maintained per the manufacturer’s requirements. Print engines from all leading manufacturers can be used in the Model 4050.

Another advantage for busy distribution centers: the labeler’s clear cover over the pneumatic system makes it easy to see and access for operation, servicing, and cleaning. There are two separate compressed air cycles: one for safety-relevant processes such as moving the tamp, and one for general functions such as label management. Color-coded tubing and LED indicators make it easy to follow the action in busy facilities.

Available in right- or left-hand application models, Model 4050 can be con gured to handle thermal-transfer or direct thermal label applications, Erbach says. Other standard features on the Model 4050 include a 7-in. LCD color touchscreen for easy operation and diagnostics.

E-commerce was also a focus at the PACK EXPO booth of Chicago Tag & Label, where two new labeling solutions for packaging and ecommerce were unveiled (5). Both are part of the Multiplex line of machines, which print and create packing slips and other crucial shipping documents at the same time a shipping label is created, saving valuable time and labor in the process.

Weber’s machine combines modulated vacuum technology with integrated sensors that constantly measure the labeling pressure required and adjust as needed during the labeling operation. Chris Erbach, integrated marketing manager at Weber Packaging Solutions, says this technology should make the 4050 appealing to distribution centers and e-commerce businesses who need variable-height labeling solutions to accurately handle the packages and envelopes coming in sequence down the line.

“For anyone doing shipping address labeling for different sized packages, this model will sense the height of the box, and bring it down to a quarter of an inch and blow the label on from there,” says Erbach. “It’s a sort of a hybrid—not completely air-free label application, but it uses signi cantly less air than what is typical in the industry.”

Two compressed air circuits allow the label to stay on the tamp pad and the thruster to stay in position when an emergency stop occurs on the production line. This eliminates the need to reset the applicator when the emergency is cleared and the line restarts. Because it is a nocontact labeling system, Model 4050 can also handle fragile items and even do product labeling, Erbach says.

In addition to its sensor-based variable-height labeling technology, Model 4050 features variable-stroke operation and increased precision with powered unwind and rewind modules that minimize wear on the printing modules while ensuring precise printing. The 13.75-in. unwind matches the label length and ribbon length for one-to-one media consumption, thereby reducing downtime and eliminating partial changeovers.

Erbach explained to Packaging World at the show how modularity and simplicity are built into the design of the 4050. “We wanted something that was more modular with parts that we could source here in the U.S. to be cost-effective,” says Erbach. Featuring a labeling module

The Multiplex comes in two variations: one is an auto-application system that applies all shipping documents directly to packages as they pass on a conveyor. The second version prints all documents for manual application to individual packages as needed.

“Once applied to the carton, you can peel the tear strips to reveal the packing list that’s covered by the outbound shipping labels,” says Ann Peterson, sales account executive at Chicago Tag & Label. “It could also have a return label that’s already applied to the carton ready for the end user to put back in the mail to be returned to the customer.”

a video of Peterson demonstrating both machines at PACK EXPO International at pwgo.to/7784.

CASE ERECTING AND PACKING

The new Trayfecta X Series case erector (6) was the star of Delkor’s PACK EXPO International booth. Unique is a dual-magazine case blank setup that lets the machine hold up to 500 case blanks at a time. It accepts Delkor’s Cabrio tray/hood Retail Ready Package, stackable club-store style display trays, and standard brown box shippers—all

at speeds to 50 cases/min. Included is Delkor’s patented case-forming technology as well as smart-machine technology to automatically correct for nonconforming corrugated blanks. Finally, the machine can be joined up monobloc-style with Delkor’s robotic loaders or Delkor’s Performance Series case packers.

a video of the machine in action at pwgo.to/7785.

SOMIC Packaging showed off the advantages of retail-ready automation with its 424 W3 wraparound case packer (7) in Lakeside Center. But the company’s message about exibility wasn’t only about using standard functional groups to make it easier to recon gure operations; it also came in the form of a new strategy for servicing U.S. customers.

climate of uncertainty in the shipping world, Fox notes. It also helps with the workload in Germany.

“The volume coming out of North America has been putting additional pressure on our manufacturing in Germany,” Fox says. SOMIC Packaging absorbing commissioning responsibilities should go a long way as local sales continue to grow. “We anticipate that SOMIC Packaging will account for 50% of the volume within the next four years.”

With the wraparound case packer it had on display at PACK EXPO International, SOMIC showed how it has mastered the art of exibility. The 424 series produces up to 25 cases/min in a small footprint. SOMIC is able to con gure its standard machine to meet customer needs, using standard functional groups to quickly achieve packaging needs. “This gives our customers and us the exibility to change for future needs,” Fox says.

This is particularly important in the labor situation that so many companies face these days, Fox notes. “Nobody has any labor anymore,” he says, noting that automation investments are based on the need to get jobs done. “ROI doesn’t even come up in our discussions.”

The 424 W3 wraparound case packer is suited to companies that need automation but don’t have the space.

In the past year, SOMIC Packaging has begun commissioning all its North American machines from its headquarters in Eagan, Minn. Engineering and design of the packaging machines will continue at the SOMIC parent company in Germany, explains Peter Fox, CEO of SOMIC Packaging. Seven German colleagues are staying in the U.S. right now to cross-train employees to make sure that the commissioning is done from Eagan exactly how it was previously done from Germany, Fox adds.

Besides the convenience of commissioning machines for the North American market out of the Minnesota location—saving time and money with a local staff—it takes a lot of the pressure away from the current

A new case packer (8) featuring horizontal loading was being demonstrated at the PACK EXPO International booth of Nuspark. Cartons exit a Nuspark cartoner at speeds to 60 cartons/min and are lined up 12 at a time on a staging plate, so that when the case is full it will hold 120 cartons. All 120 cartons are pushed into the case, which the machine erects from a at blank. Once cartons are inside, aps are closed and the case is transferred laterally so that top and bottom taping can be done. The nished case is then upended onto a discharge roller conveyor for easy transfer to palletizing.

a video of the case packer that was demonstrated at PACK EXPO at pwgo.to/7786.

New at PACK EXPO from Hamrick Packaging Systems was the Model 600D-TS, a tandem servo drop packer (9) that can run two cases per cycle on reshipper cases. “Our 600D-S topped out at about 30 reshippers/min because it could only do a single case per cycle,” says President Jordan Hamrick. “This new tandem servo machine lets us run reshippers at close to 50 per minute.”

MACHINERY

Like plenty of other exhibitors at the show, Hamrick has faced supply chain challenges over the last year or two when it comes to controls components like servo motors and drives and HMI screens. So the 600D-TS at the booth has servos from Mitsubishi and an HMI from Weintek. The 600D-TS features all-servo motion and the ability to align the tandem lug-driven indexing system to run larger formats in singlecase-per-cycle operation.

Hamrick says that the machine on the show oor is headed for Luxco in St. Louis, a contract manufacturer specializing in spirits.

In an effort to provide a complete solution for end-of-line packaging operations, adhesive tape provider Shurtape unveiled at PACK EXPO International its own line of automated case erectors and case sealers (10).

Clean, safe conveying

FlexLink’s high-performance production flow delivers results. Our solutions for the food and dairy industries are safe and modular with a one-week shorter ramp-up compared to the competition and reduced cleaning time by over 25%. The FlexLink offer, including conveying solutions, handling functions and line control, lowers your total cost of deployment, increasing your overall equipment effectiveness by one percent or more.

For more information call FlexLink on +1 610-973-

The Shurtape case erector models ET20U and ET30U are designed to handle 20 and 30 cases/min respectively, and are available in both a tape or a glue version.

The machine includes intuitive Fluid Form Controls and a SCARA robot performing pick and place tasks. A recipe-generating HMI tells the operator the adjustments that need to be made simply by putting in case dimensions. According to the company, the case erectors deliver quick and trouble-free changeovers, consistently square cases, and about 40-50% fewer wear parts than competing machines with less maintenance for maximum operational ef ciencies in end-of-line packaging operations.

Working hand-in-hand with the case erector, the ST20U automated case sealer is able to handle a large variety of case sizes and con gurations with the exibility to dynamically move from large case input to small case input. It also includes the company’s quick-change ShurSeal solution.

FlexLink is part of Coesia, a group of innovation-based industrial solutions companies operating globally headquartered in Bologna, Italy. www.coesia.com

“Our claim to fame over the last few years has been our ShurSeal technology, which is going to retro t right into these pieces of equipment,” says Rob DeVries, Shurtape’s senior vice president of sales.

a video of the machine in action at the Shurtape PACK EXPO booth at pwgo.to/7787.

ent pouches on the same system.

“The side-by-side semi-automatic pouch loader system is a great solution for customers that might be at the second or third tier of their product growth,” Bradley says. “They have a variety of pouches that they need to get out the door every day.”

HIGHSPEED TRAY ERECTING

A recurring theme at PACK EXPO International was the substitution of paper for plastic, and Mpac was among the exhibitors featuring something along these lines. In this case it was lightweight corrugated cookie trays formed from at blanks being proposed as an alternative to polystyrene or polypropylene trays.

Also focused on case packing at PACK EXPO International was Yeaman Machine Technologies. The Yeaman Top Load Case Packer (11), a newly designed product offering released in August 2022, can run up to 50 cases/min and works with a variety of regular slotted containers and other standard packages, says Chris Bradley, Yeaman director of sales.

The machine features case or carton erecting, a robotic infeed application, and high-speed intermittent or continuous motion. It utilizes Yeaman’s carousel style conveyor con gured to hold cases square through all operations of the machine.

“So we’re able to take products in continuous ow, erect the case, hold the case, pick and place the customer’s product and drop it in, either through robotics or mechanics,” Bradley says. The system can also be tted with a glue or tape sealer, and is capable of primary, secondary, and e-commerce packaging, including sift-proof seals.

The top-load setup is ideal for products that “might be a little bit more gentle, open top, and to be able to stack twos, fours, sixes, and eights and keep up with speed,” Bradley says. The model at the show demonstrated a baking application as an example.

Elsewhere at the Yeaman booth, the RIV Manufacturing-owned OEM showcased a semi-automatic pouch ller (12). It can be operated by a single laborer and maintain a lling rate of about 26 pouches/min, according to Bradley.

The ller can be integrated with any kind of feed system, including conveyor infeed, load cells, auger, and scale systems. Because the machine has dual lling heads, customer brands can ll a variety of differ-

Well established as a maker of tray and carton erecting machines, Mpac showed a carton erector (13) notable for at least two reasons. First, though its footprint is just 1.2 x 1 m (3.94 x 3.28 ft), it’s capable of erecting corrugated trays 50- to 55-mm (1.97- to 2.16-in.) deep from at blanks at 200/min. And second, the F- ute corrugated trays have a grease-resistant property that makes them suitable for such things as cookies, for example, without making them unsuitable for recycling in the regular paper recycle stream.

Partnering with Mpac on the packaging material side of this development was PilloPak, a producer of corrugated board specializing in lightweight corrugated. Also a distinguishing characteristic of PilloPak is that about 85% of its applications are in the direct food-contact category.

The grease-resistant properties of the trays is not a function of a coating. PilloPak purchases grease-resistant paper from several outside suppliers to make the paper used on the Mpac machine. While the inner and outter liner materials are virgin ber, some of the corrugated uting can be recycled content. So in the end up to 50% of the structure is in fact recycled content, says PilloPak managing director Jan Tuininga. He also con rms that 100% of the tray is compatible with the conventional paper recycling stream.

When asked if the corrugator on which the board

MACHINERY

is made is customized or special in any way, Tuininga says not really, though he does add this. “The equipment becomes, in effect, highly specialized by way of our internal expertise. Is it rocket science? No. But when it comes to converting lightweight papers like these, that’s a real specialty. Most corrugators are dealing with paper no lighter than 70 grams per square meter. We operate routinely in the range of 30 grams per square meter.”

Tuininga says that his rm has been providing lightweight corrugated cookie trays for more than a decade. But he believes that the development of Mpac’s machine, with its compact footprint and 200 cartons/min speed, opens the market for a lot of high-volume producers who previously might have wanted an alternative to plastic but needed higher output than what was previously available.

As for cost, Tuininga acknowledges that the lightweight corrugated tray will likely come with an upcharge. But as brand owners look for ways to comply with social and governmental forces increasingly unhappy about the amount of one-way plastic in use, he believes a solid business argument can be made in favor of the corrugated trays. a video of the Mpac machine operating at PACK EXPO at pwgo.to/7788.

MARKING AND CODING

A drawback to traditional CO2 laser printers has been that generally it isn’t practical to print on metal, or on applications with highly re ective surfaces. That renders most foils, foil backing in blister packs, and aluminum cans out of traditional laser printing’s range. But that’s where ber laser printers shine. Markem-Imaje debuted at PACK EXPO International a new compact and high-performance 20-W ber laser that delivers high-quality permanent coding on high-density and reective substrates. The SmartLase F250 (14) is the rst new product launched after Markem-Imaje’s acquisition of laser coding and marking solutions specialist Solaris Laser

the requirement for ink. The system delivers environmentally friendly chemical-free production that the company says helps businesses meet sustainability compliance goals.

The compact and intelligent SmartLase F250 is suitable for businesses seeking best-in-class code quality at high speeds where space is at a premium. Built for even the most challenging environments, the SmartLase F250’s controller, printhead, and touchscreen user interface come with at least IP55 ingress protection level to provide long and reliable operation in harsh, dusty, and humid conditions.

The SmartLase F250 comes Industry 4.0-ready with an array of industrial interfaces that enable its safe and seamless integration to complex plant automation and manufacturing execution systems. Once integrated, an intuitive user interface delivers an increase of up to 20% in operating ef ciency.

“The SmartLase F250 combines speed and ef ciency with simplicity, safety, and sustainability,” says Alex Koudriashov, laser product marketing manager at Markem-Imaje. “The F250 is a printer designed with the future in mind. Fewer line stoppages and the fact it uses no ink can radically reduce OPEX, while the elimination of chemical components makes it ideal for companies who are looking to reduce their impact on the planet.”

the SmartLase F250 in action at pwgo.to/7789.

Higher resolutions at longer throw distances make up the dualpronged push for many brands seeking to improve coding and marking operations. That’s why Bell-Mark used PACK EXPO International to demonstrate its InteliJet LP printer (15), featuring thermal inkjet (TIJ) 4.0 printheads. To meet current demand, the system provides an increased print resolution up to 1,200 DPI and can reach speeds up to 2400 fpm. The throw distance of the TIJ 4.0 printheads has also been increased, reaching up to 7 mm. The print heads are 22 mm (7/8 in.) wide and can be stitched together for a total of four stitched printheads, all controlled by a single user interface.

“The SmartLase F250 is a unique ber laser serving the beverage, pharmaceutical, and confectionery industry,” Mark Boska, director of sales, North America, at Markem-Imaje told PW. “It prints on aluminum products, metal foil products, blister packs, and other lms.”

Regarding the foil-backed blister packs in particular that are common to pharma and confectionery, Boska mentioned one particularly interesting tidbit. The system can print through the thermoformed plastic portion of a blister, onto the foil backing underneath. That means the mark can be placed on the inside portion of the lidding, visible through transparent plastic, after the lidding has been af xed.

According to Markem-Imaje, the reliable SmartLase F250 reduces operational expenses by reducing line stoppages, and by eliminating

The advanced user interface is displayed on a 7-in. color touch-screen HMI. The interface enables users to monitor a wide array of operating conditions and has a built-in label creation software for creating and managing labels. Users can also import labels via an ethernet connection or USB ash drive.

Bell-Mark’s InteliJet LP printer also features a new, integrated, bulk ink delivery system, utilizing two hot swappable 775-mL ink supplies. As one ink supply empties, the ink is fed automatically from the other supply allowing continuous production and uptime. This eliminates the downtime caused by changing ink cartridges, such as the ones needed on TIJ 2.5 setups. The print controller, which houses the dual bulk ink supplies, connects to each printhead with a 3-m umbilical, supplying a constant ow of ink from the bulk in reservoirs. The print controller connects all other peripherals, such as an encoder, sensor, I/O, ethernet, and the touch-screen HMI.

Innovation Through Integration

nVenia, through our legacy brands, has a long history of quality, durability and service. Whether you need primary, secondary, or end-of-line packaging equipment, nVenia will provide innovative integrated solutions.

ARPAC HAMEROHLSON FISCHBEIN

MACHINERY

Diagraph’s ResMark 5000 has 2-in. Mark 2 and 4-in. Mark 4 print heads for high-resolution coding and printing on end-of-line packaging applications. The printer serves the food, beverage, building, pharmaceutical, personal care, cosmetics, automotive, and industrial industries.

“We’ve also introduced a new feature called recirculation that allows you to cap the front end of the print system, prime the system to remove all air, and be up in less than 15 minutes on new installs or replacement installs,” Poulson says.

ResMark 5000 can be used with Diagraph’s NEXT software platform, including NEXTCreate which enables manufacturers to create and design messages on demand and send messages to print remotely. The NEXTControl platform provides exibility to select messages and even con gure print heads on any production line.

a video of this advanced coding technology at pwgo.to/7790.

Introduced at the PACK EXPO International booth of Squid Ink was an innovative combination (17) of capabilities: the CoPilot Max Turbo high-resolution printing system integrated with the VCTS (Vertical Case Transport System) from Squid Ink sister company Eastey. Flat corrugated cases blanks are transported from a magazine through the CoPilot Max for printing and then collected in a collection hopper.

The ResMark 5000 (16) was designed for sharp high-resolution prints with forgiving throw distances on secondary packaging and cases. The piezo print engine technology in the machine enables manufacturers to operate the printer 24/7, including in harsh industrial environments. The ResMark 5000 is a simple, exible, reliable and ef cient inkjet coder at a lower cost of ownership over the life of the system, says the company.

Features of the ResMark 5000 include its patented quick-disconnect print head that can be brought online quicker to reduce production line disturbances and repairs while minimizing downtime. “The quickdisconnect coupler allows the head of the print system to come off and be quickly replaced within ve minutes from a print engine already on the shelf. It also allows the system to print in a slanted fashion for incline conveyor systems. If you take the system and rotate to horizontal you can print on web printing,” says Michael Poulson, strategic marketing director, Diagraph.

Because the system is independent of an HMI, it offers the ability to continue printing until a message change is required on a production line. Wireless connectivity of the ResMark 5000 is a standard feature of the print head. ResMark 5000 can be easily installed and allows a single production line to be daisy chained with up to eight Mark 2 and/or Mark 4 print heads. The streamlined design of the ResMark 5000 requires a minimal footprint on the production line.

“The other feature we are introducing on the new Resmark is a full operating PC system using beaglebone board in the back, making it simple to operate, to communicate, and to maintain,” says Poulson. “Also, in a part of this system, we went with a septum-based interface for the ink system. Now the ink is plug-and-play. The ink system is also chipped so we can report ink levels and diagnostics of ink ow, and we can also read that information for preventative maintenance measures.”

Diagraph ink plug-and-play is called ScanMark ink. The ScanMark ink cartridge for ResMark 5000 features a clean septum system that eliminates the dripping of ink when a bottle is removed from the print head and protects the print head from collecting debris when not in use. Smart chip technology built into the ScanMark ink bottles monitors ink status, usage, and compatibility.

“This is a perfect system for printing the adjacent sides or all four sides of cases right in the customer plant,” said Jay Sinclair, director of sales eastern region at Engage Technologies/Squid Ink Manufacturing. “The hopper holds up to 80 cases, and we can do up to 60 cases/min. This lets customers buy blank corrugated cases and, instead of applying labels to them, they can customize the printing and do on-demand case printing with production runs on the y.”

The CoPilot Max Turbo printing system is designed to print top quality characters on porous or nonporous surfaces. For applications that require immediate dry times on nonporous surfaces, the printer also is able to run UV LED curable inks. With up to 2.8 in. of print height per printhead and the ability to run up to two printheads from one controller, the CoPilot Max Turbo offers a versatile yet cost effective solution for coding and marking. And with Squid Ink’s unique active ink system, users can tilt or rotate the printhead in any direction without making height adjustments to the ink supply. The system prints high-resolution characters, razor-sharp text, scannable bar codes, or logos at up to 360 dpi.

a PACK EXPO video of the printing and transport system in action at pwgo.to/7791.

NEXTGEN CIJ

When it comes to inputting variable data on thermal inkjet (TIJ) equipment, human error—or good old fat- nger syndrome—has always been a big problem. A next-generation, large-character TIJ system

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(18) from Domino Amjet, launched at PACK EXPO International, aims to eliminate that human error. It does so by using barcode scanning instead of manual input for message selection, and by adding postprint accuracy validation, which allows operators to adjust the printed content while limiting error.

back-seal assembly is stored by position per recipe so that you don’t have to make an adjustment, depending on what forming tube size you put in the machine,” he explains. Another is that the machine can run resistance sealing jaws for laminated materials or impulse sealing jaws for polyethylene, he adds.

At the show, Jack McMahon, large character ink jet business development manager at Domino Amjet, Inc., demonstrated the equipment.

“We’re at one of our automation stations where we’re barcode selecting the message, the message goes to the controller, which is printing the box, and then we have a scanner at the end with a vision system that validates the information is accurate,” he said. “That makes this a turnkey solution to make sure you’re printing the right information on the box or carton.”

According to the company, this new Gx350i is great for fast-paced production and track-and-trace applications since it’s easy to operate and easy to integrate for clean, clear codes. The innovative thermal inkjet printer is especially suitable for multi-print head operation, fast data transfer, and challenging controller (IP64 rated) environments. Whether used for healthcare, pharmaceutical, beverage, food, or another CPG vertical, the Gx350i is ideal for multi-print head applications, the company says.

Domino Amjet says its product engineers built the 350i with customer needs in mind. Thanks to exible mounting positions and small print heads, the Gx Series industrial coder will integrate into a line quickly and easily to limit downtime. Plus, with a large, intuitive 10-in. touchscreen interface, the printer will make it easy to have staff trained for error-free operation in no time, says the company. Still in use, too, is the tried-and-true inkjet technology that users have come to appreciate. In addition, the Gx350i is fully compatible with Industry 4.0 standards using the Domino Cloud centralized interface. The Domino Cloud allows for fast, error-free remote capability, providing the data and tools to ensure better packaging and processing systems management. the printing system in action at pwgo.to/7792.

ADVANCES IN F/F/S TECHNOLOGY

The CM Verus (19), new from BW Flexible Systems, a BW Packaging company, is a continuous motion, servo-driven vf/f/s packaging machine designed speci cally to meet the hygienic and sanitary requirements of wet environments. The easy-to-clean machine features a closed-module design and is IP65 rated for washdown.

According to Brian Harrison, sales executive for BW Flexible Systems, the CM Verus is notable in that it offers a number of features not available on some other continuous-motion machines. “One is that the

The servo-driven machine uses an Allen-Bradley CompactLogix PLC control system with an AB Kinetix 5500 servo control system, along with an AB 9-in. PanelView Plus color touchscreen HMI. “It’s all Allen-Bradley,” says Harrison. “A servo motor runs the back seal, and the open and close and vertical access of the XY format jaw are both done with servos. In addition, the CM Verus has one servo motor for each full belt. In the back of the machine, we’re using an AC motor to drive the lm through the machine. In the forming tube section, we’re using vacuum pull belts that combine friction and vacuum to pull the lm through the machine.”

Quick changeover between different packaging formats, product SKUs, or materials is enabled through the user-friendly HMI touchscreen. The CM Verus can accommodate a variety of materials, including more sustainable options such as multilayer polyethylene and paper, with a maximum at bag width of 400 mm and no bag-length limit. The machine can be integrated with a variety of printers, labelers, and other OEM devices, including any common feeding systems, such as augers, pumps, and scales.

a related video at pwgo.to/7793.

Triangle Package Machinery, now celebrating its 100th anniversary by the way, introduced its next-generation Delta Series vf/f/s machine (20). The Delta, which delivers zipper packaging for protein, produce, or frozen food products, allows bulky foods to be easily packaged because the bags are held fully open as food is inserted. This fully open mouth of the package also makes for easy access by consumers to the contents inside. And that can include bulky items such as large chicken parts, fresh produce like baby carrots, or even products such as sugar. Consumers can conveniently pour products out of the bag or stick their hand in to access the product or use a scoop inside the bag.

With a rated speed of about 70 packs/min, the machine has quick-change jaws that bring a great deal of versatility where product variety is concerned. Plus the latest enhancements to the platform include a rotatable jaw. This permits the production of three-side-seal packages as well as the ability to utilize zipper tape. For processors or contract packagers that need to change package styles frequently,

Single Source Supplier of

MACHINERY

the quick-change sealing jaws and rotatable jaw carriage allow conversion from a three-side sealed package to a pillow style in less than 10 minutes. And further improving quick and easy changeover is an optional centerlining system that allows for fast, color-coded adjustments.

As with all baggers from Triangle, the Delta was designed with the sanitary needs of food processors in mind. That means sanitary welds and washdown-rated electronics that make sanitation simple. Additional standard features include a pivoting control box for full machine access and a quick-change 16-sided forming tube. a related video at pwgo.to/7794.

WeighPack Systems launched its newest vf/f/s machine for highspeed applications, the VF 1200 continuous motion bagger (21). Debuted at PACK EXPO International, this bagging machine can produce up to 150 bags/min in varying sizes up to 16 ins. in length. “Our focus is to consistently deliver to our customers the products they want and need. What they have asked for is a high performance, high speed vertical bagger that delivers the best ROI. We feel strongly that we have delivered that,” says Nicholas Taraborelli, Vice president at Paxiom Group, of which WeighPack Systems is a member.

According to the company, the VF 1200 can handle multiple package formats and produces a wide range of package sizes providing exibility for both retail and club size packaging for industries ranging from snack foods and confectionery to frozen foods and baked goods.

This continuous motion bagger features vertical sealing bars that are continuously in motion, so the lm does not need to stop to receive its vertical seal. This provides an advantage over vf/f/s machines with intermittent motion seal bars which only open and close in full sequence, resulting in lower production rates.

Engineered with an open-frame design for easy operator access, the VF 1200 features stainless steel construction, vacuum pull belts, second lm roll support, lm splice table, Omron motion controller and servos, a 15-in. color touchscreen and toolless removable vertical seal bar, horizontal jaws and forming shoulder.

Options available include full sanitary washdown, bag gusset attachment, integrated printer, hole punch, and more.

the vf/f/s in action at pwgo.to/7795.

cient

“There’s three different types of llers for three different types of products, and they have their own unique characteristics,” says Kreissler. “This is perfect for soup mixes or other products that have multiple ingredients, like salad mixes or overnight breakfast oats. The middle ller is for dried fruits, and the third ller is an auger ller, so it’s a full-line solution—you make the pouches, ll them, and seal them.”

Kreissler adds that depending on customer needs, the Pouchmaster can handle bags from 2 in. x 2 in., up to 5.75 in. x 9.5 in. tall. An even larger version of the Pouchmaster currently used by a pretzel manufacturer can handle bigger bags.

Tight-pack Tech

Highlighted at the Harpak-Ulma booth was “tight-pack” technology (23) for vertical form/fill/seal machines. On a three-side-seal pouch, for example, air is pressed out of the package just ahead of sealing. This results in much tighter finished packages, which in turn means more packs per corrugated shipper. PW a related video at pwgo.to/7796.

HMC Products showcased its Pouchmaster horizontal f/f/s bagger (22) at PACK EXPO International. The Pouchmaster comes in four con gurations depending on a processor’s needs, and its high-speed capabilities can bag up to 100ppm. Dave Kreissler, president at HMC products, says the Pouchmaster is an ef

way for processors to utilize space in a facility with its comprehensive end-to-end line solution.

THE LIGHTLINE CARTONPACKER

NO MORE REASON TO PUT DECISIONS ON ICE.

The lightline machines from Schubert can be delivered quickly and are exceptionally attractive in terms of price . With the preconfi gured machines, customers can adapt more fl exibly to market trends and signifi cantly shorten their time-to-market.

The LIGHTLINE CARTONPACKER consists of a single compact machine frame, and packs boxes, cans, bags or bottles into cartons and trays with or without a lid, wrap-around cartons and RSC cartons. It offers an affordable and space-saving possibility to automate packaging processes with the most effi cient technology on the market while ensuring the highest availability and packaging quality.

The world’s leading FMCG and private label manufacturers rely on Schubert. www.schubert.group

WHAT WOULD YOU LIKE TO PACK?

WHAT TYPE OF CARTON SHOULD IT BE?

MACHINERY

CARTONER WITH SURGE SPEEDS

R.A Jones used PACK EXPO International to introduce a cartoner (24) offering surge speeds to 345 cartons/min. When it comes to cartoning beverage cans and bottles, the typical limit tends to be in the 300 cartons/min range. But when customer feedback made it clear that higher surge speeds would be a big help, the machinery builders at RA Jones, part of the Coesia Group, responded by developing the Meridian XR MPS-300, a cartoner that incorporates a Speed-up Kit designed speci cally to meet this need.

machine, coming in Q1 of 2023.

The conveying option (currently in production) allows two or more operators to work on opposite sides of the conveyor feeding into the machine, and it can be extended to t customer needs.

A highlight of the ADCO booth was the introduction of the SPI Smart Pitch Indexer. This system is designed to sit ahead of an Adco cartoner. It consists of ve belts on a Dorner conveyor each independently controlled in such a way that items to be cartoned are optimally spaced when they reach the bucket infeed of the cartoner. Keyence laser sensors are used to detect product location and send that data to a Rockwell PLC, which in turn tells the Rockwell servo motors driving each conveyor module to accelerate or decelerate to adjust the product position for the smoothest possible transfer into the infeed bucket.

“We worked with Dorner on the conveyor modules to develop this innovative cantilevered sanitary design,” says Colin Warnes, director of sales engineering. “It’s completely wide open underneath the conveyor so that any excess product can drop through to the oor without collecting on any hard-to-clean frame panels. Also, the drive cabinet is cut away to allow for easy debris and water drainage.”

a video of the Smart Pitch Indexer in action at pwgo.to/7797.

ALLELECTRIC PALLETIZER

“It was largely a matter of stepping back and looking at some of the proven technology we have in other machines to see how we could address this need,” says Rich Clifton, beverage and robotics portfolio manager. “Our Orbi-Track technology seemed like the right t. We knew it was proven and robust. We just had to nd a way to adapt it to the Meridian XR.”

The machine on display at PACK EXPO has a nominal speed of 300 cartons/min but can accommodate 345 cartons/min when line conditions call for it. “What it means on the plant oor is that our customers are now able to run their upstream llers more ef ciently because they can empty their accumulation tables at a faster rate than what is typically seen in the industry,” says Clifton. “It’s not like they’re going to run at surge speed all day long, but if they can do it for 25 minutes or so as many times as they need to in the course of the day, that helps a lot.”

Also making cartoning news at PACK EXPO International was Codi Manufacturing and its semi-automatic Codi Cartonizer (25). The machine is ideal for startup and smaller beverage companies (beer, seltzers, cannabis beverages, soft drinks, and more) where operators load pre lled cartons onto the machine, and the carton is indexed through the onboard glue system to the press plate.

The Cartonizer can run all standard beverage can packs—4, 6, and 12 on the regular machine, and 24 on a larger Cartonizer—and can load variety packs of ine without using inline production equipment.

The Cartonizer features a dual-nozzle programmable glue system that places adhesive on leading vertical edge, lower ap, and trailing vertical edge in a continuous stitch pattern. The machine can be expanded with infeed servo-controlled conveying or a fully automated

The new Maximus mid-speed case palletizer (26) from BW Integrated Systems, a BW Packaging company, shown for the rst time at PACK EXPO International, has been engineered to meet changing market needs for a smaller-footprint, more exible high-level palletizer. Maximus utilizes layer forming technology and features a small footprint with an interactive operator interface that allows for better collection of information in a more user-friendly interface. Maximus primarily serves the food, household, chemical, personal care, and speci c beverage industries, but it can serve many other markets in the mid-speed palletizing arena as well.

According to Earl Wohlrab, director, product strategy and innovation for BW Integrated Systems, the palletizer is suited to meet changing needs for smaller case sizes—what in the past would have

typically been considered a primary carton. “We’re seeing footprints that are down in the four- or ve-inch range, something we would have typically shied away from in the past for a case palletizer,” he says. “For example, the explosion of the pet food market in the last couple of years has given rise to trays of can sizes that can be ve ounces. That whole tray, with the can, is only about an inch-and-a-half tall. We’ve done some things with this palletizer to allow for special handling of these types of cases.”

Wohlrab also shares that the palletizer is 100% electric. “It’s probably the rst 100% electric machine, including the options that we’ve added,” he says. “In the past, some companies have said that their machines were all electric, but they still needed air for case stops or other functions. We don’t have that now. We use electric actuation for everything.”

Among the advantages of an all-electric system, he adds, is that it eliminates the inef ciency of air, resulting from leaks in the compressed air system. In addition, with compressed air, the system has to be running constantly in order to be ready to actuate. With an all-electric system, energy is used on-demand. “It’s idle until you need it,” he says.

To address today’s shortage of equipment operators, the Maximus has also been designed for user-friendliness, with pattern-forming software incorporated into the machine and a new vision-guided error recovery system that directs operators directly to the source of a fault via images of componentry. “So we don’t have to bring operators up to speed as quickly with that sort of inside knowledge,” Wohlrab says. “For the longest time, operators would just get an error code, and they had to gure out exactly where the problem was. Now we’re visually guiding them.”

For the Maximus, BW Integrated Systems has adopted a quick vertical start-up philosophy whereby the machine splits for shipment to get through most doorways quickly. Once on the production oor, BW sets the top frame back onto the base frame with a bolt-together construction and quick-disconnect controls.

lower-speed applications in the smallest of spaces.

“This is a good t for really small companies because it folds up and can be tucked away,” says Jake Kolakowski, chief customer of cer for Ska Fab. Both the rotary infeed table and the automated sweep can be folded and locked down for storage after canning runs. This reduces the footprint of the already small machine to about half its full size, which is much needed in many small craft brew facilities, Kolakowski notes. “These places are so packed in, they don’t have a lot of space to work with,” he says.

Ska Fab also showcased the fruits of its acquisition early this year of GR-X Manufacturing, which specializes in depalletizing and palletizing equipment systems for consumer products and food and beverage industries. Though both companies play rmly in the palletizing/ depalletizing space, there is very little overlap in their market segments.

With the acquisition of GR-X, Ska Fab has expanded its capabilities into nearly all verticals of the packaging market, including a wider range of industries, container types, and line speeds. Ska Fabricating, which has its roots in the craft beer segment, has been present primarily in beverage cans. While GR-X has some machines for cans, the focus there has been on plastic, glass, aerosol, and other types of containers.

Merging the two brands should open new markets for Ska and should also help to provide food plants with a higher level of automation, Kolakowski says, providing solutions for salsa jars, canned goods, and other formats in the food and beverage industry.

In its booth in Lakeside Center, Ska Fab showed GR-X’s Full Height Automatic (FHA) 3000 Depalletizer, which supports exible con gurations with its multiple discharge, decline, and pallet loading conveyor options. The FHA 3000 can unload a wide range of container types, including plastic containers, aluminum cans, and berboard tubes, with a lift capacity up to 1,000 lb.

GOING MOBILE

Mobile robotic palletizing continued to be a visible trend at this year’s PACK EXPO International. One of the many suppliers displaying mobile palletizing innovations at the show was SourceLink Solutions, whose SL Series (28) combines the payload capability of a standard, xed robotic palletizing cell with the cost savings of a mobile platform—all in a highly compact, foldable unit. It solves multiple problems at the same time, says Brian Stock, president of SourceLink Solutions.

Equipment for depalletizing also made a splash at PACK EXPO International, especially at Ska Fabricating. Though the U.S. has standardized on mainly one pallet size, this is not the case in Europe, where manufacturers are dealing with a much broader range of pallets. With this in mind, Ska introduced an international con guration of its Microbus depalletizer (27)—now able to handle six of the world’s common pallet sizes.

Like the original Microbus launched earlier in 2022 in the U.S. and Canada, the International Microbus, which made its debut at PACK EXPO International, is a semi-automatic empty-can depalletizer that features a manual hand crank to raise the pallet carriage and an automatic belt sweep that advances cans onto a rotary table prior to rinsing and lling. Capable of speeds to 30 CPM, the portable depalletizer is optimized for

“With labor constraints now, the days of paying someone $8 an hour to stack boxes are over, so the need for palletizing is there,” says Stock. “But many of our customers in food manufacturing, contract packaging, and others have older facilities with little space.”

The SL Series solves this problem with its truly mobile frame design that allows the palletizers to be easily transported throughout even the narrowest aisles of a facility. When its mobile frame doors are folded in and locked into place, an SL palletizer can be moved by a single operator with just a pallet jack through an opening as narrow as 4 ft. Af-

MACHINERY

ter reopening the panels and powering it up at another station, the SL Series units can be palletizing loads in another section of the plant in as little as 10 minutes.

The size of the mini palletizer also allows for quick installation, offering further time and cost savings for end users. “We can roll this into a customer’s plant and be stacking boxes in 30 minutes, without having to send a team of installers out who spend a week anchoring equip-

ment into concrete, building safety fencing, and running a bunch of wires,” says Stock.

The oor-level SL series consists of two, 6-axis models that can build loads at rates to 20 cases/min—depending on the case size and pallet pattern—and as high as 80 in. While the SL25 industrial robot lifts payloads of up to 25 kg, its collaborative robot counterpart in the series, the SL20, handles maximum payloads of 20 kg.

At the show, Stock showed several features on the SL25 that were designed to keep workers safe around its open format palletizing cell. The SL25’s safety guard has two area scanners—one serving as a light curtain and another scanner that eliminates jagged stops with a slow, controlled stop akin to what a collaborative robot would do should a worker break the barrier. Inside the cell, three sensors per side use radar-based inspectors that ignore inert objects (i.e., cases) while preventing any humans who enter the zone from inadvertently starting the robot.

The SL Series comes standard with a 24V zone infeed conveyor, and an optional extended case-infeed conveyor and case-turning devices available. SourceLink can also install the unit with an optional dualinfeed conveyor to allow for two SKUs to be palletized at a time. SourceLink offers other options on the SL Series, including special end-of-arm tooling and custom programming for slip sheet application.

Stock says the SL Series is designed as a highly versatile palletizing system that can be used across any market with a palletizing need, ranging from palletizing cases with bags of chips or heavy aluminum cans to palletizing pails of chemicals.

THE EXPANDING WORLD OF INSPECTION

Wipotec used PACK EXPO International to showcase its new Traceable Quality System with Modular Design (TQS-MD). The system (29) uses a “building block” concept yielding compatibility with a broad array of products.

“This system is designed for trays, for food products, medical device, and more,” Daniel Brandao, regional sales manager at Wipotec said at the show. “We have the system set up with infeed metal detection integrated into our weigh cell, then we have our labeling device for top and bottom labeling. The bottom labeler includes a printer for variable data. The system applies those labels and scans for position and accuracy of the print, and nally there’s a reject station for all three of the upstream devices: the metal detector, weigh cell, and labeler.”

All TQS-MD models employing a weighing station feature the company’s high-tech Electro-Magnetic Force Restoration (EMFR) weigh cells, a differentiating engineering design that guarantees precise weighing results, the company says.

Another TQS-MD setup, geared toward food applications, can weigh, label, and inspect for metallic foreign bodies in a single process step. And by adapting product handling modules to a larger dimension, TQSMD models also can be arranged to handle big boxes like shipping cartons. Since such cases generally entail unit-level information for serialization, aggregation, or shipping, a track & trace module is also usually engaged in these instances.

Wipotec’s TQS-MD series can comprise a wide array of con gurations. Typically applied to print “best before” dates, batch codes, or lot numbers on boxes, the popular basic setup marks, it veri es and weighs products on a footprint of just one meter in length, and it can be upgraded to execute full serialization where required.

A cornerstone of Wipotec’s new series is central control. Regardless of the number of functionalities a TQS-MD models entails—a lengthy list that includes weighing, marking and verifying, labeling, metal detection, and serialization/aggregation integration, among others—the unit offers one user interface. This makes product changes, article setup, and layout modi cations less error-prone and more user-friendly. The “one system, many capabilities” approach also has availability bene ts amid a challenging supply chain landscape: With 85% of components produced in-house, WIPOTEC-OCS is well positioned to deliver not only exemplary quality standards but shortest-possible delivery times.

The modular concept inherent in TQS-MD machines makes them extraordinarily adaptable, according to the company. Depending on a product’s size, shape, weight, and desired throughput speed, Wipotec can simply combine the relevant modules for a solution tailored to meet speci c needs.

the quality control system in action at pwgo.to/7798.

Pressco Technology also highlighted its lling line and high-speed vision inspection solutions (30) at PACK EXPO International. Pressco’s INTELLISPEC platform provides a comprehensive set of modular solutions for high-performance lling lines. Pressco systems are designed to be integrated into various blow-molders, llers, cap feeders, and labelers.

“This is an entire manufacturing process right here,” says Michael

Bar Wrapper

New from Campbell Wrapper was the Excel Flow Wrapper (31). Designed for high-speed wrapping of bar and chocolate products, it’s capable of speeds to 1,200 bars/ min. According to regional sales manager Keenan Stahl, a big focus behind the new machine’s development was ease of operation, sanitation, and maintenance. Special care was taken in the area of film control, too. PW

Coy, director of marketing, Pressco Technology. “Most companies that do vision systems only focus on one part of that process. We’re up and down the line, we’re everywhere. We have a modular approach, so even with all those operations in your factory, you can have one inspection system, and you only need to learn one software and train your staff once. It’s a single control point for all those inspections, so it’s a much more ef cient way to operate.”

Coy adds that Pressco’s systems not only collect inspection information on each part inspected, but correlate that data back to the speci c machine component causing the defect. This minimizes troubleshooting time, improves machine uptime, and reduces scrap.

“Our machine uses multiple cameras, so we can look all the way around a bottle closure and make sure that the closure is on correctly,” Coy says. “That’s really important for the bottling companies, because if it’s not on correctly or if it’s crooked or too high, that’s a problem, especially for carbonated beverages.”

MACHINERY

ON TO TRAY HANDLING

New at the Harpak-Ulma booth was the Cigno tray sealer, whose open design features are aimed at making it extremely user friendly and easy to access. In addition, changeover from one tray size to another can be completed in as little as two minutes. No compressed air or vacuum pumps are required, and it runs at speeds to 30 cycles/min using heat seal or gas ush. One-up tooling is easy to operate, and the machine is ideal for users whose operators are not especially sophisticated or technically minded. At 1.5 m (5 ft) in length, the Cigno ts easily into existing facilities.

a video of the machine in operation at pwgo.to/7799.

The machine’s cap reject system can identify a misapplied cap (high, low, or no cap) and reject the container to a reject collection tray. The reject system consists of a Keyence high-accuracy laser micrometer sensor and an adjustable mounting bracket. A pneumatic pusher is the standard reject mechanism; other options are available based on application. The system also includes a cap-foil detection/no-foil reject feature.

Controls include an integrated 7-in. color HMI touchscreen interface with operator controls and motorized height adjustment. A PLC package allows for up to 50 pre-programmable recipes as well as seven security levels.

CANNING LINE

The CB100C rotary counter-pressure canning system (34), new this year from Pneumatic Scale Angelus, a BW Packaging company, leverages a 12-head rotary- lling turret design, coupled with a dual-station seamer that allows for an increased throughput of more than 100 cans/ min.

Plenty of tray wrapping machines were on display at PACK EXPO International, but at the Polypack booth was a new system designed not for wrapping but rather for the automatic unwrapping of trays (32). As Polypack CEO Emmanuel Cerf explained to booth visitors, the target for such a machine is the contract packaging company or ful llment center where, under current operating conditions, laborers typically cut and remove the overwrap from trays by hand in order to repack the tray’s contents in a variety pack, for example. Not only is such an approach labor intensive, slow, and costly, it can also be dangerous when knives are being wielded by hand.

A wrapped tray fed into the new Polypack system pauses while a cutting device cuts the lm underneath and along the sides. Then a vacuum gripper picks up the lm and removes it.

a video of the machine in action at PACK EXPO

International at pwgo.to/7808

All-Fill’s Model CI fully automatic two-station in-line chuck capper (33) consists of stainless steel and anodized aluminum construction with an integrated 4.5-ft3 cap hopper and can be seamlessly integrated with ancillary packaging equipment. A standard 15-in.-wide sorting cap elevator chain feeds and orients caps for placement. The capper also features a standard cap trap for one unique cap or for both the rst and second station chuck for one unique cap, designed per application. The Model CI is available with an indexing pin package for speeds from 40 to 60 caps/ min or a timing screw option to enable rates to 60 to 80 caps/min, depending on the application.

The new system builds on the capabilities of the PSA’s CB50C counter-pressure canning line, a 50-can/min ller developed to help craft beverage producers meet the growing demand for hard seltzers, RTD cocktails, sparkling wines, and higher-carbonation beers. Like the CB50C, the CB100C uses isobarometric lling, with an onboard product supply tank rated to 60 psi. Explains the company, with isobarometric lling, the ll tank is positioned above the ll heads, allowing the product to be gravity fed, as opposed to being pumped or forced upward.

metric lling, the ll tank is positioned above the ll heads, As opposed to the CB50C ller, which features six

40 min or a timing screw option to enable rates to 60 to

through the line, lling faster without creating

As opposed to the CB50C ller, which features six individual lling heads, the CB100C features a 12-head rotary lling turret that enables the system to move a greater number of cans smoothly through the line, lling faster without creating any increase in product agitation as speeds increase. Says the company, “This gentle ll virtually eliminates the unwanted reductions in carbonation levels seen with other lling methods.”

Like PSA’s other canning systems, the CB100C also employs magnetic ow-

MACHINERY

meter technology to achieve an accurate and repeatable ll level with little waste—the system is capable of 1-mL precision with no moving parts. A gassing tunnel and Under Cover Gassing (UCG) system at the lid applicator chute keeps dissolved oxygen levels low.

The CB100C has been optimized for sleek and standard can bodies and is designed with quick-change adjustments for easy changeovers, accommodating various can heights and body diameters—including widget cans and can ends from 200 to 206—with no valve change required. Other features of the system include an intuitive HMI for individual ll-head volume adjustments that simpli es operation and a motorized, recipe-driven turret design for automatic turret height adjustment.

ADDITIVE MANUFACTURING

Schubert’s subsidiary Schubert Additive Solutions presented its newly developed Partbox 3D streaming printer (35) for increased reliability and quality. Partbox’s digital platform allows customers to produce 3D parts themselves— from grippers for robots to spare parts—using a standard lament printer. Uniquely, customers only pay for each printing hour they use as they click and print customized products on demand.

Printing 3D parts for the packaging process in-house offers manufacturers many advantages. Robotic tools can be adapted to ideal speci cations, for example. It also cuts down on lengthy transport of format parts (and the associated carbon footprint of single shipments) while offering quick replacement in the event of defective tools. And it offers the option to produce new format sets in light of product changes. “We believe that components should be produced when and where they are needed,” explains Conrad Zanzinger, CTO at Schubert Additive Solutions.

a video of the machine in action at the Schubert PACK EXPO booth at pwgo.to/7801

The objective is to offer 3D printing of technical components at the user’s facility in a sustainable, reliable, safe, and high-quality process. The company guarantees protection of the user’s digital warehouse and secure data transfer using a mobile end-to-end solution.

With its own streaming platform and printer, Schubert’s Partbox is now a complete system that enables manufacturers to produce components directly in their own operations using the raw material Partbox Black. The digital process is reported to save customers processing, shipping, and warehousing costs. The system won a 3D Pioneers Challenge Award in 2022 in the Digital category, garnering honors for its sleek design with sustainable impact, intelligent implementation of advanced technology, customization at the production line, and secure digital rights management.

BUY NOW, PAY LATER

A revolutionary “buy now, pay later” model for acquiring and nancing packaging machinery called Leap has of cially been launched by Maxpack Machinery at PACK EXPO International 2022. This model has sparked great interest among medium-sized and small CPGs across the

United States and Latin America. “Leap is a nancing scheme in which companies pay through time without having to shell out huge amounts of money in the short term; we are providing an opportunity to start with much lower payments, so CPGs can invest their money in their growth,” Sebastián Chavarría, corporate director of Business Development for Maxpack Machinery explained to us in Chicago.

With Leap, a unique model in the world for packaging machinery nancing, the company established in the United States by the Ecuadorian entrepreneurs Julio Ulich and Sebastián Chavarría facilitates access to ve complete sets of lling machines, con gured to integrally operate in different applications and a wide range of production volumes.

Among these technological packages is the vf/f/s LeapOne MFT 7 Ultimate Range machine (36), recognized as analist in PMMI’s Technology Excellence Awards in the Food and Beverage category. “Our machine was one of the top three in the food category of these PACK EXPO 2022 awards, and that recognition is due to the fact that we built a setup with super-premium machine characteristics, but accessible for its under one-hundred-thousanddollar pricing,” says Chavarría.

LeapOne MFT 7 Ultimate Range is a premium VF/S/S MFT with an open framework design that offers a width range between 60 and 350 millimeters, the broadest in its category. It includes Siemens S7-1200 PLC controllers and a KTP700 user interface, and it’s capable of forming sealable as well as stand-up pouches. Among its most outstanding characteristics are that it has a mechanical operation speed of up to 100 bags/min, a sealing system with ready-to-use easy to install clamps, rubber rollers, devices for at and triangular pouch bottoms, and an Ewon Flexy remote system.

Based on the identi cation of the product and type of packaging a client needs, Maxpack Machinery helps to specify the machine, the dosing system, and additional equipment required. Once users have chosen one of the lling-technology packages available, the next step is to de ne the best dosing technology. The company, through its Leap

MACHINERY

model, offers SolidOne alternatives, with a multi-head weight checker, a platform, and an elevator; PowderOne, with a 50-L screw ller and a food-grade elevator; and LiquidOne, which includes a STUR rotary pump with a positive displacement camshaft.

Under the slogan “Use your money to grow,” the Maxpack Leap nancing model makes it easy for small and medium companies to purchase the chosen machinery. Leap allows clients to make long-term payments and gives them the chance to start with moderate installments, so they can invest their funds in other growth fronts. Paying for the selected technology is done with a mere 15% down payment, and the pending balance can be deferred up to 18 months, while the machinery is delivered in just four months.

The reception to this initiative has translated into a 95% of orders and requests being about the Leap model and re ects the growing interest of small and medium companies in advancing their modernization projects. “We are world-wide pioneers by implementing a project like this one, which allows companies to readily access the automation and digital transformation being talked about all across the industry nowadays,” says Chavarría.

GABLETOP FILLER

Pactiv Evergreen’s servo-driven EH-84 gabletop packaging machine (37) was in operation at PACK EXPO. It’s designed to meet the needs of the dairy, juice, plant-based, and liquid food markets. Khalid Ikram, production engineering manager, told PW that the EH-84 handles ll volumes of 40 oz up to 2 L, at speeds up to 8,400 cartons/hr. Allen-Bradley PLC controls and servodriven technology provide repeatable package performance and automatically control ll volumes and pro les based on product and carton size. In nite ll capability allows for less downtime with quick and easy changes in carton size or product, he says.

The EH-84’s high visibility of components and internal machine operations make for easy accessibility and reduced maintenance time, while the infeed’s ergonomic design provides operator comfort and ease of loading. An optional SPOUT-PAK System is available to enhance consumer convenience and preserve product freshness. Shelf-life optimization features include ELL

(Extended Long Life) components, including a self-contained CIP/SIP system, environmental control features, carton decontamination, and a hermetic ll system to maintain product quality. As with all gabletop machines designed and manufactured by Pactiv Evergreen, the EH-84 is backed by 24/7 OEM parts and technical service to ful ll customer needs, according to the company.

the cartoner in action at pwgo.to/7802.

REINFORCED ORINGS

Fenner Precision Polymers, a Michelin Group Company and provider of reinforced polymer technology, launched its Eagle XLD Bimodulus O-rings (38) at PACK EXPO International. Most O rings are not reinforced and stretch out at fast rates, says the company. Depending on the weight of the load or the speed they’re running at, traditional O-rings may last anywhere from three to six months, perhaps a little longer. This can result in signi cant downtime for a company, especially if it does not have the proper inventory.

“With Eagle XLD we were trying to take the performance attributes of a poly v conveyor which provides more load capability to help you achieve more long term life for relative weight and speeds, providing better performing product development,” says Derek Forney, senior product manager for Fenner’s belting division. “We added a reinforcement capability into the Eagle XLD that removed the stretch issue. So now it will last at least six to eight times longer. We estimate around two years at a very high load and at higher speeds, depending on the project.”

Forney further explains that traditional Orings are 90% ef cient as they lose 10% of their capability overtime due to the stretch or tension factor. The Eagle XLD, however, is 99% ef cient, thanks to its adoption of poly v conveyor performance attributes. This allows the Eagle XLD to provide four times greater roller-to-roller power transfer and tension does not decay over the life of the belt. The combination of higher power transfer and load capacity allows for a conveyor design that can carry more with less motors, which translates to cost savings in belting, maintenance, and energy costs.

In addition, the D-shape optimizes the contact area to take advantage of the strength of the higher-modulus material, which results in a belt that is quick and easy to install with no need for special tools. Another aspect adopted from poly v conveyors is the use of unique center distances, which limits the Eagle XLD to a dozen sizes, which will not have a wide range of tension. With this, companies can more easily determine the size of the Eagle XLD O-ring that they need.

“The hybrid reinforcement is something that we’ve worked on with Michelin, our parent company, with their high tech materials division to develop so that you can achieve that higher load, that longer life. And then as a result, the extra savings that come with it,” says Forney.

Blown Film Changeover

Windmoller & Holscher debuted its Easy2 Change system (39) for blown film line changeovers. Easy2 Change acts as an operator assistant, reducing the number of steps for a line changeover by 70%, and the time needed to perform a line changeover by 50%, compared to an operator performing those tasks manually.

Easy2 Change features a fully automated air ring called ARCTIS, and can integrate Windmoller & Holscher’s other automated features from other systems, like EASY Change, EASY Wind, TURBOCLEAN and Profile Booster. Easy2 Change also has an intuitive HMI to help operators maintain full transparency and control throughout the changeover, detecting bubble stability and ensuring reproducible, high-quality film. PW

Signal Beacon

Patlite’s latest compact signal beacon (41), the NE-USB, is a multicolored LED signal beacon that is powered and controlled via one USB cable, which Patlite says allows for maximum efficiency in the workplace. The NE-USB is available in two distinct models: the NE-SN-USB and the NE-WN-USB.

The NE-SN-USB model features an IP20 protection rating and has the option for stationary, magnet, and 1⁄4-in. screw mounting (for a tripod, for example) for immediate and practical support. Alternatively, the NE-WNUSB features an IP65 protection rating and is able to mount via a pole or wall attachment, perfect for visual indication in high and observable locations around the factory.

Both models of the NE-USB are equipped with a milky lens that harmonizes with virtually every environment to suit a customer’s unique application. Additionally, the NE-USB models come standard with seven selectable LED colors (red,

WORKFORCE SOLUTION

Redzone introduced its Frontline Learning Module (40), an addition to the company’s workforce solutions software platform. Richard Tester, Redzone’s co-founder and CEO, says the new module aims to take tribal knowledge about operating manufacturing equipment out of the heads of machine operators and onto Redzone’s platform as video, where it can be watched as a best practice by other employees.

“If you’ve run a lling machine, for example, for 25 years, you know the best way to use it, or do the startup or changeover on it,” Tester says. “With our new module and an iPad or iPhone, you can record a quick two- or three-minute video, which can become a best practice for that machine at your company. It’s like a YouTube application for the plant oor. Like anything in life today, if we want to learn how to change a tire on a car, for example, we can go to YouTube and watch a ve-minute video, right? So we’re introducing that technology onto the plant oor,

green, blue, amber, cyan, purple, and white) for the compact and ultra-bright visual signaling.

Like the rest of Patlite’s compact beacons, the NE-USB offers clear and vibrant signaling and features simultaneous use of continuous, flashing, and audible alarm conditions with a rugged housing. Other key features include the ability for apps and sample codes to be downloaded from the company’s website. Additionally, control is possible without installing dedicated drivers because the NE-USB is an HID class device. PW

MACHINERY

and it looks at the whole frontline employee experience, which we think is something that’s been massively overlooked in manufacturing for the last couple of decades.”

The Frontline Learning Module comes on the heels of Redzone’s other recent addition, the Reliability Module, which puts basic machine maintenance knowledge into the hands of operators and tracks machine OEE and maintenance schedules, so maintenance crews can focus on crucial repairs, especially helpful for manufacturers with a labor shortage.

“The technology really drives all of the daily operating behavior for the frontline teams,” Tester explains. “Whether it’s running the line and tracking performance, whether it’s quality, whether it’s maintenance—this gives operators the ability to do basic preventive maintenance. So we shift maintenance resources away from performing dayto-day tasks and move basic care for the equipment into the role of the operator.”

FILTRATION AND CHILLERS

Atlas Copco Compressors has a strong history in compressed air, and innovation in that area will always be a strong focus, says Paul Humphreys, vice president of communications and branding. But at PACK EXPO International, the supplier was debuting

some capabilities beyond compressors, demonstrating innovations in process ltration and chillers (42). “We’re getting away from the compressor room and going more downstream,” Humphreys says.

The process ltration range—focused on liquid, steam, and air—extends Atlas Copco’s lter product portfolio into multiple industries, including food and beverage, microelectronics, pharmaceutical, cosmetics, and chemical. The lter range, which exceeds ISO 8573-1 Class 0 requirements, is designed to prevent microbial contamination and protect the quality of the nal product. All components meet the EU and U.S. requirements for food contact use in accordance with FDA CFR Title 21 and with EU Regulation No. 1935/2004 and its subsequent amendments.

The range includes bags, lters, and cartridges. The complete cartridge range comprises unit construction from melt blown ber and pleated ber for particle removal, and pleated membrane for bioburden reduction. The cartridge range includes powder sintered lters for steam and gases as well as pleated lters for high-temperature and corrosive liquid applications. Carbon powder sintered lters and carbon rolled felt lters are also available

innovations report

MACHINERY

for chlorine, odor, and color removal processes. The product range is completed with polypropylene, polyester, and nylon bag lters.

Atlas Copco’s process ltration offering also provides a wide selection of housings, including sanitary housings for food and pharmaceutical applications involving liquid, gas, or venting processes. These are available in single- or multi-cartridge con gurations.

Many of Atlas Copco’s latest innovations come from recent acquisi-

tions, Humphreys notes, and its TCX 4-90A Process Cooling Chiller range is one such example. Atlas Copco entered the industrial cooling market with its acquisition of Italian supplier Eurochiller in mid-2019.

The TCX range features a compact, all-in-one water chiller with an air-cooled condenser and integrated hydro module, with units available in a variety of sizes. The chillers are speci cally designed to cool water (or a mixture of water and glycol) for a wide range of industrial segments.

The TCX range’s state-of-the-art microchannel condensers require 30% less refrigerant, making the units more environmentally friendly while lowering potential maintenance charges over the life of the chiller.

The process chillers feature a touchscreen controller, the Elektronikon Mk5 Touch controller. Smartlink 24/7 monitoring is also available as part of the chiller’s total package. This enables Atlas Copco not only to log in to help maintain and troubleshoot the equipment, but also to trend performance over time, Humphreys comments. The TCX range can also be covered on a service contract, along with all other Atlas Copco mechanical equipment, such as air compressors, dryers, nitrogen generation systems, and low-pressure blowers.

CUSTOM MOLDED PARTS IN 10 DAYS

An array of wear components made from highperformance plastics was on display at the igus booth. Of particular note, however, is the FastLine tooling system, which delivers custom molded parts in 10 days or less, notes John Nebbia, packaging industry manager for igus’s dry-tech division.

With a slogan of “improve what moves,” igus is focused exclusively on motion plastics such as bearings, bushings, and more. In many cases, the company works closely with the customer to develop the piece that will best t production needs. As an example, Nebbia pointed out bottle grippers made for Krones for use in its bottling equipment.

Working alongside Krones, igus produced a modular design with notches in the grippers, enabling different bottle sizes on the same line. This is a considerable improvement over typical bottling lines, which would require a change in grippers to move to a different bottle size, Nebbia notes.

In fact, this kind of exibility in equipment to accommodate a variety of package sizes on the same machine is a growing trend within the industry. Nebbia highlighted linear guides that enable a quick format adjustment to switch easily from one package format to another. “This is especially good for contract packagers,” he says, noting the ability to switch a line over quickly to run product for a different customer. “It gives them the ability to buy and bid on jobs without installing new lines.”

Custom components are available in a large range of self-lubricating, high-performance polymers in the company’s iglide line of materials. This includes 3D

MACHINERY

printed parts. New at PACK EXPO International is the iglide i6-Blue (43), a powdered laser sintering material for 3D printers. Its blue coloring improves safety in the food and beverage industry because fragments are easier to detect if components break.

“The blue, high-performance plastic is easy to detect and is also food-compliant,” says Tom Kraus, head of the igus Additive Manufacturing Business Unit. The material complies with U.S. Food and Drug Administration (FDA) and EU 10/2011 regulation.

WAREHOUSE AUTOMATION

Another major family of topics that was top-of-mind for attendees at PACK EXPO International was logistics, ful llment, distribution, warehousing, and 3PL. That’s why Signode demonstrated its cart-based StorFast ASRS system (44)

“People often think that palletizing is the end of the line. Here at Signode, we understand the need to go further into the warehouse with our automation,” Shawn Semer, VP, sales and marketing at Signode, told PW at the show. “We want to start our processes at the beginning and see our automation through to the unit load being sent out to the truck.”

The StorFast ASRS is an innovative cart-based solution consisting of powered carts and lifts that automatically move pallets in and out of

storage positions in the warehouse. The newly enhanced system operates at twice the speed with improved control for acceleration and deceleration of the robotic carts. In addition, StorFast components can now handle pallets weighing up to 4,400 lb.

The StorFast system is composed of what are called Modules that exist within a distributed guide-rail storage system. Each storage Module has multiple levels and within each level is a network of central main aisles with multiple rows located on the right and left sides for storage and retrieval of pallets. Operating on the main aisle of every module level is an Aisle Cart that carries a companion Row Shuttle that undocks to navigate the many rows. The Aisle Cart and Row Shuttle are all-electric powered vehicles for automatically storing and retrieving pallets. Row access is exible to provide pallet position optimization and allow for changes in volume and prioritization, such as seasonal or new product updates.

The Aisle Cart transports a pallet to (or from) an assigned row, the Row Shuttle then undocks carrying the pallet to store (or retrieve) from a speci c row position. The movement of both the cart and shuttle is automatically controlled by system software using Programmable Logic Controller (PLC) technology communicating to a main controller. The

Bagger for E-commerce Play

PAC Machinery used PACK EXPO International to demonstrate its Rollbag R3200 fulfillment automatic bagger (45) completing e-commerce shipping orders in paper instead of poly.

“We now are running bags that have been certified as curbside recyclable,” says Greg Berguig, VP of sales and marketing. “It allows customers to really automate their outbound shipping process, and it gives their end customers a more sustainable option. They don’t have to take a polybag and throw it in the garbage or drop it off at the store. They can put it right into a curbside recycling bin.”

Beyond the paper-based bag option, according to the company website, the Rollbag R3200 Fulfillment automatic bagger also works with poly tubing, as well as bags on a roll. The benefits of poly tubing include lower material costs as well as the ability to right-size the bag to the product by changing bag length on the fly, lowering shipping costs and reducing material usage.

The Rollbag is equipped with a label printer applicator to create a fully integrated batch-less order fulfillment bagging solution. A thermal transfer printer option is also available,

carts and shuttles are equipped with Human Machine Interface (HMI) control panels. The HMI allows the operator to verify the current state of the vehicles, modify parameter, etc.

The wider StorFast product portfolio consists of high-density Automated Storage and Retrieval Systems (ASRS), and a full range of robotbased depalletizing, palletizing, and material handling solutions, to provide superior cost and performance advantages over other traditional warehouse systems. Signode manufactures fully integrated warehouse automation system solutions to maximize operational savings for the supply chain.

the full end-of-line solution at the show at pwgo. to/7803.

POWDER FILLING

nVenia’s Hamer brand VLR-B industrial powder lling equipment made its stateside debut at PACK EXPO International. The machine is designed to address the challenges of bagging free- owing products in a cost-effective, reliable manner. In the complex world of powder lling, nVenia says it has simpli ed the operation and maintenance without sacri cing speed and accuracy. The machine delivers accurate and repeatable weighments while minimizing the production of airborne particulates and dust.

According to Paul Ferrendino, SVP of sales at nVenia, the new VLR-B powder Bagger delivers fully automated bag lling, de-aeration, inner bag sealing, and outer bag closing in a single piece of equipment. He adds that the system provides highly accurate dosing of free- owing powdered products, and given its simple controls, a single operator can run multiple lines, freeing up to ve labor resources for other valueadded activities.

allowing you to print directly on the bag material. Also, this bagger can be equipped with a TwinPrint dual-sided label printer applicator to include the shipping information and packing slip on a single label. PW the bagger in action at pwgo.to/7804.

Joep Timmermans with Hamer and David Gramley with Nvenia walked PW editors through the machine at the show.

In this system, bulk powdered product, like ingredients for baby formula, animal nutrition, or plant-based protein, is dosed downward from a hopper with a spout via a vertical screw. Next, a pre-formed bulk bag is selected and presented to the ller spout. Precise servo controls on the auger ller ensure highly accurate weighments. Of note, multiple bag stack stations can be added to allow the machine to run unattended for even longer periods, and next bag stack can be automatically moved into position for selection and lling.

“We have very accurate lling, with less dust and less product ending up in the air, so it’s very hygienic,” Timmermans says.

After lling but prior to sealing, the bag is stabilized by horizontal clamps, and extra air is extracted from the bag, or de-aerated, by a probe that is also lowered downward from a vertical spout system.

“De-aeration probes come down and enter the [ lled] bag, and they will pull all the air out, which is very critical for increasing the stability and reducing the volume of the bag,” Gramley says. “For smaller bags, we use a single probe, and for larger bags, we use a double-tipped probe. Once they suck the air out and exit the bag, they’ll go through an exhaust cycle to purge the powder from the probes.”

Another critical segment of this system occurs immediately downstream, in sealing.

“The sealing unit spreads the top of the bag and presses down to remove the top air out of the bag, thus cleaning [or air-washing] the seal zone, and then [impulse] sealing it with nearly 400 pounds of pressure,” Timmermans says. “The inner liner bag is perfectly closed and airtight, the top air has been removed, so you have a perfectly stable, stackable result at the end.”

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MACHINERY

After inner bag sealing creates a sift-proof bag, producers may choose to close the outer bulk bags using various methods, like stitching, crepe taping, or pinch-top sealing, which may be integrated into the machine.

The system also features dust collection/management at each stage in the process, a bottom-up ll method to minimize generation of airborne dust, up to 500 programmable recipes, ethernet and Wi-Fi connections for remote service, an easy-to-clean structure built with hygienic design principles, and a fully welded, powder coated, structural steel frame with product contact points in 304 stainless steel. the system in action at pwgo.to/7805.

DOWN BOTTLE REJECT

Morrison Container Handling Solutions demonstrated the latest iteration of its Down Bottle Reject System (46). With it, brands and CPGs in the beverage, pharma, beauty, and personal care spaces (among any other markets using rigid or semi-rigid containers) are nding a cost-effective system that can help increase ROI and line ef ciency. And while that’s happening, they can shift their workforce to other places in the facility that matter.

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“A big feature of this system is that we maintain center lines during container changeover,” says Seth Licke, aftermarket sales and service manager/project manager at Morrison Container Handling Solutions. “So if you have, for example, 17 different containers that run on the same line, you wouldn’t have to mechanically move anything during the changeover. It would just be a simple, quick-change part for each container size, using tool-less removal and maintaining the centerline on your conveyor. And then, just by using the geometry of the bottle, and getting at least 50% of its mass off of the conveyor, that allows [gravity to take over and] the bottle to reject.”

Often, companies experience line inef ciencies due to containers falling over. Instead of having a person standing on the line looking for down containers, it’s more cost effective and ef cient to implement a Down Bottle Reject System. Plus, the mechanical system operates on a CPG’s line with no additional operating costs. Since it relies on bottle geometry, a user will need no air, pneumatics, or electric/motor to utilize the technology.

Ultimately, by reducing down-bottles, operators can increase uptime in their production and throughput of product by reducing jams on the line. While the system is in nitely scalable in theory, the most common applications are in the 50 to 400 containers/min speed range. the system in action at pwgo.to/7806

Space saving is of perennial importance to CPGs, and this year’s PACK EXPO International highlighted numerous solutions. Among them was the Dynamic Servo Laner displayed at the Container Handling Systems’ booth.

Designed for short space coupling to cartoners and case packer, the Dynamic Servo Laner is engineered for high-speed, pressureless product laning from single le to multiple lanes without interruption of product ow.

“This laner is capable of 310 feet per minute for infeed speed, which is the fastest in the marketplace,” says Pat Vincent, president of Container Handling Systems and Nalbach Engineering. “It’s completely con gurable to match any application—round, non-round containers.”

The Dynamic Servo Laner features an internal mechanism prevents product accumulation during laning and maintains spatial relationship between containers. PW a related video at pwgo.to/7807.

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FOOD PROCESSING & PACKAGING

Notable at PACK EXPO International was a brand new application (1) of Claranor’s pulsed-light decontamination, a technique used to decontaminate surfaces by killing microorganisms using short pulses of light in an intense broad spectrum that’s rich in UV-C light. This Claranor technology, in use since around 2005, brings Extended Shelf Life (ESL) to food, beverage, pharma, and cosmetics packaging.

The application debuting at PACK EXPO falls into the dairy category. Think polypropylene cups of yogurt, for example. These are usually sealed by way of a pick-and-place approach in which pre-cut lids are pulled from magazine feeds and heat-sealed to lled containers. Recently, however, a Danish rm called PrimoReels came up with a machine that replaces pre-cut lids in favor of roll-fed lids fed from perforated reels. Because as many as 40,000 lids come on a single roll, this approach greatly reduces the need for operators to re ll magazines with fresh lids. PrimoReels also says the cost of the lidding can be reduced by 30%. That’s because the cut-and-stacked lids need to be in the 50-micron range in order to be suf ciently machinable in the pick-and-place equipment, while the roll-fed lids can typically be in the 36-micron range and some metallized polyester lids can be as thin as 23 microns. PrimoReels, it’s worth noting, is also the converter and supplier of the perforated roll-fed lidding.

Until PACK EXPO, the PrimoReels machine relied on UV light for decontamination. But the system demonstrated at PACK EXPO was the rst to use Claranor’s pulsed light instead, which yields a more thorough decontamination. “This is especially true on microorganisms like molds, which are a constant quality challenge where yogurt products are concerned,” says Christophe Riedel, Claranor CEO.

On the system demonstrated at PACK EXPO, cups were being lidded eight across. The Claranor pulsed-light unit was positioned at oor level on the side near the roll-fed lid unwind cabinet. This arrangement occupies minimal space. In fact, just one Claranor pulsed light unit performs the decontamination task . The system brings eight lids into the unwind cabinet, the lids pause brie y so that the pulsed light can do its thing on the cup-contact side of the lids, and then those eight lids proceed into the part of the machine where two things happen:

• Specialized tooling—not a blade but more like a hammer—strikes the perforated reel in just the right way to cleanly separate each lid from the roll.

• Vacuum cups pick all eight lids and rotate down 180 deg to place them on the cups waiting below; a spot seal tacks the lids to the cup so the lids stay properly positioned until the cups reach the heat sealing station. Important to note here is the role played by a patented mechanism similar to a feed screw that causes the place-

ment devices to separate left and right just the right distance so that each lid lands squarely on its designated cup.

Operating speeds are in the range of 45 cycles/min when cups are being sealed 10 across. Riedel says that no commercial applications of the Claranor/PrimoReels solution are in place yet. But he believes it’s only a matter of time. “We saw a good t between PrimoReels and our pulsed-light decontamination,” says Riedel. “For one thing, pulsed light does not involve heat the way some alternative decontamination methods like hydrogen peroxide do. That’s another reason why it’s possible to use a very thin plastic material for your lidding.” Polypropylene, polyester, or metallized polyester can all be supplied by PrimoReels.

PrimoReels is now licensing suppliers in the U.S. to make it easier for brand owners to purchase roll-fed lidding materials from multiple local sources. Also worth noting is that the new decontamination system can be retro t onto existing ll/seal lines.

a video of the Claranor/ PrimoReel solution at pwgo.to/7809.

Also on display at PACK EXPO was Claranor’s range of decontamination systems for metal lids and cans. “This is a growing area of interest for all beverage producers because it lets them arrive at an ultra-clean solution without the use of post- ll thermal treatment that might have a negative impact on avor notes,” says Riedel. He adds that craft beer and kombucha are two categories that are especially suitable for such technology.

MORE CUP FILLING

Well deserving of its tagline, “a new generation of cup lling machine,” the Versatech from Synerlink, a BW Packaging company, is a modular, ultra- exible machine (2) that can ll cups from 40 to 150 mm at 12,000 cups/hr, with changeover from one format to another, including different shapes, materials, diameters, and heights, taking just 20 min from last to rst container.

One key to the exibility of the system is its modular design, which allows functions to be added, switched, or removed easily and quickly—from half a day to two days, according to Fabien Jégo, design leader and product marketing leader at Synerlink S.A. Each module is plugand-play via a centralized cabling network. Through this network, each module automatically integrates with the rest of the system, both pneumatic and electric. The indexed position of the modules allows for sim-

ple placement and calibration, with a positioning accuracy of 0.1 mm. Another feature that facilitates this exibility is the machine’s ability to automatically load and unload slats, which Jégo says allows the customer to perform a slats change “in record time.” It also allows for fast and easy cleaning of the slats, with no tools required. Another advantage of the system’s fast return system is that fewer slats are required. According to Jégo, the Versatech was engineered to address the top six issues currently facing users of cup lling machines. One is late-stage customization by brand owners. With the Versatech, “a project manager can place an order without having full speci cations,” he explains. “The modular design allows nal packaging design integration and functions modi cations until the last minute.”

The second is a need for packaging versatility, as it allows a brand to respond to rapidly changing markets without having to wait for long lead-time machine redesigns. Jégo says the potential, in terms of the range of cup sizes, shapes, and materials, that the Versatech can handle is in nite. “We can process any cup within the mechanical range of the machine [40 to 150 mm in dia and 160 mm high], from standard stackable to non-stackable cups in plastic, cardboard, and glass,” he says. “Moreover, if a new generation of cup arrives on the market, the modularity of the Versatech will allow us to develop new functions and to implement them on the machines already in production.”

The cup ller has also been designed to adapt to a customer’s changing requirements, negating the need for packagers to purchase additional equipment as their business grows. Says Jégo, “We can imagine that a yogurt producer who starts his business might equip himself with a basic machine, and later on, when his market has evolved, he might add capacities to his machine, such as decontamination of the cups with pulsed light, a second dosing device for a fruit coulis [fruit puree] at the bottom of the cup, or a snap-on lid.”

And, on the subject of exibility, the fourth issue the Versatech addresses is the ability to handle mixed batches, especially for customers such as co-packers who are running smaller-volume jobs. “It has never been so easy to ful ll mixed orders for a production manager,” says Jégo, who cites the machine’s 20-minute changeover capability.

The cup ller also tackles issues around labor, such as ease of use and ergonomics. “It is very important for a site manager to limit the turnover of his operators and to keep the experienced people,” says Jégo. “Our machine is designed to be extremely convenient to operate. The loading of consumables, such as cups, lids, and toppers, is done at chest height.” In addition, loading can be done while the machine is running. High visibility throughout the entire production process ensures the correct functioning of the machine and adjustments to the slats’ changeovers, transpar-

FOOD PROCESSING & PACKAGING

ency, weight, and size, reducing the risk of operator error.

The machine also meets a need for ef cient maintenance. The Versatech uses clean, chainless servo technology to move the cups, which eliminates the need for grease used for lubrication and for readjustment of the chain over time. Maintenance operations are also aided by the machine’s easy disassembly and reassembly technology.

Synerlink particularly recommends the Versatech for applications that include dairy products, desserts, baby food, and fruits and vegetables.

MEAT PACKAGING

An innovative semi-automatic stretch/seal application for food trays (3) made its debut at PACK EXPO International at the Point Five Packaging booth. “The idea is to address the problem of moisture buildup that you commonly see in lm-wrapped trays of poultry or meat,” says Point Five president Greg Levy. “Too often this moisture leaks out of the pack and onto the consumer’s refrigerator shelf or kitchen counter, creating a most unwelcome mess. We’re using the same basic stretch lm material but we seal it to the tray ange rather than wrapping it fully around the tray and heat sealing it on the bottom.”

truck of ground meat product without the tray.”

Removing the tray also eliminates the need for packagers to purchase, ship, store, and handle the trays. “Customers aren’t getting three or four truckloads a day of trays, so they’re able to reduce the footprint in their warehouse because they need less storage space,” Brenton remarks. “They can also reduce the amount of labor they have, which is a huge challenge for everyone right now. Just having someone move trays around the plant all day is kind of a waste when you don’t have to do it. You can then use those people somewhere else in the plant.”

Another bene t of the new process is that it eliminates a number of machines currently used in the tray-packing process. “End users can take out three machines from their current line because they no longer need a tray denester, a tray wrapper, and then an overwrapper to wrap three or four nished packs in a master pack,” Benton explains.

He adds that with the current tray-wrapped packs, the shelf life for the ground meat product is typically around 24 days, if the package stays within the master pack. Once it’s removed from the master pack for display at retail, the shelf life is just four to ve days. Packages produced using the Formost Fuji system offer a 24-day shelf life with 18 to 20 in. of mercury on the seal test, Benton shares.

The system uses a polyethylene lm with an anti-fog coating that can be preprinted with branding information. Benton says that Formost Fuji is currently working with a major ground meat producer in Nebraska to test-market the packs in a regional grocery retailer.

PILLOWPACK WRAPPER

With this approach the moisture has no opportunity to leak out. Plus it yields a lm cost savings because the lm only extends to the tray perimeter rather than wrapping around the sides and down to the tray bottom.

a PACK EXPO video of this technology in action at pwgo.to/7810.

Another PACK EXPO International exhibitor that was focused on meat packaging was Formost Fuji. But in this case it was ground meat being ow-wrapped without the foam tray so commonly found in U.S. supermarkets. The FW3710B Box-motion, wet-duty stainless steel wrapper (4) can handle ground meat portions up to 40 lb in an 8-in-wide format at speeds to 120/min plus.

The most notable advantage of the new packaging system is the elimination of the non-recyclable polystyrene foam tray traditionally used for this type of product. “That’s the obvious bene t,” says Lee Benton, South Central sales manager for Formost Fuji. “Another advantage would be related to shipping of the product. It currently takes three trucks to ship product packaged with foam trays for every one trailer

Plan IT Packaging Systems is the exclusive partner and the North American arm of Tecno Pack for the Italian machinery maker’s ow wrappers, vf/f/s machines, and semi-automatic feeding systems. At PACK EXPO International, Plan IT introduced the Tecno Pack Pack 520, a servo-driven horizonal pillow-pack wrapper (5), suitable for food and non-food products, both for single-dose and multiple packages.

Inspired by consumers and the ever-evolving world around us, we create innovative, fiber-based packaging solutions designed with the future of the planet in mind.

According to Plan IT Packaging national account manager Jonathan Evangelista, the Pack 520 offers a number of standard features of which Plan IT is very proud. Among them is its adjustable former, which can be adjusted to run different packaging materials, including heat-sealable, cold-sealable, and polyethylene lms, among others, as well as different product shapes and sizes. “So, if you have multiple SKUS—you want to run small cookies, large cookies, bagels, sandwiches, or anything in-between—the machine can be adjusted to handle all of those requirements on one machine,” he says.

Evangelista adds that the former is adjusted based on ruler adjustments, not pinhole adjustments. The problem with pinhole adjustments, he explains, is that from one pinhole to another, there is no middle ground, “and so you’re still stuck with having to choose one side or the other.” Ruler adjustments are much more precise, he says.

Another unique feature of the Pack 520 is its use of a pneumatic lm reel for the lm roll that holds the roll in place to avoid any tracking, as lm rolls are nished and new ones are added. “The traditional way a lot of our competitors do it is through a torque screw that just tightens,” Evangelista says. “But over time, that torque screw gets over-torqued, and now you have a little bit of play. Unfortunately that causes tracking and bad packaging. So we avoid that by including as standard a pneumatic lm reel to hold things in place.”

The Pack 520 is equipped with four servo motors: one on the infeed, one on the bottom seals, one on the end seals, and one on the exit conveyor. “Servo motors are enclosed, they’re brushless, they require little to no maintenance, there’s no need to oil or grease any cams, and so they enable long-term use of the machine,” Evangelista says.

The ow wrapper can handle product dimensions from 20 to 200 mm wide, 1 to 100 mm high, and 50 to 600 mm long and can reach speeds to 120 bags/min. However, says Evangelista, the machine can be retro tted to operate at speeds from 150 to 200 bags/min. a video of the Plan IT system at pwgo.to/7811.

ROBOTIC PICK AND PLACE

Demonstrated at the Orics booth in the South Hall was the D-Series delta-style robotic pick-and-place tray loading system (6) for pieces of protein products like chicken or steak.

Randomly spaced items to be picked are conveyed beside an automated tray denester that relies on servo motors to adjust width and length when a new tray size needs to be introduced. A Cognex vision system captures the location and orientation of each item on the conveyor belt and shares that data with the system’s controller. The controller then communicates with the robot so that it can go precisely where it needs to in order to make a clean pick from the conveyor belt and place the item in a tray.

The delta-style robot, designed and built by Orics, is all stainless steel and thus suitable for washdown. The product grippers are made

Wrapper Handles Bars at 250/min

SACMI Packaging & Chocolate premiered its new HTB chocolate bar wrapping machine (7) at PACK EXPO International. According to the company, this first-ever advanced electronic machine “revolutionizes wrapping technology.” With the HTB, time, pressure, and temperature are completely controlled in the sealing area, forming part of the continuously adaptive flow of the machine, which can utilize traditional and eco-friendly materials.

The HTB offers wrapping speeds to 250 bars/min and is able to control each individual operation, providing flexibility and accuracy to match the specifications of both the product’s physical requirements and the packaging material’s characteristics. This is done in a much smaller footprint than mechanical equipment performing relatively the same tasks. Says Mark Lozano, vice president North American operations, the result is a solution that’s easy to maintain and install within existing production lines.

At the show, SACMI ran double-wrapped bars on the HTB, with a sealed aluminum wrapper sleeved within a pre-cut chipboard cover. According to Lozano, SACMI has responded to the sustainability challenge by working alongside manufacturers of environmentally friendly wrapping materials, including paper-based compostable and bioplastic materials to ensure its machines can run sustainable alternatives. PW

of food-grade silicon by Soft Robot Tech. “It’s a gripper that works with a special control system from STXI Motion that regulates vacuum and pressure,” says Orics president Ori Cohen. “When you pressurize those gripper ngers, they close like the ngers of a hand. When you release the pressure, they open.”

The softMC compact size controller, developed by Servotronix with an Ethernet/IP interface developed by STXI Motion, features a powerful algorithm that can control numerous axes simultaneously and achieve the desired kinematic motion of the robot. Compared to other manufacturers’ controllers that support 3-8 axes, the softMC controller can control up to 32 axes.

The Orics D-series robot is equipped with STXI Motion motors, drives, and harmonic drive reducers with zero backlash. Engineered to allow full control of acceleration, deceleration, and velocity with highspeed performance, the Orics D-series robot is suitable for pick and place applications where high-accuracy product placement is crucial. The system also has a self-teach programmable mode. This unique system will memorize positions of pick and place and will repeat them with minimal motor motions. The system can also receive a signal from a video camera and position its actuators, vacuum suctions, or grippers for random pick and place. And an orientation position system enables the robot to orient the transferred objects as they are randomly placed in the production or assembly line.

Cohen describes one application where the robot is just what the doctor ordered. “We put in a short goods pasta line within the last few months for ready meals. If the protein component is small—like diced chicken—it can be weighed and deposited mixed in with the pasta by the combination scale that is part of the system. But for chicken cutlets, for example, which are fairly large and randomly shaped, right now the customer places them by hand. This is where our robot system will come into play.”

a video of the Orics system at pwgo.to/7812.

EBEAM DECONTAMINATION

The news at Serac’s PACK EXPO International booth was that BluStream (8), an electron beam decontamination technology that has been in development for some 15 years, now has a commercial installation that went into operation in the Summer of 2021. The user of the technology is Sources Alma, a producer of bottled water as well as juice and

Dry Steam Sanitizing

The new GVC -18000 (9) from Goodway Technologies is designed for most manual deep cleaning and sanitizing applications in food production plants.

According to the company, the low 5% moisture content lends itself to cleaning around sensitive electrical components and in dry, clean areas.

At 290°F, the dry steam melts away fats and sugars, and kills bacteria and other microorganisms on contact. The system’s multiple cleaning tools are suitable for flat surfaces as well as the cracks and crevices that are often ideal for the growth of bacteria and mold. The CVC-18000 has a heating power of 18kW and steam production of 50 lb/hr. PW

tea drinks that is located in Saint-Yorre in Central France. The rm is using BluStream to decontaminate caps in the place of paracetic acid used previously on an aseptic lling line for beverages in PET bottles.

“With Drinktec last September and now PACK EXPO, we are formally introducing BluStream to the marketplace,” said Nicolas Ricard, Managing Director at Serac. “We had a lot of interest in it at PACK EXPO, so we expect to have a U.S. customer soon.”

Serac describes its electron beam technology this way: “BluStream is a low-energy e-beam treatment that can be administered at room temperature. It’s capable of ensuring a 6-log bacteriological reduction in 1 second without any chemicals. This module is intended for use on bottling lines of non-refrigerated and ESL 90-day beverages. E-beam is a physical dry treatment. To sterilize the surface, e-beam dispenses a beam of electrons over the surface of the product. The electrons quickly destroy the microorganisms by breaking their DNA chains.”

Electron beam decontamination is not new. It’s common enough in the printing industry, and in the packaging space Tetra Pak is among those using it to decontaminate their carton board packaging. The innovation here is that to decontaminate a cap—and soon, says Serac, the inside of a blown bottle—you have to have a highly specialized emitter to get the electron beams inside the cap or bottle.

As an alternative to paracetic acid or hydrogen peroxide, both used widely today in aseptic and ESL packaging, electron beam technology is attractive to beverage bottlers because it lets them get away from chemicals. It also eliminates the need for considerable amounts of water to rinse the chemicals. The other bene t to the customer is the simplicity of use. You push a button and begin decontaminating caps immediately for aseptic applications.

On the Sources Alma line where BluStream is in operation, paracetic acid is still used to decontaminate the PET bottles. Finding an alter-

native to chemical decontamination for caps was a key driver behind the rm’s interest in BluStream. “Serac was the only solution we could nd,” says Romain Leclercq, carbonated & soft drinks division manager at Sources Alma. “It’s a real innovation in the beverage market. On the chemical preparation side, there used to be a lot of effort involved checking the concentration of paracetic acid, and of checking the temperature, too. Now for cap decontamination we just switch on the BluStream machine and it’s ready immediately. For operators it’s greater comfort at the work station and fewer tasks to perform.”

According to Serac, electron beam treatment only depends on three critical parameters: voltage, current intensity, and exposure time. By comparison, hydrogen peroxide sterilization depends on at least six: output, ambient temperature, temperature and time for hot air, and concentration and time for hydrogen peroxide.

“We also save on space,” says Leclercq. “And we now use a conventional cap hopper as opposed to several wet hoppers. Plus the BluStream module is positioned above the capping machine. So it didn’t occupy additional oor space. We’ve been very satis ed in terms of performance and decontamination ef ciency.”

Leclercq notes that where caps are concerned, the current goal is to substitute BluStream decontamination for paracetic acid throughout the company’s operations. When asked about cost, he says that with the cost of electricity uctuating so wildly at present, it’s dif cult to make an accurate comparison. “Maybe we can do so once we’ve recovered standard prices for energy,” he adds.

Nicolas Ricard, Managing Director of Serac-USA, says that Serac now plans to install a BluStream module for decontamination of bottles at a customer facility in Europe. As with the system for caps, it will once again be a rotary system. And it will be suitable for either PET or HDPE bottles. a video of the technology at pwgo.to/7813.

FOOD DEPOSITING

In Lakeside Center, Uni ller Systems demonstrated its new +Series Depositors (10), digitally controlled pneumatic depositors designed to deposit batters and other products with more ease and precision. The system brings into reach technology that often only large-scale customers have access to.

Launched in September, the +Series Depositors combine pneumatic machines with smart control. Using a smartphone or tablet connected via Bluetooth, users can control speed, volume, splash reduction, pre-charge, and deposit pressure pro ling for the most accurate deposits.

The new depositors connect to Uni ller’s cloud-based Total Care App, which provides real-time data analytics. Hundreds of recipes can be stored in the Total Care App’s cloud. Any machine settings and recipe adjustments can be digitally controlled through the app.

“This is the rst time we are offering a smart-controlled depositor with built-in Bluetooth features,” comments Sonia Bal, director of global marketing for Uni ller. “It’s a very low-cost program. Usually, this kind of

technology is reserved for more complex systems owned by large-scale customers. However, we’ve been able to develop it for our standard machines, as small as the Compact depositor, which means that even operators at a retail level can afford this innovation.”

Compared to previous depositors, the +Series can handle more complex applications, in part because of its connection to the Total Care App. “The +Series combined with the Total Care App allows for recipe storage, so complex recipes (deposit speeds and volumes) can be ne-tuned one time and stored for easy recipe recall in the future,” Bal explains.

The +Series Depositors are built for ease of use and cleaning. No special training is required to operate the machines, and detailed explanations and video instructions are provided for advanced functions. All electrical components are enclosed in a washdown case that will withstand tough, industrial washdown conditions, meeting IP69 standards.

This kind of connected technology is already in demand for large-volume producers, Bal notes. “We wanted to extend the same innovation to even our simplest machines. Customers have responded very well and are keen to try it out. We have already completed successful eld testing,” she says. “What’s great about the Total Care App is that not only does it work with the +Series Depositors, but with a simple add-on, it can actually turn previously owned manually adjusted pneumatic depositors into smart-controlled depositors.”

Another kind of food depositing technology was on display at the PACK EXPO booth of Hoosier Feeder Co. The Indiana company unveiled a unique product placing system (11) for various food products like chicken breasts or hamburger patties. It relies on a centrifugal feeder that orients products into a single le. At that point the product drops into a collator that drops individual products into a tray or, as was demonstrated at PACK EXPO, onto a hamburger bun.

a video of this product placing system at pwgo.to/7814.

FOOD PROCESSING & PACKAGING

INSPECTION TECH ON DISPLAY

Debuting at PACK EXPO International from TDI Packsys was their XR-6080SH X-Ray Inspection System (12). The detection technology built into the XR-6080SH can nd 3-mm thickness of bone, which is especially useful for chicken and poultry, since those bones can be hollow and dif cult to detect.

“Our customers were asking for something that could get a little more micron, especially for packaged meat,” says Israel Mateos, director of quality & integration at TDI Packsys. “We can also nd 0.3-mm metals, like stainless steel, ferrous, and non-ferrous, which is unheard of across the industry. We can do that with great accuracy.”

Mateos adds that while the detection technology in the XR Series is ideal for chicken and poultry, it also works for other meats too. “If this system does well on dif cult-to-detect, hollow chicken bones, it can do great on beef and pork bones that are denser and bigger.”

chines, you’ll be happy to know that Contact 4.0 can be installed on all Fortress digital Stealth, Interceptor, and Interceptor DF metal detectors as well as on the Raptor Checkweigher, Raptor XL Caseweigher, and the Raptor combination checkweigher/metal detector.

Speaking of Raptor checkweighing, it made its of cial debut for Fortress at PACK EXPO, as previously the rm did not have a checkweigher in its product portfolio. On display at the Fortress booth was a combination metal detector and checkweigher (13). Individual reject mechanisms, one for packs that are detected to have metal and one for packs that are detected to be the incorrect weight, are part of the combo system. The operator can control the entire combo system from a single HMI.

a video of the combo system at pwgo.to/7815.

Featured at the PACK EXPO booth of Schenck Process, the Global Hygienic Airlock (GHA), a USDA Dairy accepted dismountable airlock, is suited to applications where dry raw or nished products are being handled in the process and where inspection or system clean-out is required (14). At PACK EXPO International 2022, Schenck Process was displaying not only the GHA itself, but new features it has since made available on the airlock.

Technology driven by Arti cial Intelligence continues to establish itself as a xture in our world of increasingly smart factories, and Contact 4.0 from Fortress Technology is a great example. On display at PACK EXPO International, this smart data-capture solution is aimed at food manufacturers operating multiple metal detectors and weighing machines across multiple facilities.

Using web-based architecture, Contact 4.0 captures valuable production data across an entire suite of networked Fortress inspection machines. It can remotely monitor the performance of equipment, track events, and document all potential product safety risks. In other words, it turns massive data streams into tightly monitored and thus highly useful operational insight.

What’s more, for the rst time it lets food processors connect multiple front-end inspection machines to back-end reporting software in real time. It’s live, it’s streamlined, and it’s centralized. So rather than reacting to various production scenarios, customers can export dashboards and reports in the format that is most closely aligned with their common reporting standards. This enhances traceability and gives operational staff the info needed to address time-critical events. And for those already operating Fortress ma-

The Rotor Assist Device (RAD), for example, was recently made available to help disassemble the valve housing for cleaning. “These 12-, 14-, 16-, 18-inch valves can get quite heavy,” comments Jon Goecker, industry manager for Schenck Process, who demonstrated the unit at the company’s booth in Lakeside Center.

With the RAD, the valve rotor slides out easily on rails, enabling the rotor to be cleaned without workers having to lift the heavy equipment. Then it slides into the housing again easily.

Goecker also showed off the Valve Interference Detection (VID), which keeps the airlock from being damaged and protects product from contamination caused by friction between the valve rotor and the housing. “Without this, there could be metal shavings in the process,” Goecker explains. “That’s why we have metal detectors and sifters in the process,” but of course better to keep the shavings out in the rst place.

The VID system electrically isolates the moving rotor from the valve housing and drive system so that a closed circuit would indicate resistance between the rotor and housing. Any interference that’s detected would show up on the human-machine interface (HMI).

ADVANCED PICK AND PLACE FOR COOKIES AND SUCH

Following the ongoing trend towards automated material handling solutions, Syntegon Packaging Technology debuted at PACK EXPO International its new, Intelligent Direct Handling (IDH) pick-and-place system (15) designed for the at (pile) or on-edge (slug) handling of cookies, crackers, biscuits, and similar products. The advanced pick-and-place concept uses linear motor technology— Beckhoff’s XTS system to be more speci c—and the smooth movements of the linear motors ensure gentle handling of the fragile products.

“Product is fed into the IDH system from an oven or cooling towers, either random or in rows, with a tray denester positioned in parallel with the infeed,” Daniel Bossel, product manager at Syntegon, told PW at the show. “But the heart of the IDH is in the pick-and-place movers.”

Based on the XTS linear servo platform, these movers are instructed by a vision system as to the location of each layer of products. They then adjust themselves, in parallel with the product ow, to the placement of random biscuits as they are fed into the system. At the show, a row of 26 movers, arranged at an intersection with the infeed product ow, used vacuum end-of-arm tooling to gently pick up the biscuits, rearrange themselves from random to directly in-line, and carry them at a transverse 90-deg angle into waiting trays that had just been denested in parallel to the product infeed.

“The linear motor means that we have low acceleration and low

vacuum,” Bossel says. “This makes for very gentle handling of the biscuits. Also, the machine’s footprint is very small, and we can do a lot of different pack styles.”

The machine moves at around 30 cycles/min, and with 26 independent movers, that means 800 biscuits/min. These speeds with extra gentle, low-acceleration movement are meant to complement more traditional delta robot pick-and-place offerings that may be faster, but given differing acceleration and deceleration ranges, may also be less gentle.

At the booth, the IDH was also integrated with a Syntegon Pack 202 horizontal ow wrapper, with low back-pressure infeed, to form a turnkey system for packaging biscuits or cookies into trays that were then overwrapped with printed lm. The company adds that this full system could use more readily recycled monomaterial lms for the overwrap, or paperboard trays instead of plastic trays, to add to a brand’s desired sustainability pro le.

video of this system at pwgo.to/7816.

WEIGHING AND CONVEYING

Making its PACK EXPO International Debut was the Yamato Gravimetric Flex Weigher (GFW), which the company says was designed with exibility in mind (16). This bulk weigher features four weighheads to support target weights that range between 5 and 20 kg. According to the company, the Yamato GFW-1104CC scale offers high speed with supreme accuracy. At 5 kg, for example, this scale can operate at up to 60 weighments per minute, at an accuracy of ±5 g. Use this system to weigh a variety of bulk dry, free- owing grains, granules, and powders into bags, boxes, gaylords, and totes of all sizes. Automation like the GFW handles higher target weights, and complements the Yamato’s high-speed, highaccuracy combination scales, that tend to be more suited to lower weights with greater precision.

video of the Yamato technology at pwgo.to/7817.

In a dramatically different application, weight-wise at least, weighing and lling leafy greens can be a challenge to automate, and labor is getting harder to nd. To address this, Yamato demonstrated how to remove manual labor from packaging lines and ll and tamp salad with

its Yamato Automatic Diving Funnel (ADF). Featuring a rugged, low-maintenance design, this in-line tray ller (17) seamlessly places and tamps leafy greens into trays, bowls, and other rigid containers. The hygienic design keeps product safe from contamination, and ratio lling minimizes product damage. Increase production capacity while drastically reducing labor costs with the Yamato ADF. video of the weigher in action at pwgo.to/7818.

The new patented hygienic SSV-XP Drum Motor (18) from VDG (Van der Graaf), making its debut at PACK EXPO International, is designed with an exchangeable pro led sleeve that enables different belt pro les to be used without changing the drum motor. The pro led sleeve slides off the drum motor and is easily removed and replaced with another pro led sleeve to match the modular belt required on the conveyor. With the SSV-XP design, if the belt on the conveyor is required to be changed to a different belt pro le, then only the sleeve needs to be changed over and not the entire drum motor.

“From a design perspective, the main point is sanitation,” Alex Kanaris of Van der Graaf told Packaging World at the show. “The traditional way of driving conveyor belts [sprockets on a square drive shaft] is not sanitary. A traditional belt drive has many crevices and spaces that trap food byproducts and harbor bacteria, and it takes twice as long to clean using a signi cant amount of water. The drum motor with the continuous pro le sleeve eliminates these harborage areas and is faster and easier to clean, saving time and water.”

The hygienic SSV-XP Drum Motor is available in a range of diameter sizes, belt speeds, horsepower, and pro led sleeves for a variety of

HPP Now and in the Future

Several high-pressure processing (HPP) trends were presented at PACK EXPO International’s Processing Zone Innovation Stage, where Dr. Austin Lowder, food science manager at JBT Avure, discussed the current state of HPP and what the industry can expect in the future.

HPP extends the shelf life of fresh, refrigerated products like salsa, guacamole, juice, and more, by applying carefully calibrated pressure to a product inside its package, which destroys bacteria and pathogens that can cause foodborne illness. HPP can add between 90 to 120 extra days of refrigerated shelf life depending on the product, without destroying the texture, flavor, or color.

Lowder noted that bulk HPP processing for alcoholic and

non-alcoholic beverages will continue to trend upward in coming years, as well as HPP for raw pet food, which is a fastgrowing category. “I think pet food probably has the highest growth potential, especially because using HPP taps into an already existing market among pet owners. Many of them use traditional pet food processing, such as kibble, thermal processing, and high heat, and many people now want to move to more raw, less-processed diets. Probably the most effective way to do that, while maintaining a safe product for the animals and their owners is with HPP,” says Lowder. PW a video at pwgo.to/7821 to see more of Lowder’s HPP trends forecast from PACK EXPO International’s Processing Zone.

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FOOD PROCESSING & PACKAGING

conveyor belt manufacturers to suit various belt conveyor applications.

The SSV-XP also has a slide-on/slide-off continuous pro led sleeve over the drum motor that attaches simply with six screws, provides the exibility to adapt to various types of conveyor belts without removing the drum motor, and exceeds sanitary standards.

BATCH COOKING

Mepaco showcased its ThermaBlend batch cookers (19), which provide up to 50% more heat transfer area than hemispherical kettles and other conventional jacket cookers. ThermaBlend cookers deliver quick,

homogenous blending while minimizing shear with effective agitator designs, and also minimize burn-on while optimizing heat transfer with a durable, bi-directional scraper system.

“For a stew product or a chili, companies want every one of those vegetables, beans, or pieces of meat to be intact, so that it looks just like you might make in your home kitchen, but on a much larger scale. We have a steam jacket, much like you do in your kitchen where you have a pot sitting on top of a heating element, and you’re heating that pot indirectly,” says Tom Hoffman, director of sales at Mepaco.

Hoffman adds that the ThermaBlend batch cookers come with direct steam injection as well as a steam jacket for the full range of steam and cooking options. ThermaBlend also has CIP capability, and the option to batch chill as well.

“You can bring a product up to 180 degrees, cook it, and hold it through an intervention step if necessary. Then, you can actually bring it down to whatever temperature you want all the way down to 40 degrees in a relatively quick period of time.”

NEW DICER FOR MEATS, VEGGIES

The new Urschel M VersaPro Dicer (MVP) rolled out at PACK EXPO International with a slate of cutting-edge features for creating dices, strips, and shreds from meats and vegetables (20). The MVP is the fourth generation in Urschel’s M-series, with 33% increased feeding capacity compared to Urschel’s M6 due to wider, 12” infeed and takeaway belts, and increased horsepower.

MAP Packaging

Debuting at PACK EXPO International was Preco’s new AcuBreathe Nano technology for flexible MAP packaging, which nano-perforates in a range of 25-65 microns. That makes it especially suitable for vegetables, salad pouches, and some applications in the medical market, where the nano perforation can relieve pressure inside the package during changes in altitude, preventing the package from opening prematurely.

“The ability to get down to the 25 to 65 micron hole size range wasn’t possible until we just developed this,” says Kurt Hatella, EVP of laser equipment sales, Preco. “This has been a request in the market for 10 to 15 years. We just never had the technology to be able to do it until now.”

Laser micro-perforating is a process of generating a series of small through-holes for MAP. Perforations can also be used to help achieve controlled airflow and moisture release in various packaging products such as extending shelf life for fresh produce and burst protection for changing air pressure. Perforations also offer the capability of easier filling because air escapes quickly during filling while the product remains contained and compressed for improved stacking. PW

The MVP features stainless-steel construction throughout, with an IP69K certi ed electrical enclosure and double-sealed door for extra protection during washdowns, while the cutting spindles have a sanitary design and are cantilevered for quick changes. Speaking of cutting, the width is determined by a gang of circular knives followed by a series of cross-cutting knives that determine the length. The machine has the option of 5 in. diameter knives for 1 in. thick product, or 6 in. diameter knives for product thickness of 11⁄2 in.

“In addition, on the machine we have an optional HMI that gives you the ability to set cut sizes along with recipes for the different products you have,” says Tim O’Brien, sales director at Urschel Laboratories. The optional Allen Bradley HMI touchscreen also contains the entire user manual for ease of operation and maintenance.

a video of the machine in action at pwgo.to/7819.

FOOD PROCESSING & PACKAGING

Pneumatic conveyor pioneers VAC-U-MAX put their expertise on display at PACK EXPO International, showcasing several of the company’s bulk material handling systems for dry foods and other dry products.

VAC-U-MAX’s pneumatic conveyors (21) feature all stainless-steel and sanitary design, with easy disassembly for cleaning, including the lter, which is washable. Because some of the machines are positioned high in a processing facility, VAC-U-MAX developed a solution to lower the machine rather than risk injury to a worker climbing a ladder to clean it.

“We’ve come up with what we call a column lift. You put the machine on a pedestal, you raise it up by hand, and you can crank it over to get it over the process,” says Vince Macaluso, regional sales manager for VAC-U-MAX. “Now you can clean it. You just pivot the machine over and lower it down to the ground, where it’s at oor height and you’re ready to clean it out.”

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PUMPS, MIXERS, SORTERS

Fristam Pumps USA debuted its next generation colloid mixer (22) at PACK EXPO International, featuring real-time gap adjustments and hands-off clean-in-place (CIP). This new colloid mill features on-the- y gap changes with an external gap adjustment lever, which can widen or shorten the gap to produce more or less shear without moving the inlet or outlet ports, or pausing the operation.

The new mixer’s variable gap allows the user to dial in the particle size needed for shelf-stable emulsions, resulting in more consistent particle sizes with a tight distribution. Some applications for this mixer include mayonnaise, dressings, dips, oil and fat emulsions, condiments, dairy solids, and more.

“We have a blender, but blenders only go so far,” says Jim McCoy, sales manager, Americas, Fristam Pumps. “We were getting a lot of requests saying, ‘Hey, I need you to move down the particle size range.’ So this is the result of that, and we can meet their exact, precise requirements for particle size. Plus, this mixer ts in with our whole portfolio of products.”

The Fristam FCM also features CIP without disassembly, designed for hands-off use that allows you to adjust the gap to the maximum setting and CIP through the mill without removing any parts. The mixer has a max shear rate of 143,000 1/s, can handle sub-micron particle size, has a max inlet pressure of 250 psi, a max product ow rate of 50 GPM, a max CIP ow rate of 100 GPM, is bi-directional, and has a 50 HP motor size.

Axi ow Technologies debuted its bulk drum unloader (23) at PACK EXPO International. This new tool for removing uids and soft solids up to 3⁄4 in. from plastic, metal, and ber drums of 16, 20, 30, 55, and 75 gallons features a speedy 50+ gallons per minute (GPM) unloading, with discharge pressures up to 375 PSI. This CIP-ready bulk drum unloader can handle product viscosities over 500,000 centipoise, and it can be tted with custom plates for different sized drums, as well as mix kettles and pots. The plates are also removable for pumping out totes and tanks.

Graco unveiled its updated electric pump (24) for food processing, boasting energy savings up to 80% more than traditional pneumatic air diaphragm pumps. According to Jeffrey Shaffer, senior product manager and North American sales manager hygienic equipment at Graco, the company has been making electric pumps for about six years, but Graco recently developed patented technology that eliminates the need for a gearbox inside a pump, reducing the footprint and signi cantly increasing its energy savings.

“We have the motor and drive package right in the middle of the pump, but there’s no gearbox now, which reverses package size and cost to the user,” explains Shaffer. “A big bene t with electric is it reduces your energy costs as far as ef ciencies by up to 80%. So while a pneumatic pump might cost you $2000 a year to operate, this might cost you $200 a year. So big savings, and it also quali es for energy incentives from our company.”

Macaluso demonstrate VAC-U-MAX’s pneumatic conveyors at pwgo.to/7820

FOOD PROCESSING & PACKAGING

Shaffer adds that the new version of Graco’s electric pumps work seamlessly with facility control systems that can monitor the pump’s usage around the clock, which facilitates predictive maintenance, saving time and labor.

Lubriplate debuted several new products at PACK EXPO International, including re llable bulk loading grease guns and grease transfer pumps for 35-lb grease pails and 120-lb kegs (25). Lubriplate’s hand pump provides grease gun loading direct from the bulk containers, and the kegs have an option to use an automatic pump for tasks that require more volume.

Also new from Lubriplate at the show was their Lubriplate Synthetic Food Grade Drilling & Tapping Fluid, which is a full synthetic uid designed speci cally for drilling and tapping. This product is NSF H1 registered, making it ideal for food processors, food package manufacturers, and the pharmaceutical industry.

One more debut from Lubriplae is its SYN-FG SDO food grade synthetic sugar dissolving oil, ideal for beverage manufacturers or those working with sugars and syrups. SYN-FG SDO is NSF H1 registered and is speci cally designed to remove sugar deposits and to lubricate machine components exposed to sugar contamination, thus reducing and preventing future sugar buildup. All of Lubriplate’s spray cans now feature the company’s patented Secure Straw dual-spray nozzle with a permanently attached straw.

Unibloc rolled out its multi-size line of QuickStrip FoodFirst pumps (26), which now range from the QS FF 300 to the QS FF 677, featuring 1.0-in. to 6.0-in. outlet sizes and ow rates from 28 gal/min to 500 gal/ min, depending on the model size. All QS FF pumps feature Unibloc’s patented CIP features with tool-free disassembly.

“The largest version of our FoodFirst pumps was originally made for meat and poultry. But over time we realized there’s more than just those markets that can use this technology, so we expanded across the product line with different sizes, and our customers love it,” says Mark Boyd, VP of sales, Unibloc.

supports the diaphragm when you put in the CIP pressure. It’s so unique that most engineers don’t even know it can be done. So one of the big things is to educate engineers so they can spec this double diaphragm pump on a CIP application.”

Elsewhere in the world of pump manufacturing, Alfa Laval has been making several advances over the past year or so that work, in particular, to ease maintenance concerns from a number of vantage points. Last year, Alfa Laval introduced its DuraCirc positive displacement pump (27), a departure from the typical circumferential piston pump (CPP), delivering on durability, reliability, ef ciency, and hygienic performance. Rather than compromise on trade-offs, manufacturers across the dairy, food, beverage, confectionery, and personal care industries can get it all.

“We spent years guring out how to get into the U.S. market. We were looking at all our customers’ sore points,” says Russell Jones, commercial manager for pumps at Alfa Laval. “This tackles about ve common problems.”

One improvement is the elimination of contact between the pump’s rotor and casing. Traditional CPPs have constant contact between the

Also new at PACK EXPO International from Unibloc was the company’s Flotronic Air Operated Double Diaphragm OneNut Pump. The stainless steel pump’s unique design allows for disassembly and cleaning in a fraction of the time it takes to do the same with a standard pump—from an hour or more down to just minutes—signi cantly reducing downtime.

product line with different sizes, and our customers love it,” says Mark Also new at PACK EXPO International of

“It’s the only air-operated double diaphragm pump in the world where you can use CIP rig,” explains Leighton Jones, director of sales at Unibloc. “We added a reinforced backing plate, and that

rotor

rotor and plate, Jones notes. Alfa Laval guarantees no contact until at least 360 psi, he adds, helping to increase durability and pump life while also reducing the chance of media contamination.

The pump is certi ed to meet 3-A Sanitary Standards, but goes beyond those standards to ensure cleanliness. The fully CIPable design is standard. “After the CIP cycle, it’s not only clean, but there’s no residue,” Jones says. That’s true even with viscous products, which can have challenging particulates, he adds. Also meeting EHEDG guidelines, the DuraCirc pump assures process integrity and product quality. For a crevice-free

challenging lines, the DuraCirc pump assures process integrity and product quality. For a crevice-free

and plate, Jones notes. Alfa Laval

design with no dead zones, all product-wetted elastomers are made of FDA-conforming materials and pro led and de ned compression as standard; this reduces contamination risks and cuts both cleaning time and costs. The all-stainless steel construction is also suitable for hygienic washdown.

Maintenance is also reduced through an FDA-conforming oil lubricant that has an extended service interval—about 3,000 hours vs. 750

hours for a typical competitor. Front-loading self-setting mechanical seals are easy to get to, making them quick and easy to change without the need to remove the pump from the system.

“We don’t like to make incremental improvements,” Jones says. “We like to make leaps.”

More recently, Alfa Laval has introduced a subscription-based digital monitoring system for pumps and other rotating equipment such as agitators and mixers in hygienic processing industries. CM Connect enables operators to access data from a remote location. It provides operators the information they need to make informed maintenance decisions— such as actual runtime, trend analysis, and time to the next service. Advanced vibration analysis enables early detection of any deviation from pre-set equipment threshold values.

Acting as a gateway communicating via Bluetooth, CM Connect can link up to 10 Alfa Laval CM wireless vibration monitors and transmit the data to the cloud over a 4G cellular network for review and analysis on a dashboard.

“People in our industry don’t know what condition monitoring is. In oil and gas, they’re all over it,” Jones comments. “But it’s always too complicated and too expensive for our industry.”

Alfa Laval aimed to change that equation with CM Connect, making it simple for operators to use. “If they see a red light, they just quiz it with their phone,” Jones explains, also noting a low price point. PW

PMMI ProSource is a free online directory with 900 categories of validated suppliers of food processing and handling equipment solutions. With a powerful search engine and the ability to filter solutions by machine feature and package type, ProSource brings vetted suppliers to you. Visit www.prosource.org today.

SUSTAINABLE PACKAGING

Many times at a PACK EXPO booth it’s the display case that best re ects recent innovations an exhibitor has successfully brought to the marketplace. This was certainly the case at Berry Global. Two we’ve already reported on, a lightweight Mars candy container using PCR (pwgo.to/7822), and a 100% rPET food color bottle by McCormick (pwgo.to/7823).

But three other notable items not familiar to our editorial team were also on display:

• Tchibo coffee capsules—A partnership among Berry Global, its customer Tchibo, and its feedstock supplier Neste has resulted in a potentially game-changing development in the coffee capsule market with the introduction of a thermoformed PP capsule made partly from renewable sources (1). Rather than virgin PP that is made from nonrenewable fossil fuel sources, the polymers used for the Tchibo capsules are sourced from renewable raw materials such as residue cooking oils and fats. A life cycle assessment by the Technical University of Berlin, carried out in compliance with ISO 14040/44, has shown that the conversion of the Qbo capsule material results in around 35% fewer CO2 emissions compared to materials more commonly used today.

“We are pleased to offer Qbo capsules made of PP, now produced from 70% renewable raw materials,” says Marius-Konstantin Wiche, development manager, capsule and innovation at Hamburg, Germany-based Tchibo. “This makes the entire Qbo range—containing sustainably grown Qbo coffee brewed in Qbo machines— one of the most sustainable capsule systems on the market.”

The renewable materials are supplied via an approach certi ed by the International Sustainability & Carbon (ISCC PLUS) system. This certi cation makes it possible to articulate on the packaging the proportion of renewable raw materials used to make the package. So the certi cation provides full traceability throughout the supply chain, from raw materials to nished coffee capsule, as well as sustainability validation of the raw materials. Just as important, the new capsules provide an identical performance and consumer experience. Plus the renewable feedstock can be easily introduced into existing production lines with no changes required.

“We needed to ensure that the high quality and great taste of the Qbo coffee would not be affected,” says Wiche. “That’s why we focused on replacing the raw materials for the capsules, not the PP itself. The renewable materials go into producing PP polymers with the same quality as virgin PP; you won’t see or taste any difference.”

Berry says it combined its sustainability leadership in the selection of the right quali ed raw materials with its technical skills for the efcient manufacture of the capsules to accelerate the conversion to this more sustainable, circular solution. The company’s expertise in design for circularity allows for multiple potential solutions to be developed

for the future manufacture of coffee capsules, thanks to its ISCC PLUS certi ed site in Bremervörde, Germany. The ISCC PLUS certi cation not only ensured that food contact approval was granted for the new materials, it also allows for the quick transition to additional applications over time.

“We chose Berry for this project as they have experience with our product and hold the required ISCC PLUS certi cation to produce the capsules from renewable materials,” says Wiche. “The company’s knowledge of extrusion and thermoforming for our capsules is excellent, and we also appreciate their in-house engineering and machining of related parts for our products.”

For Berry, the introduction of the new capsules supports its recently announced commitment to achieve 30% circular plastics use across its fast-moving consumer goods packaging by 2030 as the company envisions decoupling from virgin plastic and fossil fuels in the long term.

“Supporting our customers’ growing sustainability commitments is a key priority as we plan for the future needs of a net-zero, circular economy,” says Jean-Marc Galvez, President of Berry’s Consumer Packaging International Division. “Delivering the infrastructure and manufacturing capabilities to design products for circularity is one of our core competencies. I am incredibly proud of this partnership and its commitment to demonstrate the potential of renewable raw materials to lower the environmental impact of capsules.”

“Together,” says Wiche, “our Tchibo/Neste/Berry team has created a fantastic result. The Qbo coffee still maintains its premium quality, but now in a capsule produced with less CO2 emissions.”

• Tesco/Heinz/Berry project—Berry Global is collaborating in a rst-of-its kind project launched by Heinz and Tesco in the UK to permit the chemical recycling of exible lm packaging dropped off by customers at Tesco’s in-store collection points. Also on the team are recycling technology experts Plastic Energy and SABIC, and together the team has launched a pioneering trial with the development of new Heinz Beanz Snap Pots (2) that incorporate 39% ISCC PLUS-certi ed recycled exible lm.

According to Berry, the exible lms collected in Tesco’s stores are taken to Plastic Energy and physically segregated for conversion by pyrolysis—the thermal decomposition of materials at elevated temperatures in the absence of oxygen—into an optimal oil feedstock. This feedstock, which Plastic Energy calls TACOIL, is combined with virgin material by SABIC to produce an alternative feedstock for making food-contact-approved plastic pellets. These pellets are sent to an ISCCcerti ed Berry Global site and combined in a coextrusion of PP/EVOH/

White Masterbatch/PP-based adhesive. Then comes thermoforming, also by Berry. After Heinz lls and lids the pots, they undergo thermal treatment at 121ºC for about 30 minutes to render them shelf stable at ambient temperatures.

“This is a prime example of an innovative advancement in circular packaging design made possible by collaboration across the entire value chain,” says Berry’s Galvez. “This approach helps capture and reuse plastics that currently go unrecycled, to keep materials in use and out of our oceans and land lls.”

The 50/50 joint venture between London-based Plastic Energy and Saudi-based SABIC is fascinating to say the least. It’s called SPEAR (SABIC Plastic Energy Advanced Recycling BV), and it’s being executed with a Top Sector Energy Subsidy from the Ministry of Economic Affairs in the Netherlands. That country, speci cally the town of Geleen, is also the site of the new production facility. SABIC and Plastic Energy have worked together with leading customers and converters to produce and commercialize certi ed circular polymers since early 2019. But with the Geleen facility in commercial operation, SABIC can signi cantly upscale the production of certi ed circular polymers to provide customers with greater access to sustainable materials that have been recycled, repurposed, and produced in a way that can provide a drop-in solution that helps protect the planet’s natural resources.

“Advancements in this pioneering project take us one step closer to driving the change needed to become a circular global industry,” says Fahad Al Swailem, vice president, PE & sales at SABIC. “We have overcome signi cant external, global challenges to reach this important milestone and remain fully committed to closing the loop on used plastic. We are continuing to collaborate on an unprecedented level with our partners upstream and downstream to achieve this.”

“It has been an exciting journey in making our vision of building advanced recycling plants come to life,” says Carlos Monreal, Founder and CEO of Plastic Energy. “We have worked jointly with SABIC towards our common goal of making plastics more sustainable and moving towards a more circular economy for plastics.”

The 39% recycled plastic that the new snap pots contain was vali-

dated using an approach endorsed by ISCC. This makes it possible to track the amount and sustainability characteristics of materials used in the manufacturing process. The recycled material meets the requirements of food-contact safety regulations and provides a replacement for virgin polypropylene in the thin-wall pack with no compromise on processability or mechanical performance.

“We want our Snap Pots to be more sustainable while retaining the features that make them so popular with consumers: their convenience, handy snappable format, microwavability, and ensuring the product remains fresh,” says Héloïse Carlier, senior packaging development technologist at Heinz. “With this project and our introduction of the new Heinz Beanz Snap Pots, 22 tons of [ exible lm] will be recycled.”

To date exible lm packaging has been notoriously dif cult to recycle. Until 2020, just 6% of the material was being recycled in the UK. It is hoped this venture will inspire the wider industry to take action in tackling this issue, both in the UK and other countries across Europe.

“We’re proud to have teamed up with leading experts to bring this important innovation to our customers,” says Jojo de Noronha, Heinz’s president Northern Europe. “Our hope is that this prompts an industrywide look at what more can be done to address the lack of [ exible lm] being recycled in the UK, and we can, as a collective, get better when it comes to developing new packaging solutions that are good for both our consumers and for our planet.”

• Technology Award Winner—Also newsworthy is that Berry Global’s Proxima tethered closure (3) with tamper-evident band was named a winner of a PACK EXPO Technology Excellence Award in Sustainability from PMMI.

The Proxima tethered closure enhances opportunities for reducing litter and increasing recyclability of the closure, while still offering consumers a convenient and comfortable drinking experience for cold ll and aseptic applications, including still water and functional drinks. The design of the injection-molded polypropylene closure features a special tamper-evident band that, once broken, does not affect the closure’s ability to remain attached. When opened for drinking or pouring, the closure is positioned at a wide angle, adjacent to the neck of the bottle, thus ensuring the bottle can be easily reclosed for consumer convenience.

This solution provides two important sustainability bene ts. Because the closure is designed to remain intact with the bottle, it is less likely to be thrown away or littered. This can greatly reduce the possibility of the closure leaking into the environment. Equally important, keeping the closure on the bottle decreases the danger of littering and unnecessary plastic waste when closures are carelessly or thoughtlessly discarded.

Proxima is available in 29-mm and 38-mm diameters to t various

SUSTAINABLE PACKAGING

neck nishes. In addition to its user-friendly features, the closure can be speci ed in a variety of colors to help individualize product branding and maximize on-shelf appeal. Proxima meets current legislation on single-use plastics including the EU Directive 2019/204, which requires plastic beverage bottles up to 3 L in size to have closures that remain attached to the container throughout its intended use from 2024 onwards.

PAPERBASED CAN CARRIERS

ClipCombo was big news at the PACK EXPO International booth of Graphic Packaging International. An innovation that combines multiple packaging solutions over a modular machinery system, it was selected as one of four PACK EXPO International Technology Excellence Awards by PMMI. This new machinery approach to beverage packaging comes in two avors, one for cans and one for PET bottles. ClipCombo for cans runs EnviroClip™, which is essentially a at piece of paperboard that ef ciently holds cans together. But the same machine can also run KeelClip™, (4) which is positioned as more of a premium option because it folds over the top and has more room for graphics—not to mention the fact that cans can be oriented to maximize branding opportunities. A third option that can also be run on this machine is GripClip, which is similar to KeelClip except that it doesn’t include the center keel, which means it brings savings in paperboard cost.

ClipCombo for PET bottles runs EnviroClip or Cap-It (5). Designed for PET bottles with neck rings, Cap-It provides an on-the-shelf differentiation from other multipacks by combining both a beautifully printable paperboard billboard while still allowing a portion of the bottles to be visible. Like other options in GPI’s clip portfolio, Cap-It is designed to maintain its pack integrity through the supply chain while also providing a comfortable consumer experience.

Boasting high speeds of up to 400 packs per minute (depending on application) and rapid changeovers as part of an impressive list of bene ts, ClipCombo enables customers to differentiate between brands and position premium or standard options—all on one machine. Worth noting is that GPI also supplies the paperboard material for its various paperboard carrier offerings.

“We know many of our customers take their sustainability goals seriously, as do we,” says Doug Hicks, vice president of the packaging machinery division at Graphic Packaging. “We also know that markets change and there is a need to future-proof machine system choices. That’s why we’re delighted to reveal the ClipCombo concept, a game-changing machinery philosophy that enables customers to select from a wide range of existing and new packaging options as well as container and con guration choices. Packers can combine products over a single machinery system, and be con dent they have the options needed as the market evolves.”

GPI is by no means the only company on the supply side of the packaging arena working diligently on paper-based substitutes for plastic ring carriers, and PACK EXPO Interna-

SUSTAINABLE PACKAGING

tional was a great place to catch up on at least three others:

• Krones offers equipment for the standard LitePac Top, a at piece of paperboard that holds cans together. But it also has equipment for LitePac Top Promo Skirt (6) should customers want more room for graphics and branding. Also part of the portfolio is equipment for LitePac Top for bottles where a paperboard strap or “banderole” provides additional holding properties (7). Krones in its approach to these novel packaging concepts stays focused on mechanical machine engineering and partners with a number of paperboard packaging material suppliers.

• KHS offers a variety of paperboard can “toppers” that can be applied by its Innopack Kisters CNP (Carton Nature Packer) systems, including both a GreenClip option, which is a standard at piece of paperboard that holds cans together, as well as the more premium-level TopClip (8) for more graphics and branding opportunities. Even more recently, KHS has introduced a paper wrapping concept that replaces plastic shrink lm with paper (9). Like Krones, KHS focuses on the machinery side of the equation and partners with packaging machinery suppliers.

• Westrock’s CanCollar family of sustainable beverage packaging solutions (10) comprises six options. Like GPI, Westrock takes the “razor and the razor blade” approach in going to market, as users of CanCollar technology purchase the paperboard from Westrock. In the center is CanCollar Classic. Left to right are CanCollar Shield, CanCollar Shield Plus, CanCollar

EcoPlus, PremCollar, and CanCollar X. Most impressively, the CanCollar Fortuna machine featured at Westrock’s PACK EXPO booth is capable of producing ve of the six members of the CanCollar family. This capability is due in large part to the machine’s use of the ACOPOStrak linear drive system from B&R a video of Westrock’s CanCollar Fortuna at pwgo.to/7824.

WHAT ABOUT FOODSERVICE PACKAGING?

ProAmpac used PACK EXPO International to launch in the U.S. its Fresh Food To-Go line of sustainable, ber-based packaging (11) designed speci cally for the on-the-go convenience retailer. ProAmpac says it specializes in the design and manufacture of fresh sandwich packs, trays, wraps, and soft packs for hot and cold food applications in deli, quick service restaurant (QSR), convenience store, and supermarket in-store markets, among others. According to the company, these products use two distinct routes toward sustainability in that they reduce avoidable packaging and offer extended shelf-life formats to reduce food waste.

“ProAmpac’s fresh food to-go

It’s more than a bulk material handling system. It’s a chance to help your team perform at the highest level. By leveraging our experience across thousands of applications, you gain a solution that drives process improvement, increases productivity, enhances safety and more.

Imagine how we can transform your operation!

SUSTAINABLE PACKAGING

packaging has been used in the UK and Europe fresh food market for decades. We are pleased to bring these products to North America. Our HandRap has just hit store shelves for the rst time in the USA and we are getting great feedback from the stores on ease of use,” says Irma Randles, marketing director for ProAmpac.

The company says the format keeps food fresh and offers an elevated appearance in either a hot cabinet or chiller. Also, by weight, the

largest component of ProAmpac’s fresh food to-go packaging is paperboard and paper, a renewable resource from certi ed, well-managed forests. In many formats, the paperboard can be recycled after being easily separated from the lm by the consumer.

Having received the above information in advance, PW editors were primed to check out the foodservice packaging spread at the show, and Sal Pellingra, VP global package design, applications & business development at ProAmpac, didn’t disappoint.

“I think one of the biggest game-changers in North America is really this movement toward sustainability,” says Pelllingra. “Sustainability can mean a lot of things. It can be the trend toward mono-materials that can be recycled, and also the use of PCR. But another really big one is a huge change in moving from rigid plastic and thermoformed plastic structures, like plastic trays or clamshells, to paper-based or ber-based structures.”

Different models of use for QSRs, deli, and convenience can use these packs for day-fresh products, for medium fresh with some shelf life, “or they can be modi ed atmosphere packaging (MAP), and depending on what’s inside, can stay fresh for anywhere from seven to 28 days,” Pellingra adds. “The oxygen barrier on some of these products gets down to 1%.”

At PACK EXPO, Pellingra speci cally demonstrated a product in the line aptly called a sandwich wedge. He describes further, “These are two materials, a combination of ber and lm. There’s a dual label on these, where you remove the [unrecyclable] plastic lm, but the paperboard is recyclable. On current [thermoformed] clamshells, there’s no printability, so you can only put a label on them. On [the Fresh Food To-Go sandwich slice pack], you can put artwork all the way around. And you’re reducing the amount of virgin packaging materials, which is key. They’re customizable, use modi ed atmosphere, they reduce the amount of packaging materials, and they reduce the amount of virgin plastic resins.”

Pellingra says that the sandwich wedge pack formats are all over shelves in the UK already, for instance at upscale convenience retailer/QSR Pret a Manger.

While ProAmpac supplies the packaging materials, the company has partnered with JBT Proseal, a tray sealing machine manufacturer, to offer North America’s rst in-line sandwich packaging testing lab at ProAmpac’s Collaboration & Innovation Center (CIC). Designed to form and seal fresh sandwich packaging, Proseal’s GTSV machine will be used to optimize packaging design while allowing customers to run trials on new packaging formats without disrupting commercial production operations.

“The recyclable ber board sandwich packaging format is in early-stage adoption in North America. Having a facility to showcase the packaging functionality on a commercial-scale sealing line allows our

Harness the collective intelligence

SUSTAINABLE PACKAGING

customers to experience this new technology,” says Randles. “The ber format has been an industry mainstay in the UK for years and continues to grow. However, Proseal’s GTSV is the rst in-line sandwich high-speed sealing machine in North America.” a related video at pwgo.to/7825.

NEW SHRINK FILM

Debuted at PACK EXPO International, the recyclable Clysar Ultra LEG shrink lm is an advanced new polyethylene (PE)-based polyole n shrink lm that is prequali ed for Store Drop-Off by How2Recycle. We’ll begin with a list of features this new lm exhibits to set the stage, then dive into a new, in-market product that Clysar President Vicki Larson talked about in the booth.

Ultra LEG shrink lm is a gentle, or “low-energy” polyole n that can improve shelf appeal by being gentle to the products around which it shrinks. In fact, the lm exerts approximately 40% less force on products during shrinking than competitive low-energy lm, according to the company. This makes it ideal for delicate or collapsible products, allowing them to retain their natural shape without the shrink force bending or otherwise distorting the products. Its high

availability shrink makes for crisp, tight shrink packages, and its balanced, all-around shrink eliminates dog-ears and other aws. With all these factors considered, it results in good shelf impact where it’s applied. The company says that Ultra LEG is easy to use and creates consistent, attractive packages without major ne-tuning, rejects, or waste.

The lm also can be processed at lower temperatures, making it a good choice for heat-sensitive products. Low seal and shrink tunnel temperatures reduce energy use in packaging operations. Tunnel temperature for clean shrink typically starts 25°F cooler than traditional polyole n shrink lms, and sealing for hot knives starts at approximately 300°F. Energy reduction is good for both sustainability measures, and for the bottom line given energy input costs. The thin-gauge lm also provides material reduction or lightweighting opportunities, again good for a brand’s sustainability pro le.

With these stated qualities, Clysar’s Ultra LEG lm is an ideal t for many markets. But center of the bullseye and demonstrated at PACK EXPO International was an application for furnace lter packages (12). Furnace lters are so delicate that most non-PVC lms would end up bending the lter pack while shrinking in the heat tunnel. But as fur22_004406_Packaging_World_JAN Mod: November 28, 2022 9:35 AM Print: 12/08/22 page 1 v2.5

SUSTAINABLE PACKAGING

nace lter producers seek to eliminate PVC from their lineup for health and sustainability reasons, they still need to maintain a thin, light lm that requires only low heat to shrink. The Clysar Ultra LEG lm stands out for this application, as well as calendars, school paper, and other product ranges with similar qualities.

“Traditionally, furnace lters have tended to use PVC,” says Larson. “And the reason why they’re in PVC is because PVC uses a single bubble. It’s more of a cast technology. So they can control how much the lm shrinks in the machine direction and in the transverse direction. That’s why PVC has been so prominent in the furnace lter industry, because nobody wants this to bend on the shelf.

“But our Clysar technology uses a double bubble. We blow a tube, and then we blow a big bubble. You get equal shrink in both the machine direction and the transverse direction,” she continues. “We’ve been able to develop a lm through process and formulation (chemistry rules and technology rocks, right?) that allows us to do this in a true polyole n. Any other polyole n would bend this [package, a furnace lter in a primary paperboard carton]. Ours doesn’t.”

Clysar’s Ultra LEG Film is very thin, lightweight, 40-gauge material. In the PACK EXPO International furnace lter demonstration, the lm makes up only 0.5% of the total package.

“From a lm standpoint, we’ve also been able to make it in a way that is approved for store drop-off [recycling]. So we have three approval items already for this product, launching it so that they’re commercially in stores today [Oct. 23, 2022].”

Beyond furnace or air lter type of products as described above, good applications for the Ultra LEG Film include protective apparel, like face masks; stationary, stickers, and thin paper products; open-sided chipboard cartons; magazines, calendars, and other low-pro le items;

craft, hobby, and collectible products; bundled printed materials; and candy and confectionery products.

The recently improved EVO-C (Con dential) shrink lm (13), displayed at the Clysar booth at PACK EXPO International, is a recyclable, ultra-durable, opaque lm now available with Post Consumer Content (PCR). The company says it is ideal for secondary shipping and stabilization, UV protection, product masking, and containment.

EVO-C lm is part of a larger Clysar EVO family of shrink lms that is safe for the recycling stream, having undergone signi cant testing to ensure that it meets the rigorous new protocols and revised requirements of the How2Recycle program. These lms are one of the few current polyole n shrink lm structures that qualify for the of cial How2Recycle Store Drop-Off label, the company says.

The opacity of the lm provides privacy for consumers ordering sensitive materials through the e-comm channel. It also adds a layer of protection against porch piracy since potential thieves can’t see what the shrinkwrapped pack contains to assess its value.

The EVO-C product has been around for three years, so PW asked Vicki Larson, Clysar president, what’s new about it? Why display it here and now?

“Clysar has improved the environmental appeal of our EVO-C lm on several fronts. We have been able get the same ‘hide,’ or the same opacity level with some downgauging—formulation is so important. What we’re launching today at PACK EXPO is that EVO-C has PCR (postconsumer recycled content),” she says. “Now, we can answer the P&Gs of the world who say we need to be using recycled content material.

“Clysar addresses the e-commerce market from all sides—whether you just want the privacy feature, so the shrink-wrapped product goes into an Amazon overbox, or whether your product goes through the mail without the overboxing, so our shrink lm serves as the second-

Odorless Concentrate Using Recycled PP

Milliken & Company and PureCycle Technologies, Inc. have created a new concentrate for polypropylene (PP) designed to allow for greater use of 100% recycled content. Additionally, the companies report that when used in combination with PureCycle’s recycled PP (rPP), it produces a formulation with a carbon footprint that is approximately 35% lower than that of virgin PP.

A common concern among those looking to incorporate recycled content is whether the material’s color and formulation will compare to virgin material and the aesthetic that consumers are used to. Because PureCycle’s technology separates color, odor, and other contaminants from PP waste feedstock to transform it into ultra-pure, virgin-like resin, the new concentrate offers promise in making rPP an attractive

option for PP converters seeking quality and crystal-clear clarity.

The new concentrate has been formulated using Milliken’s Millad NX 8000 ECO clarifier, which as Milliken’s Brian Burton explained at the show, has been on the market for some time. Also of note is that the certified energy savings by using resin produced with this clarifier allows brand owners to display the UL Environmental Claim Validation label on their injectionmolded parts.

As Burton noted, while some recycled content is downcycled into products such as flower pots and park benches, this is FDA-approved material that can be incorporated right back into food packaging, “so it really opens up the applications you can use it for.” PW

SUSTAINABLE PACKAGING

ary package.” (According to Clysar LCA data, packaging volume can be reduced by as much as 80% using EVO-C shipping lm to replace the overbox.)

Speaking of P&G, displayed at the Clysar booth was P&G’s now-famous Tide box, a SIOC (ships in own container) format that eliminates the need for overboxing, and instead uses EVO-C shrink lm. By removing the need for overboxing and using shrink instead, it reduces weight, size, and the amount of material used, all sustainable qualities that brands like Tide are looking for.

And now, brand-owners can also say their packaging lms are using PCR, as well, building toward a more circular plastic economy.

“Right now, everyone wants to use recycled content, but it’s not vastly available, especially not in the highly transparent qualities that brands need to display their products,” Larson adds. “But because this is an opaque shrink lm, I can get a white [as opposed to the usually preferred clear] lm into the formulation for both opacity and use of PCR.”

A PORTFOLIO OF SUSTAINABLE CHOICES

Recycle-ready with no compromise on performance was a prominent theme at the Amcor booth, as Amcor Flexibles introduced a range of AmPrima PE PLUS applications (14). A portfolio of more sustainable

by ASSET, Amcor’s unique Carbon Trust-certi ed Life Cycle Assessment service, and the results are impressive. Compared to a current market offering such as 48-ga OPET/PE/EVOH-PE/mLLDPE, AmPrima Plus lm, when recycled, delivers a 75% reduction in non-renewable energy use, a 58% reduction in carbon footprint, and a 54% reduction in water consumption.

• Flow wrap applications for wet wipes—Typically, wet wipe packages use OPET or OPP layers, rendering them unrecyclable. This presents a problem for brand owners. Amcor has developed a new, more sustainable exible lm for wet wipes that provides all the heat resistance, clarity, and stiffness compared to standard laminations currently in use.

Also on the innovation front, Amcor Rigid Packaging introduced its DairySeal line of packaging (15) that features ClearCor, an advancement in oxygen barrier technology for PET bottles. The new barrier technology, says the company, has “higher levels of concentration encapsulation in the center of the preform, allowing less barrier to be used while being more effective.” This allows for more PCR in use, longer empty bottle shelf life, and improved design options (compared to other packaging formats) for the uid dairy segment. The technology has a positive impact on the overall performance of the barrier and maintains recyclablilty. “PET is the most recycled plastic in the world, with more than 1.8 billion pounds of used PET bottles and containers recovered in the U.S. each year alone,” notes Greg Rosati, Amcor Rigid Packaging vice president of marketing & strategy for specialty containers. “With the development of our DairySeal line, we are able to offer PET packaging that helps improve sustainability for brands in the dairy alternatives, nutritional drinks, and ready-to-drink coffee space.”

choices, AmPrima employs a variety of technologies that deliver the stiffness, clarity, graphics, and machineability that match the performance of current nonrecyclable alternatives. Especially impressive were these:

• Beverage, puree, and sauce pouches—These pouches require moisture and oxygen barriers to preserve the contents inside, as well as highly durable hermetic seals along pack edges and around opening spout tments. Previously, only mixed-material lm structures have delivered such performance characteristics, structures that are dif cult to recycle. But now Amcor offers an innovative and recycle-ready highbarrier exible lm providing superior heat-resistance, a custom-engineered sealed layer for improved hermeticity and leak prevention, and puncture and scuff-resistance for durability throughout distribution. Amcor describes it as the rst high-barrier, high-speed, heat-resistant, recycle-ready solution for beverage, puree, and sauce spouted pouches.

• Shredded cheese pouches—Capable of running at high speed and offering all the heat-resistant properties needed, AmPrima PE Plus lm for shredded cheese offers high barrier and is compatible with recycleready zipper solutions. Its environmental bene ts have been calculated

The DairySeal line in PET is available in 8-, 11-, 12-, and 14-oz stock options, with additional sizes and shapes planned for the future.

Also new from Amcor Rigid Packaging is PowerPost. By actively displacing the vacuum in a hot- lled PET container after lling, this technology delivers a bottle that allows for up to 100% recycled material use, is nearly one-third lighter, and offers 30% energy reduction and 30% carbon savings over most 20-oz bottles available today, says Amcor. PowerPost builds on Amcor’s patented vacuum-absorbing PowerStrap technology, a exible ring surrounding the PowerPost. After hot- lling, the post is inverted to actively displace vacuum inside the container,

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SUSTAINABLE PACKAGING

and as the product cools down, the surrounding ring exes to passively absorb any remaining vacuum pressure.

“Our engineers have developed technology that pushes the boundaries of lightweighting in the hot- ll arena to help our customers meet their cost and sustainability needs,” says Terry Patcheak, vice president of R&D, sustainability, and project management at Amcor Rigid Packaging. “This next-generation innovation will improve the consumer experience while addressing widespread commitments to reduce material use and lower greenhouse gas emissions.”

HOME, PERSONAL CARE, AND PET MARKETS

Rolling out at PACK EXPO International this year was TC Transcontinental’s vieVERTe recycle-ready PCR exible packaging material, which comes in two variations: one with 38% PCR, and the other with 50% PCR. Rebecca Casey, senior VP of marketing & strategy at TC Transcontinental, says vieVERTe is aimed at the home and personal care market, but is also ideal for the evolving pet food market (16).

“Pretty much the whole premium pet food side of the business revolves around having recyclable packaging,” says Casey. “That’s driven by consumers. And when we look at back at 2018, when China decided they didn’t want to take our plastic waste anymore, it became more evident to consumers that, as a country, we weren’t really recycling our materials. And I think they’ve become more educated. When we talk about only 9% of plastic is recycled in the U.S., consumers know they put more than 9% of plastic in their recycle bins. So they’re putting a bit more pressure on the consumer product companies, and a lot of consumer product companies are saying we need to do the right thing for our planet. So it’s kind of a push forward in all directions.”

Casey adds that according to a recent Mintel study, 49% of new consumer products—like premium pet food, for example—include some claim of environmentally friendly packaging, so TC Transcontinental’s vieVERTe exible packaging material ts right into this trend.

SUSTAINABILITY THROUGH COLLABORATION

Debuting at PACK EXPO was a rst-of-its kind exible pouch from Printpack, the Preserve PE Advanced Recycled Content Polyethylene Pouch (17), that is not only recyclable after use, but also contains 30% post-consumer recycled material obtained through advanced recycling technologies. The pouch is the result of a partnership between Printpack, Pregis, and ExxonMobil, where Printpack’s machine directionoriented PE print lm is used in combination with Pregis Performance Flexibles Renew™ Series sealant lm made with ExxonMobil Exxtend™ advanced recycling resin technology.

Preserve PE Advanced Recycled Content is the latest addition to Printpack’s Preserve sustainable packaging platform. “This encompasses a portfolio of eco-friendly structures that use renewable and postconsumer recycled content, as well as maximizing design opportunities for greenhouse gas and source reduction and an optimal end-of-life condition,” explains Bill Barlow, sustainable innovations manager for Printpack. “The Preserve Recyclable PE packaging solutions offer many of the bene ts of current exible packaging, including ease of transport, product-to-package weight ratio, and reduction of carbon footprint, as well as several barrier options.”

The Preserve Recyclable PE line meets brand owners’ growing desire for mono-material exible packaging that can be recycled via store drop-off. As Barlow shares, this past year, Printpack was part of the largest store drop-off recyclable PE launch for the snack bar market in collaboration with General Mills and the Nature Valley brand.

While there are quite a few options available today for exible lms that can be recycled through store drop-off, more of a challenge has been to provide brands with lm that contains recycled content—especially for food applications—given the limitations of mechanical recycling and FDA guidelines for food contact.

“We actually have been successful with mechanically recycled PCR

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SUSTAINABLE PACKAGING

content within a nished package up to about 30% recycled content, however, there are limitations due to the grades available in the market—with FDA no objection letters—and also due to performance issues with the addition of high levels of mechanically recycled content,” says Barlow. “Additionally, there are still some aesthetic issues with mechanical PCR such as gels, degraded material, bers, and other contaminants; these are dif cult to mask in a exible package.”

Using resins made from an advanced recycling process completely eliminates these issues, as the resins from the process are identical to those made with virgin plastics. In addition, Barlow notes that with advanced recycling technology, the potential to create a exible lm pack with greater than 90% PCR has become a reality.

Getting Started with Sustainable Packaging

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ExxonMobil’s Exxtend advanced recycling technology breaks down plastic waste to its molecular building blocks while removing contaminants. These are the molecular building blocks that form the raw materials for making its products, which are identical to those made from virgin fossil feedstocks.

According to Barlow, ExxonMobil approached Printpack in August 2022 regarding the project, which the company welcomed without hesitation. “We view both Pregis and ExxonMobil as strategic partners of polyethylene resin and lm in the exible packaging market, and we were looking for an opportunity to collaborate with companies like this that share a similar sustainability vision to ours.

“We cannot meet the demands for sustainability alone, and this was a perfect opportunity to collaborate and bring something to the market that folks have been talking about for some time. We turned this project around in less than 30 days. That takes a true team effort.”

Exxtend circular polymers are certi ed according to the ISCC PLUS (the International Sustainability and Carbon Certi cation Plus) program. The resin can be offered in an array of PE grades, which Barlow says is attractive for Printpack and Pregis, as it allows them to develop exible packaging lms to meet the same performance requirements as conventional packaging structures. “Ultimately, with this technology, we don’t have to compromise on performance, that’s why it’s attractive,” he says.

Pregis’ sealant lm contains 45% advanced recycled content. When laminated to Printpack’s PE lm, the overall pouch structure contains

30% recycled content. The resulting structure also is prequali ed for the How2Recycle store drop-off label and meets the Association of Plastic Recyclers (APR) Design Guidelines for Flexible Packaging. Says Barlow, “As far as I know, this is the rst recyclable polyethylene pouch in the market that employs the advanced recycling technology and certi ed circular resins.”

As with most advanced recycling technologies currently on the market, product is limited, as these companies work to scale up production. Barlow says Printpack hopes to have a major brand on-board soon to commercialize the new lm and help build volume. “There is material available for Printpack and Pregis from ExxonMobil, and we expect to scale it up all the way into the rst quarter of next year and beyond,” he says. “Ultimately, we have to get a brand that’s going to pull this through and really get some volume commitments. Knowing that there’s demand for this and that our brands and consumers need it and want it really helps with future investments and capital expenditures.”

70% PCR POLYETHYLENE RESINS

As manufacturers across sectors look to incorporate post-consumer recycled content (PCR) into their packaging and reduce CO2 emissions and energy footprints, Dow showcased its REVOLOOP recycled plastic polyethylene (PE) resins product portfolio at PACK EXPO International. This marks the rst commercial REVOLOOP launch in North America.

The REVOLOOP resin is designed with 70% PCR, which provides up to 40% recycled content in the nal product, Dow reports, while providing similar quality and performance as materials made with virgin resins. Two commercial grades are available for packaging like shrink wrap and stretch.

REVOLOOP resins are the rst polyethylene (PE) compounds to achieve certi cation in accordance with the Standard UNE-EN 15343 for plastics recycling traceability and recycled content by Spain-based AENOR.

“Our customers have consistently asked us for more recycled plastic feedstock for packaging,” says Alex Saba, senior marketing director, packaging & specialty plastics at Dow. He emphasizes Dow’s ambition—not in merely stopping the waste—but to “Transform the Waste” in support of efforts to limit the amount of plastic waste that ends up in land lls and reduce greenhouse gases.

Saba adds that Dow is positioned to offer supply chain continuity for those looking to incorporate PCR content, with their own compatibilizers, virgin resin supply, and a large footprint of global assets to deliver consistent supply in the formulation needed. With customers looking for resin upgrades without building entirely new lines, Dow is prepared to work with customers and address challenges that companies face as they look to switch to resins that rely less on virgin plastics.

While the company has begun with shrink lms, they are also looking at sustainable materials for rigid and food-contacting applications.

PROTECTING THE OCEANS

Today, only around 10% of plastic waste globally gets recycled, while the rest ends up in land lls, in incinerations, and leakage to nature or the ocean, according to UPM Ra atac. In fact, one of the most visible issues in packaging today is plastic pollution in the ocean. And the 10 largest sources of ocean contamination with plastics exist in Southeast Asia, where massive rivers carry plastic waste to the ocean.

The problem is that the world needs ways to reuse existing, post-

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SUSTAINABLE PACKAGING

consumer plastics. Packaging World spoke with Bob Taylor of UPM Raflatac at PACK EXPO International about the issue, and what his company is doing to address it.

“We’re trying to create pull-through [markets] for the plastic that’s been recovered, either from the ocean or before it enters the ocean, to be used as a raw material for plastic packaging and labeling going forward,” he said at the show.

In Southeast Asia, efforts are being made to recover ocean-bound post-consumer plastics before they even get to the ocean, where they could perhaps degrade. But in a wrinkle, both suppliers and brands operating in this new supply chain need to be cautious about regional issues like the use of child labor. To ensure a clean, ESG-friendly supply chain, UPM Ra atac is sourcing certi ed Ocean-Bound Plastic (OBP)*.

To do so, the company is working with several certifying NGOs to arrive at its Ocean Action line of p-s labels.

Collected ocean-bound plastics are rst sorted, so anything that can be recycled mechanically in traditional recycling formats, will be. But the worst-of-the-worst is then redirected to a chemical (also called advanced) recycling process, where the degraded polymers are reduced to monomers, then built back up into higher quality polymers, in this case polypropylene (PP).

“And then we’re using that material to make the lm which is creating the base for these two new products,” Taylor says, noting that his company acts as the converter in the supply chain, supplying labels to printers who supply brands.

The two new label products UPM Ra atac launched, called its Ocean Action products, are its Ocean Bound PP C-PCR White, and its Ocean Bound PP C-PCR Clear. White contains 85% ISCC (International Sustainability & Carbon Certi cation) PLUS Certi ed chemically recycled PCR material using a mass balance approach. Clear contains 90% of those C-PCR certi ed materials.

Since the two PP labels are mono-material themselves, as long as they’re on a PP package, their end of life should consist of recycling yet again, in exactly the same way as any other mono-material plastic.

“Mono-materials is the way that packaging designers are pushing, so as long as [these C-PCR labels are] on the right package, they should be able to be fully recycled again,” Taylor concludes, referencing the truly circular model that brands and their suppliers aspire to.

According to the company, “Ocean Action is a perfect t for fastmoving consumer goods (FMCG), such as household products, personal care, packaged foods, and beverages.”

“Our goals are to help companies reduce their packaging footprint, reach their sustainability goals, and create added brand value among environmentally aware consumers,” states Ashley Drew, sustainability manager, UPM Ra atac, Americas.

* According to ZERO PLASTIC OCEANS, Ocean Bound Plastic (OBP) is plastic waste de ned as “at risk of ending of in the ocean.” OBP is estimated to generate 80% of plastic marine litter. OBP is an “Abandoned Plastic Waste” located within 50 km from shore where waste management is nonexistent or inef cient.

SUSTAINABLE PACKAGING

MONOMATERIALS

From Constantia Flexibles is a line of mono-material lm solutions (18), the Ecolutions family of recyclable packaging, which includes the EcoLam, EcoVer, EcoPaper, and EcoAlu product lines. Says Pim Vervaat, chief executive of cer of Constantia Flexibles, “Multi-material packaging, in particular, causes major challenges for the industry, as it is difcult to recycle. Therefore, we are focusing on safe and equally highperforming mono-material solutions to meet the circular economy and to promote a more sustainable tomorrow.”

sustainable capsules, notes the company.

Together with Dutch lm manufacturer Plasthill B.V., Constantia Flexibles has developed its latest innovation, the CompresSeal technology. It is based on a new micro-embossing technology that enables the basis weight of polyole n sealing lms to be reduced by up to 30% without any change in packaging thickness.

Shares Vervaat, “We are most proud of our EcoPressoLid and CompresSeal innovations. They perfectly re ect how crucial investments in research and development are to make the packaging industry more sustainable.”

ALTERNATIVE TO GLASS AND RIGID PLASTICS

At PACK EXPO International, Glenroy previewed for PW a recyclable STANDCAP. It was soon after announced on Dec. 1, ve weeks later, that after a two-year development process, Glenroy had received critical guidance recognition from APR (Association of Plastics Recyclers) for its 100% PE recyclable STANDCAP (19). The company says this is a completely eco-friendly alternative to rigid plastic and glass bottles.

Shown at its booth, Constantia Flexibles’ EcoLam mono PE laminates are thinner, more heat resistant, and are said to offer a wider sealing window than other products in the sector. Another feature of the lm is its barrier characteristics, which can be adapted to the content. For example, Constantia says, EcoLam offers a water vapor barrier, EcoLamPlus has an additional barrier against oxygen, aromas, and mineral oils, and EcoLamHighPlus provides aluminum-like barrier properties.

The recyclable EcoPaper family includes a range of individual paper solutions. Among them is EcoPaperPlus, which is recommended for applications that require a medium barrier against aromas and grease, such as confectionery, snacks, and household and personal care products.

EcoVer mono-polypropylene solutions are available in various barrier levels and can be used for a number of different packaging applications. According to Constantia Flexibles, EcoVer’s high thermal resistance offers new possibilities. “The packaging solution features an improved outer layer in combination with a sealing layer that starts to seal already at low temperatures to allow a wider sealing window,” the company says.

With 50% less thickness than standard coatings, the EcoPeelCover from the company’s EcoAlu product line provides a more sustainable sealing solution for PP and paper cups. The EcoPeelCover does not use solvent, is printed via UV exo, and offers a sealing temperature range of 200°C to 280°C.

The EcoPressoLid capsule lid from Constantia Flexibles is compostable and bio-based, and it is suitable for sealing the top and bottom of compostable coffee capsules. The EN13432certi ed material was awarded OK Compost Industrial by TÜV Austria in 2022 and features a high oxygen barrier and excellent performance during the brewing process—two essential properties for high-quality,

The recognition as a #2 recyclable package enables brands to move closer to meeting their Environmental, Social & Governance (ESG) goals and enables retailers to offer consumers an even more sustainable exible packaging alternative to rigid plastics and glass.

“The availability of the recyclable STANDCAP is a major win for consumers, retailers, food manufacturers, and the overall health of our environment,” says Evan Arnold, vice president of business development at Glenroy. “For consumers, this means being able to choose all the bene ts of sustainable exible packaging while also supporting a circular economy. For retailers and food manufacturers, it means a more environmentally friendly product on store shelves. And, for the environment, this helps put America on the path to signi cantly reducing plastic waste.”

Instead of waiting for recycling technology to improve, Glenroy invested two years in developing a product that can be recycled now, using the existing infrastructure. This investment can pay immediate dividends for food and personal care manufacturers’ and retailers’ sustainability goals.

As part of Glenroy’s TruRenu sustainable exible packaging portfolio, STANDCAP can have profound effects across the spectrum and is poised to help major brands and retailers in their efforts to achieve their sustainability and ESG goals. Not only does the recyclable STANDCAP have the potential to eliminate millions of pounds of plastic from being produced every year (Glenroy estimates that if just one leading condiment manufacturer switched only 10% of its ketchup bottles to the recyclable STANDCAP, it would eliminate 2,600,000 lbs of plastic from being produced and land lled every year–the equivalent weight of about 28 Boeing 737-800 airliners), but it also delivers a lower carbon footprint through using 42% less fossil fuel, emitting 52% less greenhouse gas emissions, using 70% less water, and reducing land ll waste by 30% (as compared to the rigid plastic alternative). PW

ROBOTICS

Numerous new robotic technologies have debuted over the past two decades. But the new ATRO robot system (1) from Beckhoff shown at PACK EXPO International may be one of the rst modular, DIY (do-ityourself) robot technologies for the industrial market. The ATRO (Automation Technology for Robotics) system is a modular industrial robot system that allows end users, integrators, and machine builders to create an optimal robot con guration for their application with payload capacities ranging from 3 kg to 10 kg and reaches from 0.6 meters to 1.3 meters.

Beckhoff says all electronics needed to control the axes are built into the ATRO motor modules, including an EtherCAT-based servo inverter, brake, and a compact gearbox. With these built-in features, the robot controller only requires a basic control unit.

Beyond its customizable design con guration, two other interesting aspects of ATRO are its assembly and the visual reinforcements it provides to the assembler and user that each module is correctly connected and ready for operation. As each module is connected, a light lining the joint connection illuminates. When the light is yellow, it has veri ed that EtherCAT communications between modules is effective; a green light indicates the module is ready for operation; and a blue light indicates the unit is ready for manual teach mode.

Regarding speci c applications for which ATRO is best suited, Prellwitz says “ATRO can be added to any application, and the exible design helps users easily t the system into new and existing machine designs. Common applications include assembly, material handling, lab automation, and packaging.”

ECOMMERCE AND ORDER FULFILLMENT

The system comprises standardized motor modules with integrated drive functionality, linking modules of various designs and lengths, and the TwinCAT control platform. With these components, users can create robotic systems ranging from 1-axis rotary indexing tables and 3-axis delta robots to 6- and 7-axis articulated robots.

Beckhoff notes that all ATRO modules feature an internal media feed for data, power, and uids (vacuum, air, and water). This allows ATRO to use a variety of tools, such as mechanical, pneumatic, or electric grippers. Because these media feeds are internal, it allows for endless rotation of ATRO axes and end effector tools, as there are no external cables to hinder the robot’s range of motion.

Assembly of an ATRO robot is accomplished using a method similar to a slip ring to connect each module and an adjustable tool to secure the joint in place. “Through this simple assembly process, all power, communication, and uids are routed internally, using an innovative method that enables continuous rotation,” says Matt Prellwitz, drive technology product manager at Beckhoff Automation. “The robot never needs to stop to unwind a compressed air cord, for example. As such, users save time not only during commissioning, but also during production.”

Because the ATRO system is built on an open control architecture, it can be connected to “all conceivable interfaces in cell/plant communication, such as Pro net, EtherNet/IP, OPC UA, or to the cloud,” says Prellwitz. Also, the ATRO system allows for all functions such as robotics, vision, safety, and machine learning to be integrated on a single control platform.

At Yaskawa Motoman’s booth, the company demonstrated its new robotic automation solution (2) for fast and accurate parcel induction and singulation in dynamic order ful llment settings. Easily integrated with a range of traditional sortation and packaging applications, the company’s customized robotic solutions can facilitate uid piece picking and placing of items onto conveyors for rapid material handling of boxes, polybags, and padded envelopes of varying sizes.

Running at the booth was a robotic parcel induction workcell equipped with a high-speed six-axis GP12 robot. Highlighting high-volume capability, the GP12 offers a 1,440-mm horizontal reach, a 2,511mm vertical reach, and a 12-kg payload capacity. Intelligent 3D scene capturing, utilizing a Zivid Two 3D camera, combined with Fizyr AI image processing—which proposes multiple grasp poses—enables single robot pick rates of 1,000 to 1,700/hr.

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ROBOTICS

Integrating an intelligent 3D scene-capturing solution is simpli ed by the Yaskawa Perception Option Package. This software con guration bundle enables integrators, distributors, and customers to utilize a wide variety of third-party perception products that are needed for complex application support. Along with functions for Relative Job, PMT (Position Modi cation for Tool Deformation), Macro Job, and 3D Shift, the Perception Option Package features MotoPlus runtime, which provides real-time access and communication with the robot controller and enables interaction with any computing device.

The GP12 robot featured at the booth was being controlled by the YRC1000 controller, which is built to a global standard and does not require a transformer for input voltages ranging from 380 VAC to 480 VAC. With a highly compact cabinet (598 mm W x 490 mm H x 427 mm D), the YRC1000 uses a lightweight teach pendant with intuitive programming.

related video at pwgo.to/7830.

Yet another example of increased packaging automation muscle in the ful llment center and e-commerce space came from ABB, which debuted its new Robotic Item Picker (3) at the show. The Item Picker helps customers automate order picking and sorter induction operations, and it ful lls ABB’s vision of a fully automated warehouse by combining automated storage with automated order picking, the company says.

According to a company release, ABB’s internally developed AI Solution provides unprecedented accuracy in picking items from unstructured scenery. It also allows for high throughput application, again up to 1,500/hour, thanks to reduced computing time. The advanced software leverages arti cial intelligence, allowing the robot to learn and adapt to a wide variety of items including cuboids, cylinders, pouches, blisters, and random shapes, as found in electronics, pharma, healthcare, cosmetics, and other consumer product industries.

Prior to integration, the robotic item picking system’s scope of supply consists of a fully integrated Functional Module including robot, gripper, vision box, AI-based vision software, and application control software. a related video at pwgo.to/7831.

AUTONOMOUS PRODUCT PICKING

The result of a decade of R&D, the Bastian Solutions SmartPick fuses a warehouse execution system with a six-axis robot, machine vision, and advanced arti cial intelligence (AI) to create an autonomous product picking system (4).

This advancement in robotic order ful llment offers customers faster, more accurate orders while answering the need for a more reliable solution that can grow alongside operations—turning a goods-toperson (GTP) system into an ef cient goods-to-robot (GTR) system.

Bastian Solutions presented its rst vision-driven bin-picking robot back in 2010. It relied on a pre-trained vision platform, transporting products from one stationary bin to another. The company has improved on those capabilities considerably since then, and can now pick a complex assortment of products from the back end of a GTP system with 99% accuracy.

“The key to the SmartPick is the autonomy—the ability to route orders through our warehouse execution system down to the robot autonomously with pickable products for the robot to handle,” says Steven Hogg, applications engineering manager for Bastian Solutions. “We also have an AI-based vision system that has deep machine learning to where we can learn on the y—we don’t have to pre-program any of the images in, and the vision system continuously improves as it picks.” At the heart of the system is a robotic piece-picking system with customdesigned end-of-arm tools that can adapt to a wide variety of product shapes, sizes, and surfaces, he adds.

“This is a fantastic new application that we’re unveiling here at PACK EXPO,” Ali Raja, global marketing and sales director, ABB, says. “It’s powered by ABB’s own AI software, some of the latest techniques in machine vision, and of course, our famous robot planning. All of that in combination allows us to be the fastest item picker on the market. We’re achieving peak throughput of 1,500 picks per hour.”

Target customers include system integrators serving e-commerce, logistics, healthcare, and CPG. It also takes aim at end-user customers in 3PL, e-commerce, and ful llment centers, all to serve common applications such as order picking, replenishment, receipt picking, and fashion sorting.

Raja says the Robotic Item Picker provides high picking quality of 99%+, meaning no double picks and no dropped items. He says it also offers ease of use and it’s easy to integrate. Plus it has easy-to-operate application control con guration and parametrization for integrators and sophisticated, yet intuitive controls for end-users. He also claims best in class price/performance ratio.

ROBOTICS

The system integrates seamlessly with Bastian’s ML2 autonomous mobile robot (AMR). “It is designed to be autonomously routed throughout the warehouse facility or throughout the manufacturing facility to deliver products to various manufacturing lines or also order ful llment,” Hogg says. “It can have a static stand on top of the AMR or a conveyor to route totes between the various production lines.”

The AI and physical systems integrate with Exacta, the company’s proprietary intralogistics software, to enable the cells to run with higher autonomy. “This is what is driving the orders being brought down to the autoserve port,” Hogg says. “This right here is showing the bin that’s being delivered to the workstation. The robot is working in the background to start and stop the cell. We go to the individual bin and are picking pieces out and are placing to the AMR ML2.”

SmartPick is a turnkey GTR ful llment system that increases picking throughput, adjusts to labor availability, reduces picking errors, allows for 24/7 automated operations, and improves customer satisfaction. a video of the system in action at pwgo.to/7832.

In a trend toward food processors designating less space for their palletizing operations, EnSight Solutions has developed a fenceless robotic palletizer (5) that gets the job done in a footprint of just 12 x 5 ft. The system combines Sick safety sensors with a Stäubli collaborative robot (cobot) to eliminate the need for fencing.

“With our area scanners, as the robot moves, you have a warning area where the light will turn yellow. It’ll move the robot very slowly,” explains Heath Clifton, director of automation and controls for EnSight

Solutions. “As you walk in closer, you’ll get a red area, which is a safety stop for the robot. As you move back out of the area, it’ll slowly start speeding up. And then once you get into the green area, it’ll move back to its full speed.”

Unlike standard robots, the payloads that cobots can handle tend to be smaller. The Staübli cobot, however, enables larger payloads. “The thing that differentiates our cobot palletizer from others is it can lift up to 75 pounds,” Clifton says. “If we’re doing a single pick, we can pick up to 18 boxes a minute. But with a 75-pound weight limit, we can pick up multiple boxes at a time to hit a higher rate.”

ROBOTICS

Stäubli also has cobot options with hygiene standards suitable for food processing areas. “One of the great options about our palletizer is that it’s a full stainless-steel design,” Clifton says. “We’re using a Stäubli robot, so it’s a full washdown robot as well. It’s a great application for the food industry. You can put it in a full washdown room if you’re palletizing in there, or a secondary pack application that’s wipe-down.” a video of the system in action at pwgo.to/7833.

MONOBLOC CARTONING, CASE PACKING

A unique system for robotic cartoning and case packing in a monobloc system (7) was demonstrated at the Cama booth. First is a carton forming module followed by a vision system that detects the position of the item to be picked by the robots. In the demonstration at Cama’s

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Talk about labor-saving automation in the e-commerce space, consider what was on display at PACK EXPO International at the Sealed Air booth. It comes from OSARO, namely the OSARO vision system for robotic pick-and-place. In this application (6), a Fanuc M10/12 small-payload robot arm and a Cognex vision system for barcode scanning team up to replace a traditionally manual fulfillment center activity, namely the picking and placing of variable products into polybag or paper mailers.

PACK EXPO booth, the item being cartoned was a pie shell in an aluminum tray overwrapped in exible lm. Once the carton is loaded, it advances into a closing system that features a 2-axis robot. Cartons are then gathered in a collecting device where they’re grouped and stacked prior to insertion into the corrugated case. Stacked cartons are pushed into a corrugated case that has been pulled from a magazine and erected. Case aps are then closed and sealed by hot melt adhesive. Openap detection ensures that any case with an open ap will be rejected. a related video at pwgo.to/7834.

Making its debut at PACK EXPO International was the compact and highly versatile Matrix TL case packer (8) from MGS, a Coesia company. According to MGS product portfolio manager A.J. Lee, the MGS top-load case packer features a Festo gantry-style robot loading arm. “It’s proven technology in the gantry style, and since it can handle a 40-pound payload at full speed it gives us a good operating range,” says Lee. “In designing this machine, we focused on leveraging proven functionality that we’ve had in our case packers over the years, including the ability to maintain positive control of the case while offering strong product handling and transport functions. It also has a balcony-style design, so it’s a very open machine, easy to get into for servicing and maintenance.”

The Matrix TL, which made its of cial debut at PACK EXPO, is especially notable for its small footprint: 160.6 in. long by 90.3 in. wide. As for throughput, it’s designed to reach 15 cases/min generally but for certain applications it can go as high as 20 cases/min.

In this system, “we are recognizing the [variable] items, we are determining the right grasp for the item, we pick the item, and we place it directly into the Sealed Air 850 autobagging system,” Tracy Perdue, VP of Sales at OSARO told PW at the booth. “The value of this system is obviously time and money. With the labor shortage the way it is today, people are looking for robotics and an alternate way of doing things. This can run three shifts and exhibits high performance—it can pick at the rate of a human, or higher.” Automated EoaT change is also a feature of this system. PW a related video at pwgo.to/7847

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ROBOTICS

Another strong emphasis was versatility, and in fact the Matrix TL can handle case sizes from 4 x 5 x 6 in. all the way up to 16 x 16 x 12 in. Integrated into the machine running at the show was a 3M taper, but adhesive case sealing is also an option, says Lee. a related video at pwgo.to/7835.

From PMI Kyoto comes a brand new KTB -100 case packer (9) that is an all-in-one, compact, fully integrated system—case erection, robotic case loading, and case sealing by either tape or glue. Running at about 15 cases/min, the system uses machine vision technology to detect product position, and a variety of end effectors can be used depending on the nature of the product to be picked and packed.

New at the Douglas Machine booth was the INSITE E30T case erector (10), which relies on a SCARA robot and Rockwell controls to pick case blanks from a magazine and erect them. According to Todd Davis, manager of Douglas’ INSITE Packaging Automation, this new machine is notable for the massive reduction in the number of parts it requires compared to comparable units available today. With 50-60% fewer parts comes simpli cation in operation, maintenance, and machine accessibility on this walk-in-style erector, says Davis. “And because we build and control our own robot, we can create a recipe and change it over to a new case size within ve minutes,” adds Davis.

This top-load case packer is just 15 ft long. A key characteristic is its versatility, as it can handle cans, cartons, or standup pouches lled with either granular or liquid product. a related video at pwgo.to/7836.

The machine has a total of 11 adjustment points. Smart features include electronic case squaring, where photo eyes above each side belt measure each side of the case to ensure that the front panel is perpendicular to the side panel. The E30T runs at speeds to 30 cases/min and is virtually maintenance-free as the bearings on the machine are “lubed for life.” The only maintenance points are vacuum cups, side belts, and a tape head. a related video at pwgo.to/7837.

Robosorter for Pumps, Trigger Sprayers

The Tirellli Robosorter (11) from Arol Group uses a Stäubli robot to mechanically pick and place pumps or trigger sprayers from an infeed conveyor. A vision system from Cognex detects where items on the belted infeed conveyor are located and sends that data to the robot. Once the part is picked, it’s fed into a chute leading to a conventional pump placer.

Arol is positioning the Robosorter as an alternative to the conventional pocket sorter widely used today. These sorters have a rotating disk into whose pockets a pump or trigger sprayer falls with its dip tube pointing downward. As the disk continues to rotate, the pump or trigger sprayer falls down a chute leading to filled bottles below. “There’s a lot of mechanisms and components in such a system,” says Dan Waldron, sales manager at Arol North America. “If a customer needs to run 500 containers a minute, the pocket sorter is the way to go. But a number of companies are also looking for an option where speeds of 40 bottles a minute is acceptable as long as quick changeover is possible and minimal change parts are involved. That’s where the Robosorter fits in. And speeds can be in the range of 80 a minute if we combine two robots.”

The Robosorter, says Arol, reduces noise pollution and energy consumption as it does not use compressed air. In addition, the system can increase flexibility and reduce the time of format change from 25 minutes to 3. And because so few parts are needed for a format change, the cost of parts is said to be substantially lower than what is common in the industry. PW a related video at pwgo.to/7844.

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ROBOTICS

DEMOCRATIZING AI

Arti cial intelligence applications have been growing rapidly in a variety of industrial technologies, ranging from data analytics and quality inspections to autonomous mobile robots. Now the technology is being applied to robotic grasping applications to enable accurate picking and placing of random objects in unstructured and changing environments.

Siemens says it is working to “democratize arti cial intelligence (AI)enabled robotics by encapsulating systems for complex problems in easy-to-use software.” To this end, the company is developing an as-yetto-be-named software technology designed for use by system integrators and OEMs to create cost-effective, advanced AI-driven piece-picking systems that can “reliably pick and place objects that are unknown to the system at runtime.”

Traditional automated pick-and-place systems follow xed, pre-programmed routines in a structured environment. Applying AI enables robotics to perform generic tasks in unstructured and dynamically changing environments.

Explaining how the technology Siemens is developing differs from the use of 3D vision to enable robots to pick and place random objects, Dr. Eugen Solowjow, head of the Robotics & AI Research Group at Siemens, says, “picking and placing unknown objects is still relatively new. It has existed for, at most, two years in the market and, up until now, has not been very commonly distributed. These existing systems rely on AI—more precisely Deep Neural Network technology—to randomly pick oriented objects that are known to the system during setup and/or engineering.

Thus, the key differentiator with the developing Siemens technology is its ability to pick unknown objects.

According to Siemens, this new software will enable users to move from using robotic systems with static pick points to AI-driven piecepicking robots in less than an hour. Setup for the system is accomplished in four steps: Set the robot arm and related end-of-arm tooling to move safely to static pick-and-place points; mount the 3D camera; install the Siemens software for piece picking on the target runtime hardware of choice; follow the guided setup via the user interface for calibration.

With these steps implemented, calculated pick points are then continuously provided to the robot motion program, enabling the robot to grasp any object.

“The set up takes only 30 minutes through an easy and straightforward calibration process,” said Solowjow. “The user interface is very simple and clear.”

Target applications for this technology include order ful llment operations with a high number of SKUs requiring 500-1,200 picks per hour, such as goods-to-person tote picking, conveyor induction and sortation in e-commerce, e-grocery warehouse automation, and food and beverage packaging.

Inputs to the Siemens pre-trained, AI-powered vision software in the PLC come from the 3D camera’s point cloud, with the output being the grasp pose for any object at runtime. A Siemens HMI is used to interface with the PLC and software; and Siemens TIA Portal can be used to program the entire system—Siemens PLC and HMI as well as the robots,

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ROBOTICS

vision system, and gripper.

The Siemens AI-driven piece-picking system also provides for collision avoidance for all actions in the robot workspace, enables robots to master challenges such as handling tightly packed boxes using low-cost 3D cameras, and reduces errors through features such as automatic bin detection.

“We pretrain the AI skill for grasping using simulation,” says Solowjow. “Similar to a human, the AI learns how to grasp in general—as opposed to speci c objects—so that grasping of unknown or previously unseen objects is possible.”

The Siemens AI picking software is robot and end-of-arm tooling agnostic. In its exhibit at PACK EXPO International (12), Siemens used a KUKA Agilus KR3 robot and a Robotiq EPick vacuum gripper to demonstrate the technology.

COLLABORATING ON LABELING SYSTEM

Precision Automation chose PACK EXPO International to highlight its automation expertise, presenting a solution (14) for the robotic application of a multi-page label onto a package. The system combined a Zebra ZT620 industrial printer, a collaborative robot, and the MultiPlex Enclosed Packing List label from Chicago Tag & Label

The MultiPlex self-adhesive label can include up to 15 sheets, allowing users to add promotional and gift messages, packing lists, return labels, and other information, into one integrated label. With the Precision Automation system, the MultiPlex label is printed and dispensed onto a metal tray, from which the cobot arm picks it up and applies it to a shipping case. According to Steve Huvane, quality, marketing, and sales support for Precision Automation, the cobot arm can place the label anywhere on the package. a related video at pwgo.to/7838. related video on Chicago Tag & Label’s MultiPlex labeling solution at pwgo.to/7839

Variety-packs

Sophisticated variety-pack capabilities (13) were on display at the Aagard booth. That’s where a Comau robot powered by Rockwell controls—said to be the first such combination in the packaging space—was picking three different items from the movers of a Rockwell iTrack linear servo motor system and placing them in a carrier in the order specified by an operator at the HMI. That HMI, says applications engineering manager Jonas Capistrant, was the Rockwell ASEM 6300 HMI. A new automation arrow in the Aagard quiver, it permits Aagard to offer more features, including better analytics and the ability to play training videos, while offering an improved HMI experience all around. PW related video at pwgo.to/7845.

On display at the Capmatic booth was the Galaxy Platform (15), an impressive demonstration of multiple packaging capabilities commonly called for in the life sciences industry. Each of these capabilities was being executed at one of ve stations along the more or less ovalshaped track of a B&R Industrial Automation ACOPOStrak linear servo motor module. Along its track were independent movers that carried various containers to the stations they needed to reach.

Each mover had a bar code on it, and at the beginning of the demo cycle this bar code got scanned for track-and-trace purposes. In the rst demo station, a Stäubli robot picked a vial from one of the ACOPOStrak movers and placed it in a Wipotec high-precision load cell for weight veri cation. In the next station, a Capmatic counter counted 30 small beads into a funnel that discharged them into a vial carried on a mover. In the next station, a second Stäubli robot picked a multi-cavity plate from an Acopos mover and positioned it beneath a Capmatic peristaltic pump that simulated each cavity being lled by the pump. The multicavity plate was then carried to a point further ahead on the ACOPOStrak and placed on a waiting ACOPOStrak mover.

In the nal station on the demo, an ACOPOStrak mover holding a capped vial paused beneath a pressure-sensitive labeling unit to simulate application of a label to the top of each cap. a related video at pwgo.to/7849.

BIGGEST COBOT YET

Universal Robots chose PACK EXPO as the place to unveil the UR20 (16), the biggest cobot in the rm’s offerings so far. Especially suitable for palletizing, the UR20 being demonstrated at the booth was put together by cobot integrator Robotiq and featured Robotiq’s vacuum gripper. a related video at pwgo.to/7840.

According to Universal Robots’ Joe Campbell, senior manager, strategic marketing & applications development, the UR20 features redesigned joint technology that makes it easier than ever to maintain. It handles a payload up to 44 lb. and has a reach of 1,750 mm (5.75 ft).

Among the robotic palletizing integrators eager to leverage the capabilities of the UR20 is Columbia/Okura LLC. The UR20 will be part of the new Columbia/Okura miniPAL+, to be launched as an integrated

system in 2023. The compact design of miniPAL features an integrated lifting column for tall loads, dual stacking locations for continuous load building, built-in fork pockets that make it easy to reposition it within a plant, and area scanners and pressure mats for additional safety.

Cobots from Universal Robots feature compatibility with Pally software from Rocketfarm. A palletizing software that not only optimizes case con guration and operating speed but also offers a digital twin simulation tool, it’s certi ed to work seamlessly with the UR robots through the UR+ platform. Pally’s digital twin simulation tool was being highlighted on the miniPAL 2.0 that was running at Columbia/Okura’s PACK EXPO booth. Columbia/Okura president Brian Hutton explains what was being demonstrated.

“What we were demonstrating physically with the miniPAL running in our booth we were also running virtually on a big screen display,” says Hutton. “The software has the ability to rapidly incorporate new case dimensions, new pattern con gurations, new pattern shapes, and new productivity requirements. So we’re able to enter these new parameters and watch, virtually, to see if any of them are going to be detrimental to the operation of the actual palletizer. It’s a way of quickly determining if a new pattern or speed or case will work or not. Without this software, you’re looking at a lot of trial and error, a lot of building things out and physically testing them. Instead of that, the software lets you just put in a set of parameters and have the software run the algorithms to determine ‘can this reach or lift or speed be done or not?’”

Another thing about Rocketfarm’s Pally software is how user-friendly it is, says Michael Stuyvesant, director of sales at Columbia Okura. “The Pallyscope user interface is a touch pad,” says Stuyvesant. “There’s no need for any special language or training, if you will, so it’s easy to change patterns or speeds or case sizes.”

When asked for a recent example of how the Pally software proved useful to an end user customer, Rocketfarm pointed to Nortura Sogndal, one of Norway’s largest meat producers. An early adaptor of Universal Robots’ solutions, Nortura installed its earliest cobots in 2015. By 2020, the rm saw a need to upgrade end-of-line production and reached out to Rocketfarm to hear what might be done. Through Pally’s digital twin simulation, Rocketfarm was able to make an upfront veri cation that Nortura could improve performance by 30%.

a video summary of how the Nortura Sogndal project unfolded at pwgo.to/7841.

ROBOTICS

ROBOTICS AS A SERVICE

In a move meant to remove the barriers of automation for small and mid-size manufacturers, robot start-up Formic, founded in 2020, is building a robotics-as-a-service business model that democratizes automation to make it more affordable and accessible.

Buying a robot can be a pricy proposition requiring much more than just the initial hardware investment. After buying, say, a $40,000 robot, the additional cost of integration with other machinery can escalate the total investment to upwards of $200,000. That is cost-prohibitive for many manufacturers.

Having worked in the robot industry for years, Formic co-founder Misa Ilkhechi also recognized that manufacturers are struggling to nd labor. Formic was created to solve these problems. The company takes over the design and deployment of turnkey robotic systems and charges customers an hourly rate vs. an upfront investment. That means manufacturers only pay for operational output with performance guarantees and unlimited 24/7 service.

“We are a nancing meets service meets robotics company,” Ilkhechi says. “Our business has to have all three working well, because at the end of the day the customer is not buying a machine or components, they are buying productivity.”

Charging an hourly rate for a robot is just like hiring a person, but with the built-in guarantee that the machine will run. Each machine Formic supplies includes an edge device that sends machine data back to the Formic service team, who proactively solve problems before downtime happens. This is important for the customer and important for Formic. “In order for us to make money our machine has to work,” Ilkhechi says.

The SL20 is available now with a six-month trial period available for rst-time customers.

In addition to small and medium-sized manufacturers, the Formic robots are suitable for co-manufacturers and co-packers that are dealing with hundreds of SKUs and need exibility.

PALLETIZING

More manufacturers are turning to palletizing operations with collaborative robots (cobots), and ONExia is a system integrator that has made it easier for its clients to use cobots as a drop-in replacement for end-of-line workers. With the drag-and-drop software that comes with the PalletizHD collaborative palletizing system (18), anybody can program the cobot easily to achieve the desired palletizing operations.

The company partners with robot suppliers and machine builders to build custom turnkey systems. The plan is to have a large portfolio of robots, with the rst being the SL20 Palletizer (17) launched at PACK EXPO.

Key features of the SL20 Palletizer include:

• Robotic palletizing system designed for end-of-line packaging processes

• Small footprint (10x12’)

• Palletizes up to 20 cases/min

• Lifts up to 20kg/cycle

• Proven to safely work alongside people

• Deployable in less than eight weeks

• Built by Sourcelink Solutions LLC, based around the Yaskawa HC Series collaborative robot

Tim Pelesky, marketing manager for ONExia, was at PACK EXPO to demonstrate how easy it is to set up the system. Users have complete control of the entire system through the embedded touchscreen on the PalletizHD lifter base. To create a program, a user can touch the screen to select a new pallet con guration, and then add box dimensions (weight, length, width, and height) and pallet dimensions (length and width). “We also offer a box edge gap in the event that you’re worried that your boxes might not be completely uniform or your pallet con guration requires it,” Pelesky says, noting the ability also to create a reference edge. “We also offer the ability to do a dual pick in the event that you want to pick two boxes at one time using the 38-pound payload.”

Once the box and pallet parameters are entered, it’s time to create your pallet con guration. “To get started to create your rst layer, press the plus, hit Edit Layer, and your boxes are on the screen ready to go. All you’ve got to do is drag and drop them into place. There’s no programming; nothing like that,” Pelesky says. “Once you’ve completed your entire layer, you’re able to center it left and right and up and down to make sure the robot’s going to place a good and tight pallet con guration.”

After the rst layer is created, it’s easy to copy and paste it as the next layer or customize each layer differently.

“The last step in building this pallet is we have to teach certain points because we’re not using any integrated vision,” Pelesky says. Just two points need to be taught—the nesting position, where the box comes from the infeed conveyor; and the rst-place position on one of the pallets.

“You would then come over, hit that button where the position’s taught, and then you’re able to mirror it on the other side,” Pelesky says.

ROBOTICS

“The last step would be to press Save, go back Home, and all of your pallet con gurations are there, ready to go, on the y, and can be adjusted as production changes within the line.”

Users can easily save and recall different pallet con gurations based on production demands.

a video of the system at pwgo.to/7842.

AUTOMATING PARTS HANDLING

The Mantis Robotic Trim Press Handler from Nalle Automation Systems (NAS), a subsidiary of BMG, a thermoforming, tooling, and automation solutions provider, is a robotic automated system (20) that reliably handles the ow of parts ejected from trim presses, speci cally for the thermoforming industry. The robot is designed to be compact, intuitive, and a con gurable system that enables full automation of the entire thermoforming process—from resin to palletized product—for medium- to high-volume production lines using either non-servo continuous ow or servo-driven long eject trim presses.

Previously, parts ejected from non-servo trim presses needed to be manually separated and counted, which was a labor-intensive, errorprone, and inconsistent process that limited the automation of downstream packaging functions. NAS strives to resolve this problem with the patent-pending Trim Press Receiver (TPR) which uses a separating mechanism to count and contain stacks of product, followed by a raking mechanism to take the product into the receiver for transfer by the robot.

“Consistent and reliable separation of product on a continuously owing, non-servo eject trim press was the key to the development of Mantis,” says Kurt Huelsman, president of NAS. “The design of the receiver coupled with NAS’s robotic automation capabilities brings a safe, productive, and cost-effective solution to a historically very manual process.”

Magic Gripper

Vmeca, a PACK EXPO International exhibitor based in South Korea that specializes in compressed air driven vacuum pumps, suction cups, and other accessories, introduced its Magic Gripper head (19) at the show.

Suitable for being attached to either an industrial robot or a cobot, it has a decentralized vacuum that lets it use as many or as few grippers as an application needs. Suitable for cartons, cases, or flexible packages, it also features a silencing technology that deadens some of the noise traditionally generated in compressed air applications. PW related video at pwgo.to/7846.

product loss. Additional highlights include VeriTool RFID tool veri cation (patent pending), little to no product contamination, simple intuitive controls, product isolation, and reject through HMI.

The TPR presents the parts to a six-axis robot equipped with product matching end-of-arm tooling that in turn automatically transfers the product to a shuttle station, which integrates with downstream packaging functions that may include wrapping, boxing, case packing, sealing, and palletizing. Incorporating the robot allows the Mantis system to be very compact and con gurable, making installation possible where the available oor space is limited or obstructed.

Product containment throughout the process reduces jams and

“The key bene t to the product line is that the speci c tooling matches up to the trim press die that allows for complete product containment throughout the process. The robot is used in order to have complete exibility in layout so it can t into any plant’s design. We can move it around to make it work at your site,” says Huelsman.

The Mantis Robotic Trim Press Handler is compatible with all trim presses, including BMG brands Brown and Lyle. The fully automated system can reduce labor requirements by up to 75% and the modular robotic design allows for tool changeovers in under an hour.

a related video at pwgo.to/7843.

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INTEGRATED SYSTEMS

At Starview Packaging’s PACK EXPO International booth, one emphasis was on the kind of comprehensive automation that can be brought to a rotary blister packaging system by integrating additional packaging machinery functions. Think robotic product loading, laser coding, and 100% code inspection.

“The demand for automation is higher than ever,” says Director of Sales and Marketing Rob van Gilse, “mostly because customers don’t want to rst look for and then rely on people to perform packaging tasks. So customers who were running semiautomatic want to go automatic, and the ones who were already pretty automated want to go further by adding robotic feeding of products, for example, or automated vision inspection.”

A good example of the kind of system van Gilse is talking about is the Model BSC 18-1418 (21), a rotary blister packing machine with 18 stations with a rated speed of about 18 cycles/min. The sequence of operation is picking and placing of paperboard front card, insertion of clear blister into card, robotic product loading thanks to a Mitsubishi Electric RV-FR Series 6-axis robot, then placement of the paperboard backing card. But also integrated into the system is a Videojet Xtract Pro Laser Marking System that adds tracking data by lot number and date, and a Keyence OCR Vision System with

CV-X322F SR-2000 Code Reader that checks the bar code on the back card to verify that all materials are correct. As for controls integration, that comes courtesy of Omron. According to van Gilse, the 6-axis articulated robotic arm is a high-speed durable component that can address a variety of customer needs, which makes it ideal for packaging applications. He added that the system on display at PACK EXPO is headed for a maker of medical devices.

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ROBOTICS

STORAGE AND RETRIEVAL

A popular theme at PACK EXPO International seemed to be companies that developed systems to solve problems in their own production environments and then decided to market it outside their companies after customers saw what they had done and wanted it for themselves. One such solution is an automated storage and retrieval system (ASRS) that PBC Linear developed (22) to deal with its own struggle to nd the labor it needed at its bearing manufacturing facility in Roscoe, Ill.

“We were struggling to nd people to work, so we brought cobots [collaborative robots] in-house,” says Tim Stellmacher, vice president of sales and development for PBC Linear. “But there was still a lot of manual labor needed to bring the trays to the cobot.”

PBC Linear found that a single tray of parts did not take advantage of a cobot’s potential. When operators get pulled away to tend to other tasks or change shifts, a cobot could experience considerable downtime. PBC Linear developed a system to feed multiple cobots. By assisting robots with consistent loading and unloading of material parts trays within the robot-accessible work area, the ASRS addresses the problem of nding enough workers to tend machines. The ASRS eliminates the need to manually replace parts trays, allowing for enhanced robot automation and lights-out manufacturing.

The Cobot Feeder from Applied Cobotics—an arm of PBC Linear that provides automation solutions—features a vertical lead screw-driven

shelf and a horizontal tray loader/unloader with accurate, repeatable motion. PBC Linear can provide trays that are thermoformed for particular parts—feeding CNCs, lathes, mills, grinders, and other machines with necessary parts. The repeatable action of the Cobot Feeder in conjunction with the parts trays results in consistent robot performance.

With the Cobot Feeder, robots can now run longer unattended projects, include a higher mix of parts, and ultimately achieve lights-out production.

Each Cobot Feeder base package comes with a dunnage tray rack tower that is engineered to securely lock in place with the ASRS. It can hold up to 17 trays, eliminating the need for a worker to periodically remove and reload material from the cobot work zone. It also offers open-spaced shelving that accommodates various part sizes up to 18 in. tall, and it offers stationto-station mobility.

A standard xed robot mount offers 45 deg of adjustability and a custom bolt pattern that is compatible with any cobot/robot. The robot mount can be upgraded to a more exible swivel stand that offers four times the amount of adjustability over the standard model. This means a robot can be moved to different angles quickly and accurately.

PBC Linear has been partnering with Universal Robots (UR), Stellmacher says, and has been working on obtaining UR+ certi cation. The UR+ ecosystem provides access to kits, components, grippers, software, and safety accessories that integrate seamlessly with UR’s cobots. PW

At the Econocorp booth we saw a real, branded application. It was the company’s E-2000 automatic horizontal carton erecting and cartoning equipment, and it was cartoning foil pouches using a Fanuc LR Mate series of lightweight robots (23).

“This was an application that we did for P&G’s Tide brand washing machine cleaner,” said Sam Goldberg at the show. “The packets can be randomly placed on the infeed conveyor, where we are snapping a picture with a camera [vision] telling the robot how and where to pick up the product.”

The foil pouches are loaded into the cartoner’s loading bucket in a reciprocating pattern, three at a time for a threepack carton. Product is then automatically push-loaded into

the erected carton, which is finally sealed with adhesive to head for case packing or other downstream operations. PW a related video at pwgo.to/7848.

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The eXtended Transport System (XTS) was naturally a highlight of the Beckhoff booth at PACK EXPO International. The unique technology features movers that can move independently or be synchronized in groups for material handling in a variety of applications, such as CPG (consumer packaged goods) packaging applications. The XTS features built-in collision avoidance, and tooling on the XTS movers can be used to open and close bags, cap bottles, or move parts down the line.

Jeff Johnson, mechatronics product manager at Beckhoff Automation, says, “XTS is not just a substitute for lower-cost solutions like chaindriven systems with lugs and buckets, it’s a fundamentally different way to approach material handling transport processes.”

synchronizes positioning of the movers in real time, and the central software approach in TwinCAT allows synchronization with external processing stations. These features enable the movers to become an active part of the manufacturing process as a mobile processing station. For example, the mover can be used to manipulate a product to position a carton or screw on a cap.

With this level of synchronization, process times for feeding and removal at alternative processing stations are eliminated and the product ow no longer need be interrupted. As a result, the ef ciency of the machine increases, as does the production output.

Throughput can be increased by adding movers. Beckhoff notes that each mover can perform multi-axis movements, allowing for product alignment along the X, Y, and Z axes. Additional degrees of freedom can be achieved by rotary movements using TwinCAT to control the interaction of the axes via CNC functions. Johnson says this integration turns XTS into a exible multi-robot system that increases sorting performance while reducing the required installation space.

MAGNETIC LEVITATING SHUTTLES

The news at PACK EXPO was that Beckhoff has updated its XTS (1) with its No-Cable Technology (NCT) for contactless, continuous power supply and synchronous real-time data transmission to the XTS movers. To enable this, the XTS modular system has been expanded to include a special motor module and electronics mounted on the mover. With this addition, no further connections or supply lines are required, meaning that processing steps and quality control can be accomplished directly on the mover while a process is running.

“Traditionally, if you wanted to grip something on linear transport systems you’d have to have two movers mechanically linked to do the gripping,” says Johnson. “Now that we’ve integrated power and data on the movers, you can mount things like vacuum generators on the movers to do vacuum pickup of materials. You can even use mechanical actuators—really any end of arm robot tooling can be mounted on the movers to pick and place product.”

A few XTS with NCT application examples include the ability to:

• divide and reunite product ows using mechatronic transfers between two movers;

• sort products using an integrated pusher on the mover;

• pick and place products for product sorting using vacuum suction units; and

• pick up individual products from unsorted and irregular product ows and be able to sort them into good and bad parts or place them correctly for nal packaging.

Explaining how XTS with NCT can increase production output, Johnson says with energy being wirelessly transferred to the mover with NCT, this energy is available to realize different motion sequences directly on the mover with the help of motors. The system’s CNC-based motion

High-margin CPG industries like spirits, confectionery, and cosmetics are early adopters of a trend toward heightened personalization, both in what’s placed in packaging by automation and on the packaging itself. Healthcare is also blazing new trails in personalized medicine and individualized—down to a single person—pharmaceutical/nutrimental regimens, or medical device kits. And among e-comm ful llment centers, no two orders are alike. In these highly personalized environments, often referred to as “batch size one,” we see packaging applications emerging that are on the leading, bleeding edge.

One such technology that plays in this space, demonstrated by B&R at PACK EXPO International, is called ACOPOS 6D (six degrees of freedom) (2). In it, magnetic levitating shuttles move individual products freely through the machine environment, potentially carrying products to be packaged. According to a company press release, “gone are the days when conventional transport systems imposed rigidly de ned timing on the production process. ACOPOS 6D is ideal for small-batch pro-

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duction with frequent changeover between products of different designs and dimensions.

Corey Morton of B&R demonstrated the tech for at the show. “What we’re creating here is mixed packages [of different dice colors and types, in the demo] that are built to order, so it’s actually batch size one production,” he says. “This type of technology gives you no wear, since there’s no rails that it’s riding on. The other thing is it gives you six degrees of freedom of movement.”

Even when only using the X and Y planes in the demonstration at the show, the demo format would allow packagers to collate product, buffer product, and pull product for a speci c order from any position within the buffer. The levitating shuttles can also move on other planes, like vertical Z access, tipping on edge, and rotating. That’s why, in a small footprint, this technology could provide packagers a high degree of order customization.

a video of this system in action at pwgo.to/7862.

EXPANSION IN PNEUMATICS

Norgren has expanded its pneumatic portfolio to include new IOLink enabled products (3) that connect to industrial networks to facilitate automation and provide data on circuit performance. “Connected pneumatics can help improve productivity and reduce machine downtime, which are invaluable to the packaging industry,” explains Ken Chung, director of product management at Norgren. “Our new IO-Link enabled products make that connection possible. So, we can not only offer a complete pneumatic circuit, but also help customers upgrade to a new, modern circuit.”

Norgren’s IO-Link Masters, I/O Modules (Hubs), and range of cables and connectors are available as part of the NC-Series. The IOLink Masters for eld applications are the gateways for the connection of up to eight IO-Link devices and the higher-level communication system, such as an Industrial Ethernet. The master transmits machine data, process parameters, and diagnostic data to the controller over various networks, making the data accessible for immediate action or long-term analysis via an industrial information system (PLC, HMI, etc.)

One of the IO-Link enabled products demonstrated at the show was the company’s new Excelon Plus air preparation equipment with an integrated electronic pressure sensor (IEPS). Both generalpurpose regulators and lter regulators are now available with an optional integrated digital pressure switch and gauge. Offering Industry 4.0 connectivity via IO-Link, the digital gauge allows for remote setup and visibility of application performance data for improved monitoring.

Another product from the company featuring IO-Link connectivity is its Norgren VR valve manifold range, which features a simple plug-

in, sub-base style that allows valves to be easily exchanged for simple installation and maintenance. Available in two body sizes—10 and 15 mm—the VR10/15 Series can be used across a range of industrial automation markets, including food and beverage, packaging, and labeling, among others.

Other IO-Link enabled products highlighted at the show were Norgren’s N34D and 54D electronic pressure sensors and its M/50/IOP magnetically operated solid-state switch, which is fully compatible with all Norgren actuator ranges.

Also focused on pneumatics was automation provider SMC, which used PACK EXPO International to soft-launch what it says is the industry-leading, innovative Air Management System (AMS) technology ( ). The tech monitors and measures pressure, air ow, and temperature to provide the optimal supply of air pressure and volume for ef cient process control to reduce demand on air compressors.

“The Air Management System from SMC is the most technologically advanced, modular air preparation system in the industrial automation workspace. It reduces compressed air use while simultaneously digitally nger-printing the machine’s current performance,” Nathan Eisel, SMC national product development manager, SMC, says.

But air compressors and pneumatic controls can be found in almost every industry. What makes them appropriate for packaging speci cally?

“Let’s use a case packer as an example. Typically, these machines have many, large actuators that are operating at very high run-time use,” Eisel continues. “If the case packer is out tted with an Air Management System, the end user can very quickly realize the deep energy savings (25 to 40 percent) by the machine switching into 1 of the 2 Eco modes when the machine is at idle. The end-user can also take full advantage of the onboard OPC-UA interface to collect and analyze machine performance and establish conditional based maintenance (CBM) algorithms minimizing breakdowns due to pneumatic component failure. This data stream by-passes the traditional methods of PLC mining and goes directly to the end-user SCADA system with minimal integration effort.”

ADVANCED APPROACHES TO HANDLING DATA

Data centers—which are typically housed in their own separate section of a facility for consolidation of routers, switches, rewalls, storage systems, servers, and application controllers—are a key aspect of enterprise IT. Micro data centers (MDCs) are small, modular versions of data centers used to manage the computing workloads of speci c op-

erations. With their ability to be installed nearly anywhere in a facility, MDCs are quickly being recognized for their key role in industry’s IT/ operations technology (OT) convergence.

At PACK EXPO International, Stratus Technologies and Schneider Electric showcased three sizes of the EcoStruxure MDC (5), which feature the Stratus ftServer (Fault Tolerant), to highlight their use in CPG and pharma/life sciences applications:

• Small: Stratus ftServer powered by a 1.5kVA Smart-UPS in a 6U enclosure;

• Medium: Stratus ftServer powered by a 2.2kVA Smart-UPS in a single 12U enclosure; and

• Large: Stratus ftServer powered by a 3kVA Smart-UPS in a 42U, NEMA-12 rated enclosure.

The different size options were presented to highlight the MDCs’ application exibility in a range of CPG operations. Size can scale up from 6U to 42U depending on how many devices and how much networking equipment need to be embedded in the panel with the ftServer and UPS (uninterruptible power supply).

Key features of the edge ftServer include embedded cybersecurity, no unscheduled downtime with failure prediction capabilities, single button restoration, and remote monitoring ability.

While MDCs are typically designed for IT workloads, Stratus and Schneider Electric note the EcoStruxure Micro Data Center is suitable for OT applications like on-premise automation and control systems in the CPG and pharmaceutical/life sciences industries.

“In effect, what we are providing customers and partners is a complete offering—originally meant for IT applications—that can be used for HMI/SCADA, historians, batch processing, manufacturing execution systems, asset performance management, and cybersecurity solutions,” says Jay David, senior manager for solutions marketing at Stratus.

Integration with existing equipment in a production facility is handled in the same manner as any brown eld project, he adds. “The Micro Data Center can replace any or all of the components associated with the server control panel, such as automation and control software, computers where the software is installed, UPS and power supplies, and networking equipment.”

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Because the MDC comes with everything pre-installed and tested, it is easier for non-IT customers to deploy the automation and control systems, says David.

“OEMs can use the MDCs to develop repeatable automation and control systems; system integrators can create solutions that contain standardized code and applications, which they can then drop into a virtual image of the ftServer; and end users can use the MDCs to consolidate

disparate applications in a single platform,” says Elliott Jepson, strategy and innovation manager for the Secure Power Division at Schneider Electric. “And thin clients can be used with the MDCs to enable monitoring and control outside of the control room via mobile phones, tablets, and laptops.”

Jepson adds that the EcoStruxure MDC with Stratus ftServer comes completely validated, pre-wired, and with the automation and control software pre-loaded. “This way, customers, integrators, and OEMs can focus on their key expertise,” he says.

“Because everything is tested and prebuilt, the MDC can be commissioned by controls engineers or technicians who don’t have any IT experience.”

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Jepson says Schneider Electric and Stratus estimate “huge engineering and operations savings when an MDC is deployed versus typically built control panels, with 40% less eld engineering time, 20% faster timeto-market, and 7% less maintenance costs overall.”

NEW FOCUS ON INDUSTRIAL CONTROLLERS

When we think about modernizing manufacturing, automation is the rst thing that comes to mind, speci cally in the form of robots and integrated lines of machines. But for Kenneth Tran, the founder and , a Seattle-based startup, yes, automation is key. But when optimizing output, the focus should be on industrial controllers.

According to Tran, who for several years was a principal research engineer working on machine learning algorithms at Microsoft, there is a basic problem that impairs operational ef ciency. It stems from the machine controller—that PLC that has behaved the same way for decades—which follows static, hard-coded instructions implemented by automation engineers during the time of project development. It is hard to update that PLC ladder logic that executes the program.

Meanwhile, however, depending on who is operating the machine, what data is being collected, and the environmental conditions, the machine runs differently. This lack of consistency is hard to overcome.

This became clear to Tran while he was working at his family’s biomass production facility in Vietnam which was built with traditional PLC, HMI, and SCADA technology. The dryer machines, for example, were not operating ef ciently, and when he would ask operators why, they gave different answers. He couldn’t gure it out on his own either because the PLCs were not equipped to receive data from different sources and therefore could not present the big picture view of what was going on in a format that was understandable.

So Tran was on a mission to improve the processes without getting into the weeds of complex and expensive programming. Instead, he pulled the PLC source data to an edge computer running arti cial intelligence IoT software, which added sensor data and op-

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erational parameters. Without getting into the ladder logic, they were able to apply a low-code language to improve control logic and algorithms for optimizing operations.

Subsequently, that turned into the commercial Koidra IoT Suite, which was on display at PACK EXPO International. The industrial IoT platform can be integrated with sensors, existing control systems, and databases or legacy systems for data management. That information is then brought into Koidra’s user-friendly web interface, called Opera, which enables operators to de ne control strategies and change operating conditions using a low-code Excel-like option vs. using ladder logic.

The Koidra decision intelligence platform solves the problem associated with antiquated industrial automation that sits static in ladder logic programs, and the data silos that lack interoperability among machine control systems. It also creates scalability and easy operational interfaces for unskilled workers.

“We advanced automation technologies using modern software engineering practices, moved it to the cloud, and made it operatorfriendly,” Tran says. The automation logic exists as a layer above the PLC to augment it, but in some cases, like new dryers for the biomass facility, the Koidra technology is used as a soft PLC for micro control of machines. It can also automate set point logic, which was demonstrated in the autonomous greenhouse challenge, organized by Wageningen University and Research in the Netherlands, that Tran has personally participated in multiple times—and won.

This past summer, Koidra won the international contest for the second time, applying reinforcement learning, a subdomain of machine learning, which uses real-time decision making for optimization of control processes based on conditions.

The efforts have not gone unnoticed in the Agtech space, as Koidra was recently awarded a $3.77 million research grant by the U.S. De-

partment of Agriculture, which it will share with Ohio State University, Rutgers University, Cornell University, and the University of Arizona. The new grant will allow Koidra to work with the universities on the continued development and validation of data-driven decision making to help grow produce.

Now, there are new ways to grow things and scale operations. “We keep making modi cations to the plant, and the automation needs to follow the modernizations,” Tran says.

AI FOR PREDICTIVE MAINTENANCE

Though it’s been discussed for years, and its capabilities are increasingly being incorporated into automation hardware and software of all types, arti cial intelligence (AI) remains a bit of a mystery to many end users. The mystery is not necessarily created by a lack of understanding about AI, it’s the application of the technology that raises many questions since it can be used for everything from machine control to cloud-based data analytics.

To demonstrate how AI can be used in CPG (consumer packaged goods) production operations, Festo introduced its Festo Automation Experience (AX) at PACK EXPO International (7). By using advanced analytics, Festo AX maps data to learn a component, machine, product, or system’s healthy state and provide information for the correction of anomalies when data begins trending out of the normal range. Festo AX can be operated directly on equipment at the edge of the network, on data center servers for general on-premises applications, or in the cloud.

Festo AX begins with condition monitoring and preventive maintenance calculations for components, machines, and complete systems. Data collected from the factory oor is used to make uptime-based maintenance suggestions, enabling maintenance to be more ef cient. From this starting point, the capabilities of Festo AX can be extended

SaaS Approach to Data Recording

The SaniTrend Cloud Lite online process data recording system from sanitary process cleaning systems provider SaniMatic is a software-as-a-service (SaaS) product (6) that provides automated, secure data acquisition of critical process or cleaning data for any cleaning system, including Clean-in-Place (CIP) and Clean-Out-of-Place (COP), in a customer’s facility. SaniTrend Cloud Lite captures continuous process data, while SaniTrend Cloud Lite+ uses running signals from equipment to consolidate the process data into individual reports.

Among the capabilities of SaniTrend Cloud Lite, it provides cloud access to all accessible data, via phone, tablet, or mobile; it allows for unlimited users; it has store and forward capabilities; it provides cloud documentation storage, live dashboard

views, and email and SMS notifications; and it delivers analog and digital data trending information, with comments. SaniTrend Cloud Lite+ offers all of these features, as well as cycle-based reporting, downloadable cycle reports, and cyclebased comments and approvals. Both Lite and Lite+ can handle up to eight analog input signals and up to 12 digital input signals.

Sani-Matic has partnered with Rockwell Automation and PTC to provide its SaniTrend Cloud line, which also includes SaniTrend Cloud and SaniTrend Cloud Pro, through PTC’s Cloud platform, utilizing PTC’s ThingWorx® product. All of PTC Cloud’s data and user security has been integrated into the SaniTrend Cloud offering. PW related video at pwgo.to/7864.

Introducing

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with AI. The AI technology used in Festo AX analyzes live data in real time, meaning that users are made aware as soon as an anomaly occurs.

According to Festo, Festo AX can lower waste by more than 50%, reduce product rejection costs by more than 45%, increase machine availability by more than 25%, and reduce unplanned downtime by more than 20%.

While Festo AX, of course, works with any Festo components, its use of common industry communications and networking technologies such as OPC UA and MQTT means that it can also be integrated with third-party components and machines. For example, linking Festo AX to Festo Smartenance or a third-party maintenance management program can extend Festo AX’s effectiveness by providing the maintenance department with a tool to help them keep automated equipment performing at optimum energy consumption.

process steps that are dif cult to detect in a PLC program.”

Festo’s turnkey system for monitoring energy use in pneumatic devices is called E2M/C2M. “By monitoring the E2M/C2M with Festo AX AI, anomalies can be detected with respect to compressed air related to energy loss. Having this level of oversight on compressed air loss, CO2 emissions, etc., can improve packaging machinery energy use,” Latino says.

USING DIGITALIZATION TO IMPROVE PRODUCTIVITY

The complex operation of packaging lines now nds an essential analysis and data sharing tool to elevate its productivity levels in digitalization. Through solutions like Share2Act, the IIoT cloud-based platform by Krones, it is possible to supervise from any place and in real time the state of a packaging line and its machines, as well as visualizing Key Performance Indicators (KPI).

Martin Braun, digitalization sales director at Krones North America, explained to us during PACK EXPO International how “these tools provide a general view in real time of the current states of your machines and allow you to visualize the production process’s most important KPIs. Therefore, they can pinpoint exactly those areas with untapped potential so you can continue growing your packaging line’s productivity.”

“One of the key strengths of Festo AX is its ability to work with small data sets, meaning that it’s not necessary to have prepared Big Data available,” says Frank Latino, product manager at Festo. “To detect data anomalies, for example, Festo AX relies on unsupervised learning algorithms to t a use case, such as eld maintenance, quality, or energy use applications.”

Festo AX continuously learns about the state of your assets in a process that continuously improves the algorithms.

But these algorithms don’t work in a vacuum. Festo AX keeps the human in the loop by incorporating their feedback into the process to classify anomalies and connect them with recommended courses of action. As a result, the next time the anomaly occurs, the individual receiving the noti cation will know exactly which system is affected, what happened, and what to do next.

Festo offers AX turnkey systems for food and beverage packaging, pneumatic components, welding systems, and machine tools.

Explaining Festo’s standard AX package for monitoring pneumatic cylinders, Latino says, “Packaging machines consist of many pneumatic actuators moving in short cycle times. This can complicate the process of nding the single component that may be causing the failure. But continuous monitoring of pneumatic actuators can result in early detection of anomalies because the trained AI model can identify which actuators need to be replaced before they fail. The AI model can also detect deviations in cycle times over a larger number of actuators and

Considered as a social network for manufacturing plants in the food and beverage industry due to their intuitive and collaborative use, the tools presented during the Chicago trade show last October guarantee total transparency of production processes and gather critical information needed to timely implement any needed maintenance actions or to correct issues during the operation of a production line.

The traceability offered by Krones through their new digitalization tools —which are part of the Krones Digital Factory concept—along with the availability of data for operators, managers, and maintenance personnel, extend from beginning to end of a process. “With these new digitalization tools, we can connect every system with each other and provide a complete tracking report. So if, for example, there is a problem with a bottle, its full trajectory can be traced, from the in ow of raw materials to the delivery of nished products at a warehouse,” Braun told us at PACK EXPO.

With Share2Act, you can also generate what Krones calls plant guides, essentially systems dedicated to providing data to operators in real time that provide them with guidance whenever they need to take special actions. Through a cellphone or an app, operators receive precise information about what they need to do, regardless of where they are.

Real-time visualization of a production line’s performance—with diagrams summarizing the information on the state of the machine, its speed, and the number of units being produced, among other indicators—optimizes running times and increases ef ciency. It’s a way of guaranteeing the transparency of processes for the operator and generating information that is essential for the decision-making process regarding line transformations or expansions.

The presence of dedicated sensors along the lines with an approach called Action-Based Monitoring gives these new digitalization services

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by Krones the ability to guarantee a high availability of equipment and machinery in a line. It also facilitates the assigning of production or maintenance actions to the appropriate area. “Not only are operators using these solutions, we at Krones also use them to offer speci c services and recommendations to our clients on how to maintain their equipment ef ciency at very high levels,” said Braun at PACK EXPO Internanational.

video of this digitalization solution at pwgo.to/7863.

DIGITAL PRINTING MEETS SMART PACKAGING

At the nexus of digital printing and smart packaging resides Prismiq, a division of Sealed Air (SEE) that made its PACK EXPO International debut. At rst glance, Prismiq seems like highly conceptual stuff, and it is. That’s because it’s not a single product offering, like a machine or software. Rather, it’s a set of capabilities, products, and options that can be intelligently strung together to achieve a range of outcomes that really depends on the brand’s or CPG’s preference.

From the widest possible angle, Prismiq creates a digital twin for each individual unit that a brand or CPG is producing within a chosen SKU or group of SKUs. That happens thanks to a unique watermark (visible or invisible) that is digitally printed onto the packaging of each and every product unit. The watermark can be read and reacted to in different ways by scanners, sensors, and smartphones as it travels through the supply chain. And upon each interaction with a sensor or smartphone, data is added to the digital twin to better describe that individual product’s unique journey.

According to the company, Prismiq could impact CPGs at two levels. The more obvious use is in the realm of consumerfacing, experiential smart packaging. A brand can delight its end consumers by providing product provenance information, product-speci c nutritional information, or hyper-personalization. That content is made available on a website or app that the consumer can access by scanning a digitally printed watermark on the pack with a smartphone.

But perhaps more foundationally, Prismiq could have big impacts upstream, at the processing, packaging, and supply chain logistics levels. That’s because of the many ef ciencies that a company can realize by managing both the digitally printed/watermarked products traveling through the supply chain—gathering and storing data associated with each product as it’s packaged, palletized, and transported—and each product’s digital twin that exists in the cloud, but is uniquely linked to that single product. All the ef ciency-borne savings and insights gained by CPGs upstream can end up paying for the enhanced consumer experience with a product downstream.

At PACK EXPO, PW editors spoke with Nathan Henson, the global director for smart packaging and design solutions at Prismiq, to try to wrap our minds around all of this. It’s a prime PACK EXPO example of active, intelligent packaging. Read more on the topic on page 104

“Our Prismiq brand is a holistic approach to how we look at digital. It’s our graphic services, it’s our digital printing, and it’s our smart packaging,” he says. “We have two things here. First is our digital printing, which is an inline packaging solution that prints variable data onto products [primary or secondary packaging] in full color graphics [in what could be called a digital watermark, potentially invisible to a consumer]. That allows the [CPG] customer to print variable data, inline and in real time, about each product, onto each product. That data [can serve as the basis for] all the content that the end-consumer is looking to have, whether it’s personalized [or contains pertinent product provenance facts].

“Then second, if we go into the [CPG or brand] customer’s production facilities, that’s where we have both a vision solution along with a coding solution. Inside a customer’s four walls, we have a digitally printed bag that has a code embedded—there’s a watermark in it. So as this product is going down the production line, [vision and sensors] capture product-speci c information about each product, and we store the data. We’ve taken the physical product, created its digital twin, and we’ve put it in the cloud. And once that product is in the cloud, we can do a bunch with that information,” he continues. “We can support internal operational ef ciency things such as rework or recalls. There’s just a ton of use cases there. But what’s cool about this is once we have that digital twin, we can then track that package through supply chain as well. So that’s track and trace, authentication, fraud prevention, those kinds of use cases, which then translate all the way over to, again, that consumerfacing side.”

To ground all these possibilities in a real product, consider boxed wine. Notably, only a week after the show on Nov. 1, Sealed Air’s Cryovac brand announced the acquisition of bag-in-box format packaging supplier Liquibox. According to a Nov. 1 press release from Sealed Air, “E-commerce ready solutions for uids & liquids will bene t from SEE’s integrated approach to digital and the advancement of Prismiq digital packaging and printing solutions.”

It so happened that at its PACK EXPO booth, Sealed Air was demonstrating bag-in-box form/ ll/seal equipment alongside a wall of model bag-in-box wines (8), all having been digitally printed with an on-pack digital watermark, as a use case for Prismiq.

As Sealed Air’s Jaime Hansen described, imagine information about the provenance of the grapes used for a speci c bag-in-box wine, or a speci c vintage of wine (for instance, a particularly dry year or a particularly short summer) being associated with a digital twin of each

bag-in-box format as it comes off the packaging line. All that data can be captured at packaging and embedded in a digital watermark that’s been digitally printed on-pack and becomes accessible to a consumer via smartphone on as beautiful an interface as a CPG chooses to invest in. Beyond that, consider consumers interacting with the digitally watermarked box of wine, again via a smartphone interface, that presents them with a countdown clock for shelf-life in the fridge once the package is opened.

“Another piece is that [thanks to the digital twin] we’re then connecting the processor or brand with the interaction at the consumer level,” Hansen says. “It can produce powerful insights for the processors. Think about that consumer countdown clock. If they have a consumer who uses it, the interaction goes to the cloud and is associated with the digital twin, and they know when that clock starts ticking. They can then piece together just how long that box of wine has taken to get through distribution to be consumed. They could understand when that speci c box was purchased, versus a SKU of it. Remember, alcohol often goes through a distributor, so producers really lose a lot of that valuable information once the box of wine goes out the door. And there could also be bene ts for that distributor, too, through this process. It allows those brand owners to get other insights, too. In the case of recalls, if a consumer interacted with a recalled box, the brand can learn exactly when the recalled box was opened, and when that speci c box was bottled.”

Meanwhile, all of the other process-oriented data that’s not for consumer consumption and won’t appear in the consumer interface—say shelf life of an unopened box of wine as it travels through the supply chain and sits on a retailer’s shelf—also can be associated with the digital twin that’s been created for each box. Could a retailer bene t from knowing a box of wine was approaching an expiration date, revealing that maybe some discounting should happen to move that wine soon? Sure. And even further upstream, consider a winery having to navigate realities like recalls or line inef ciencies, all made more ef cient by managing through a digital twin with speci c data associated with each product. And all these upstream, B2B ef ciency bene ts ultimately pay for the consumer experience piece, interaction piece, and consumer insights piece mentioned above.

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LABELER HAS NEW CONTROLS PLATFORM

Sometimes in a discussion of controls technology it’s instructive to zero in on one speci c piece of packaging equipment to see how advances in controls make it possible to build a better packaging machine. One good example of this found at PACK EXPO International was the NJM Bronco 130 pressure-sensitive labeler, which can be con gured to apply single, dual, wraparound, and/or multi-panel labels to round, square, rectangular, and/or oval bottles in a variety of sizes.

This year, the enhanced Bronco 130 (9) features a new PLC from Rockwell, the CompactLogix 5380. Also new and also from Rockwell is the Panelview Plus 7 Performance HMI or, as an optional upgrade, the Versaview Windows-based HMI. The new servo drive controls platform, Rockwell’s Kinetix 5300, offers advanced software capabilities. And an encoder-based fail-safe reject tracking of labels and containers is available to ensure that “bad” labels and bottles are rejected and veri ed.

Running at speeds to 250 bottles/min, the inline, servo-driven system is suited to manufacturers and contract packers handling nutraceuticals, pharmaceuticals, food, beverages, cosmetics, personal care products, and other applications. The system can be con gured for a variety of challenges, such as applying clear mylar labels on curved bottles and orienting labels on bottles with handles. The Bronco 130 is available with a variety of bottle handling devices, including a spacing wheel, a starwheel, a chain aligner, and a single or dual feedscrew drive. To apply a range of label types and sizes, each labeler is available with an assortment of label application and wipedown devices, including either one or two servo-driven label dispensers.

NJM can equip the enhanced Bronco 130 with an inline hot stamp printer or a serialization-capable thermal transfer or laser printer. An optional inspection system detects label accuracy, label placement, variable data, and more, and an optional reject system removes bottles with out-of-tolerance labels.

For a seamless user experience, customers can choose to upgrade to a PC-based HMI that supports fully integrated vision inspection. Additionally, the Bronco 130 is now available with software options for audit trails, electronic signatures, and advanced user management through LDAP for 21 CFR Part 11 compliance. Onboard production batch reporting tools for machine operation, statistics, and OEE are also supported through the PC-based HMI. PW

By Anne Marie Mohan, Senior Editor

Wild Tonic’s Packaging Goes from Boring to Bee-utiful

Sedona, Ariz.-based Wild Tonic occupies a unique space in the kombucha category. Rather than being fermented with cane sugar like traditional kombucha, the non-alcoholic, Jun-style kombucha uses honey, which is said to result in a smoother, lighter avor and a better-for-you beverage. With the aim of delivering a “farm to bottle” experience, Wild Tonic infuses its kombucha with organic fruits, herbs, and botanicals, many of which are grown locally among Sedona’s red rocks. According to the brand, Wild Tonic is the only Jun kombucha nationally and is among the top 50 brands in the kombucha market.

was inspired by “beer cans and cool local breweries with landscapes and energy.”

According to Brady Waggoner, creative director at HOOK, the agency’s task was to put Gerth’s design inspiration to paper and create a refreshed look for the brand overall. Before embarking on the redesign, HOOK surveyed stakeholders and reviewed consumer research in the category. It then set up brand messaging, with a primary focus on kombucha versus Jun. “We used this information to convey what’s in the can and what the differentiators are—for example, taste, mouth feel, pure ingredients, etc.,” he says. “As far

However, despite its distinctive product positioning and premium, locally grown ingredients, Wild Tonic Director of Sales & Marketing Jessi Gerth says that before the recent redesign of the graphics for its packaging, which started with its slim can and expanded to its blue glass bottle, the can was so boring, “it totally got lost on shelf.” She adds, “You could literally stand in front of the set and still not see it.”

What the previous packaging lacked, says Gerth, was vision and design. “It’s hard to pinpoint a single element [of the design that lacked shelf appeal], we were just itching to change all of it,” she says. “It felt like, as a group, we are such quirky and fun people, and the labels weren’t serving that. It didn’t feel like us. The blue glass bottle was magical, but the cans and the labels lacked that magical element that felt inherently us.”

The initial starting point for the redesign—a collaboration with digital marketing and ad agency HOOK that began in 2022—was a mood board compiled four years previously by Gerth that she says

as the competitive landscape, while we identified what consumers like about Wild Tonic, we also zeroed in on aspects that traditional kombucha fans like and dislike about competitors’ products.

“This all funneled into our designs and concepts of what was true to the heart of the brand: honey, bees, Sedona, and Jun in general.”

What was retained of the existing packaging was its shapely, blue glass bottle, which Trish Ward, associate creative director at HOOK, says is a huge standout in the kombucha market. The typography remained much the same as well. As for the changes to the design, one of the most alluring elements is a new logo that features a gold honeybee.

Explains Ward, “We kept a similar sans-serif font to the one in the original logo, keeping the typography simple. We always remind each other, there’s only one punchline in a joke, and if you have a logo that is mystical and super intricate with sacred geometry, the lettering that comes with it must be more subdued and simple. We created

that balance with the new Wild Tonic logo.”

The logo is designed and positioned on the label against a deep blue background to look like a constellation, under which is a gorgeously colored illustration of the Sedona mountains. “We wanted to create a constellation using the Sedona Cathedral Rocks and the bee as a symbol of our differentiation using honey,” explains Waggoner. “Through all of this, the personality of the brand was born ... . It is a queenbee, mystical, Mother Earth-vibe that represents the core leadership of the brand today, an energy that no other kombucha brand has. It’s more than just a package, it sets the stage for the future of the brand, where it lives, and who is behind the brand. It’s truly authentic.”

Shares Ward, a tagline in the design, “Bee Wild,” provides a nod to both the wild honey and the wellness aspects of Wild Tonic’s ingredients. “Bee Wild as a tagline, serves as an inspirational message to the consumer to drink better while feeling better—and hopefully to behave in a new and pronounced way,” she says. “All in all, we believe the product, the package, the design theory, and the elements are all working together to inspire the consumer to be different, better, wild.”

The labels are converted by Precision Label, which uses a metallic paper for both the can and bottle to create a gold foil effect for the logo and brand name. The label is printed in six colors, consisting of four-color process plus violet and orange, which Waggoner says helped the brand to meet the saturated orange colors and vibrant purples and blues in the background of the label and the Sedona mountain illustration. “This addition of two complementary colors to our traditional four-color print process created a pop, sheen, and quality that couldn’t have been achieved in any other way,” he says.

“It pulled the night sky with the sunset together in a beautiful way.”

Wild Tonic is sold in a range of retail outlets, including Sprouts, Natural Grocers, Whole Foods, Wegmans, Safeway, The Fresh Market, Erewhon, and other major retailers. Its glass bottle and slim can for eight flavors with the new label landed on shelves in December 2022.

Says Gerth, “It was such a highlight of my career and exceeded my expectations on every level. While it’s too soon to comment on consumer response to the new design, we expect our fans will be as enamored with it as we are.” PW ustsubaki.com

Companies

TC Transcontinental Packaging opened its Recycling Technology Lab at the Art, Science and Technology Research and Applications Center (ASTRA Center) in Menasha, Wis.

ePac Flexible Packaging launched ePacONE (One Network Everywhere), creating the world’s first and largest integrated network of packaging plants across the globe.

GEA began construction on a 85,000-sq ft-repair, logistics, assembly, production, and training facility in Janesville, Wis.

Atlantic Packaging opened a 34,000-sq-ft facility in Henderson, Nev., that will support its West Coast customers as well as continue its transition to sustainable packaging.

Signode opened a 360,000-sq-ft facility for its Automation and Packaging Technologies (APT) division that will feature a state-of-the-art customer experience center, training facility, and expanded equipment manufacturing capabilities.

PPC Flexible Packaging acquired Plastic Packaging Technologies

Specright donated $500,000 to the MSU School of Packaging to refresh the school’s computer lab and enhance student preparation for careers in the packaging industry.

Sidel opened a PET recycling facility in Octeville, France, dedicated to recycling primary packaging.

AlliedFlex became IMA Ilapak’s exclusive North America, Canada, and Mexico sales and marketing partner to handle the sales and marketing of IMA Ilapak LUX series stand-up pouch packaging machinery.

Plastipak opened a recycling investment at its manufacturing site in Toledo, Spain. It will convert PET flake into food-grade rPET pellets suitable for use in new preforms, bottles, and containers.

Delta ModTech and Frontier recently hosted the 2022 Technology Showcase, unveiling several new innovations and demonstrating them on-site in their Ramsey, Minn., facility.

People

Jack Lee was appointed president, Key Technology – Americas.

Formost Fuji promoted Mike Alexander to sales manager, Eastern United States and Canada, and named Michael Schaefer North Central regional sales manager.

Michael Hays was appointed president of Integreon Global.

PPG appointed Tim Knavish president and chief executive officer and named Michael McGarry executive chairman.

Plexpack Corp. hired Chris Stoner as director of sales.

Barry-Wehmiller CEO Bob Chapman was named Tharseo - CEO of the Year by the Society for Human Resource Management.

Robert Bunting was appointed president and chief executive officer of Bunting.

Jaisen Kohmuench was appointed chief operating officer for Eriez.

Mike Lynch was appointed director, North America for Shemesh Automation.

Dr. Chuck Xu was appointed to Michelman’s Board of Directors. He is vice president and general manager of Strategy and M&A, Electronics and Industrial Segment, DuPont de Nemours, Inc.

Joseph Weber Jr., past president and chief executive officer of Weber Packaging, passed away on October 17, 2022.

Packaging journalist John Kalkowski passed away on October 12, 2022.

innovator and founder of Schneider Packaging Equipment Co., Richard F. “Dick” Schneider, passed

on December 14, 2022.

ProFood World added a new category to its annual Sustainability Excellence in Manufacturing Awards. The Processor/Supplier Partnership Category recognizes the growth and importance of collaboration between processors and industry suppliers in protecting the planet.

Learn how past winners in this new category— Li ey Meats and Graphic Packaging International—worked in tandem to create a new PaperSeal tray for Lidl.

View video at pfwgo.to/meat.

DEADLINE FOR ENTRIES IS MARCH 1, 2023.

Learn how to enter at pfwgo.to/sema.

Produced by Awards to be presented at

Laser Coder

Domino’s UV-based U510 laser coder is designed for high-speed, high-precision coding on recyclable, mono-material, and colored plastics, including exible food packaging lms in hf/f/s and vf/f/s applications.

Domino pwgo.to/7738

HMI

Plexpack’s C-80 Multi-Touch HTML5-based HMI features advanced data tools that streamline troubleshooting, reporting, and audit trails. It also helps reduce downtime and effects of operator variability. Plexpack Corp. pwgo.to/7777

X-ray Inspection Technology for Hard-to-Find Contaminants

Mettler-Toledo launches DXD and DXD+ dual energy detector technology designed to detect low-density contaminants, such as calci ed bone, low-mineral glass, rubber, and some plastics in packaged food products.

Mettler-Toledo Product Inspection pwgo.to/7739

Water-soluble Inner Garment Bag

Hero Packaging’s Aquahero 100% water-soluble garment bag is made using plant-based PLA, PBAT, and water-based inks. It contains no microplastics, can be composted at home, and can be completely dissolved in boiling water within 30 sec.

Hero Packaging pwgo.to/7722

Continue your search for the right packaging solution. Visit prosource.org

Pouch Loader for Belted Chambers

Multivac introduces a pouch loader and pouch rack designed to provide a exible, ergonomic, and hygienic process for packaging on belted chambers.

Multivac pwgo.to/7776

Stretch Blow Molder

Krones’ Contiform stretch blow molder is designed to reduce energy consumption, lower compressed air consumption, and reduce downtimes, and it can be equipped with AI.

Krones pwgo.to/7718

Automatic Dosing Closure

Silgan Dispensing’s MeaSURE closure features a built-in chamber that delivers convenient, controlled dosing with the use of one hand. When inverted, the closure dispenses the exact amount needed for the intended application and reloads within seconds.

Silgan Dispensing pwgo.to/7723

Search Packworld.com for additional information on any of the advertisers listed or visit their website directly

ADVERTISER WEBSITE

PAGE ADVERTISER WEBSITE

A-B-C Packaging Machine Corp. www.abcpackaging.com 17

Aagard Group, LLC www.aagard.com 77

All Packaging Machinery www.allpackagingmachinery.com 161

All-Fill Inc. www.all-fill.com 27

ALLIEDFLEX Technologies, Inc. www.alliedflex.com 101

AMCI www.amci.com 137

American Film and Machinery www.afmsleeves.com 223

Anritsu Product Inspection www.anritsu.com/infivis 235

Axon www.www.promachbuilt.com/our-brands/axon 221

B&R Industrial Automation www.br-automation.com 3

Beckhoff Automation www.beckhoff.com 13

BELL-MARK www.bell-mark.com 32

BestCode www.bestcode.co 265

Bevcorp LLC www.bevcorp.com 50

BluePrint Automation www.blueprintautomation.com 78

Brenton www.brentonengineering.com 210

Brother USA Machinery LLC www.usabrother.com 159

BUNTING www.buntingmagnetics.com 9

Busch Vacuum Solutions www.buschusa.com 169

Buskro Ltd. www.buskro.com 25

BW Integrated Systems www.bwintegratedsystems.com 127

BW Flexible Systems www.bwflexiblesystems.com 167

BW Packaging www.berry-wehmiller.com 231

Cama North America www.camagroup.com 6

Cassel Inspection www.cassel-inspection.com 255

Charter Next Generation www.cnginc.com 249

Chase-Logeman Corporation www.chaselogeman.com 227

Clysar LLC www.clysar.com 245

Columbia Machine, Inc. www.palletizing.com 94

Columbia/Okura www.columbiaokura.com 189

CTM Labeling Systems Inc. www.ctmlabelingsystems.com 46

Dekka www.dekkaindustries.com 52

Delkor Systems, Inc. www.delkorsystems.com 243

Diagraph Marking & Coding, An ITW Company www.diagraph.com 5

Digimarc www.digimarc.com 23

Dodge Industrial, Inc. www.dodgeindustrial.com 247

Domino Amjet Inc. www.domino-na.com 229

Doosan Robotics Inc. www.doosanrobotics.com 267

Dorner Mfg. Corp. www.dtmpackaging.com 199

Douglas Machine Inc. www.www.douglas-machine.com 193

DTM Packaging www.dtmpackaging.com 89

Duravant www.duravant.com 233

Eastey www.eastey.com 239

Econocorp, Inc. www.econocorp.com 185

ECORRCRATE www.ecorrcrate.com 173

EDL Packaging, A Massman Company www.edlpackaging.com 90

Encoder Products Company www.encoder.com 130

Enercon Industries www.enerconind.com 22

Eriez www.eriez.com 20

Fallas Automation Inc. www.fallasautomation.com 197

FANUC America Corporation www.fanucamerica.com 111

FAWEMA Inc. www.fawema.com 79

FlexLink Systems, Inc www.flexlink.com 138

Focke & Company www.focke.com 154

Formost Fuji Corporation www.formostfuji.com 107

Fortress Technology Inc. www.fortresstechnology.com 109

Frain Industries www.fraingroup.com 151

Garvey Corporation www.garvey.com 230

Glenroy, Inc. www.glenroy.com 155

Graphic Packaging International www.graphicpkg.com 181

H.B. Fuller Company www.hbfuller.com 263

Harpak-ULMA Packaging LLC www.harpak-ulma.com 203

Haver & Boecker USA, Inc. www.haverusa.com 177

High Tek USA, Inc. www.hightekusa.com 241

Heat and Control, Inc. www.heatandcontrol.com 100 Hitachi www.hitachi-iesa.com 135

Ideal-Pak / PASE Group, A Massman Company www.idealpakpase.com 89

Ilapak, Inc. www.Ilapak.com 45 Independent Can Co. www.independentcan.com 21

Inline Plastics Corp www.inlineplastics.com 269

INSITE Packaging Automation www.insitepackaging.com 97

Intertape Polymer Group www.itape.com 168

ITW Hartness www.hartness 67

James Alexander Corp. www.james-alexander.com 102

JLS Automation www.jlsautomation.com OBC

Kaufman Engineered Systems, Inc. www.kes-usa.com 166

Keyence Corporation of America www.keyence.com 99

King Plastic Corporation www.kingplastic.com 190

Krones www.kronesusa.com 85

Label-Aire, Inc. www.label-airecom 43

Lenze Americas www.lenze.com 75

Leibinger www.leibinger-group.com 31

Markem-Imaje www.markem-imaje.com 103

Massman Automation Designs, LLC www.massmanllc.com 87, 91

Material Transfer www.materialtransfer.com 209

Matrix Packaging Machinery, Inc. www.matrixpm.com 105

Meler USA Corporation www.meler.eu 81

Metsä Board Americas www.metsagroup.com 95

Mettler Toledo Product Inspection www.mt.com/pi 37

MFT Automation www.mftautomation.com 119

mk North America, Inc www.mknorthamerica.com 254

Modular Conveyor Express www.modularconveyor.com 270

Morrison Container Handling Solutions www.morrison-chs.com 69

MRP Solutions www.mrpsolutions.com 83

Mpac Group www.mpac-group.com 51

Multi-Conveyor www.multi-conveyor.com 113

Multivac Inc. www.multivac.com 147

nVenia www.nvenia.com 143

National Bulk Equipment www.nbe-inc.com 117

Nercon Conveyor Systems www.nerconconveyors.com 206

New England Machinery, Inc. www.neminc.com 88

Nita Labeling Systems www.nitalabeling.com 19

Nordson Corporation www.nordsonadhesive.com 131

Norgren, Inc. www.norgren.com 225

Norwix www.norwix.com 71

Novembal www.novembal.com 256

ONExia Inc. www.onexia.com 153

Orion Packaging Systems, Inc www.orionpackaging.com 57

PAC Machinery www.pacmachinery.com 121

PakTech www.paktech-opi.com 59

PDC International Corp. www.pdc-corp.com 47

P ow Industries, Inc. www.pflow.com 49

Phoenix Wrappers www.phoenixwrappers.com 33

PIAB www.piab.com 35

Plan IT Packaging Systems Inc. www.planitpackaging.com 207

PMI KYOTO Packaging Systems www.pmikyoto.com 7

PMMI, The Association for Packaging and Processing Technologies www.pmmi.org 273

Point Five Packaging, LLC www..p5pkg.com 163

Precision Automation Company, Inc. www.precisionautomationinc.com.com 191

Pregis LLC www.pregis.com 11

Printpack www.printpack.com 237

ProFoodWorld www.profoodworld.com 201, 271

Propack Processing & Packaging Systems, Inc. www.propack.cal 251

Quadrel Labeling Systems www.quadrel.com 175

R.A Jones www.rajones.com 15

Reynolds Company www.reynoldsglue.com 205

Robatech USA Inc. www.robatechusa.com 129

Ronchi America www.ronchiamerica.com 61

Ryson International Inc. www.ryson.com 115

Schneider Packaging Equipment www.schneiderequip.com 123

Schubert North America LLC www.schubert.group 149

Sealstrip www.sealstrip.com 29

Serac Inc www.serac-group.com IBC

Serpa Packaging Solutions www.serpapackaging.com 246

Shemesh Automation www.shemeshautomation.com 145

Shibuya Hoppmann Corp. www.shibuyahoppmann.com 157

Sleeve Seal www.sleeveseal.com 236

Shurtape Technologies www.shurtape.com 125

Sidel Inc. www.sidel.com 48

Signode www.signode.com 178

Siko Products, Inc. www.siko-global.com 170

Ska Fabricating www.skafabricating.com 171

SMC Corporation of America www.smcusa.com 141

Soft Robotics www.softroboticsinc.com 139

Sourcelink Solutions, LLC www.sourcelinkcorp.net 195

SpanTech LLC. www.spantechconveyors.com 133

Sparck Technologies www.sparcktechnologies.com 187

Specialty Equipment www.specialtyequipment.com 42

Squid Ink Manufacturing www.squidink.com 183

STA, LLC www.sta-tape.com 257

Standard-Knapp, Inc. www.standard-knapp.com 96

Starview Packaging Machinery www.starviewpackaging.com 179

Syntegon www.syntegon.com 1

Taisei Lamick USA, Inc. www.taiseilamick.com 261

Tawi USA www.tawi.com/en-us/ 55 Teledyne Taptone www.taptone.com 165 Texwrap www.texwrap.com 259

TopTier Palletizers www.toptier.com 219

TRIPACK, LLC www.tripack.net 213

U.S. Tsubaki, Inc. www.ustsubaki.com 268 Uline www.uline.com 212

Uni ed Flex Packaging Technologies www.unitedflex.com 65

Universal Labeling Systems www.universal1.com 222

Weber Packaging Solutions www.weberpackaging.com 63

WestRock www.westrock.com OFC, IFC

Weightpack, Inc. www.weightpack.com 39

Wexxar Bel www.wexxar.com 98

WIPOTEC www.wipotec.com 18

Vacuum Barrier Corporation www.vacuumbarrier.com 215

Valco Melton www.valcomelton.com 217

Van der Graaf www.vandergraaf.com 72a

Videojet Technologies Inc. www.videojet.com 211

Viking Masek Global Packaging Technologies www.vikingmasek.com 41

Yamato Corporation www.yamatoamericas.com 200

Yaskawa America, Inc. www.yaskawa.com 253

Yaskawa America, Inc. Motoman Robotics Division www.motoman.com 53

Zima-Pack LLC www.zimapack.com 93

By Jane Chase, CPPL, Fellow

Revived IoPP Committee

Envisions Sustainable Packaging Community

We at The Institute of Packaging Professionals have the good fortune of having a front-row seat to the many ways the great minds in our industry collaborate and adeptly solve complex problems. I can’t think of a more here-and-now, multi-faceted challenge than packaging sustainability (some call it responsibility) and the need to advance and grow a circular economy within our industry.

In some ways, significant progress has been made with regard to sustainability, but much work remains. What has become clear is that earlier siloed efforts within individual companies, while wellintentioned, aren’t enough. We need to work together.

A huge step in that direction is taking shape with the re-kick-off of IoPP’s Sustainable Packaging Technical Committee (SPTC). One of eight technical committees within IoPP, this group was first launched in 2007. Among its initial tasks were the creation of subgroups that functioned as working platforms for different areas of involvement in sustainable packaging—including consensus around definitions, metrics and building a knowledge base around issues. The SPTC, over time, fell dormant as members cycled out, and for others, the daily responsibilities consumed more of their time at their “day jobs.”

But discussion around the need for a functioning committee never stopped. As sustainability and recycling continue to evolve, from collaborative approaches to the emergence of new bio-based materials to regulatory standards, our industry needs to keep the energy and momentum going. We need to make it better focused among collaborators and innovative thinkers. That’s what the SPTC intends to do.

And now that social responsibility around packaging is much more prominent in their jobs than it might have been 15 years ago, we’re very optimistic that sustained engagement in the SPTC will be possible so the committee can do great things.

Communicate, educate

The SPTC’s aim is to communicate and educate professionals on all aspects of current and emerging issues related to sustainable packaging. The new leadership team consists of Mike Ross, Global R&D Packaging Leader, Food Solutions and Team Leader–Rigid Plastics Sustainability, Unilever; Patrick Keenan, Associate Packaging Principal Engineer, General Mills; Steve Carter, Manager Packaging R&D, Treehouse Foods; and Eric Gassaway, Head of Sustainability, TricorBraun.

The leadership team has developed a list of relevant topics and is looking for input from our members. This input will help us identify where to concentrate effort so IoPP may create a library of training

and learning modules.

Ross explains his interest in getting involved with the SPTC: “Packaging has become increasingly scrutinized for the presence of used packaging in the environment. It is important to understand, however, that what the world does not have a packaging problem. What it has is a litter issue. All that material can be collected and put into circular economic systems that can turn what people call waste into an unexploited valuable resource.”

The vast makeup of IoPP’s membership means inherently that the SPTC’s objectives touch all packaging segments. IoPP members work across many products, from food and beverage to medical devices to chemical packaging. They use all forms of packaging and materials. This diversity will ensure that challenges and solutions are thoroughly discussed from all segments and perspectives.

Topics identified for initial discussion include:

• Definitions of sustainability and a description of the circular economy

• Business topics around the Triple Bottom Line framework and Environmental, Social, and Governance (ESG) principles

• Packaging’s impact on climate, Life Cycle Assessment, Life Cycle Inventory, and carbon credits

• Bio/compost—materials and end-of-life

• Recycling—definitions, Post-Consumer Recycled (PCR) issues, mechanical and chemical considerations, recyclable versus recycled

• Labeling—Federal Trade Commission (FTC) Green Guides, How-2-Recycle, and other topics

• Regulation—Extended Producer Responsibility (EPR), PCR mandates

Collaboration is key

As Ross aptly notes, success will require the entire industry and eco-system partners to work together to create a circular economy. It takes a community—consumers will not look at sustainability in terms of competitive advantage but instead will demand that it be a minimum requirement to sell products into the market. How will we as an industry respond?

Are you interested in lending your time and voice to the SPTC? Membership in IoPP is a requirement to participate. If interested in contributing content or joining, let us know at IoPP.SPTC@gmail.com.

Let’s move forward together on a meaningful sustainable packaging dialogue. PW

The author, Jane Chase, is the Executive Director of the Institute of Packaging Professionals. In addition to being a Certi ed Packaging Professional Lifetime and an IoPP Fellow, she is a member of the Packaging & Processing Hall of Fame. For more information on IoPP, visit www.iopp.org.