Issuu

Visit us at the

International Woodworking Fair Booth #A10236

JUL2022 packworld.com

Iconic Heinz Ketchup Tests Paper Bottle 18

Window Packaging Drops EPS 32

Paperboard Spirits Bottle a CO2 Saver 34

D2C Shoes Walk the SIOC Walk Subscribe to our email newsletters!

Stretch Wrap Tech Protects Huge Pallets 46

New Packaging Products on Page 55 Cover_0722_DigitalEdition.indd 1

Craft Brewer Automates Canning Ops

6/17/22 13:52

FAST. EASY. RECYCLABLE. From apparel to cosmetics and books to small electronics, Pak On Demand™ Mailer System is a sustainable e-commerce automation solution that eliminates plastic, optimizes labor and cuts out unnecessary void ﬁll. See it in action at PACK EXPO International, October 23-26, booth #S-2130. westrock.com/pod ©2022 WestRock Company. WESTROCK, WestRock and Design, and the WestRock Logo are trademarks owned by WestRock Company. All rights reserved.

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Together under one roof: Six of the most iconic names in packaging machinery. Doboy. Elematic. Kliklok. Osgood. Sigpack. Woodman. For more than 75 years, our companies have provided packaging machinery to the producers of everyday trusted brands. Today, as Syntegon Technology, we offer a one-stop shop for everything from standalone machines to complete manufacturing systems — from processing to packaging — with a world-class service team to back it up. Visit our new, redesigned website! www.syntegon.com/food Inquiries +1 (770) 981-5200 connectwithus@syntegon.com www.syntegon.com/food

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VOL29

NO7

Heinz has announced that it is teaming up with Pulpex to develop a paperbased, renewable, and recyclable bottle made from 100% sustainably sourced wood pulp.

FEATURES 32 World’s First Tequila in a Paperboard Bottle Distilled in Jalisco, Mexico, Buen Vato is the world’s first tequila in a bottle-shaped paperboard container and 750-mL pouch, made from 84% recycled material.

34 PACKAGING FOR E-COMMERCE D2C SIOC Shoes Make Sustainable Statement Micah Heftman hadn’t yet heard the acronym SIOC (ships in own container) when he designed a shoebox for his new product line. He was just pleased to have eliminated the ‘box within a box’ experience. Only when he heard about SIOC did he realize there was a name for what he had just created.

40 AUTOMATION OEM’s Head-to-head Pneumatic vs. Servo Test Reveals TCO Stacking equipment manufacturer Forpak devised a test to see how incumbent pneumatic actuators stacked up against newer mechatronic servo technology, specifically on a frozen food stacking and laning application. These are the results.

44 Stretch Wrapper Shuts the Door on Freight Damage A new portable stretch wrapper with roping device helps custom-closet company Closet Works reduce damaged shipments from one per week to one or less a month.

46 Capable Filling and Seaming Anchor Custom Canning Line When adding canning capability, MacKinnon Brothers Brewing needed flexible filling and seaming operations that would reduce labor, improve precision, and speed up throughput—all the while integrating into a home-built, highly customized line.

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6/17/22 11:18

NEW

VIVO 18.

AS EASY AS THIS Make customers happy with practical tear strips and increase production speed in packaging production up to 200 m/min. robatech.com/e-commerce

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DEPARTMENTS 18

packworld.com VIDEO

COLUMNS

7 20 22 24 52 56

Tear Apart a Paper Tequila Bottle

Lead Off The Legal Side The Big Picture Sustainable Packaging Shelf Impact! Professional Perspective

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NEWS/EVENTS

VIDEO

8 News 16 Quotables/By the Numbers 54 Industry Watch 52

Unboxing SIOC Kengos Shoes with Fuseneo

INTERVIEW

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18 First Person PRODUCTS

55 Technology

TAKE FIVE VIDEO

Educating Consumers to Recycle Sustainable E-commerce Packaging

ADVERTISING

26 Leaders in Packaging Product Directory 55 Advertiser Index

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EDITORIAL ADVISORY BOARD Aladin Alkhawam Director, Packaging Operations, Par Pharmaceutical

Jan Brücklmeier Technical Application Group Packaging Technology Expert, Nestlé

M. Shawn French Director – Innovation & Packaging Engineering (Beverage), Danone North America Patrick Keenan R&D Packaging Engineer, General Mills/Annie’s Organic Snacks Mike Marcinkowski Global R&D Officer, GPA Global & Hub Folding Box Co. Paul Schaum Chief Operations Officer, Pretzels Inc.

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David Smith, PhD Principal, David S. Smith & Associates Brian Stepowany Packaging R&D, Senior Manager, B&G Foods, Inc. Jasmine Sutherland President, Texas Food Solutions; Vice President, Perfect Fit Meals

Connect with a Leaders in Packaging supplier and support packaging education!

Connect with us:

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Packaging World® (ISSN # 1073-7367) is a registered trademark of PMMI, The Association for Packaging and Processing Technologies. Packaging World® is published monthly by PMMI with its publishing office, PMMI Media Group, located at 401 N. Michigan Avenue, Suite 1700, Chicago, IL 60611; 312.222.1010; Fax: 312.222.1310. Periodicals postage paid at Chicago, IL, and additional mailing offices. Copyright 2022 by PMMI. All rights reserved. Materials in this publication must not be reproduced in any form without written permission of the publisher. Applications for a free subscription may be made online at www.packworld.com/subscribe. Paid subscription rates per year are $254 in the U.S., $363 Canada and Mexico by surface mail; $605 Europe and South America; $907 Far East, Australia, and other countries by air mail. Single copy price in U.S. is $20. To subscribe or manage your subscription to Packaging World, visit Packworld.com/subscribe. Free digital edition available to qualified individuals outside the United States. POSTMASTER; Send address changes to Packaging World®, 401 N. Michigan Avenue, Suite 1700, Chicago, IL 60611. PRINTED IN USA by Quad. The opinions expressed in articles are those of the authors and not necessarily those of PMMI. Comments, questions and letters to the editor are welcome and can be sent to: editors@packworld.com. Mailing List: We make a portion of our mailing list available to reputable firms. If you would prefer that we don’t include your name, please write us at the Chicago, IL address.

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

ART David Bacho Creative Director

AUDIENCE & DIGITAL Elizabeth Kachoris Senior Director, Digital and Data Jen Krepelka Director, Websites + UX/UI

ADVERTISING Wendy Sawtell Vice President, Sales • wsawtell@pmmimediagroup.com Lara Krieger Production Manager • lkrieger@pmmimediagroup.com Kelly Greeby Senior Director, Client Success & Media Operations Alicia Pettigrew Director, Product Strategy

PMMI MEDIA GROUP Joseph Angel President, Publisher David Newcorn Executive Vice President Sharon Taylor Director, Marketing Amber Miller Senior Marketing Manager Janet Fabiano Financial Services Manager Lloyd Ferguson Founding Partner

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LEAD OFF

NEW

Don’t Ship Air by Air As a courier, 3PL, and “in-Distribution Center (in-DC)” contract packager, DHL, especially DHL Supply Chain, occupies a unique space in e-comm and packaging. That’s why, back in a simpler, bygone era (three months before the onset of the pandemic), I sought out the perspective of Alicemarie Geoffrion, VP Packaging Operations, DHL Supply Chain (read our November 2019 discussion on the emergence of D2C holiday gifting at pwgo.to/7603). Boy were we in for a surprise back then. The omnichannel has seriously accelerated since then, undergoing and in some ways overcoming growing pains, shortages, and related system shocks. So I reached back out to Geoffrion recently to get an update on D2C contract packaging, now that we appear to be approaching a post-COVID (or maybe more accurately, a COVID-coexistent) world. “Now that things are settling down, we’re trying to see what are the trends that have stuck around,” she says. “One of the things that we still have as a challenge is labor. That’s been a struggle for us, and there’s been a significant increase in wage rates. But we are looking at other ways to combat that problem, and not just with increases in wages and other types of benefits. We’ve also been looking at more and more automation too, because we want to make sure that there is always capacity in the market.” That’s not the first (or last) time we’ll hear that automation is the likely path forward in a tight labor market, and more specifically, packaging automation is a good way out for CPGs and brand owners. On page 8 of this issue in an article on the Great Resignation, Sean Riley speaks to one CPG team leader who says “any manual operation is being discussed [for automating], as labor appears to be a challenge for the foreseeable future.” Coincidentally, just as I’m typing this, I received an embargoed notification of a big upcoming robotic installation—mostly picking & placing for order fulfillment—for a major D2C brand that we’ve covered in the past. This will fully automate a previously manual to semiautomatic operation that was suboptimal due to a thin and transient workforce. “We are looking at different types of automation and robotics more so than we did before [the pandemic],” Geoffrion says. “One, we want to increase capacity for our customers. And two, it’s difficult to get the labor we need to do some of the work. So we’re trying to address two different problems.” Two big areas of automation interest for DHL Supply Chain are in collaborative robots within packaging lines and automatic guidance systems at the end of them. “We are looking at doing things like leveraging auto-systems for things as simple as trash removal,” she says. “You don’t realize how many people you need at the end of the line to be removing trash, putting it into bags, and taking it out of the way, so if we can automate that, we will. [Our automation efforts] range from automated trash removal to end-of-line palletizers, cartoners, robotics—we’re looking at all of them to get to that next level.” What else is top-of-mind for DHL decision makers? You guessed it, sustainability. As a modality, CO2-emitting air freight is a big part of DHL’s business, and e-comm is only increasing the output. I asked Geoffrion about that dynamic. “Everybody knows that e-commerce significantly rose during COVID, but it stayed up as well,” she says. “There’s more demand for the air freight because people have become so accustomed to ordering online and receiving things quite quickly. One of the things that we’re also starting to see though, is that if you look at a lot of the e-comm formats and how they’re packaged, there’s a lot of air—you have a small product in a large box, and a lot of fillers. “From a packaging perspective, we have automated tools that will build algorithms to tell us what size box a product should use,” she says. “And then we’ve been leveraging on-demand packaging systems, so we only produce the right size box, at that right time. That will help combat the problem with the increase in e-comm orders going via air.” Geoffrion has been looking at different tools and technologies to make sure shippers are rightsized. The company has worked with Packsize and other similar suppliers in the space, but a lot of that equipment is standalone at the moment The next or 2.0 iteration will be to build these technologies in-line and build in new efficiencies that way to offset air freight emissions. “Ultimately, we want to make sure we’re not just shipping air, via air,” she says, which is a catchy way to phrase a serious issue. PW

mreynolds@pmmimediagroup.com

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NEWS

Great Resignation Driving Employee Poaching It’s a buyer’s market for job seekers as 81,000 left manufacturing from Aug. 2020 through Aug. 2021. Manufacturers are climbing over each other to poach workers to meet increases in production. CPGs at PMMI’s recent Top to Top Summit were nearly unanimous in pinpointing the labor shortage caused by employees not returning to work after COVID-induced shutdowns as a critical challenge. Furthermore, turnover of staff who have returned is high. While quit rates in manufacturing are lower than in certain poorly paid service sectors, the number of people leaving manufacturing jobs accelerated from 1.9% of the workforce in Aug. 2020 to 2.5% in August 2021—a loss of over 80,000 workers in an industry that was already in crisis mode before the pandemic. To make matters worse, many CPGs continue to cite a lack of skilled labor capable of operating and troubleshooting complex packaging ma-

Manufacturing employee quit rates are accelerating rapidly. “Quits“ Comparison

225,000 August 2020

2.5%

306,000 August 2021

Source: U.S. Bureau of Labor Statistics

Change in employee quitting rates from the manufacturing sector by length of tenure and age group (Jan-Aug 2021).

Percentage Change

60% 50% 40% 30% 20% 10% 0%

53.8%

55.4%

56.8%

54.6%

32.3%

0-3 yrs

3-5 yrs

5-10 yrs

10-15 yrs

15-20 yrs

Tenure

50% 40% 30% 20% 10% 0%

46.7% 35.6% 38.2%

21%

38.7% 38.1% 14.5%

20-25

35-40

40-45

Source: Visier Inc. 2021

25-30

30-35

Age

45-50

50-60

chinery. As one respondent noted, “We continue to struggle with workforce shortages and the difficulty in training on equipment. As things become more complicated, it becomes more difficult to ‘plug and play’ when training new employees.” CPGs suggested that OEMs need to provide more and better online training resources, but training takes time, and staff turnover–even of trained staff–continues to rise. As a result, facilities are racing faster to poach each other’s workers to increase production. CPGs consider automation the long-term solution to the labor shortage as long as the technology also engages staff, keeping them on board. In the words of one CPG team leader, “We need to automate every operation we can. Frankly, any manual operation is being discussed, as labor appears to be a challenge for the foreseeable future.” But the situation is already critical in some areas. Food industry production lines are reportedly standing idle because of a lack of staffing, where processors specifically pinpointed high retirement rates. Visier data from January to August 2021 highlights that it’s not just young people quitting jobs. There has been a significant increase in the number of people leaving in the 40- to 45-year-old age group and who have five to fifteen years of tenure. While automating less attractive manual jobs coupled with upskilling workers to retain labor in more attractive ones was seen as a solution, CPGs also mentioned the need for OEMs to offer more intuitive equipment. The head of engineering at a major personal care products company with ultra-clean and aseptic processes and lines said that automated machines need to be easier to operate and maintain. Another respondent called for “high-speed automation that has the dexterity and decisionmaking of a line worker in the space of a line worker.” However, as was pointed out by a representative from the food industry, ensuring that machines operate with minimum downtime remains a risk. —Sean Riley

Free Download: Shaping the Future of Packaging Operations PMMI’s 2022 Top to Top networking summit in Florida looked at key issues for the packaging industry as it emerges from the first two years of the pandemic. Input from a wide range of stakeholders representing CPGs and OEMs created a comprehensive and clear picture of the main challenges in packaging. This report focuses on opportunities for addressing better collaboration, labor issues, productivity, and sustainability. To download the free report, visit pwgo.to/7602.

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6/16/22 15:44

Find New Suppliers Quickly on PMMI ProSource

SUSTAINABLE PACKAGING SOLUTIONS

If you have searched for equipment online lately, you know that it can be daunting to wade through search results: “cartoning equipment” at Google currently returns 33.8 million results. Enter PMMI ProSource, the most authoritative online directory of validated machinery and material suppliers of packaging or processing equipment. Developed for end users like you, this free directory brings machinery, materials, and service providers to your fingertips by connecting you quickly to the validated members of PMMI who specialize in those solutions.

Providing Sustainable Packaging Solutions to the Food and Beverage Industry Since 1923 Try www.prosource.org today and you’ll find: • Robust search tools. There are three ways to search using PMMI ProSource. Use the search bar at the top of the page to leverage ProSource’s robust and fast search engine or drill down by category from the home page. ProSource also allows you to search for machines by package type and then narrow down results even further by selecting detailed filters, such as level of automation or configuration. • User-friendly experience. Not sure what the machine or package type you’re searching for is called? PMMI ProSource is highly visual, using graphics of package types, machines, and materials to speed up the search for your next supplier. Product categories, features, and package types are also defined in plain language. • Validated and curated content. Another time-saving feature: a full-time editor at PMMI validates each supplier’s listing prior to publication and curates content for the end user. Unlike with the Google search, you can be confident that a ProSource search for “cartoners” will display vetted companies that actually make cartoners. Scan ProSource’s categories to quickly find a supplier that matches up with your company’s budget and project requirements. For example, ProSource makes it easy to distinguish suppliers of tabletop liquid filling machines from those offering fully automatic bottling lines. Be sure to also check out the ever-growing section of how-to articles that can help you solve common problems in the plant. Recent articles have included “The Top Five Considerations When Purchasing New Cartoning Equipment” and “Best Practices For Specifying Stretch-Wrapping Equipment.” Visit www.prosource.org today. —Joseph Derr

News_0722.indd 9

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6/16/22 15:44

10 PW JUL2022

NEWS

Cannabis Company Pioneers Compostable, CR Pouch for Edibles In 2016, Clackamas, Ore.-based edibles brand Wyld was launched to deliver to the cannabis market what its founders felt was lacking: edibles that actually tasted good. Today it offers a range of cannabis-infused gummy selections made with real fruit, such

as strawberries, peaches, huckleberries, marionberries, lemons, and others in paperboard packaging beautifully decorated with illustrations of the fruit from which each variety is derived. Says the Wyld team, “Our reputation is built by providing trustworthy, repeatable cannabis experiences that consumers can rely on made with highquality ingredients and consistent dosing. Not PROCESSING AND PACKAGING SOLUTIONS only do our gummies • Food processing systems have great flavor, but • On-machine and process area seasoning application they’re also designed • Conveying and product handling and continuously • Multihead/combination scale weighing and filling improved upon by our • Snack bagmaking and case packing team of food scientists • Metal detection and x-ray and quality experts.” • Check weighing and seal checking While the team says • Controls and information systems its products certainly set the brand apart from its competitors, they add that they are most proud of Wyld’s mission to give back to We are successful when you are successful. That’s communities, protect the ecosystem, and contribute why we apply creativity, engineering excellence, and to progressive change within society. “Most brands determined perseverance to every project to help can talk the talk, but our commitments and the our customers get the performance their business actions we’ve taken certainly walk the walk,” the demands—whether measured by flavor, efficiencies, team says. “This includes our actions in service to sustainability, improvement, or innovation. our four Pillars of Commitment: Social and Racial Justice, Health and Wellness, Combatting the Failed War on Drugs, and Environmental Sustainability.” In preparation for the launch of its products in Canada in late 2021, Wyld collaborated with a number of suppliers and manufacturers— all proprietary—to develop a fully compostable pouch, the truly challenging part of which was creating one with a childresistant feature that was also compostable. Oct. 23-26, 2022 Booth N-4706, McCormick Place Explains the team, the Chicago, IL USA requirement for CR packaging eliminated the use of any preexisting packaging. “Our pouches needed to be fully compostable, child-resistant, and market-compliant, along with info@heatandcontrol.com | heatandcontrol.com meeting Wyld brand standards,” the team says.

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“Packaging in other industries often starts with brand standards, but because of Wyld’s commitment to sustainability and compliance, we worked in the other direction. We began our package design process with the fully compostable and child-resistant/marketcompliant requirements.” While Wyld doesn’t name suppliers, it reveals that all of the materials used in its Canadian packaging are certified compostable and biodegradable and are made from renewable resources like bio-based polybutylene succinate, wood pulp, and bio-resins. This includes all adhesives and inks, as well as the CR zipper. “A fully compostable child-resistant zipper is something that was a complete innovation, it had never been done before,” says the Wyld team. The petite, flexible pouch holds two gummies per pack, with all Canadian products packaged in this format, including hybrid-enhanced Huckleberry, Pomegranate 1:1, and Peach varieties, sativa-enhanced Raspberry, and indica-enhanced Marionberry and Elderberry CBN flavors. The pouches are digitally printed on an HP Indigo press and are designed to be fully compliant with the Canadian Cannabis Act’s requirements for packaging. Wyld’s edibles are available in seven U.S. states, in addition to Canada, and will soon be sold in an additional five U.S. states. According to the Wyld team, the compostable packaging has been universally well received by Canadian consumers. “Everywhere we go, people are excited, saying things like, ‘Why haven’t other companies done this?!’ The packaging is earning us customer loyalty and is a prominent selling feature in addition to our greattasting gummies.” In April, Wyld was named as Climate Neutral Certified, becoming the only cannabis edibles brand on the list. Climate Neutral is a non-profit committed to solving climate change by making carbon neutrality simple and accessible by way of the Climate Neutral Certified label, which will now appear on Wyld’s packaging. In the U.S., Wyld shares that it will be

transitioning to compostable drams and bottles as well as executing a massive overhaul of its supply chain. Says the team, “By converting to more sustainable packaging, we are able to get one step closer to our goal of net zero emissions.” —Anne Marie Mohan

NOP (No-Plastic Program) means we promote eco-friendly plastic substitutes for the packages manufactured on IMA machines. Through the research and testing of alternative processes and materials, together with our partners, we foster plastic-free and sustainable, compostable, biodegradable or recyclable packaging solutions.

ACHEMA Hall 3.0 Stand F49

According to these objectives, IMA established OPENLab: the Group’s network of technological laboratories and testing area, dedicated to the research on sustainable materials, technologies and production optimization processes. Discover more about IMA NOP ima.it/imazero and IMA OPENLab on ima.it/open-lab

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NEWS

Wax-Free Cases: Poultry Processor’s Win is Landfills’ Loss With some of its contract farmers “powered by the sun,” its nothing-goesto-waste philosophy for its chicken processing business, and its efforts to decrease its use of land and water, Montaire Farms in Millsboro, Del., strives to be a model for sustainability in the poultry industry. And that commitment extends to its packaging, as well.

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In 2021, Montaire—the fourth largest poultry processor in the nation—began using DS Smith’s Greencoat recyclable, corrugated shipper as a replacement for the wax-coated cases traditionally used for meat, poultry, and seafood products. While wax- or paraffin- based coatings prevent the moisture that results from the cold and wet environments in which these products are found from damaging the corrugated cases, it makes the shippers non-recyclable. According to DS Smith, not only do these cases end up in landfill, but the cost for companies to get rid of them is steep as well. “U.S. retailers and restaurants pay approximately $50 million annually to dispose of roughly 1.47 million tons of these wax-coated boxes,” it shares.

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DS Smith’s proprietary Greencoat coated material is certified by USDA, the Canadian Food Inspection Agency, and FDA as being a food-safe alternative to wax-coated boxes that provides the same performance characteristics while being certified 100% recyclable and repulpable by the Fibre Box Association. Says DS Smith, this eliminates wax disposal fees for customers, creates a revenue stream from recycling, and decreases the amount of corrugated going to landfills, thereby reducing greenhouse gas emissions. In 2021, Mountaire used the recyclable case to replace nearly 87,766 tons of wax-coated containers that would have otherwise gone to landfill. This saved 205,254 tons of GHGs from being emitted and set the brand up to achieve the conservation of more than 2 million tons of GHGs in the next 10 years with the same rate of replacement. Says DS Smith, “That’s enough to offset emissions from 432,110 vehicles, more than 1.5 million barrels of oil, and the energy spent by 78,870 households every year.” Says Catherine M. Bassett, Director of Communications and Community Relations for Mountaire Farms, “DS Smith’s Greencoat boxes have helped Mountaire meet our growing customer demand while offering the best possible solution for recyclable boxes. We’re proud to use a product that is fully recyclable and biodegradable while still holding up to the harsh conditions of the supply chain.” —Anne Marie Mohan

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Refillable Aluminum Bubble Container Goes Against the Norm American Bubble, a Los Angelesbased bubble company, was created when toy industry veterans saw an opportunity to make the segment more sustainable. “We knew the bubble market very well and saw that it was only saturated with plastic bottles that aren’t even 100% recyclable,” says Susan Wasserman, founder and President of American Bubble. “After seeing how some countries— especially the Maldives—have decided to eliminate one time-use plastic bottles, we researched a better alternative. It turned out to be aluminum, not only for its highly recyclable material, but also because of the quality.” The company launched its Bubble Tree product with an aluminum bottle designed to reflect the brand’s goals of sustainability and environmental safety. Bubble Tree Original Multi-Packs system comes with two aluminum bubble bottles filled with eco-friendly bubble solutions that can be refilled, reused, and recycled. Its refill system is made from corrugated,

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and the cap and wand are made from recycled plastic and are produced by American Bubble. Bubble Tree worked with Trivium, a metal packaging supplier, to develop the package, which was recently recognized with a World Packaging Organization WorldStar Award. Trivium tested for long-term compatibility between the bubble formulation and the aluminum bottles, according to Chas Aylsworth, Business Development Manager, Trivium Packaging. American Bubble wanted to make sure the bottles were easily held by kids even while wet, so Trivium created a package with an ergonomic indentation near the top for kids to easily hold. On top of the indentation and graphics, Trivium applies a special coating to help reduce the bottles from becoming slippery when wet. According to the company, Bubble Tree is the first to create a bubble bottle out of aluminum and develop a sustainable refill system that aims to eliminate single-use plastic. —Natalie Craig

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NEWS

Hotel Toiletries in Bioplastics Serve the Eco-Friendly Traveler As with most consumer-facing markets today, the hotel industry is being challenged to meet guests’ increasing desire for more sustainable lodgings. According to a 2021 study from Statista, 81% of travelers surveyed said they plan to choose a sustainable accommodation option in the coming year—a percentage that has grown consistently over the past six years, the study adds. Says Chris Breen, Head of Partnerships at Public Goods, a producer of sustainable personal care products for the hotel industry and a D2C provider of good-for-you home essentials, “I saw the trend starting before the pandemic, and since the industry has recovered, it is moving even more quickly now. Eco-friendly ingredients are a priority, but the most important is the product [packaging] material and how we use it. For example, small-format products create quite a lot of waste and are generally made with virgin plastic.” With sustainability at the heart of its brand since its founding, Public Goods’ first offerings were personal care products formulated with toxin-free ingredients in bottles made from sugarcane-based plastics, as well as biodegradable, tree-free toilet paper and toothbrushes made from bamboo. “Since then, we’ve only expanded on that, with products that are refillable, reusable, and made from recycled materials,” says Public Goods co-founder and Head of Product Development Michael Ferchak. “We also partner with Eden Reforestation Projects to plant a tree for every order launched.” Both in their formulations and their aesthetics, Public Goods’ personal care products are simple, beautiful, and neutral. “The hospitality industry serves all types of people with different preferences,” says Breen. “Products that lean too heavily toward a scent, for example, or the branding will have a hard time being received well by all guests. This applies mainly to the ingredients deck; some people don’t want certain ingredients.” To package its shampoo, conditioner, body wash, hand soap, moisturizer, and lotion, Public Goods uses a white bullet-round bottle with a black cap or dispensing pump and minimal copy. According to Ferchek, for design-savvy businesses and shoppers, Public Goods’ products add a non-intrusive, soothing look to their spaces. The refillable 12-oz containers are high-density polyethylene, approximately 90% of which comes from Braskem’s I’m Green sugarcane-based PE. The company also offers a number of products in 3-oz travel-size bottles, also made from Braskem’s bioplastic. Says Ferchak of the company’s decision to go with I’m Green PE, “The benefit to sugarcane-based plastics is that it doesn’t require petroleum to produce, therefore it does not support the petroleum industry. Furthermore, Braskem has research showing that production of sugarcane plastic is actually carbon neutral since the production of the sugarcane used as the raw material removes carbon from the atmosphere.” Caps are made from virgin polypropylene, however Ferchak says the company is currently working on transitioning all of its plastic componentry to post-consumer recycled material. And that switch applies to the bottles as well. When Public Goods first sought “greener” packaging in which to launch its products, it considered both bioplastics and PCR plastic. “Back then, it was not possible to get recycled plastic in a pure white, which is why we opted to go with I’m Green PE,” explains Ferchek. “However, the PCR industry has improved lately, and it is possible now to get pure white PCR. As such, we’ve recently made a decision that it’s better to reuse existing plastic than to introduce new plastic into the environment, even I’m Green PE. So we are in the process of transitioning our products over to PCR.” Refills for personal care products are in a 34-oz flexible pouch. The decision to go with the nonrecyclable material was a tough one, says Ferchek, but given plastic’s poor recycling rate of 8.7%, Public Goods felt it was wiser to prioritize reducing the amount of plastic it used. He adds that on a per-ounce basis of liquid product, the refillable plastic bottles use 5.4-times more plastic than the refills. Always striving for a more sustainable option, Ferchek says Public Goods is in the process of working with its packaging vendors to transition to curbside-recyclable plastic pouches. Public Goods’ line of personal care products are available in bulk for businesses and can also be purchased individually by consumers via its website, www.publicgoods.com. —Anne Marie Mohan

www.nerconconveyors.com 844-293-2814

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6/16/22 16:21

Econocorp Vertical Ad_FA.pdf 1 04/06/2022 4:26:55 AM

Refillable Personal Care Products a Boon for Boutique Hotel Hero Beach Club is a 30-room boutique hotel located in the popular summertime destination town of Montauk, N.Y. Offering a “unique blend of tranquility and tradition offset by the backdrop of the Atlantic Ocean,” the hotel offers its guest rooms, including its five suites, at a price fit for what is the most expensive summer destination in the U.S.: $400 to $2,500 per night, depending on the season. According to the hotel’s general manager, Alexander Eberle, Hero Beach Club strives to be an environmentally conscious establishment. “In this age of climate change, we look for ways in which we can contribute to reducing waste by offering quality organic products that come in eco-friendly packaging.” Until recently, the hotel was using single-use, disposable packaging for its hotel toiletries, which Eberle says resulted in more waste and more work for hotel staff. For the sake of economics and the environment, Hero Beach Club switched to Public Goods’ non-toxic body lotion, hand soap, conditioner, shampoo, and body wash products in 12-oz refillable bottles made from 90% sugarcane-based bioplastic from Braskem (see article on facing page). Bottles are displayed in the shower in double and triple wall-mounted holders, also supplied by Public Goods. Following the departure of each guest, housekeeping staff tops the bottles off with product from 32-oz bulk refills—a process that is mess- and spill-free, Eberle says. To ensure the bottles are safe and clean for the next guest, housekeeping wipes down and sanitizes them. The hotel also stocks the shower stalls of its guest rooms with a 3-oz travel-size bottle of body wash, also made from bioplastic. Although the packaging is not recyclable or refillable, Eberle says the hotel opted for the smaller size to give guests an option to use them and take them home or for outside shower use. Environmental benefits aside, Public Goods’ personal care toiletries also meet Hero Beach Club’s desire for products that fit into its décor, which it says is “inspired by the great rolling breakers moving in on miles of white gleaming sand.” Eberle describes the products as “sleek, modern, simple, laid back— products that fit into our sunny summer beach vibe.” As for the products, he says they are “creamy, fragrant, clean, and smooth.” —Anne Marie Mohan

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CMY

6/16/22 16:23

16 PW JUL2022

BY THE NUMBERS

$25B The value of the overall cannabis market across legalized U.S. state markets, with 40% sales growth for 2021

The number of states that have passed laws in the last five years to promote the use of advanced recycling for plastic waste

42%

The percentage of a traditional wine bottle’s carbon footprint resulting from the packaging (29%) and its transportation (13%)

$34M The costs incurred by glass and metal packaging manufacturer Ardagh Group after a cyberattack last year that caused shipping delays and interruptions in some supply chain operations

Quotables_BTN_0722.indd 16

QUOTABLES

“While it will take complete collaboration between the full industry and our partners at all levels of government to solve this crisis, people from across Nestlé have worked around the clock to be part of the solution—ramping up production, partnering with retailers to accelerate getting product onto shelves and providing guidance to caregivers through our 24/7 helplines and other resources. Our hope is that this progress gives concerned parents a little more comfort during this challenging time.” –Steve Presley, CEO of Nestlé Zone North America, in an article from DairyReporter.com, “Danone, Nestlé, Kendal ramp up infant formula shipments from Europe as FDA hails flexibility and collaboration to combat crisis”

“There is no straightforward way to monitor a product’s provenance and authenticity in today’s supply chain networks. Centralized systems are fundamentally insecure as they rely on centralized certificate authorities and centralized databases having single points of failure. Blockchain solutions, which are decentralized and immutable, enable product traceability and authenticity by tracking the products back to their origin and through the supply chain.” –Abhishek Paul Choudhury, Senior Disruptive Tech Analyst at GlobalData, as quoted in a release from the company, “Blockchain improves product authenticity in supply chain, finds GlobalData”

“Real Magic is immersed in all the special moments of connection in the world of Coca-Cola. The new returnable Coca-Cola glass bottle will allow our consumers to dive into a unique meal occasion experience uplifted by the refreshing taste brought by Coca-Cola, and also by increasing our use of returnable packaging, we promote a circular economy as our return to reuse bottles have high levels of collection and are [a] low-carbon-footprint beverage container because the bottles collection is built into our beverage direct delivery model.” –Marella Canepa Risso, Franchise Director for Hong Kong & Macau at The Coca-Cola Company, in an article from Taiwan News, “Coca-Cola Brand New Glass Bottle Beverages Relaunch in Market”

6/16/22 17:22

Bunting’s “Big Bag Detector” Gives You Big Results

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6/15/22 12:17

18 PW JUL2022

FIRST PERSON

EPS-Free Packaging Passes the Test for Heavy, Fragile Windows Tina Mayn, Senior Vice President of Products, Innovation, & R&D at global sloped roof window manufacturer VELUX, talks with PW about a recent pack format shift away from EPS, and toward corrugated. The shift to paper-based packaging for sustainability purposes is common these days, but it’s noteworthy in this case since the products are notoriously heavy, unwieldy, and highly breakable glass windows and frames.

Window manufacturer VELUX Group is converting 90% of its slopedroof window [skylight] packaging to a plastic-free, paper-based single material in all its most popular SKUs. This will save up to 900 tonnes [992 tons] of plastic per year, the company says, and the new format will consist of Forest Stewardship Council- (FSC-) certified corrugated. This transformation has led to a 13% reduction of the carbon footprint for the sloped roof product range and is key to delivering on the company’s overall sustainability strategy target to make its packaging single material, zero plastic, and 100% recyclable by 2030. It also marks the first step in an extensive sustainable transformation of how the VELUX Group does business and what products and solutions it brings to market. Packaging World spoke with SVP Tina Mayn about the project.

Packaging World:

What kinds of plastic had been prevalent in your packaging, and are now being removed?

Tina Mayn The main type of plastic used in our legacy window packaging was expanded polystyrene (EPS), which was by far the biggest plastic contributor in our sloped roof window [skylight] packaging portfolio. There are also other small plastic components being removed, for example plastic tape is now replaced by paper tape, the screw bags used to be of plastic and now they consist of paper bag, and our beipacks [extra packs for components and bracing within the larger package structure] previously made of PET are now made of corrugated.

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What functions did these EPS structures accomplish? EPS was used for protection of our windows and used both as side and bottom protection, as well as a flap fixation for our handlebar and ventilation gap. Why the switch? By removing EPS and other plastic components, VELUX customers will save time on separating and sorting packaging waste, making disposal processes both more efficient and cheaper. As corrugated is a single material, it increases the likelihood of proper sorting when being recycled, and corrugated recycling is easier and more efficient to recycle that plastic. Previously, several materials, including different types of plastics, would require more sorting, which is both more time consuming and leaves a bigger risk for mis-sorting. Also, corrugated has a higher recycled content compared to most plastics, including EPS. It also possesses a lower carbon footprint compared to plastics and can be recycled many times. In most countries, there are very well-established recycling systems for corrugated in comparison to what is available for EPS and other plastics. The value of waste cardboard is higher than most waste plastics, which again contributes to it being properly recycled Was any testing or validation involved to ensure the paper-based corrugated format would perform as well as the legacy EPS? Our new packaging concept has been thoroughly tested in accordance with

6/16/22 15:17

VELUX packaging requirements. The new components have undergone the same comprehensive testing as our existing packaging. The new packaging has undergone and passed transportation testing, vibration testing, stacking testing, humidity testing, and handling testing.

How did you design the new fully corrugated pack format, and can you give us any details? VELUX has designed and specified all the new components for the packaging. We work with wellknown global suppliers who supply us with the corrugated, ready to use. The specs vary depending on the size of the sloped roof window, its finish and glazing options (two- or three-layer glazing). For example, a bigger size/heavier roof window would require a thicker side protection compared to the smaller size/lighter roof window, in order to protect the product during transportation. The team has tested different thicknesses of the corrugated solution per product type and size, in order to identify which one could absorb the impact caused during the transportation phase. Is the format self-locking, or do you use adhesive, tape, etc. to hold it all together? The new packaging incorporates a corrugated solution that includes tear tape. This can be disposed of in the corrugated waste channel in accordance with design guidelines. Has the project met your goals? Our goal was to ensure we have a packaging concept which can be 100% recycled, whilst making disposal of packaging waste as easy as possible. Our new packaging means installers will be able to discard everything into the cardboard waste channel, instead of sorting and discarding into multiple waste channels—one a waste channel, another 100% recycling. Corrugated comes with the advantage of being able to be recycled many times. If we make the recycling process as easy as possible, then the waste management process can ensure that the raw material is recycled—allowing us to close the loop and achieve circularity. We receive the corrugated board ready-to-use which means all cutting and component creation is completed in advance. Overall, less space is then needed when transporting our components compared to the previous setup. How does the project fit into larger sustainability initiatives at VELUX? At VELUX, we are committed to doing our part to achieve a more sustainable future by putting the planet and nature at the heart of our product decisions. Our packaging is an important component of our products and must therefore also be as environmentally friendly as possible. We’re proud to be significantly reducing the amount of plastic we use to package and protect our sloped roof windows. It’s an important step towards achieving what we call the ‘Green our packaging’ sustainability target. —Matt Reynolds

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6/16/22 18:24

20 PW JUL2022

THE LEGAL SIDE

By Eric F. Greenberg, Attorney-at-law

GRAS Goes to Congress toxicity (including consideration of “an endocrine mode of action”). Remember that whole business involving There’s also a specific prohibition on cancer-causing substances being NGOs and other folks objecting to the legal considered GRAS. (Currently, they could be, if the evidence supports system that allows companies to selfthe safety of a low-enough exposure to it.) determine that their uses of substances All that supportive information would be made publicly available are Generally Recognized As Safe (“GRAS”)? and the public would be given at least 90 days to raise objections And remember how some groups had gone to court to get the system to it. Those requirements make the GRAS system closer in kind to declared unlawful, but late last year the court ruled against them? the rulemaking process, where proposals are published and are Well, there’s a new chapter to this story. Now, some members of subject to public review and comment before the agency issues a Congress have proposed a bill that would make changes to the law to final regulation. Other provisions would require FDA to address those very same objections. set standards “prohibiting conflicts of interest” among the The GRAS pathway to clearance of the use of substances experts providing data (rather than, for example, simply in packaging and in food is crucially important, and this disclosing such actual or potential conflicts). proposed law has the potential to make enormous changes Advocates of the bill were quoted in news reports saying in various legal obligations. For that reason, packagers Read one of my it will “close the GRAS loophole” that allows companies to should keep a close eye on this latest chapter in the previous columns decide what’s safe and that the changes would help assure ongoing debate over the policy issues surrounding the GRAS where I discuss “healthy, toxic-free food.” system. a recent court Here’s the thing, though: In concept, there’s nothing In my view, addressing the complaints we’ve heard ruling regarding the GRAS system. wrong with changing legal requirements if they are for years about the GRAS program required changes in resulting in a lack of safety or are permitting mistaken or the law, so at least the objectors are in the correct forum. corrupt conclusions, but I simply don’t think they are. In There’s been so much criticism of the Food and Drug other words, the missing link here is any evidence that the Administration lately, what with its slow reaction to the current legal framework has resulted in lots of examples of infant formula contamination problem, on top of its dangerous levels of dangerous substances getting into food handling of issues relating to heavy metals in baby food and as a result of the current framework. various complaints about its handling of COVID and other Of the various proposed measures in the bill, I am drug approvals, for some examples. But when it comes to sympathetic to one aspect, and that is the idea of giving FDA notice the GRAS program, it’s always seemed that most of the objectors’ of GRAS uses of substances. Because the current system allows objections were better directed at Congress than at FDA. companies to make independent decisions about what experts believe The bill, which would create the Ensuring Safe and Toxic-Free is GRAS, FDA is not fully aware of what substances, and how much Foods Act of 2022, would instruct FDA to make revisions to its of any specific substance, the average person gets in their diet. FDA current regulations about GRAS substances such that manufacturers would have better oversight over the safety of the food supply with would have to give FDA notice of their GRAS conclusion. Right now, more information. But a notice system like that proposed in the bill companies may, but don’t have to, share their GRAS conclusion with is complex to implement, and would require a great deal of new FDA, and if they do submit it to FDA, the agency will review it and will and additional time and expense for both FDA and the regulated let the company know if it “has no questions” about the company’s companies, time and expense that should be weighed carefully conclusion. (That letter is not quite the same as FDA saying that it, against the actual benefits to safety that could result. too, finds the use to be GRAS, but it’s still rather useful.) In short, it’s not clear to me that the independence that individual If the company doesn’t submit it to FDA, they still are legally companies now enjoy is resulting in danger to the public, or that the required to thoroughly evaluate the safety of the use of the substance decisions companies have made are somehow corrupt or that the and assure that relevant scientists would agree that it’s safe based on conclusions are simply mistaken. Moreover, the occasional example of publicly available and generally accepted information. the appearance of new evidence about the safety of putatively GRAS Among the bill’s other key provisions is one that would require the substances that are then removed from the market does not mean manufacturer to provide FDA with information about the cumulative the whole system is flawed. effects of the substance and adequately protective safety factors in Does the bill have a good chance of becoming law? That’s always evaluating exposure to it, with particular accounting for vulnerable difficult to predict, but regardless, what’s clear is that these issues are human populations. They’d also have to provide “information not going away anytime soon, and their importance requires careful indicating that the weight of evidence shows” the substance hasn’t monitoring. PW been found to cause cancer or reproductive or developmental Eric Greenberg can be reached at greenberg@efg-law.com. Or visit his firm’s website at www.ericfgreenbergpc.com. INFORMATIONAL ONLY, NOT LEGAL ADVICE.

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Increase Uptime with Optimized CIP System Is your Clean-in-Place system working as quickly and efficiently as it could? Inaccurate measurement and lack of visibility in your current processes can lead to equipment failure, wasted energy and expensive product loss. Emerson’s process equipment and control systems can help improve your existing CIP to increase production and reduce costs. With proven solutions that can achieve improved accuracy, enhanced visibility and greater control, you can ensure that your CIP is operating at its very best. Explore solutions at Emerson.com/FoodandBeverageCIP

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6/15/22 12:18

22 PW JUL2022

THE BIG PICTURE

By Sterling Anthony, CPP, Contributing Editor

Point-of-Purchase Displays Brand owners expend time and resources getting their products on retail shelves. There, within a crowded self-service environment, the packaging must attract and induce. Point-of-purchase displays (hereafter, displays) are a reverse step; their purpose is to get the products off the shelves and into a showcase setting. There are displays that are acquired and owned by the retailer, with display cases and dump bins being examples. This article, however, is about displays that are supplied to retailers by brand owners. Packaging professionals are accustomed to the primary, secondary, and tertiary levels of packaging. Well, displays can be thought of as quaternary. And true of all sequential levels, displays are expected to build on the preceding levels. That’s done with structure and graphics that produce a synergistic pairing of the display and the packaging, triggering product recognition and impulse buying. The display’s structure should allow advantageous positioning of the packaging via facings and quantities. The ideal is to create a visual effect (for example, billboard or geometric) that’s superior to shelfimpact. The display’s graphics, on the other hand, should communicate useful information not contained on the packaging, while embodying and enhancing salient features from the packaging (for example, brand colors and slogans.) If the preceding isn’t sufficient yeoman’s work, a display also can sport a cellphone-scannable QR code, a portal to product-relevant information, offers, etc. The real estate maxim of value being a factor of “location, location, location” can be applied to displays. A display relies on interception, placed in the path of target consumers. Basic considerations include: whether the display should be located within an aisle or at its end, or even whether the location should be outside the area assigned to the product category. The brand owner should suggest the best location, aware that the retailer has the final say. Negotiations need not be contentious, however, because brand owner and retailer share the same objective: product turnover and the sales and profits it generates. Like shelf space, aisle space is an asset for which a retailer will seek optimal utilization. The retailer, therefore, must be convinced of the display’s ability to achieve its purpose before allocating a valuable asset. That purpose will depend on a variety of factors. One is the lifestage of the product: is it a launch, a category leader, or something in-between? Another factor is whether the display is to house a single brand or a family of branded products. Yet another factor is whether there is a seasonal or promotional theme. And more generally on the subject of time, there’s the factor of how long any given display is expected to be in service. The performance-life of displays is classified as temporary, semipermanent, and permanent, roughly translating to three months, six months, and a year-plus, respectively. Permanence is related to the display’s assigned purpose, sure. However, it also is a determining

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factor regarding its design and construction. To illustrate: corrugated paperboard can be suitable for temporary duty, but might not be for permanent, or even semi-permanent. Segueing into a discussion about procurement, there are two options: in-house, or outside-sourcing. Typically, the former is a capability of larger CPGs with package design departments. The latter consists of design firms that specialize in displays. Working with a display design firm requires the same partnership approach and mentality given to design firms specializing in primary and other levels of packaging. Such is not to imply mutual exclusivity given that some design firms specialize in displays in addition to other levels of packaging. Regardless of the source, displays should be designed and constructed with the retailer’s convenience in mind. If the display is not shipped fully stocked, it should be easily assembled, characteristics consistent with this era of retail-ready packaging. And just as competition among materials characterizes other levels of packaging, so too does it with displays. The sales pitch of a design firm that uses durable plastic or metal might be that longer-service displays are more economical compared to shorter-service corrugated displays, citing die-cutting/tooling costs, frequent replacement, and minimum quantity requirements. The effectiveness of that pitch is contingent on the brand owner’s ability to sell the retailer on a longer-term display. By the way, a brand owner might have to prove itself with a short-term display before receiving the retailer’s acceptance for something longer term. Displays can be versatile, effective tools, but potential and performance are not synonymous. Any brand owner that uses research and testing to evaluate its primary packaging should do so with its displays. As a final mention, displays are not only for brick-and-mortar retailers, given the exponential growth of e-commerce. The knowledge pool is deepening regarding how and where to present displays on a website for maximum impact. Customer interception, after all, is a natural for carryover to click-browsing digital-shopping. PW

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6/16/22 17:21

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6/15/22 12:14

24 PW JUL2022

SUSTAINABLE PACKAGING

By Anne Marie Mohan, Senior Editor

Kraft Heinz Explores Potential of Paper-Based Ketchup Bottle Kraft Heinz announced in May that it’s teaming up with Pulpex to develop a paper-based, renewable, and recyclable bottle for its ketchup. While it’s not the first Consumer Packaged Goods brand to explore the use of Pulpex paper bottles—Diageo, PepsiCo, Unilever, and Estée Lauder, among others are already exploring the technology—Heinz is the first sauce brand to test the potential of the bottle for condiments. Says Rashida La Lande, EVP & Global General Counsel and Chief Sustainability and Corporate Affairs Officer at The Kraft Heinz Company, “We hope to bring this bottle to market and to be the first sauce brand to provide consumers this choice in their purchasing decisions, as many consumers today are looking for more sustainable packaging options.” Notes the company, its collaboration with Pulpex is the latest step in its journey to reduce its environmental footprint. The new packaging is expected to help advance the company’s sustainable packaging ambitions as it aligns with Kraft Heinz’s goal to make all packaging globally recyclable, reusable, or compostable by 2025. It is also an innovation the company says will help it to achieve net-zero greenhouse gas emissions by 2050. “Partners like Pulpex are critical to achieving our goals,” explains Jonah Smith, Global Head of ESG at The Kraft Heinz Company. “We’re confident in the sustainability performance of Pulpex bottles; they’re made with sustainably sourced pulp from 100% renewable feedstocks and FSC- (Forest Stewardship Council-) certified, responsibly managed forests. The Heinz Pulpex bottles are made with proprietary, food-grade coatings that are compatible with the product inside the bottle. All coatings are PET-, HDPE-, and BPA-free. Working with collaborators like Pulpex helps us reduce our overall environmental footprint.” Unlike some other paper bottle technologies currently on the market that use a plastic bladder or liner to provide

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a barrier, Pulpex bottles are sprayed on the inside with a proprietary food-grade coating, customized to handle either oil- or aqueous-based products. This means the bottle is curbside-recyclable with no new recycling infrastructure required. According to the company, its patented bottle technology also allows the packaging to be easily incorporated into any packaging manufacturer’s current filling operations. In addition to its use of sustainably sourced feedstocks and its ability to be recycled, Smith says another advantage of the paper bottle that drove Kraft Heinz’s interest in the technology is its lower carbon footprint versus traditional packaging materials—90% less than glass and 30% less than PET—on a bottle-tobottle basis. Heinz and Pulpex are currently developing a prototype to test how the technology could be used for the Heinz Tomato Ketchup bottle and other packaging formats in years to come. Given that the bottle is still in the early stages of development, Smith reports that Heinz is unable to announce a launch date for the new packaging. “Developing a whole new packaging format is a long and complicated process, and we need to ensure that the new product packaging is as safe and convenient as our other formats, and that the product retains its famous great taste, too,” he says. For Pulpex’s part, it’s in the midst of scaling up its capabilities, with high-speed production lines scheduled to be mass producing the bottles by the end of 2022. The company’s goal is to be able to produce over 750 million bottles per year for an array of global brands by 2025. Says Pulpex CEO Scott Winston, “We are delighted to work with Heinz to bring our patented packaging technology to such a famous name in food and are excited about the potential of this collaboration. We believe that the scope for paper-based packaging is huge, and when global household names like Heinz embrace this type of innovative technology, it’s good news for everyone— consumers and the planet.” PW

6/16/22 17:15

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6/15/22 12:15

Controls, Software & Components The following companies are leading suppliers of controls & machine components, and software. To see all product categories, please visit Packworld.com/leaders. Controls & maChine Components

Controls & maChine Components

XPlanar®: Agile packaging machines with adaptive automation

For motion feedback, Encoder Products Company has your solution

With XPlanar from Beckhoff, your packaging machinery and processes can achieve the impossible. Levitating and flying movers offer 360-degree rotation, 6 degrees of freedom, and nearly limitless tile path options for total flexibility in production.

Encoder Products Company (EPC) has been a leading designer and manufacturer of motion sensing devices in the US for more than five decades. Call EPC to talk to experts who will help you find the right motion feedback solution for your application.

Controls & maChine Components

Fabco-Air NFPA and OEM-NFPA Air Cylinders

Changeover solutions for efficient machine adjustments

NFPA pneumatic cylinders combine rugged construction and versatility. Available in 17 mounting styles, these interchangeable units allow users to directly replace other NFPA units of the same type and dimensions for greater design freedom.

Three solutions, one supplier for effective machine adjustments, include: - Low cost mechanical indicators - Electronic indicators to monitor changeovers - Compact actuators for fully automated machine adjustments

Controls & maChine Components

SMC promotes advanced automation through automated control

High Efficiency, No Maintenance, One-component Conveyor Drive

SMC offers technology in pneumatic components such as actuators; cylinders; directional control valves; airline preparation equipment; chillers and dryers; vacuum components; static elimination products; fittings and tubing; electric actuators; grippers.

The IntelliDrive™ features permanent magnet drum motor technology, delivers over 40% increased energy efficiency and performance with wider belt speed selection without loss of torque, and 80,000 hrs. of operation before maintenance, reducing operating costs.

Controls & maChine Components

Software

Rethink What’s Possible in Packaging Automation

Providing Innovative Solutions that Increase Productivity

At Yaskawa, we help you explore what’s possible, and open new doors to opportunity. Rather than accepting the status quo, we invite you to wonder, “What if …?” And then we make it possible.

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Emerson Automation Solutions provides solutions that empower packaging and food and beverage manufacturers to start or advance their digital transformation strategies to drive profitability.

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These market-leading companies participating in Packaging World’s 2022 Leaders in Packaging Program are named sponsors of PW’s Future Leaders in Packaging scholarship. This year’s recipient is Alexandria Technical & Community College, Mechatronics program. We appreciate the support of all participants on behalf of packaging education.

Coding, Labeling & Printing Equipment The following companies are leading suppliers of coding/marking, digital printing, and labeling equipment. To see all product categories, please visit Packworld.com/leaders. Coding/marking

Coding/marking

High Speed Precision Printing with BestCode AutoCoding Automation

Complete solutions for package personalization with Workflow software

Maintain product quality and control with BestCode’s Coding and Marking systems. Over 50 configurations and a wide variety of inks available. Evaluate BestCode options before your aging date coder is unrepairable. Trybefore-you-buy. Request a trial.

Personalization solutions with Workflow to manage all aspects of the personalization process resulting in less product waste, reduced inventory, and maximum production up-time. Configurable elements include inkjet printing, labeling and inspection options.

Coding/marking

The most efficient and reliable ALL-ELECTRIC automated labeling system

In “CASE” you didn’t know...we have a solution for that

Diagraph’s all-electric label print & apply systems and label applicators are simply the smartest, most efficient and reliable in the industry. Leading smart technology uses sensors to ensure a one-to-one label to product match.

Coding/marking

Are you looking for high quality box coding? Considering replacing label printers and preprinted boxes to boost your environmental credentials? Meet the Cx350i, the new high resolution case coder from Domino.

Coding/marking

The Domino Case Coder that is changing the game - Big on Boxes.

Efficient, Accurate, Clean Ways to Mark, Label, and Code Products

Direct printing on boxes is a brilliant way for manufacturers to reduce complexity, cost and waste. The Domino Cx350i case coder is the answer you didn’t even know you needed to drive your efficiency and sustainability goals.

Package printing solutions include wireless, portable, hand-held printers that print on virtually any surface and replace outdated manual marking methods and large and small character printers for non-contact continuous in-line package labeling.

Coding/marking

See Tomorrow’s Production Line Today

The right code on the right product

The future of coding solutions is here today with Hitachi. Whether you are looking for safety features, better efficiency and reliability, the Hitachi coding solutions can help you to achieve all of this and more.

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The industry’s most comprehensive range of coding systems seamlessly integrated with scalable software, services and consumables. Maximize uptime while ensuring your packaging and industrial coding is accurate and traceable.

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Coding/marking

Reliable and Efficient Coding and Marking Systems

Print Solutions for Form Fill Sealers

We solve your marking and coding challenges throughout your whole production line, from out-of-the-box solutions to custom engineered systems. You can count on us for effective solutions that add value to your product line – we’ve got you covered.

The high resolution iSP printers from Norwix provide a versatile and cost-effective, coding and marking solution for Vertical Form and Fill Sealers (VFFS). The units can be bolted into almost any VFFS machine with very little effort.

Coding/marking

Make Your Mark With Squid Ink’s CoPilot Max Turbo Printing System

Advanced continuous inkjet printer

With up to 2.8” of print height per printhead and the ability to run up to 2 printheads from one controller, the CoPilot Max Turbo offers a versatile yet cost-effective solution for your coding and marking applications.

Digital printing

The line integration and code management capabilities of the digitally enabled Videojet 1880 continuous inkjet (CIJ) printer help to both reduce the potential for human error and ensure that the right code is printed at the right quality, every time.

LabeLing

InteliJet HD, Inline Piezo Inkjet Printing System

Let us help solve your labeling challenges.

Print all artwork, including variable information. Available in single, two, and full color CMYK with UV curable or water-based inks for printing on most substrates. All BELL-MARK printers include remote training and support at no extra cost.

CTM Labeling Systems has been a trusted industry partner since 1991. Let us help you increase productivity and decrease downtime with our robust labeling solutions! We engineer pre-printed label applicators as well as print-and-apply machines.

LabeLing

Pressure Sensitive Label and Label Printer Applicators

ID Technology – a Leader in Labeling & Coding Solutions

Applying primary, secondary, and reclosable labels to numerous types of packaging. Whether a standalone application or custom solution, these systems integrate easily with your new or existing equipment.

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ID Technology, part of ProMach Labeling & Coding, provides a complete line of highquality labeling equipment and product coding solutions for a wide range of industries. Print & apply labeling | Labels | Coding technologies | Nationwide service & support.

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SmartCycle® Pro

Pressure-Sensitive Labeling Machinery For A Wide Variety Of Industries SmartCycle® Pro is our newest label film that is not only recyclable, but also contains 30% post-consumer recycled content which closes the circular economy loop!

See Our Full Range of Labelers. Get Your Free Quote Today!

LabeLing

Custom Labeling Systems Designed To Save You Money

Sanitary, Hygienic Labeling Solutions for the Food Industry

We offer a wide variety of custom labeling systems for a wide array of products. These include Zero Downtime, Vertical Trunnion, Hugger Belts and Neck Labelers.

LabeLing

The hygienic labeler is designed for endcustomers in the food industry that need to repetitively and aggressively clean their production floor equipment. This clean-inpace labeler allows for minimal disassembly for easy cleaning and maintenance.

LabeLing

Unrivaled Labeling Performance … and SUPPORT!

Panther – Labeling Automation Solutions

100% speed synchronized, Self-diagnosing system, Wi-Fi enabled Panel PC HMI, Preventative Maintenance schedules, NitaCare lifetime no-charge live tech support, Oh, and so much more!

Panther, part of ProMach Labeling & Coding, designs and builds labeling automation systems for e-commerce, logistics, warehousing and much more.

LabeLing

Shrink Sleeve Labelers, Tamper Evident Banders, and Shrink Tunnels

LABELING TECHNOLOGY FOR THE FUTURE

We provide our machines and expertise to a wide array of industries, such as foods, beverage, pharmaceutical, beer, wine and spirits, household, and personal care. Featured here is the R-100 Shrink Labeler, moderately priced for speeds up to 80 bpm.

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Let Quadrel move your packaging line into the future. Quadrel Labeling Systems is a world leader in the design and manufacturing of Pressure Sensitive label application equipment.

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Shrink Labeling with High Efficiencies and Low Operating Costs

Shrink Sleeve Solutions

Sleeve Seal shrink sleeve labelers are intelligent systems engineered for repeatable performance. Durable construction and Allen Bradley controls are combined for efficiencies of 99.5% or more with low operating costs at speeds from 25 to 1600CPM.

Tripack provides solutions for entry-level and fully integrated high-speed systems. Our custom engineered solutions are designed for simple setup and quick changeovers to maximize OEE. All systems are backed by our industry leading 3-year warranty!

LabeLing

Welcome to Universal Labeling Systems! We are Labeling!

Discover New Innovations in Labels & Labeling Systems

We are a leader in labeling machinery. Since 1984, no one designs & builds more custom labeling systems than ULS. We ship over a 1,000 labeling systems per year. All machines are designed and built in the USA at our St. Petersburg, FL facility.

Weber Packaging is a family-owned labeling company that has been helping customers look their best for 90 years. We provide turn-key solutions that, whether locally or globally, can change labeling nightmares into labeling dreams.

Labels The following company is a leading supplier of labels. To see all product categories, please visit Packworld.com/leaders.

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Axon’s shrink sleeve, stretch sleeve, and tamper band labeling systems offer dependable performance in key sleeving applications including full and partial body sleeves, tamper evident bands, multipacks, and full body over-the-cap sleeves.

Leader in high-speed, high-performance sleeving solutions

Future leaders IN PACKAGING SC

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YOU HAVE TO SEE IT, EXPLORE IT, EXPERIENCE IT. REGISTER TODAY! Interested in learning about the latest developments in controls, software & components, coding, labeling & printing equipment, and labels? Don’t miss PACK EXPO International 2022 to see, explore, and experience the newest innovations in these packaging categories as well as an abundance of other packaging and processing equipment, materials, and business drivers. Visit packexpointernational.com for more information, and to register today.

October 23-26, 2022 ■ Chicago, Illinois, USA

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Industry Training Cost-effective, convenient training... just for you.

Certified Trainer Workshop Provide better machinery training for your customers while enhancing safety Aug. 25-26, 2022 Delkor Systems; Arden Hills, MN Oct. 23-24, 2022 PACK EXPO International; Chicago, IL

Risk Assessment Workshop Learn risk assessment basics and how to incorporate risk assessment into machine design Oct. 21-22, 2022 PACK EXPO International; Chicago, IL

Support your training through the PMMI U Skills Fund, a workforce investment matching program. pmmi.org/skills-fund

Want a workshop tailored to your company? Consider a PMMI in-plant workshop, customizing these workshops to meet your company’s specific needs and goals.

Learn more and register at pmmi.org/industry-training

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World’s First Tequila in a Paperboard Bottle Distilled in Jalisco, Mexico, Buen Vato is the world’s first tequila in a bottle-shaped paperboard container and 750-mL pouch, made from 84% recycled material.

The bottle is closed with a standard roll-onpilfer-proof (ROPP) aluminum cap with a 33-mm diameter.

sustainably as possible is the right way. We went to all the distributors, all the other providers we’ve been working with for many years, and we said, ‘guys, look, this is the future, and we know how to do it. Let’s do it.’” Location is important here. By launching in famously sustainabilityminded Sweden, the land of Greta Thunberg, he expects that spirits lovers will be willing to pay a little extra for his premium tequila offering in what he says is an ecologically friendlier pack format. And when they do, he thinks his company will help to establish a toehold for the paperboard bottle format in tequila, and blaze a trail that peers and competitors in the tequila and larger spirits categories will willingly follow. “We’re on a mission to shake-up the drinks industry by investing in sustainable manufacturing, transportation processes, and CSR (corporate social responsibility) initiatives,” Puebla Smith says. The Swedish monopoly, a governmentally controlled retailing entity that handles all of Sweden’s alcoholic beverage market, will be the first retailer in the world to launch and sell Buen Vato.

Why take the paperboard bottle plunge?

Claes Puebla Smith, CEO of emerging tequila brand Buen Vato, understands that by electing to launch in a paperboard bottle system with internal pouch, he isn’t choosing the easiest or least expensive path to market. He knows the brand will face the headwinds of a more expensive product for the consumer. He overcame some of those headwinds himself when convincing his team, investors, and distributors to try this paperboard route, even when the math on ROI and turning a profit looked daunting. “Everybody was skeptical, saying there was no return on investment and this would never work. They thought that consumers wouldn’t pay more for a product that is packaged in a more ethical way,” Puebla Smith says. “And the more they told us, ‘You cannot do this,’ the surer we became that we needed to prove to the world that doing things as ethically and

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The Buen Vato brand comes from AliasSmith AB, a brand owner and importer based in Stockholm, Sweden. For 18 years, the company has developed and invested in Mexican brands in Europe—largely in the beer, wine, and spirits category. In fact, it had already for a decade been distributing bottled tequila from the high-end Mexican distillery that would eventually produce Buen Vato. But when the process of importing heavy, liquid-filled glass bottles from across the Atlantic was examined by thirdparty environmental auditors, it was deemed ecologically untenable. “[The auditing body] is called amfori BSCI, a certification that audits food and beverage in monopolies in the north of Europe,” Puebla Smith says of the organization with a stated goal of improving social performance in global supply chains. “They put this distillery under an audit to see if the CSR compliance was good enough. We had a few decent audits, then a few bad ones, and finally they told me, ‘Claes, this is a problem. If [the distillery doesn’t] fulfill our expectations next year, they’re out [Swedish monopoly won’t sell product that isn’t meeting certain amfori BSCI CSR qualifications].’” In response, since 2019, AliasSmith AB spent almost 1,500 hours reshaping the processes and physical packaging structure for its preferred specialty distillery. The company went so far as to join the Swedish Beverage Industry’s Climate Initiative (DKI), with the goal of reducing the industry’s carbon footprint. Subsequently, AliasSmith decided to invest

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An internal metalized film pouch reduces the oxygen transfer and vapor rate for spirits. in projects with the lowest possible negative impact and inspire the industry to do better. “After all, in our business of importing Mexican products in Europe, we sell in 27 countries through 54 different distributors. We bring in about three 40-foot containers a month,’ Puebla Smith says. “We joined the initiative of mapping all the carbon dioxide that we were generating with all the products we were selling. If you can measure it, you can probably improve it. That’s the whole idea.”

“Bag-in-bottle” format To accomplish its recalibrated goals, and keep the third-party sustainability auditors happy, Buen Vato partnered with U.K.-based Frugalpac to incorporate its Frugal Bottle concept. Frugalpac “creates and supplies recycled paper-based products with the lowest carbon footprint, that are easily recycled again and don’t need to go to landfill,” it says in a briefing. “The format is lighter to transport than the glass alternative and offers major CO2 reduction in comparison to traditional industry methods.” The format is functionally bag-in-box. In this case, the “box” portion begins as a die-cut and geometrically creased blank of printed paperboard. Being printed paperboard, no additional labels—or labeling equipment—are necessary. The rigid bottle is formed from one flat piece of paperboard, a blank with water-based adhesive used as part of the assembly process. The paperboard is then molded around a mandrelshaped, hollow mold that has already had the pouch inserted within (watch this process at pwgo.to/7598).

Sustainability chops The Frugal Bottle itself is made from 94% recycled paperboard that acts as a rigid container protecting an internal, food-grade metalized PET pouch. At only 83 g, the bottle system is five times lighter than

Watch a video of the paperboard bottle forming in action on Frugalpac machinery first, then watch a consumer interacting with the Buen Vato pack, separating the paperboard from the pouch.

a glass bottle and, crucially, uses a lot less carbon and energy to produce and dispose. “An independent Life Cycle Analysis (LCA) by Intertek found the Frugal Bottle, which is made from recycled paperboard with no chemicals, has a carbon footprint up to six times (84%) lower than a glass bottle, and more than a third less than a bottle made from 100% recycled plastic. The Frugal Bottle’s water footprint is also at least four times lower than glass,” the company says in a briefing. “It’s easy to recycle again. Simply separate the plastic food-grade pouch from the paper bottle and put them in your respective recycling bins. Or you can put the whole bottle in your paper recycling bin and the pouch will be easily separated in the paper re-pulping process. It also uses less plastic than a plastic bottle. The Frugal Bottle uses up to 77% less plastic—only 15 g, compared to a 64-g bottle made from 100% recycled plastic. The LCA looked at the ‘cradle to grave’ life cycle of all bottles, including mineral extraction, manufacture, transportation, distribution, filling and recycling or incineration.” The food-grade pouch is a polyethylene terephthalate (PET) metallized polyester lamination, the same material used in bag in box wines. The company says it is recyclable, though capability to recycle such laminated, multi-layered materials may be limited and varies by region. In the case of the Buen Vato application, the tequila is distilled in small batches in Jalisco, Mexico, then bulk shipped to the Netherlands. There it’s “bottled,” or more accurately, filled into flexible film liners that safely and securely reside inside the paperboard bottle structure. The fully erected “bag-in-bottle” containers are shipped empty to the Netherlands from the U.K., where Frugalpac operates bespoke bottle erecting and pouch attaching equipment. “Frugalpac has been very enthusiastic in supporting us in the whole process,” Puebla Smith says. “Since the bottle is quite a bit different to what the bottler is used to [glass or rigid PET bottles], the Frugalpac people flew over to the Netherlands and spent the whole day together with the bottler to make sure that all the fine-tuning was well done. And this is something they didn’t charge us for.” Adds Omar Corona, Mexican environmental engineer and head of the pollution reduction program of AliasSmith, “It’s time for a change where conscious consumers buy the nice [paper] board bottles and, if they wish to, pour their tequila into a crystal bottle at home. Why continue polluting so much to enjoy a tequila?” Buen Vato is in negotiation with distributors in the U.K., Italy, France, and Spain. —Matt Reynolds At press time, Canadian packaging firm KinsBrae Packaging agreed on a deal to buy the first Frugal Bottle Assembly Machine, called FBAM-1, and install it in Canada. Puebla Smith is aiming to use capacity at that facility to sell Buen Vato into the North American market, without having to expend CO2 on shipping product from Mexico to Europe to be bottled, then sent back to the U.S. and Canada. The Mexican market is another target for Buen Vato, though some packaging standards red tape will need to be cut since Mexico doesn’t currently consider the paper bottle format to be within the pack format norm for tequila.

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D2C SIOC Shoes Make Sustainable Statement Micah Heftman hadn’t yet heard the acronym SIOC (ships in own container) when he designed a shoebox for his new product line. He was just pleased to have eliminated the ‘box within a box’ experience. Only when he heard about SIOC did he realize there was a name for what he had just created. WHAT YOU’LL LEARN

Mechanical, adhesive-free tab construction

Tactile tear strip

By Matt Reynolds, Chief Editor Sustainable footwear startup Kengos kicked off its e-commerce journey as soon as it first hung out a shingle in early 2021. There are a few others in the marketplace already, including entries from heavy hitters Nike and Adidas—Space Hippie and Parley, respectively—and a challenger brand in All Birds. But partners Dave Costello, CEO and Founder, and Micah Heftman, Chief Product Officer, say Kengo’s has a unique niche in the market identified. “How could the market need another sustainable shoe brand?” Heftman asked the audience at Smithers’ E-Pack event in Chicago in No-

vember 2021. “Kengos exists to be a force for good in the fight against climate change, and we do that by producing the world’s most sustainable shoe. We chose footwear as our first product because it’s globally ubiquitous and it’s personally expressive—everyone has shoes, and everyone wants more shoes. The dirty secret in the industry is that it’s a wasteful and resource-intensive product to produce, and if we could just produce them in a more sustainable way we could have a huge impact since there are so many of them produced.” This upstart challenger brand without a doubt has an interesting product and a unique entry into this market. A visit to the website will explain why in more detail, but the big picture is that the shoes are made from plants and can be considered vegan, using no animal products. They are mechanically held together with no glue or other adhesive, and only use five discrete components compared to the industry average of 30 to 50 components. But my packaging-trained ears really perked up when I heard Heftman mention the amount of greenhouse gasses produced by the footwear industry, and how he believes that truly sustainable footwear requires drastic changes to existing supply chains and packaging norms. And that’s where Kengos’ unique SIOC (ships in own container) e-commerce story began to unfold. Ultimately, Heftman and Kengos decided that if Kengos was going to disrupt the shoe market with a commitment to sustainability, it’d have to walk the walk with its packaging.

Packaging follows the product’s ‘North Star’ Kengos shoes’ most visually striking design element stems from the whip-stitching that mechanically attaches the sole to the upper without adhesive. That design element is reinforced in the packaging design, which is also entirely mechanical.

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According to Heftman, the driving force for the entire Kengos concept was to follow two North Stars: “One is to use the fewest varieties and lowest volume of materials possible; to take away as much as we possibly could while still giving someone a shoe that’s incredible and comfortable and wearable,” he says. “And the second one is, of the remaining materials that we do have to use, make the highest percentage possible of materials used plant-based. Those

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The corrugated SIOC shipper is printed in three colors on both sides, so all branding and messaging space is used as a billboard.

corrugated shoebox couldn’t either. The same applied to size; since the shoes were as minimalistic as possible, the shoebox had to use as little material as possible. And finally, Heftman early recognized the inherent wastefulness of shipping “a box within a box.” All those factors combined to shine a spotlight on SIOC as the answer.

two North Stars are what created the shoe, so when I went to create the packaging, we applied the exact same two driving forces. “After all, I only make two things, I make shoes and I make shoeboxes,” Heftman says. “I’m a D2C e-comm brand; there are no other touch Rather than turning to packpoints. I have to have my packagaging professionals, Heftman relied on ing be just as good as my shoes. The his own shoe business supply chain package is the product. The shoes are more experience to develop shoebox that complex to manufacture than is the shoebox, but he says, like the shoes, are completely the shoebox is just as important.” unique to the industry. The boxes lock toIn a brief describing his vision for a shoebox, a memorable gether mechanically—a physical attribute unboxing was identified as a key, as it can reinforce the brand for extended from the mechanically stitched shoes themweeks or months in the customers’ mind. The shoebox would also have selves—and all available corrugated space is printed for to serve as billboard space; other than the website, the shoebox is the branding and consumer engagement. He initially landed on 180 GSM only physical space that Kengos has for branding. He needed all surweight corrugated with fluting between two layers of cardstock. After faces doing branding work. Further demonstrating that the packaging first experimenting with a lighter gauge, he realized the D2C channel is the product, the shoe doesn’t have any glue or adhesive, so the kraft needed to be more robust. And since that first round of kraft corrugated 22_1138_Packaging_World_JUL Mod: April 26, 2022 12:17 PM Print: 05/13/22 page 1 v2.5

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shoeboxes, Kengos continue to iterate smaller. “Over the course of very early development, I was doing a little bit of shipping internationally to test out the box and I was getting a lot of broken boxes,” Heftman says. “I’d gotten to 180 GPM, and now my next box is an even a heavier weight, it’s the next step up from that. That thing is bulletproof. It uses three-tab mechanical construction instead of two. We’re just making it smaller and smaller, and more robust.”

A tear strip, printed to reference to the product’s stitched design, gives consumers a satisfying, controlled rip when opening the shoebox.

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Kengos shoes span 12 unisex sizes, and two shoebox sizes cover the whole range—one size for the largest shoes, the other for the smallest. Heftman says that in a perfect world, where he’s able to fully follow that reduced material North Star, he might have six different shoebox sizes, with each optimized to fit only two shoe sizes within millimeters. That would keep material usage at a minimum. But with packaging suppliers needing to tool up for each specific shoebox size, and with MOQs being too high for a single shoebox to work only for, say, sizes 6 and 7, that level of optimization isn’t yet practical. Two shoeboxes for a range of 12, though, was doable, and a good material reduction compromise for now. As the business grows and Heftman’s better able to justify MOQs and paying for tooling, look for Kengos to have six shoebox sizes for his 12 shoe sizes. He points out that this creates wins across COGS (cost of goods sold), since: “less material is always cheaper,” he says. “Less material consumption, less volume, and lower dimensional weight is going to lead to cascading bottom-line wins. You consume lest material, in transit and in storage, you save on last-mile shipping, on labeling, on trim, on collateral, on all of these things that are the status quo [in the footwear industry]. But you don’t need any of that.” All Kengos uses when it comes to labels is a UPC label since cost-effectively printing a barcode onto the corrugated has been elusive. Also, a ground shipping label is affixed by UPS in a designated window that’s printed onto the corrugated. This makes shipping label placement mindless for whoever is doing the applying, and the brand knows that placement will be repeatable, never covering any design assets. Kengos shoes are hand-crafted by an artisan finished goods manufacturer in the North American hub for footwear manufacturing and its attendant shoeboxes: Leon, Mexico. These bulk shoes are bulk cartoned, and sent “down the street” to be hand-boxed in the SIOC shoeboxes for individual orders. “And even my bulk packaging gets customized,” Heftman says. “I customized the last-mile box, but if I can customize the bulk shippers that the shoes ship in from the finished goods manufacturer, to the ware-

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house, I can optimize even further, and ensure that 100 percent of the internal volume of the larger cartons are used. I can ensure that the footprint of the pallet is being completely filled, and I can ensure that the maximum shipping height is being utilized. This way we can generate wins across the board.” Industry standard bulk cartons for finished footwear usually contain 12-18 pairs of shoes. Heftman gets between 24 and 32 of his shoes into his customized bulk cartons.

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Kengos shoeboxes use a built-in tear strip that consumers use to open the boxes, and people say they remember this unboxing experience because of this satisfying, controlled rip it produces. “It’s a little journey that [consumers] go on that reveals unexpected messaging underneath. Then, they arrive at the shoes themselves, which are in 100% cotton shoe bags, complete with 100 percent cotton closures rope,” Heftman says. “It’s the little touches that are so important.” Speaking of little touches, a few other details on the box help create a full story that connects the features of the product to the shoebox. The visible, one-knot con-

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Exterior (left) and interior (right) layouts of the first iteration of the Kengos SIOC shoebox. The company has since iterated smaller, more robust versions with three mechanical lock tabs instead of two. struction that adjoins the sole to the upper body of the shoe is integral to the brand’s entire aesthetic, so Kengos reinforces the same visual on the tear strip by printing it with the shoe’s characteristic whip-stitch closure stitching. Design agency The Working Assembly out of New York City assisted with brand design elements such as these. Despite all the special touches and thought behind the SIOC pack, Heftman realizes that once the unboxing is complete, that packaging will be headed out with the recycling almost immediately. So it’s during that unboxing that he seeks to make a big impression. Between the shoes and the box, he added a branded, reusable cotton shoe bag that can be repurposed, thus live on longer than the soon-to-be-discarded corrugated. Brent Lindberg of Fuseneo, a Chicago agency specializing in e-comm, SIOC, and package design testing for D2C, had created an unboxing video with the SIOC Kengos shoes. Watch it here.

The time of the unboxing is also the time when consumers are most likely to share information on their purchase on social media. That’s why the three-color screen-printed corrugated prompts consumers on how to correctly @ and # (‘at’ and ‘hashtag’) the brand on Instagram, or whatever the latest social media site might be. “There’s a call to action,” he says. “Share, tag us, etc. This leads to lots of engagement on social media.”

Unique challenges of SIOC As pumped as Heftman is about his unique shoeboxes, he recognizes that SIOC is not without challenges. Since these corrugated boxes are designed to be single-use, that makes return logistics more difficult. If a consumer wants a different color or size shoe and needs to make a return, he or she is likely able to re-close the existing shoebox and shoes with overtape. However, that means an entirely new single-use SIOC shoebox will be required to send the new shoes. Also, since Kengos decided to go the custom route, that means that

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printing plates and knives for cutting the corrugated had to be created from scratch by his suppliers. There’s certainly some tooling involved if a D2C retailer decides not buy off-the-shelf packaging, and frankly there aren’t a lot of options that are available off-the-shelf at the moment. “SIOC is also great for single item orders, but not for multi-item orders,” Heftman says. “What I end up having to do is going to the status quo and overboxing it. I don’t have a current solution on how I take two pairs of shoes, in a two-pair order, without overboxing.” Speaking over overboxing, the entire idea is to avoid overboxing altogether, meaning the single remaining box needs to be that much more durable and robust—it won’t have the assistance of another internal box to help it withstand the rigors of the many-touch e-comm channel. Corrugated used for SIOC needs to be more robust than a shoebox sent to retail, and that costs more and uses more materials. “And finally, these boxes lock mechanically, so once they’re locked, they’re locked,” he says. “Once they’re locked in the warehouse, I can’t check the contents or add collateral. And if I do, I’d destroy the existing shoebox and need to then invest in a new one. … That said, until now, even though there are improvements that I’ll make and things I need to figure out with SIOC on the whole, it’s been well-worth it from a branding perspective and bottom line,” Heftman concludes.

its brightly colored appearance and in its engaging, tactile tear strip. “I love tearing the box open to reveal the prize inside,” reported one Kengos customer in the research. This comment, above all others, validated Heftman’s original goal of creating a SIOC shoebox that would act like a treasure chest, with consumers eagerly engaging with the corrugated to reveal a treasure inside—and who knows, maybe even post about that treasure on Instagram? PW

A SCALE FOR ANY APPLICATION

Consumer reaction makes it worthwhile Kengo’s customer interviews reinforce Heftman’s belief and reflect that the SIOC packaging hits its mark. These reports indicate that the brand’s larger sustainability goal is well-reflected and recognized in the corrugated, with people noticing that there’s no “box in a box.” Also, the stuffing, dunnage, or product dividers that people are used to seeing in a shoebox are conspicuously absent, and the customer immediately understands why such things aren’t used. People also report that it’s fun packaging, both in

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AUTOMATION

OEM APPLICATION NOTE

OEM’s Head-to-head Pneumatic vs. Servo Test Reveals TCO Stacking equipment manufacturer Forpak devised a test to see how incumbent pneumatic actuators stacked up against newer mechatronic servo technology, specifically on a frozen food stacking and laning application. These are the results. WHAT YOU’LL LEARN

Input cost comparison

CO2 output comparison

Downtime comparison

Matt Reynolds, Chief Editor Dave Brownson, Engineering Manager at Forpak, was the first engineer hired onto the food stacking equipment OEM when it opened its doors more than 30 years ago. With three decades under his belt as an engineer with the company, Brownson remembers the days when pneumatics were the only actuator game in town for Forpak machinery applications. He also recalls the first introduction of linear servo in the place of incumbent pneumatic technology about six or seven years ago. “I was looking for a IP69K solution for a project that we had, so I went to my vendors and they came up with [linear drive system supplier] LinMot,” he says. “I was introduced to them, and we’ve never looked back.” More recently, Brownson has had his sights set on building an all-electric, pneumatic actuator-free stacker. But it was a matter of waiting for the right size and shape of linear motion tech to be ready—nothing existed on the market that could fit his application. “I had kept on pushing Peter [Zafiro of LinMot] to make a smaller and smaller motor, and he asked me, ‘How many would you buy?’” Brownson recalls. “I answered, ‘Well, how many can you make?’ Because if I can make an all-electric stacker, it would really make efficiencies go up.” Brownson finally saw the LinMot prototype that would do the job at a recent PACK EXPO. Forpak is now developing a machine that is 100% electric with no pneumatic technology. The plan is to exhibit the new machine at PACK EXPO International, to be held Oct. 23-26, 2022 in Chicago. It bears mentioning that pneumatics aren’t going anywhere, and they are firmly ensconced in the controls and automation tool kit. And some operations require pneumatics for safety reasons, in explosive environments for instance, so switching out pneumatic for electric isn’t always possible. Still, Brownson sought producing an all-electric model because he says LinMot linear servo motors save energy and are highly efficient for his specific set of applications and customer base. Plus, they allow for a lower total cost of ownership thanks to their comparatively few wear items, and that results in less downtime—especially unexpected downtime. In his experience, these factors bring real-world, long-term savings that are attractive to Forpak’s CPG and brand-owner customers.

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Forpak manufactures electric vertical stackers with pneumatic horizontal cylinders used for stacking products The test model was a four-lane unit (model number – GSS5-4), similar to the eight-lane unit (model number GSS5-8) pictured here. But so far, that’s just been Brownson’s anecdotal experience—one man’s opinion. To test the efficiency and power savings, Zafiro enlisted Brownson, along with Joel Geisel and Adam Shank, both from Hamilton Automation, a LinMot Manufacturer Representative, and JB Korte of Van Meter Inc., a LinMot distributor. The OEM, automation supplier, and distributor together devised a test of Forpak’s machine using pneumatic actuators as compared to all-electic actuators. The idea was to establish actual power consumption and develop actual energy savings data, and what follows is what came of this testing.

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Equipment being tested Forpak stackers occupy a niche in baked product and protein packaging lines that exists between upstream freezers and downstream flow-wrapping, bagging, or hand-packaging. Typical products might be frozen hamburger patties, waffles, or cookies that exit the freezer either randomly or semi-organized. That product needs to be oriented, laned, and stacked for downstream packaging equipment. “The slide plate and push parts of the stacking were pneumatic, and they always have been, up until just recently,” Brownson says. “Now that LinMot developed the right size actuator, we’re able to do both traditional pneumatic and all-electric, and we performed this test to see the difference.” Forpak assisted by allowing the team access to a typical stacker machine in operation at many end-user sites. The stacker machine is a four-lane machine, with eight pneumatic actuators operating in a horizontal direction. With the help of Korte from Van Meter Inc. and a Rockwell Automation Power Monitor 5000, actual power consumption was recorded. The Power Monitor traced data points including amperage, time, and kWh from an independent, high-efficiency 7 cfm electric air compressor. The team ran the machine for 30 minutes and sampled every 10 msec. This setup does not account for pneumatic line losses as the air provided to the cylinders had a very short run from the compressor, with no other devices operating on the same air supply.

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The AMI812x integrated servo drive: integrated servo drive for compact drive technology (up to 48 V DC) combines highly compact servomotor, output stage and ﬁeldbus connection for all motion requirements in the power range up to 400 watts for single axes or with daisy-chain solutions on the machine supports machine concepts without control cabinets IP65 protection degree possible with sealing ring option Safe torque off (STO) safety over FSoE (Safety over EtherCAT) reduces installation and integrates seamlessly into safety solutions

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Findings The test team ran into one limitation during the test run—the number of data points able to be stored in the PLC. As such, the data pulled was for 15 minutes of run time, and the average power was consistent throughout the study. Running the machine for an additional 45 minutes to achieve an hourly count proved that the data would not have changed. The compressor never turned off in the entire 60 minutes.

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So, the team says it’s confident that the data pulled for the entire 60 minutes would have been nearly identical as the 15 minutes test data, extrapolated for the 60-minute test. The power consumption was consistent at 5161 kWh throughout the test. LinMot’s Lin Designer program shows this specific horizontal pusher application and provides for calculated power consumption for the LinMot actuators and an equivalent pneumatic cylinder. Lin Designer’s pneumatic cylinder power consumption calculations are based on “the two most popular pneumatic cylinder manufacturers’ energy power consumption calculations. These are direct-from-the-factory expected energy consumption rates,” the team says. For this specific cycle, LinMot’s Lin Designer program estimates 4575 kWh power consumption. The test used the lower of the two values to calculate pneumatic cylinder energy operational cost, as follows: The 4575 kWh multiplied by a fully loaded $0.20 per kWh (test note: this value is usually much higher, especially when plants run during peak surcharge periods during the daylight hours for most of the calendar year) would yield an expected cost of $915 per cylinder per 8,000 hours of operation per year. Since this machine uses eight pneumatic cylinders, the operating cost for this specific machine would be $7,320 per 8,000 hours of operation per year. The equivalent machine using LinMot actuators provided linear motor yields the following power consumption result: The same cycle resulted in 243 kWh for a PS0123x80F-HP-SSCP-R20 motor in a 175-mm cycle in 200 msec and -175 mm in 200 msec with a 600 msec dwell time. The 243 kWh multiplied by a fully loaded $0.20 per kWh would equal $48.60 per LinMot actuator. All eight actuators would cost $388.80 to operate 8,000 hours of operation per year. The savings here are calculated to be $7,320 (pneumatic) minus $388.80 (electric), or $6,931.20 per calendar year. If a plant operates at lower output, say to a 6,000 hours per year schedule, the savings would be $5198.40 per calendar year. Zafiro, Geisel, and Korte note that these values do not include any maintenance or unexpected downtime costs when a pneumatic cylinder fails. “Such fails are more common in with frequent cycling applications, such as the one in this study,” Brownson notes. “I’d estimate that replacing a pneumatic cylinder usually takes between 30 to 90 minutes, with typical plant downtime being valued at $15,000 to $20,000 per hour. Even though it’s not considered in this test, downtime is huge.” “There are very few mechanical pieces with this type of actuator, so you essentially limit the amount of wear that could happen,” Geisel adds. “And by limiting the amount of wear, it requires less maintenance than what a pneumatic cylinder would require. You don’t

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Slider 270 mm

Stroke 177.8 mm

have seals that are breaking down. You’re not losing air, and you’re not having to replace cheaper components more often. There’s just very little wear or necessary downtime.”

Results The test study revealed that, at least for this specific application, running eight pneumatic cylinders costs signifi111.2 mm 16.15 mm cantly more than eight linear motors. According to data the Stator 175 mm team cites from the world’s two largest pneumatic cylinder manufacturers, the carbon emission savings would be over 4,600 lbs. per cylinder, or more than 36,000 lbs. of CO2 emission savings for this specific machine with the 8,000 hours per year operation. Adding this to the more than $6,900 worth of electricity cost savings, Brownson was impressed. He notes that this test was done on a four-lane Forpack stacker machine. A typical Forpak stacker uses between six and 10 lanes, meaning for 66.65 mm 161.6 mm those machines, the savings will be higher as extrapolated over more lanes. The stroke of the LinMot actuator in the Forpak application—this graphic “I was expecting a savings, but I wasn’t expecting this demonstrates the footprint of the axis. amount of savings,” Brownson he says. “It really will help me Test notes: Testing was completed on November 2, 2021, at Forpak’s in showcasing the new machine in the future—as far as at PACK EXPO manufacturing facility. It was completed by Adam Shank of Hamilton International, and for sales in the future also. It shows that the cost of Automation and JB Korte of Van Meter Inc., with the help of Dave Brownson ownership on the front side is going to be a little bit higher, but overall, of Forpak. Evaluation and analysis of results were completed by Joel Geisel the course of the life of the machine, it’ll be less.” PW of Hamilton Automation.

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Stretch Wrapper Shuts the Door on Freight Damage A new portable stretch wrapper with roping device helps custom-closet company Closet Works reduce damaged shipments from one per week to one or less a month. WHAT YOU’LL LEARN

Stretch wrapping for oversized pallets

Film reduction technology

By Anne Marie Mohan, Senior Editor the AWFS (Association of Woodworking & Furnishings Suppliers) trade show in Las Vegas looking for a packaging solution. There they were introduced to Robopac’s line of automatic and semi-automatic stretch wrappers. After working to understand Closet Works’ specific needs, Robopac Regional Sales Manager Nick Szczechowski recommended the Robopac Robot S7 portable, semi-automatic stretch wrapper with roping device, which was subsequently installed at Closet Works’ facility in September 2021.

Portable model accommodates oversized pallet

Chicago-based manufacturer Closet Works, a subsidiary of The Container Store, offers premium custom-made closets and organization systems. Chicago-based manufacturer Closet Works, a subsidiary of The Container Store, has been setting the standard for premium custom-made closets and organization systems since 1987. Like most successful businesses, Closet Works is always looking for ways to improve its processes—especially when it comes to ensuring the quality of its products. Closet Works ships its cabinets and closet components in corrugated boxes from its facility to locations both domestically and globally. In 2020 and 2021, a perfect storm of increased freight volumes and a lack of equipment and personnel resources resulted in an increase in freight-related product damage. Closet Works was particularly vulnerable as its cabinet and closet components ship on larger-than-average pallets: 4 x 8 ft versus the standard 48 x 40-in. (4 x 3.33-ft) size. “The product was shifting laterally on the four by eight-foot pallets,” says Closet Works President Tom Happ. “We were getting damage claims, and we wanted to correct the issue.” In July 2021, the company attended

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Previous to the purchase of the Robot 7, Closet Works was manually loading containers onto the pallet and wrapping them by hand. “Handwrapped pallets are never the same,” says Happ. “It’s inconsistent at best.” The company’s goal was to find a solution that could accommodate a 4 x 8-ft pallet and provide better load containment by roping the products to the skid. The Robot S7 with the optional roping device was an ideal solution due to its ability to handle most load lengths and widths, as well as any weight. “Turntable stretch wrappers are restricted by the size of the turntable,” explains Happ. “The Robot S7 allows us to wrap our four- by eight-foot pallets with no problem. The machine moves around the entire pallet with no issues.” The standard configuration for the Robot S7 semiautomated stretch wrapper features a 20-in. film carriage and a 110-in. wrap-height mast. The portable wrapper is equipped with the company’s Cube technology, which allows the machine to precisely control the stretch film on the pallet to ensure load containment and reduce potential product damage. According to Robopac, it can also reduce film usage by 30% to 50%.

The Robot S7 stretch wrapper can accommodate virtually any length and width of pallet, with a maximum height of up to 110 in.

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Closet Works also opted for Robopac’s roping device, which can convert a 20-in. roll of film to a full rope or a variable-width band to provide better load protection and lock the load to the pallet. The roping device is attached to the roll carriage and ropes the entire web of film from the top down. Roping from the top allows the machine to apply a high tension-strength rope of film to the pallet wherever it’s needed to improve load integrity.

Happ. “We were pretty much having damaged skids once per week. It’s now one or less per month.” Closet Works plans to expand to multiple facilities in the near future. To continue their packaging recipe for success, they plan to order more Robopac Robot S7 portable stretch wrappers for their new facilities. PW

The portable, semi-automatic stretch wrapper moves around the load to apply the stretch-wrap film.

Says Happ, “Nick adjusted the roping to specific placement on the loads using Robopac’s Cube technology. Cube technology allows you to wrap in nine sections, instead of just one total pallet. This means we can dial in how much containment force, pre-stretch, etc., that we want.”

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Investment reduces damage Given the AWFS show was held in late July, Robopac shipped the Robot S7 in record time, arriving that September. Of the installation, Happ says, “Robopac was great.” He adds, “Nick [Szczechowski] came to our facility multiple times. He helped us make adjustments to our program to make sure we were wrapping right.” The investment has quickly paid dividends. “The Robot S7 dramatically reduced our damage,” says

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Capable Filling and Seaming Anchor Custom Canning Line When adding canning capability, MacKinnon Brothers Brewing needed flexible filling and seaming operations that would reduce labor, improve precision, and speed up throughput—all the while integrating into a home-built, highly customized line. WHAT YOU’LL LEARN

Digital can printing

Repurposed & custom equipment

By Melissa Griffen, Contributing Editor, PMMI Media Group, and Matt Reynolds, Chief Editor, Packaging World Founded in 2013 by brothers Ivan and Dan, MacKinnon Brothers Brewing Company is a farm-based operation, sourcing its fresh ingredients from its own farm and other local farms to produce unique beers. The facility is ideally located on a beautiful bicentennial family farm surrounded by fields of hops, barley, wheat, and corn in rural Ontario, Canada, just outside of the city of Kingston. Two of the company’s canned products are made entirely from ingredients grown on its farm. MacKinnon Brothers is a true local brewery in the sense that it sells 80 to 85% of its products within a 50-km (30-mile) radius of its facility. Product is also sold directly from the farm when it hosts concerts, music festivals, weddings, and other events. A QR code on the cans of its Harvest Ale variety educates consumers on the growing season, the malt from that season, and how those factors affect the flavor of the beer. But before guests even get to a taste what they’re learning about, the beautifully decorated cans make a farm-fresh impression.

Stand-out can designs inspired by the farm The brewery began in a keg format, but as MacKinnon’s business grew, it expanded into cans. A 473-mL (16-oz) can format gave the brewery the chance to make a visual impression on customers, and it did so in spades. At the outset of its pivot into cans, the MacKinnons enlisted design and branding agency RedRhino, Inc. in nearby London, Ontario. At that

A wide view of the canning line (left), with cans being conveyed from depalletizer in the upper left to a canner and seaming station in the upper middle. A can dryer and checkweigher are on the right, and cans enter accumulation in the foreground before tray packing downstream. Can design for Philomena Pilsner (above) celebrates the brothers’ grandmother Philomena, who used beer to bake her bread.

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Seasonal brews, like this Wild Peppermint Stout, use digitally printed cans with practically no MOQ. MacKinnon prefers the look and feel of digitally printed cans to the shrink sleeve alternative. point, the company was only making two beers—8 Man English Pale Ale and Crosscut Traditional Canadian Ale. “We didn’t want a can that was really busy, with 500 awards and logos stamped on it,” Dan MacKinnon, coowner and head brewer says. “We wanted something a bit simpler and something we could keep consistent across all of our offerings.” With that opening salvo of direction, RedRhino sat down with the brothers to find out what each beer made them think about. Even though the two young men were worldly and educated—Ivan is a mechanical engineer, and Dan had both brewed beer and played rugby in England—their roots, like the roots of the beers, are firmly planted on the Ontario farm. And the ideation session bore that out. “We know what beers people want to drink around here, and what kind of beers we wanted to drink,” MacKinnon says. “The folks at RedRhino asked us, ‘Well, when would you drink a beer like Crosscut?’ And we answered, “If you’re out cutting wood someday, you might drink that beer.’ And 8 Man was the kind of beer I used to drink when I played rugby in England. We would drink that after the games. It’s a style of beer that wasn’t very well-represented in Canada, so we wanted to help introduce it.” The pencil sketch-drawing design pattern that resulted is indeed simple but sophisticated. A single, centrally located signifier or totem— Watch a brief Take a cross-section of a tree, or a vintage take on a rugby player, respecFive video about tively—communicates how the brothers felt about each of the beers Canadian brewers’ and locates them in the MacKinnon’s life experiences. experiences with Since then, the brewery has expanded to six mainstay or higher both shrink sleeving volume varieties, and those offerings’ respective can designs follow the and digitally printing on cans. same initial design template that was forged with Crosscut and 8 Man. Philomena, for instance, depicts the brothers’ grandmother who they remember used pilsner beer in her bread baking. Naturally, the eponymous Philomena variety is a pilsner. Even more recently—and like a lot of brewery-related duties on the farm, we’ll find out—design has been taken in-house, and a team-member is now using the original template to create a can design for each new beer. Today, the company buys printed cans from Crown for its primary six beers, but there are a few lower volume or seasonal exceptions that might not meet an MOQ for a printed can order. One example is the seasonal Wild Peppermint Stout. “We use a company called Hart Print out of Quebec, they digitally print right on the can so they can do small runs. It’s more expensive per can, but it’s worth it.” MacKinnon says. “There are restrictions on shrink sleeves related to the recycling system. And I much prefer the printed can. I think it has a more premium feel. The shrink sleeves have come a long way, but from an environmental point of view and a quality-feel point of view, I still prefer the printed can. “They are able to do low volumes, too, way less than we’re ordering,” he adds. “If we only want only one or two pallets of cans or even half a pallet—say for a batch from a 40-hL fermenter— then it makes sense to get them from the digital printing.”

Counter-pressure integrated canning line provides precise filling When turning to cans to augment what started as a largely keg-based operations, filling and seaming equipment was needed. To facilitate this, MacKinnon Brothers began bringing in mobile canning in 2015, however, as sales grew, this proved to be cost prohibitive. A few years down the road, the company opened a new production facility with an eye on purchasing its own reliable

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canning line to increase production, and save costs and time wasted on manual canning. After exploring its options, the company decided on a counter-pressure unit with low dissolved oxygen from Pneumatic Scale Angelus (PSA), a BW Packaging Systems Co.

The CB50C counter-pressure integrated canning line uses isobarometric counter-pressure technology.

PSA’s CB50C counter-pressure integrated canning line uses isobarometric counter-pressure technology—for equal pressure between can and product, maintaining carbonation solubility throughout the filling process—coupled with proprietary magnetic flowmeters, to deliver a system capable of 1-mL filling precision. It employs six individual filling heads and a single-head seamer, and with the fill tank positioned above the fill heads, the product is gravity-fed to decrease the likelihood of agitation causing unwanted reductions in carbonation levels. The line is rated for continuous operation at speeds up to 50 cans/min. The purchase was solidified just before the start of the pandemic, and installation was not hindered by the shutdown. “There weren’t any huge issues from COVID in regards to the installation and procurement of the machine,” says MacKinnon. “It was a little trickier to get the folks from PSA up from the States. There was a bit more paperwork than there normally would be.” MacKinnon further explained that the timing was perfect; due to the pandemic-related lockdowns and the resulting distribution challenges, the company was transitioning a large amount of products from kegs to cans, which would have been greatly hindered had installation been slowed. The machine was installed at the MacKinnon Brothers facility within three months. MacKinnon explained that as the line ran into small mechanical hiccups, PSA has provided excellent customer service. He says PSA could FaceTime technicians to show them what the operators were doing and how the machine was reacting, and the technicians could

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send us up replacement parts or improve parts or work with us on improving the machine. If we had an idea, we could discuss with them about how we could implement an improvement.” Referring to a specific issue the company encountered shortly after installation, MacKinnon says that the infeed was causing the cans to slide into the machine too quickly and not perfectly straight. PSA suggested an improved star wheel infeed of a different size that solved these issues; its programmers connected to MacKinnon Brothers’ internet to program the changes into the line once the new star wheel infeed arrived.

Technicians train and work with operators to speed up production PSA offered MacKinnon Brothers three days of training, but soon after MacKinnon Brothers experienced some company turnover which resulted in new Downstream of the filler and seamer is a rinser, an enclosed can dryer, checkweigher employees working with the CB50C. PSA trained the prior to accumulation, and tray packing. new employees and continued to remind them about the steps for proper machine operation through FaceTime and emailed then provide walk-through directions. “PSA was right there all along the instructional documents. “We’re learning and they are understanding way to work with us,” MacKinnon says. “If there’s any issues with the about that,” says MacKinnon. “They’re helping us get the machine runmachine or we thought this part wore out a little bit faster, or we think ning just right.” this could be changed, they were really willing to work with us and

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State of the Industry: Is the Pint Glass Half Full or Half Empty? Packaging World attended the Craft Brew Conference and Expo in Minneapolis in late May, where we heard from Bart Watson, Brewers’ Association Economist, about the current landscape of craft brew as an industry. Pandemic-related channel shifts subsided in 2021, and on-premises sales bounced back, but the craft brew industry is in a state of flux as it matures, growth slows, and new category competitors emerge. Read a long-form report on Watson’s findings, or watch a brief Take Five video on new equipment and materials found at the expo. PW Bart Watson, the Brewing Association’s Economist, in Minneapolis at the Craft Brew Conference. Read the article here.

Watch the video here.

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MacKinnon says the operators took well to the machine. “We were all thrilled to have our own canning line, to see the product moving. You’re really stacking up product and draining those tanks fast with less downtime,” he says. “It’s a better quality of work, better quality of life. [The operators] get to go home earlier. No one wants to sit there packing cans by hand. You want to start up a good machine, can a whole bunch of beer, clean everything up, put the beer away, and still have time for a nice enjoyable time at the end of the day. And I think we’ve finally reached that.” Gabrielle Charette Le Meur, production operator providing quality control, quality management, and production management, adds, “With the machine, we eliminate a lot of jobs that were redundant and I’m thrilled about getting to know more how the machine works as I do problem solving.” MacKinnon is pleased with the canning line’s benefits such as the electromagnetic flowmeters for precise filling that avoid product waste, which had been a significant issue with mobile canning. The brewing company has seen a reduction in damaged product coming off the line— another issue that was common with mobile canning. In addition, mobile canning had to be scheduled weeks to a month in advance and took time for setup. With this increase in flexibility, MacKinnon Brothers hopes to pursue its goal of continuing to increase the amount of ingredients grown on its own farm or sourced from local farms to produce a wider range of keg and canned products for its local community.

Farm-style approach to packaging line As mentioned earlier, the farm mentality at MacKinnon Brothers means that a lot of the packaging line design is a result of in-house modifications, customization, and just getting things to work by their own elbow-grease. Still, the brewery has a well-oiled machine of a can filling operation, anchored by the PSA filler and seamer. The line begins with a Ska Can-I-Bus depalletizer, and cans are single-filed into the line via a Ska twist shoot. Before filling and while inverted, cans are air-rinsed and date coded. “We went away from rinsing with water and instead put in a small air ionizer and filter ourselves that also UV light,” MacKinnon says. “The manufacturer is Takk Industries. That decision was based off a bit of research and a really good talk we heard on different options for air rinsing

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given by MBAA, the Master Brewers Association of the Americas.” The brothers also opted for a simpler design for a date coder, going with a local company called RN Mark. The unit codes the bottoms of the inverted cans as they pass through the twist shoot. “Pricing-wise, it was so much more affordable and it’s pretty simple,” MacKinnon says. “The cost-per-print is super low as well. Knock on wood, we haven’t had any issues with it once we got it set up.” Filling and seaming operations well-described already. Upon exiting those operations, cans go through a quick rinse, then a sharp 90-deg right turn toward an enclosed air dryer. But before entering the dryer, a simple, home-engineered (remember, this is a farm) reject station uses sensors to catch and reject cans that escaped filling without a seamedon lid. MacKinnon says these are rare, but better to have a system in place to catch these un-lidded, but full cans of beer before they enter the can dryer with its dual blowers. Not catching them would make for a mess within the enclosed dryer space, and likely downtime. “We got the dryer from China on Alibaba because the price was right, and it’s works amazing. The conveyor goes right through it,” MacKinnon says. “We knew the height of the conveyor that we had, so they custom-made the air dryer. We went with this rather than just using two air knives with one big blower and no shroud, that we would’ve just attached to the side of the conveyor, I found when I went to visit other breweries, that format was super noisy.” Dried cans then undergo a QC check on an Anritsu checkweigher, a retread from another customized local manufacturing plant and purchased from Abbey Equipment in Canada. With can weights checked, they then enter an accumulation table that acts as an upstream buffer from an automated tray former and tray packer. Oddly enough, the tray former was originally built for bottles, and had served another brewery well in its first life. That other brewery switched from bottles to cans and decided to sell the bottle tray packer. MacKinnon, who also runs cans, purchased the equipment, and retrofitted it for use as a can tray packer. “It’s actually a really great unit and a really good value for the money,” MacKinnon says. “Repurposing it actually wasn’t that much work. We changed some stuff in the programming, took some stuff out we added a suction head from Millibar to pick up the cans. The cans are a

Four lanes of filled cans enter the tray packer from the accumulation table. All sections of the line were assembled in-house. little bit different size than the bottles, so we needed to resize the lanes, but it was mostly stuff that, with a piece of stainless steel and a zip disc, and a little bit of welding and some programming here, we can make.” This farm-oriented re-use and re-purpose attitude might make some massive, ultra-fast line operators cringe, but it works well for MacKinnon Brothers Brewing. Palletizing is done by hand, another hallmark of the hard work ethic at the brewery. “For 50 cans a minute I mean, if I can’t keep up and stack those up, that’s on me,” MacKinnon says. PW

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By Anne Marie Mohan, Senior Editor

Clinical, Wellness Aspects Fuse in Cannabis Rebrand Katonah, N.Y.-based medical and recreational marijuana company Etain was founded in 2015 by Amy Peckham and her daughters, Hillary and Keeley, after they watched their “Granny Franny”—Amy Peckham’s mother, the late Frances Keefe—battle with and seek treatments for ALS. It was this experience that brought home to them the importance of accessible, high-quality medical marijuana in their home state and propelled them in their quest to make a difference in people’s lives through premium cannabis products. Etain’s first offering was a line of healing tinctures, which it sold at its first two medical marijuana dispensaries, located in Albany and Kingston, N.Y. Today the company offers a comprehensive product range, including capsules, flower, lotion, powder, lozenges, sprays, and a vaporizer, from its five dispensaries located across the state. Depending on the CBD-to-THC level of a product, it falls under one of four lines: Dolce, Mezzo, Balance, or Forte. Based on tempos in the music world, the strains produce a calming effect, a bounce of energy, increased energy and mental stimulation, or strong euphoria and cognitive stimulation, respectively. In its early days, Etain was more focused on getting product on shelf and keeping its stores open than on developing its branding and packaging, both of which were simple and utilitarian. Primary

containers consisted mainly of standard plastic medicine bottles in blue, red, and green, labeled with stickers, while packaging for vape pens, lotions, and sprays was generic and mostly made of plastic. There was no secondary packaging. In fall 2019, with the legalization of recreational cannabis on the horizon in New York, Etain reached out to global brand consultancy and creative agency 50,000feet to rebrand its packaging and give the company a fresh look for market entry. Of Etain’s requirements for the new design, Nette Gaastra, Creative Director at 50,000feet, says, “On a higher level, the packaging had to strike a balance between the clinical and wellness aspects of the brand to convey the company’s story of whole health and self-care. On a more practical level, it had to convey the premium quality of their products—and price—and communicate a clear differentiation of the various product lines.” She adds that the packaging also had to use as little plastic as possible. The resulting design is clean and minimalist, which Gaastra says is a reflection of the founders’ strong personal preferences, Etain’s clinical background, and the need to convey the company’s premium-quality product, in particular its multi-filtrated cannabis oil. “It underscores the pillars of their brand promise, which are simplicity—Etain’s products are simple and easy to understand—and trust—Etain has a legacy of

See more images of Etain’s new packaging

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transparency around quality, safety, and ingredients,” she explains. The design centers around the Etain logo mark, which was reimagined for the new packaging. The original logo used a tiny, flower-like icon over the “i” in the company’s name. The redesigned version uses the symbol as the main logo mark and can be interpreted as a flower, the sun, petals, or droplets of oil. According to Gaastra, the logo mark is meant to symbolize transformation through everyday moments. The icon is also used in a variety of graphic patterns against the white background of the secondary packaging, in colors that correspond to product variety: teal for Dolce, lavender for Mezzo, lime green for Balance, and deep red for Forte. Adding personality and depth to the system is the use of vividly colored, immersive macro-photography of the high-quality cannabis oils used in Etain’s products. The photography shows up within each droplet, or petal, of the repeating logo-mark pattern. It’s also printed throughout the inside of the carton to provide an element of surprise. Of the new typography and logo wordmark, Gaastra says “it’s modern yet friendly, bold yet approachable, just like Etain.” Lastly, in addition to the names of the product lines, each carton carries a statement starting with a big verb—restore, transcend, embrace, or relieve—to underscore the benefits of the different formulations. Another small, inspiring product statement can be found upon opening the carton, playing up the brand’s tagline, “Take a Moment with Etain.” Once 50,000feet completed the graphic design, packaging supplier Zenpack worked with Etain to engineer the packaging structures. Aligning with Etain’s desire to eliminate plastic wherever possible, Zenpack selected SBS paperboard as the primary material for most of the products and wrapped, rigid board for the vape pens and batteries. It also designed a custom rigid box and cardboard insert for Etain’s line of rechargeable vaporizers, as well as a custom two-piece interior structure for boxes holding glass jars and bottles. Packaging is litho-printed in four colors plus one key Pantone color for each product line, and from bottle to box, it’s coated with a matte finish that unifies the materials. A subtle, black foil adds depth to the logo and to the black type used on the carton while adding to the textural experience. The new packaging was partially revealed at the end of 2020, with a bigger reveal in spring and summer 2021. The project initially encompassed 35 SKUs; 15 more were added within the year. PW

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Worker shortage? Automate your Drum and Tote filling operation.

INDUSTRY WATCH

Companies TricorBraun entered into an agreement to acquire PBFY, a flexible packaging distributor in North America. The acquisition will expand TricorBraun’s flexible packaging division, TricorBraun Flex. It also acquired Continental Bottle Co., Ltd., a U.K. glass packaging provider, and its affiliate, U.K. glass decorator DiBro Ltd., which will expand TricorBraun’s European presence. Eriez is celebrating its 80th anniversary. Soft Robotics partnered with Quest and Ossid to offer a robotic handling and packaging solution for the food industry powered by Soft Robotics’ mGripAI technology. Videojet and Loftware formed a strategic partnership that they say will change the paradigm for how companies automate printing across production lines, factories, and warehouses, and remove reliance on a proprietary printer/software combination. Weber Packaging Solutions is celebrating its 90th anniversary. SEE launched prismiq, a digital packaging brand with a portfolio of solutions for design services, digital printing, and smart packaging. Smurfit Kappa UK Limited, a manufacturer of paper-based packaging products, acquired Atlas Packaging, an independent corrugated packaging provider. CoreTigo expanded into the North America market with the opening of a U.S.-based entity and office, CoreTigo Inc., in Grand Rapids, Mich.

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BellatRx is celebrating its 20th anniversary. Essentra Packaging and Advanced Materials Development (AMD) partnered to develop a new generation of time temperature indicators, a smart packaging technology for the pharmaceutical sector. Sidel received French Qualiopi Certification for its global training methodology, reinforcing its commitment to provide additional value to customers through long-term support programs. Alpek, S.A.B. de C.V. finalized its acquisition of Octal Holding SAOC. The BoxMaker launched a redesigned website featuring an improved user experience, including an interface design, site speed performance, and an educational content library.

People Jason Santamaria was named CEO of ABX.

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Ralph Hernandez, Vice President of Sales and Marketing for Triangle Package Machinery, will retire after seven years with the company. Michelle Kiernan was named VP, Supply Chain/Customer Service for Formulated Solutions. Rudolf Hausladen was named CEO of the Beumer Group.

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Chris Frank was named Vice President, Operations for BW Flexible Systems, a Barry-Wehmiller Packaging Systems company. Shannon Few was named Vice President and General Manager of The Packaging School.

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Rob Mogren joined UltraSource LLC as Chief Financial Officer. Pactiv Evergreen named Tom Fahrenkrug Manager of Training & Support and Tim Barnett Southern U.S. Sales Representative.

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Scott Butler was rehired as Chief Operating Officer for the Jones Family of Companies.

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TECHNOLOGY

AD INDEX Search Packworld.com for additional information on any of the advertisers listed or visit their website directly ADVERTISER WEBSITE

PAGE

Alliance Rubber Company www.rubberband.com

AmbaFlex Inc. www.ambaflex.com

Beckhoff Automation www.beckhoff.com

BUNTING www.buntingmagnetics.com

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Dekka www.dekkaindustries.com

Newtec’s 2008PCM Mini Weigher is designed for accurate, highspeed weighing of a variety of processed food products such as fresh and dried fruit, snacks, and frozen foods.

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Duravant www.duravant.com

Econocorp, Inc. www.econocorp.com

Emerson Automation Solutions www.emerson.com

Eriez Magnetics www.eriez.com

H.B. Fuller Company www.hbfuller.com

Heat and Control, Inc. www.heatandcontrol.com

IMA - S.p.A. www.iima.it/en/ima-group

Institute of Packaging Professionals (IoPP) www.iopp.org

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PET Aerosol Container Sidel’s PressureSAFE™ PET container is designed to provide home and personal care product brands with a more environmentally sustainable dispensing spray packaging. It is approved for the traditional PET recycling stream.

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Rotary Counter-Pressure Filler Pneumatic Scale Angelus, a Berry-Wehmiller Packaging Company, introduces the CB100C rotary counter-pressure filler, featuring a 12-head rotaryfilling turret design, coupled with a dual-station seamer, to allow craft beverage producers to increase their throughput to more than 100 cans/min.

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MFT Automation www.multifeeder.com

Michelman Inc. www.michelman.com

Modular Conveyor Express www.modularconveyor.com

Nercon Conveyor Systems www.nerconconveyors.com

PFlow Industries, Inc. www.pflow.com

PMI KYOTO Packaging Systems www.pmikyoto.com PMMI, The Association for Packaging and Processing Technologies www.pmmi.org

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Robatech USA Inc. www.robatechusa.com

Siko Products, Inc. www.siko-global.com

Smart Plastic Technologies www.sptweb.com Specialty Equipment www.specialtyequipment.com Syntegon Packaging Company www.syntegon.com

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Uline www.uline.com

Valco Melton www.valcomelton.com

Van der Graaf www.vandergraaf.com

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Vinco Automation www.vincoautomation.com

WEIMA America, Inc. www.weima.com

WestRock www.westrock.com/aps Yamato Corporation www.yamatoamericas.com

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6/15/22 12:11

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PROFESSIONAL PERSPECTIVE

By Jim George, Director of Education at IoPP

Partnerships: One Path to Training to Ease Talent Shortages Pick your industry. Some long-timers are realizing that the next generation of expertise their teams require isn’t being groomed as they need it. Yet, market conditions continue to change and knowledgeable staff veterans continue to retire. Why the talent gap? Blame continues to be placed on a lack of sufficient budget, a suitable pool of qualified recruits, or even a coordinated plan of action. Fortunately, we’re starting to hear stories where industrious people are taking their own initiative to make things better. I want to share one such success story in the packaging industry. It started with one individual’s observations that fostered an idea. Momentum accelerated quickly around that idea with the resolve of industry peers having a shared need. The Institute of Packaging Professionals got involved, eventually with an assist from PMMI. The partnership that blossomed has proven essential for the impending launch of a much-needed new training course–but more on that later.

An idea germinates Let me take you back to the beginning. Six years ago, Jennifer Benolken wanted to develop a packaging engineering group at a former employer in medical devices. But no training course existed with the requisite focus on just that industry segment, and her one-time employer lacked an on-site packaging facility for learning. Furthermore, an existing handbook on medical device packaging was dated. “I was struggling with my group and didn’t really have anything to give these junior professionals,” says Benolken, today an MDM and Regulatory Specialist in Packaging Engineering at DuPont. Once upon a time, she notes, senior professionals had spare time to coach green recruits on medical device packaging—and junior associates were allowed to learn from their mistakes, because at that stage of their careers, any missteps generally weren’t crucial to the company’s bottom line. Those days are gone. “Now, you’re expected to be perfect from day one,” Benolken says. But today’s senior packaging experts have little or no time to help train them as they go. Adding to the challenge, those interested in learning about medical device packaging are at another disadvantage. While any packaged food or household product is readily available for observation and discussion, medical device packages lack similar exposure. “You can’t go to the store and point out to people, ‘Hey, I packaged that (medical device),’” Benolken explains. That’s when the idea for a focused training course, developed by industry experts, came to her. Over the past few years, she and

others have been marshalling the expertise of IoPP’s Medical Device Packaging Technical Committee to create a course this industry segment so sorely needs. The project was slowed but never halted by the COVID-19 pandemic. IoPP staff jumped into the planning several years ago to help with the coordination and eventually handle marketing and registration. IoPP, in turn, has been working with PMMI through the logistics to hold the inaugural Fundamentals of Medical Device Packaging course at PACK EXPO International, beginning with this fall’s show in Chicago (Oct. 23-26). The objective was for an in-person immersion course in which students could learn concepts in the classroom and then observe how medical device packaging is made on actual machines. PACK EXPO provides an ideal environment for the course; the classroom will be at McCormick Place during the show and will include time on the show floor with machinery demonstrations and discussion at booths of participating exhibitors. Fundamentals of Medical Device Packaging will be offered through IoPP and cover the basics of packaging regulations, standards, materials, equipment, sterilization, design, qualification, and troubleshooting. It targets professionals with two to three years of industry experience to continue to build, strengthen and sustain their technical expertise in medical device packaging. In this first classroom session, 14 industry professionals have volunteered as instructors in one or more segments of the course.

More partnerships needed Now, about that partnership. This is exactly what the packaging industry needs more of, given the continuing shortage of experienced packaging engineers and related professionals who, with additional training, can be shaped to become tomorrow’s leaders. Creative partnerships can make more of these successes possible and help ease staff shortages. Each of us knows of others in our networks who may be outside of packaging and contemplating a new career direction, or who are mulling a move elsewhere within packaging. These individuals are the low-hanging fruit that could be trained or retrained to ease the staff shortages in our industry. They might be unaware of all the opportunities in packaging, but they do share one thing in common: They want to make a difference in the world. It’s up to us in this industry to build the associations that can help them make those richly rewarding careers possible and keep the knowledge moving forward. PW

The author, Jim George, is the Director of Education at IoPP. For more information on IoPP, visit www.iopp.org.

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Each of the following market-leading companies participating in Packaging World’s 2022 Leaders in Packaging Program are named sponsors of PW ’s Future Leaders in Packaging scholarship. This year’s recipient is Alexandria Technical & Community College, Mechatronics program. We appreciate the support of all participants on behalf of packaging education.

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