Packaging World March 2022

Visit us at MODEX Booth #B8407

MAR2022 packworld.com

28

Absolut Tests FSC-Certified Paper Bottle 13

P&G’s Dawn Flips Bottle on its Head 25

Dove Debuts Concentrated Refill Packs 36

Stretch Blow Molder Keeps Tempo 43

Kao’s Reusable Personal Care Program 46

New Products on Pages

Cannabis Brand Licenses Blister Pack System

42/53 Cover_0322_DigitalEdition.indd 1

2/25/22 5:42 AM

REPACKAGING THE FUTURE SUSTAINABLE. CONNECTED. AUTOMATED.

The supply chains of today and tomorrow require next-gen innovations. As a vertically integrated manufacturer of innovative packaging design to automation solutions, WestRock is committed to helping our customers address their most pressing challenges. We offer a differentiated portfolio of sustainable fiber-based packaging and automation solutions designed to increase your efficiency, optimize your supply chain and lower your total cost.

Join us at MODEX, March 28-31, in Booth #B8407 to learn more.

© 2022 WestRock Company. All rights reserved.

_PW_Ad_PreflightTemplate_UpdatedSpecs.indd 1

2/15/22 9:23 AM

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.

Inquiries +1 (770) 981-5200 connectwithus@syntegon.com www.syntegon.com/food

_PW_Ad_PreflightTemplate_UpdatedSpecs.indd 2

2/11/22 11:29 AM

2 PW MAR2022

VOL29 36

NO3

28

40

Absolut is exploring paper bottles as an alternative to glass, in a partnership with paper bottle company Paboco and a number of major brand owners.

FEATURES 43

28 COVER STORY Pernod Ricard Commits to ‘Circular Making’ Believing that from grain to glass, there can be no conviviality in excess, the spirits giant commits to actions that move it toward a circular system for its packaging, with innovations around brands such as Absolut, Malibu, and Beefeater, among others.

36 New Blow/fill Line for Israel’s Tempo Beverages

46

A new one-way PET line for Israeli beverage producer Tempo Beverages combines a latestgeneration stretch blow molding technology with a new filler.

40 AUTOMATION iCam-Based Linear Pick-andPlace Mechanism Maintains Control of Empty Cartons Transferring empty cartons from a highspeed forming machine into a smart carton identification and loading system helps to maintain control of the lightweight boxes prior to use.

Contents_0322.indd 2

43 New Reusable Packaging Systems Embody the ‘Beautiful Lifestyle’ With its MyKirei personal care brand, Kao Corp. brings to life its ESG strategy, the Kirei Lifestyle Plan, launching two reusable packaging systems, one featuring a counter-worthy, decorative holder and one with an inclusive container design and enchanting dispensing system.

46 Cheeba Chews Tackles New Markets with Swabbing Station Owners at Cheeba Chews noticed that a lot of early packaging solutions offered to the emerging cannabis market—whether machinery, materials, or child-resistance— lacked flexibility or customization, seeking instead to apply existing approaches to a fundamentally new and different market.

So, they took matters into their own hands, improved their process and packaging knowledge, and came up with an equipment solution on their own.

2/24/22 12:30 PM

NEW

VIVO 18.

AS EASY AS THIS Make customers happy with reliable silicone release liners and save up to 30 % on adhesives in packaging production. robatech.com/e-commerce

Untitled-3 1

2/10/22 5:31 AM

4 PW MAR2022

DEPARTMENTS 13

packworld.com VIDEO

COLUMNS

7 22 24 25 50 56

Swabbing System for Trays of Cannabis Taffy

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

Professional Perspective

pwgo.to/7501

NEWS/EVENTS

TAKE FIVE VIDEO

8 News 18 Quotables/By the Numbers 52 Industry Watch

50

Five Disruptive Design Trends

INTERVIEW

20 First Person

pwgo.to/7502

PRODUCTS

42 Automation Technology 53 Technology

FREE DOWNLOAD

Sustainable Packaging How-To Starter Guide

ADVERTISING

26 Leaders in Packaging Product Directory 55 Advertiser Index

pwgo.to/7345

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

VIDEO

Jan Brücklmeier Technical Application Group Packaging Technology Expert, Nestlé

Mike Marcinkowski Global R&D Officer, GPA Global & Hub Folding Box Co.

Craft Brewery Automates Tray Packing

Paul Schaum Chief Operations Officer, Pretzels Inc.

pwgo.to/7503

M. Shawn French Director – Innovation & Packaging Engineering (Beverage), Danone North America Patrick Keenan R&D Packaging Engineer, General Mills/Annie’s Organic Snacks

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:

www.packworld.com/leaders

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.

Contents_0322.indd 4

2/24/22 12:30 PM

BULK BAG DISCHARGING: EQUIPMENT

CLEAN. DESIGN.

BRING SANITARY PERFORMANCE TO HYGIENIC APPLICATIONS.

EQUIPMENT ENGINEERING & CONSTRUCTION ADVANTAGES.

Sanitary design is not disguising a general-purpose unit in stainless steel so it can pose in a hygienic environment. National Bulk Equipment sanitary design systems are engineered-to-application, ensuring confidence in changeovers and compliance.

Designed & Built to Hygienic Area Criteria Fabricated and assembled to prevent liquid pooling and bacteria growth; sanitary design criteria are built-in features, not bolt-on risks.

Engineered to Aid CIP Cleaning Protocols Sealed and enclosed product contact areas are thoroughly cleaned, without disassembly.

CIP integration ensures efficient cleaning.

Tool-less Cleaning & Inspection Access Process-specific design of access points and closures aids cleaning and inspection, improves process and product safety.

E3TM Dust-tight Bag Spout Interface Bag spout is fully enclosed during discharge; 3/4-inch thick clamp plate prevents deflection and dust release.

Upstream, Downstream, and Between From raw material discharging to finished-product packaging, NBE bulk material handling equipment spans the fullstream of processing and packaging applications. Leverage the full portfolio of NBE equipment to bring optimal process performance to your production operation.

Move beyond the constraints of build-to-order and engineered-to-order equipment builders.

Avoid settling for application input that falls short and project and production resources too limited to keep pace. Ensure optimal project performance from pre-RFQ feasibility testing through installation and turnover, with NBE engineered-to-application project delivery.

See for yourself. View product feature demos, watch a test of your material from your computer or mobile device, or request a rep visit. To get started, visit: nbe-inc.com or, call: 616.344.6250

© 2022 NBE Holdings Company

_PW_Ad_PreflightTemplate_UpdatedSpecs.indd 1

2/20/22 6:14 AM

6 PW MAR2022

Follow us on twitter @PackagingWorld

EDITORIAL Matt Reynolds Chief Editor Iris Zavala Managing Editor Anne Marie Mohan Senior Editor @PackagingTrends Natalie Craig Features Editor Jim Chrzan Vice President, Content and Brand Strategy Kim Overstreet Senior Content Strategist, Alignment 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

Packaging World • PMMI Media Group

401 N. Michigan Ave., Suite 1700, Chicago, IL 60611 Phone: 312/222-1010 • Fax: 312/222-1310 E-Mail: info@packworld.com • Web: www.packworld.com

PMMI The Association for Packaging and Processing Technologies 12930 Worldgate Dr., Suite 200, Herndon VA, 20170 Phone: 571/612-3200 • Fax: 703/243-8556 • Web: www.pmmi.org

Staff at PMMI Media Group can be contacted at info@pmmimediagroup.com

Masthead_0322.indd 6

2/24/22 3:14 PM

7

LEAD OFF

Cannabis Packaging Keeps Evolving Last month, PW focused on cannabis packaging, and we had so much content that some spilled over to this month.

When editing so many cannabis packaging articles in such a short time, it’s easy to spot trends. One pre-existing trend that has only gained steam is cannabis brands’ embracing of automation. They’re facing the same labor shortages and demand spikes as any other consumer product, after all. But to get a sense of how sophisticated the cannabis crowd has gotten where machine design and automation are concerned, look no further than the machine shown by Orics Industries at PACK EXPO Las Vegas (pwgo.to/7505). We’ve also covered a Spee-Dee tare gross weighing system for flower by Green Thumb (pwgo.to/7474). And a few interesting automated pre-roll installations have come to our attention, including Paxiom’s Canapa JuanaRoll at 314 Pure Cannabis, and an in-market automated pre-roll machine developed by Accelerant Manufacturing, Cutting Edge Automation, and Eriez. That’s just to name a few. A parallel story is that more OEMs are willing to serve a market that was once considered borderline, indicating the industry’s momentum toward perception as fully legit, with or without Uncle Sam’s say so.

The other packaging story on the street has been that cannabis brands haven’t been keeping pace with their more traditional brand owner peers in the sustainability realm. Common knowledge had said that child-resistant requirements and other hoops designed to make cannabis purchases clandestine and highly secure tended toward overpackaging and use of complex, notso-recyclable materials. “Historically, we’ve been handcuffed by regulation,” says Riley Ruano, marketing director at Oregrown on page 13.

But he also says things have recently changed, and his peers and competitors validate that claim. The market has taken square aim at sustainability, it just has to be creative when some industry hurdles are unavoidable. Oregrown has shifted packaging to as much FSC-certified paperboard as possible, and in its case the paperboard is produced using wind power (both promoted on-pack). Vape specialist STIIIZY (page 9) went the material reduction route, and that’s nothing to sneeze at when you consider the volume. STIIIZY is California’s top selling cannabis pod brand, and one of the nation’s top three sellers. And live-rosin cannabis maker äkta, having told PW about the special cannabis packaging considerations around sustainability (pwgo.to/7506), selected a paper tube package for its vape cartridges and concentrates for its sustainability profile.

What’s new here, why the shift? Like many OEMs before them, packaging materials vendors— who once tried to fit the square cannabis peg into the round hole of previously existing packaging supplies—are specializing in knowing, understanding, and supplying the industry.

So what’s next for cannabis packaging? A January 2022 study (pwgo.to/7507) commissioned by regulatory compliance specialist SICPA North America shows support among cannabis users for more in-depth information about the products they may use. The poll was conducted online by The Harris Poll among 2,056 U.S. adults.

Results reveal that nearly three in five cannabis users (58%) (defined as those who have ever used cannabis products) say they don’t know how to determine which cannabis products are worth consuming and which are not, likely given the myriad of product options in the marketplace. More than four in five cannabis users, or 83%, support requiring cannabis retailers to provide verified certificates to consumers to validate that their products have been legitimately tested for safety and potency. Four in five cannabis users (80%) say it is important to them to have a way to verify the safety of a cannabis product before using it. And almost four in five cannabis users (78%) say it would be important to them to be able to validate whether a cannabis product has ever been recalled prior to making a purchase.

“Cannabis users clearly crave a greater depth of information about the safety of cannabis products, whether they’re using flower, concentrates, edibles, tinctures or topical products,” says Karen Gardner, Chief Marketing Officer at SICPA US. “The desire among consumers for more safety information about the cannabis products they consume aligns with SICPA’s survey last fall that showed a broad appetite for secure, tamper-proof labeling of cannabis products to provide assurance that cannabis products are legitimate and safe.” PW mreynolds@pmmimediagroup.com

LeadOff_0322.indd 7

Brand New

Compact Packaging

BUILT TO PERFORM IN SMALL FOOTPRINTS

Come see the debut of PMI KYOTO’S NEW SYSTEM

2/24/22 3:46 PM

8 PW MAR2022

NEWS

Smaller Cannabis Vape Pod Carton Brings Big Sustainability Benefits “With great power comes great responsibility,” so the saying goes. That’s why when cannabis provider STIIIZY’s cannabis pod was recognized as the best-selling brand in California and the third best-selling brand in the U.S., the company felt compelled to provide its consumers with more eco-conscious packaging.

STIIIZY, a brand of Los Angeles-based cannabis holding company Shryne Group, was “born out of authentic Los Angeles culture and a desire to provide the highest-quality cannabis products at affordable prices.” That’s according to Jackie Kim, STIIIZY’s Director of Integrated Marketing, who adds that the brand name itself is inspired by the term “steez,” style and ease.

“The three ‘I’s represent ‘innovate,’ ‘inspire,’ and ‘influence,’” she adds.

STIIIZY’s pod is part of a proprietary vape system that includes the custom-made pod filled with high-grade cannabis oil and a sleek, proprietary handheld battery into which the pods are inserted for vaping. In late 2019, the company began working on a redesign of the paperboard packaging for the pod that would use less material in order to gain cost and resource efficiencies.

The new packaging was created inhouse by STIIIZY’s large team of in-house designers. Shares Kim, when recreational cannabis took off, the company had a difficult time working with third-party designers and companies, which were not yet familiar with cannabis laws, culture, and compliance. “So we built our own team, and never looked back,” she says.

To set the stage, the existing packaging comprised an outer paperboard carton, with an inner tray, die-cut to hold the pod.

The tray took up two-thirds of the package, on the right side, of the carton, with the left side empty. Each carton was customized, with the variety name included with the logo lockup. An anti-counterfeit authentication sticker appeared on the front of the carton, but only for those products sold in California. The child-resistant mechanism was positioned on the left side of the box.

In creating the new package design, the guiding principle was to use less material. One of the biggest material savings came from right-sizing the carton so that its dimensions are the same as the tray, getting rid of the empty space on the left side of the carton. Another was eliminating a paper-insert user manual—measuring from 2.5 to 3.5 in.—and replacing it with a QR code printed on the left side of the inner tray through which consumers can easily access, by way of a smartphone, user instructions, information on product features, and disclaimers.

“We realized things like this were a total waste of money, material, and production time,” says Kim. “By getting rid of this insert and decreasing the size of our package, we easily reduced our material use by more than 25%.

Another modification made to the package that helped make a smaller carton possible was a change in placement of the child-resistant feature and some of the graphics. As Kim explains, the CR mechanism comprises a round die-cut in the carton that exposes the inner tray. The “button” acts

News_0322.indd 8

as a latch. To get to the product, consumers hold down the button, while pulling a tab at the top of the package, which allows the tray to slide out.

For the new design, the CR feature was moved from the side panel to the back of the carton. In its place, STIIIZY positioned the tamper-evident label, which now also carries batch information. Says Kim, “Before the redesign, our packages featured both a batch and a tamper-evident function. Moving forward, our tamper-evident stickers will pull double duty. Aside from keeping the contents inside each carton safe and secure, the labels will also feature batch information, which is required by state. By combining these two, we really maximized our use of space.”

To enhance its anti-counterfeit measures and ensure consumers they are getting authentic product, STIIIZY also changed its use of the holographic sticker. Instead of being added only to those products sold in California, the sticker will be used on all packaging.

While to the casual observer, the changes in STIIIZY’s packaging may not be that noticeable, given that the graphics remain largely the same, the redesign has had a significant effect all across the STIIIZY supply chain. “In the very early days, we produced packaging in the tens of thousands of units. Today we produce millions of units,” Kim says. “Reducing the amount of packaging we use, whether an insert or a reduction in the overall size of the package, has a tremendous impact on our operations and bottom line. Our products are available in multiple states, and the total savings in aggregate across all of these state lines really adds up. It also takes less time for our teams to package our pods, we’re saving a ton of paper, and we’ve reduced our overall waste impact.”

—Anne Marie Mohan

2/23/22 2:14 PM

DOD_000

Troubleshoot from anywhere with a Dodge expert by your side.

Dodge Virtual Support allows you to connect directly with a Dodge expert, show and describe the issue, and safely collaborate on a solution—all from your laptop, tablet, or smartphone.

de u t r t . co bo po p R Q r e a Su e l o a th n r n m ir t u a Sc lea e V t o o dg D

Expert Advice at Your Fingertips Speak directly with a product subject matter expert Share pictures, files, and audio Draw and point on your screen to show where you’re looking Share a real-time video of the issue or problem area

DOD_000937-PrintAd_PackagingWorld_FINAL.indd 1 News_0322.indd 9

2/9/22 1:22 PM 2/23/22 2:14 PM

10 PW MAR2022

NEWS

Bondi Sands Makes Waves with New Skincare Range Package Bondi Sands self-tan and suncare products are known for their environmentally conscious formulas and packaging. Last November, the Australian brand ventured from sun-specific products into the skincare market and chose Texas-based Quadpack to develop the packaging for its new Everyday Skincare Range.

The challenge during product development, which took 18 months, was to offer innovative and environmentally friendly packaging without compromising the formula and functionality of the product.

“We wanted packaging that sets us apart from other skincare brands while staying true to our brand value, look, and feel,” says Blair James, CEO and co-founder, Bondi Sands. “Quadpack offers innovative packaging solutions and pushes the boundaries in what can be achieved in packaging.”

The range uses PP for rigid bottles and all caps, as well as flexible five-layer tubes with PCR content, depending on the application. Both constructions are 100% recyclable. The decoration techniques used are silk-screen printing and hot stamping. Bondi Sand’s Everyday Skincare product packaging differs from that of similar products because the closure mechanism doesn’t use springs or other non-recyclable elements. This makes it easier to recycle because it doesn’t require customers to pull apart

different packaging elements to discard the products.

“Each of our products is marked with a Mobius loop to identify its recyclability, alongside a ‘Made with Recycled Materials’ icon to educate consumers on our efforts to reuse materials as part of our ongoing sustainable efforts,” James says. “From point of sale to marketing communications, we’ve made it very clear that our entire range has been packaged in fully recyclable packaging that customers can confidently place into the recycling bin once finished.”

Another challenge the brand faced is that suncare and skincare product development follow disparate legal requirements. This means choosing materials that are suitable for both the formula and providing a positive user experience for customers, James says.

“Formulas are important when developing product packaging, where each product formulation can follow different processes to ensure functionality and ease of use,” James says. “For example, serums and sunscreen aerosols may both follow legal requirements to ensure functionality, but the extent of these processes are truly determined on the formulation and best usability experience.”

The five-layer construction of the tube ensures perfect sealability and formula protection so that the product remains in optimal condition, according to Isabelle de Maistre, head of product communications at Quadpack. The PE tube has a central layer

VALCO MELTON THE ULTIMATE ALL-ELECTRIC PACKAGING SOLUTION FOR GLUING & SEALING CASES AND CARTONS FOR THE FOOD & BEVERAGE INDUSTRY.

Adhesive Dispensing & Quality Inspection Systems World HQ: +1.513.874.6550 | ask@valcomelton.com For more information visit: www.valcomelton.com

Precise, programmable dots with the VD2P valve driver

News_0322.indd 10

Valco Melton’s All-Electric EcoStitch Solution reduces adhesive usage from 40-70%

VD2P VALVE DRIVER

MXM ECOSTITCH VALVE

ALL-NEW ECOSTITCH MELTERS

Traditional Pneumatic System

The EcoStitch guns are available in nearly any possible configuration required by your packaging application

All EcoStitch melters are electric and do not require the use of compressed air. The melters use precision gear pumps to deliver adhesive in a constant, reliable and repeatable fashion.

2/23/22 2:24 PM

11

of ethylene vinyl alcohol (EVOH), which acts as a barrier against oxygen, moisture, and migration while extending the shelf life of the product.

“One of our key focuses when developing new products is to consider sustainable materials and practices,” James says. “Our

commitment is to have fully recyclable packaging across all our products and have packaging made from recycled materials by 2025. We worked alongside Quadpack to produce eco-friendly packaging that wouldn’t force consumers to compromise on the effectiveness or experience of their products.”

Being a new category for the brand, Bondi Sands wanted to explore different colors and textures for the packaging that it hadn’t considered for its other products. There are 12 products within the new skincare line, which are divided into five categories that are coded with different shapes and colors so that their target demographic—Gen Z and Millennials— can easily shop the range and tailor products to their existing skin routines, according to James.

“These consumers drive beauty trends across social spaces and look for a skin-deep experience when buying into beauty, preferring to enhance their natural features rather than conceal them.

Knowing how extensive the skincare beauty market is, and how educated our consumers are in the skin space, we wanted to ensure simplicity in range navigation and really thought through each color and shape to segment our products into categories. These shapes and colors bring our creative vision to life, setting us aside from other skincare brands on shelves,” he says. —Natalie Craig

TH E O NLY C A S E F ORM , PACK & S E A L S YS TE M MA DE F OR

E -COMM E R C E

The BEL 5150E is designed from the ground up to work with any e-commerce system so it can adapt to your needs. Integrate with any input device or your ERP/e-commerce system to trigger automatic size changes for quick and ergonomic case forming, packing and sealing. Visit our website to book a free virtual demo today!

do not The s to able

Wexxar@ProMachBuilt.com News_0322.indd 11

|

1.888.565.3219

|

www.Wexxar.com 2/24/22 3:53 PM

12 PW MAR2022

NEWS

Re:Water is First in the Market with a 100% PCR Aluminum Bottle Earning Metal Pack of the Year recognition in the UK Packaging Awards and described by the judges as “a total game changer in the bottled water market,” as well as “one of the most disruptive and innovative products available,” metal packaging supplier Tecnocap’s PURE 100% post-consumer recycled aluminum bottle is understandably finding great commercial success as well.

In May 2021, U.K. brand owner Sauce Connections introduced Re:Water, a refillable bottled spring water product sourced from Herefordshire, U.K.’s Berrington Water, packaged in Tecnocap’s 100% PCR aluminum bottle—which Tecnocap says is a world first for spring water. Under development for three years by Sauce and Berrington, the brand was created to provide consumers with a new, more environmentally friendly way of consuming bottled water.

According to Re:Water Director Matt Crocker, the name of the brand encompasses its mission statement, which is Re:Use, Re:Fill, and Re:Cycle.

“A secondary reason [we chose the name] is it fits in with the email subject line Re:, or regarding,” he adds. “Regarding bottled water, we want to have an honest conversation with our users about the pros and cons of bottled water and how we can all be more environmentally aware and friendly.”

Shares Crocker, the project involved meeting three targets: to make a product that was genuinely environmentally friendly, one consumers would like drinking from, and one that was commercially viable for the full supply chain. Re:Water chose the 100% PCR aluminum bottle because of its low carbon footprint and its ability to be refilled and reused. To top the bottle, it selected a 28-mm aluminum closure that can also be easily recycled across the U.K., with no separation required.

Re:Water was fortunate to find an aluminum bottle with 100% recycled content; until recently, this type of package was not being produced.

Explains Elio Lamberti, Managing Director of Tecnocap Aerosol & Bottles Division, the challenge in the past to creating a bottle from 100% PCR aluminum was that there was not an adequate supply of the material. “Postconsumer recycled aluminum is created by consumers after a product has reached the end of its use, diverted from the landfill, and utilized in the production of other products,” he says. “To realize this packaging solution, we needed a specific supply chain dedicated exclusively to PCR aluminum that was always available. Through a partnership we formed two years ago with some of our top-class European suppliers of aluminum [slugs], we were among the first in Europe to have the availability of this PCR aluminum for our entire range of products. There is also another difficulty in the process. Our aluminum supplier must have a furnace dedicated exclusively to recycled aluminum, which is processed in a different way than standard aluminum.”

Among the benefits listed by Tecnocap of the PURE bottle are that it generates more than 50% fewer CO2 emissions than virgin aluminum bottles; it is sturdy, yet lightweight, weighing 60 g when empty, which the company says further reduces CO2 emissions; it has a thin, BPA-free coating inside that acts as a barrier between the water and the aluminum, but does not affect recyclability; its aluminum cap allows for resealability and easy recycling; and once the consumer has finished the product, they can refill the bottle or dispose of it in standard U.K. recycling systems.

Lamberti confirms that Tecnocap has measured the environmental impacts of the bottle through a Life Cycle Assessment and has certified the results, obtaining a third-party EPD – Environmental Product Declaration.

News_0322.indd 12

He notes, “The bottle is well aligned with the Circular Economy model in that, once produced, it can be used, reused, and recycled to infinity, without any loss of quality, minimizing also the possibility of it becoming waste in the environment.”

The adoption of the bottle did not come without challenges for Re:Water though. Says Croker, “While glass and PET bottles are molded, aluminum bottles are not. This means batches can be different each time, which causes a huge capping challenge. We needed to create and design new machinery from scratch in order to successfully run the product at high speed.”

The aluminum bottle is also more expensive than PET, approximately 90 pence (or approximately US$1.22) across the supply chain. “This cost is passed on [to the consumer],” he explains. “But if you consider the reusable nature of the pack, the consumer is getting both 500 milliliters of spring water as well as a refillable bottle—a strong value proposition.”

And, consumers are refilling the bottle—up to five to 10 times, according to Crocker. “That said, we also have messages from consumers who have used the bottle for months,” he adds. “Most users buy it on the go, refill it at work or the gym for the journey home, and then either continue to use it, or recycle it.”

Re:Water is available in still and sparkling varieties in a 500-mL size, sold at retail and online. Sauce also manufactures the product for other brands in the U.K., such as Itsu, a British chain of East Asian-inspired fastfood shops and restaurants, and a grocery company, Benugo cafes and restaurants, and TGI Fridays restaurants. Notably, it also supplied custom bottles for the COP26 Glasgow Climate Change Conference last fall and for the 2021 G7 Summit in Cornwall in June 2021. —Anne Marie Mohan

2/23/22 2:26 PM

13

P&G’s New Inverted Dawn Bottle Flips Dishwashing on its Head In the realm of new packaging for household cleaning products, reusable packaging and concentrated products for greater sustainability have stolen the show of late. But a new bottle from Procter & Gamble for its Dawn liquid dish soap takes a different approach, tackling the issue of ease-of-use for consumers, including those with disabilities, and giving new meaning to the moniker “frustration-free packaging.” New Dawn EZ-Squeeze comprises an inverted bottle with patented no-flip cap technology that allows the bottle to stand on its “head” and dispense from the bottom with a self-sealing valve that protects against leaks.

According to Corey Brugh, Senior Brand Manager, North America Hand Dish at P&G, the impetus for the design came from what the brand saw consumers doing every day: turning the bottle upside down. “We began iterating from there—knowing we wanted to solve the frustration that comes from trying to get the last drop of soap out, in a bottle that would stay clean and wouldn’t require a cap to flip,” he shares.

Dawn reports that it devoted more than five years, hundreds of designs, and thousands of hours of testing in the development of Dawn EZ-Squeeze, making it one of P&G’s most researched and rigorously tested products in the company’s 50-year history within the dish soap category. According to Brugh, the goal of P&G’s in-house design, packaging, and manufacturing teams was to create something with beautiful, functional aesthetics that would meet consumer needs and that could also be made at scale.

“We are truly consumer-obsessed,” he says, “so our first area of focus was consumer behavior and how we could make the ease of use better and more efficient.” The answer was an inverted bottle with a multi-patented, no-flip, no-mess cap technology that allows consumers to dispense product with one hand and enables them to get every last drop of the Dawn dish liquid out of the bottle.

The proprietary closure is a round, opaque, screw-on cap measuring a bit over 5.5 mm in diameter that acts as a base for the bottle to stand upon. In the center of the cap is the dispensing valve. Before use, consumers remove an adhesive seal over the valve. To dispense the dish soap, consumers squeeze the bottle,

News_0322.indd 13

which causes pressure to build up and results in the valve opening to release product. When the consumer stops squeezing the bottle, the pressure applied to the bottle is released, which results in change in the direction of the flow of product. The dish soap then stops dispensing, and any residual product is sucked back into the bottle, along with air, to reach an equilibrium pressure. This mechanism allows the bottle to return to its original shape, and the valve returns to a closed position without any product being wasted.

During its extensive consumer testing of the bottle, Dawn found that the package’s unique valve design not only delivered a mess-free experience, but the lack of a cap also improved ease of use for populations who have challenges with existing bottle designs since it can be dispensed easily with one hand.

In engineering the bottle, Brugh shares that the P&G team wanted to create a counter-worthy design that would be easy to use. The custom,14.7-oz, clear PET bottle has an oblong shape

with vertical ridges along each side that aid in gripping the bottle and provide consistency with the existing Dawn packaging design. The cap sports a label reading, “No Flip No Mess,” and a How2Recycle icon on the back of the container indicates the bottle can be recycled once the cap is removed.

The new packaging design, which P&G promises will eliminate time spent by the consumer in “shaking, flipping, and banging their dish soap bottle on the countertop in a messy attempt to make the most of every drop,” was launched in midJanuary. With the debut of the new bottle, P&G also introduced an enhanced product formula, updated to help dissolve both everyday grease and tough, cooked-on messes quickly and easily. Says Dawn, when compared with its non-concentrate products, the new Dawn Platinum formula removes 99% of grease and food residues with 4x faster grease-cleaning.

Dawn EZ-Squeeze is now available at mass retailers nationwide in Platinum and Original formulas. —Anne Marie Mohan

2/23/22 2:26 PM

14 PW MAR2022

NEWS

ACTIPH Water Tips Cap to Active Lifestyles, Proposed Regulations As the first alkaline ionized bottled water in Europe, the U.K.’s ACTIPH Water brand differentiates itself among a sea of hydrating competitors with an electrolyteand mineral-rich formula and ionization process that optimizes the water for athletes and active lifestyles. Starting with Shropshire spring water, ACTIPH Water applies a process of purification, ionization, and the addition of electrolytes achieving a pH level of 9.0 or higher.

This optimizes the hydration process for athletes and on-the-go consumers with busy lifestyles; all of whom have a constant need to hydrate, and many of whom don’t get the recommended amount of water in a day.

This active consumer led Jamie Douglas-Hamilton, founder of ACTIPH Water, to consider an often-neglected element of a water bottle: the cap and closure. He selected Aptar’s new Rocket closure as the right one for his application and his athletic and active consumer base.

“ACTIPH Water is unlike any other water available because of

the unique way we produce it and its high alkaline level,” Douglas-Hamilton says. “It made perfect sense to partner with Aptar, who is leading the way in safety standards and sustainable solutions, to offer a sports cap that is cohesive with the ACTIPH brand and promises of an overall premium experience.”

Aptar says that the Rocket closure redefines beverage packaging safety standards by offering a unique, highly visible, and non-detachable tamper evidence system to the market. The sports cap complies with upcoming sustainability regulations, including the Single Use Plastics (SUP) directive proposal in Europe.

In addition to its visible safety, Rocket offers a “no-dust,” double wall lid design that protects the drinking area from external contaminants. A large finger recess and audible closing “click” makes opening and closing Rocket easy and reassuring for consumers. Rocket’s hinge technology offers a wide opening angle, ensuring the elimination of a lid spring-back effect. Furthermore, Rocket was designed to adhere to child safety standards (BSDA).

Wind Energy Powers Sustainable CR Cannabis Packs

A square carton for extracts, and rectangular carton for 510 cartridges, each use soft-touch finish and debossing for a tactile feel (above).

Beneath the cartons (inset) are logos and icons communicating the paperboard is a recyclable material, produced using wind power, with FSC certifications.

News_0322.indd 14

In general, cannabis brands have not been able to venture as deeply into sustainable packaging as their traditional brand-owner peers due to specific industry hurdles. Regulatory requirements select for a robust, secure, child-resistant (CR) package, and state-dependent rules around product leaving dispensaries, package opaqueness, etc., have tended to lean toward overpackaging out of an abundance of caution, and reliance on often multi-material plastics for functional or CR purposes.

But as the industry matures, that’s changing. One example is Oregrown Industries, a vertically integrated Oregon cannabis grower, processer, packager, and brand owner that’s keeping the robustness and CR, but adding sustainable packaging measures in clever ways. The packaging in question here centers around the company’s cannabis extracts and its vape offerings in what are called Pax Era Pods and Oregrown 510 Cartridges.

“Historically, we’ve been handcuffed by regulation,” says Riley Ruano, marketing director at Oregrown. “We’ve recently been in a transitional phase to where we are taking as many of the necessary steps toward sustainability as we can, but there’s only so much you can do—everything has to be either childproof or leave in a childproof exit bag. In the past, that meant a plastic pop-top here, a jar and a pop-top there. There was just so much plastic. More recently, we started transitioning away from that into paper boxes. But then we were still using things like foam and transparent plastic for a window. We’ve steadily taken steps away from all those things to get to where we’re at now.”

2/23/22 2:27 PM

15

SAFE | EFFICIENT | COST-EFFECTIVE VERTICAL MATERIAL HANDLING SOLUTIONS

To meet upcoming sustainability standards, the closure is tethered to the neck of the bottle. This system ensures the closure and bottle remain connected through its lifecycle, and therefore, increases the likelihood of the closure being collected and sent through the recycling stream with the bottle.

“Our goal was to develop a cap that meets consumers’ expectations of safety and drinking experience, while also addressing the increasing demand for companies to offer solutions that include sustainable packaging,” says David Haig, Aptar’s sales director, EMEA. “Partnering with ACTIPH Water to combine the Rocket sports cap with its brand speaks to the innovative nature of both companies, where ACTIPH wants to match the overall consumer experience with the quality of its water.” —Matt Reynolds

VISIT PFLOW INDUSTRIES AT MODEX 2022 - BOOTH B4622 www.pflow.com | 414.352.9000

Where they are now is in fully recyclable paperboard packaging from nearby Colorado packaging materials supplier All Packaging Company.

“Specifically for the PAX Era Pods and the Oregrown 510, they have an off-the-shelf childproof box that we were able to customize,” Ruano says.

“Part of their production is they use wind energy, they use recyclable paperboard, and then we can also opt in to use the FSC paper tracking which essentially certifies that the paperboard is produced responsibly.”

Customization doesn’t extend to changes to the carton’s structure since the structure accomplishes the CR requirement. Customization might jeopardize the integrity of the CR capability. But look, feel, and print are all fair game. Oregrown went with a soft-touch paperboard carton with debossed logos on the side, and an all-black interior and spot UV printing for important info, like social media @s and #s. Consumers can expect both a tactile and visual experience with this packaging.

“All Packaging Company been great to work with. They’re really knowledgeable when it comes to their whole process and what they’re capable of doing,” Ruano concludes. —Matt Reynolds

Cannabis brand, Ätka is another early adopter of what it says is sustainable paperboard packaging that still has CR qualities. Read the full story.

MATERIAL HANDLING SOLUTIONS

News_0322.indd 15

2/23/22 2:28 PM

16 PW MAR2022

NEWS

Iceland Freezes Use of Unnecessary Plastic with Launch of Paper Packaging U.K.-based frozen food company Iceland aims to be the first U.K. supermarket to become plastic neutral by adapting to paper packaging wherever possible and offsetting its remaining plastic footprint by recovering and recycling environmental and nature-bound waste plastic. To achieve this, Iceland partnered with U.K.-based Mondi to reduce the amount of plastic used in its product packaging by 80% and eliminate plastic packaging altogether by the end of 2023.

Iceland replaced its previous plastic packaging with Mondi’s EcoSolutions functional barrier paper across several ranges. The first newly packaged product to hit the shelves in December 2021 was the retailer’s frozen chicken dippers.

The functional barrier paper is made from renewable resources with Mondi managing the paper production and coating in-house, providing a fully integrated solution. The package is also recyclable, and according to Mondi, it’s easy for consumers to recycle the paper packaging in existing waste streams. More than 74% of paper and 83% of paper-based packaging in Europe is recycled, which ensures that this material can be recycled at the end of its life, contributing to a circular economy, according to Falk Paulsen, sales and business development director of Extrusion Solutions, Mondi.

To better inform its customers of how to recycle the new packaging, Iceland leverages On-Pack Recycling Labeling (OPRL). Iceland is a member of the OPRL program, which is an initiative that aims to deliver simple and consistent U.K.-specific recycling messages on the retailer and brand packaging to help consumers reuse and recycle more often and correctly.

“We’ve been bold in our aims to remove plastic,” says Stuart Lendrum, head of packaging, Quality and Food Safety at Iceland. “We were the first U.K. retailer to publish our plastic footprint along with our pledge to ultimately become plastic-free. Mondi’s collaborative EcoSolutions approach meant that our teams worked together to consider all elements of the product manufacturing and delivery journey. We now have a sustainable solution that is efficient to use, protects the products, and meets the expectations of our customers.”

One of the challenges of using paper-based packaging—compared to plastic packaging—in frozen food applications is having the right meXtremeVersaAd.qxp_Layout 1 2/11/22 4:34 PM Page 1

Models available in our

Quick Ship 2-Day program!

chanical strength in combination with easy processability on the filling lines. According to Mondi, frozen food can be very abrasive, which means the package’s mechanical strength, puncture resistance, and tear strength need to be as robust as possible while also ensuring flexibility at high production speeds. In addition, the packaging needs to keep its integrity at both low and elevated temperatures.

“Some products need more specialized solutions to ensure consumers get safe, high-quality food,” says Paulsen. “Mondi’s functional barrier paper uses a wafer-thin coating that provides all the necessary barriers to keep food fresh and can still be recycled.” —Natalie Craig

Xtreme Versatility.

Metal Detectors for every process

Xtreme Metal Detector Advantages • • • •

Liquid Line

Conveyor News_0322.indd 16

Vertical Flow

Best-in-Class Sensitivity Easy Setup and Operation Multi-Language Interface Remote Factory Support

Vertical Fill & Seal

Eriez.com | 814.835.6000 2/23/22 2:29 PM

17

International Delight’s Redesign is the Golden Ticket In January, Danone’s International Delight debuted a new partnership with Warner Bros.

Consumer Products for its new Wonka Whipple Scrumptious Fudgy Caramel Coffee Creamers. Along with this partnership and limited-time flavor, the company unveiled a new package and logo, signaling a redesign that will soon be applied across its product range.

The new International Delight bottles are composed of 100% recyclable and HDPE, the cap is PP, and the label sleeve is PETG, all commonly recyclable materials. On a sustainability note, Olivia Sanchez, vice president of marketing, International Delight, says the company always encourages consumers to recycle properly. At Danone, the company is committed to having 100% of its packaging be reusable, recyclable, or compostable by 2025.

The package design was led by the internal design team at Danone North America. And in true Willy Wonka fashion, International Delight hid 10 coveted golden tickets on bottles of the new limited-edition creamers.

“There was no better time to introduce our new look than with the launch of our new Wonka Whipple Scrumptious Fudgy Caramel Creamer,” Sanchez says.

“Willy Wonka and his confectionery creations are bold and whimsical, so it was easy to incorporate the franchise’s iconic and magical aesthetic on our new product.”

The “golden tickets” were applied to the bottles as stickers and placed in hard-to-find places for consumers to uncover.

“Obstacles come with every design challenge, big or small,” Sanchez says. “For this specific limited-time offering, we wanted to be sure we were mindful of production and the complexity of adding the sticker, while also creating the excitement around finding the golden ticket on our package, just like in the original Willy Wonka movie.”

Delight is using this promotion to offer an advanced look at new packaging with dynamic, flavor-forward photography and a sleek logo upgrade. The new look begins with these Willy Wonka-inspired creamers before it is rolled out across the entire portfolio in 2022.

International Delight leverages yellow as a key color choice for the brand and new package, which Sanchez says allows consumers to always feel connected to Delight.

Furthermore, the yellow lines featured in the new logo are made up of the sun, peaking through the clouds, and a music note to represent that moment of harmony, brightness, and joy that International Delight brings to a coffee drinker’s day, the company says.

“As we looked toward a new design, we want to ensure that we were staying relevant to our current consumers, but also evolving our brand to appeal to the next generation of coffee creamer fans,” Sanchez says. “Millennials and Gen-Zer’s are constantly experimenting with different creamer flavors to get to that perfect cup of coffee. The objective of this redesign was to help modernize the brand while staying true to our core values: joy, flavor obsession, self-expression, and fun. We aimed to create a brand identity system that expresses International Delight’s vision for everyday delight by leading the category with bold flavor and celebration.” —Natalie Craig

News_0322.indd 17

2/23/22 2:30 PM

18 PW MAR2022

BY THE NUMBERS

200

The approximate number of environmental and community groups that demanded the Biden administration stop purchasing plastic bags and other single-use products, in a formal petition filed in February

6%

The approximate CAGR for the global packaging machinery market from 2019 to 2026, according to a report from Transparency Market Research

$30B

Total sales for the legal cannabis market in the U.S. in 2022, as forecast by cannabis market research firm BSDA

28

The number of countries out of a total of 30 studied by McKinsey & Co. that have collection, sorting, and extended producer responsibility (EPR) schemes in place or in development

QuotablesBTN_0322.indd 18

QUOTABLES

“Paper cups can be recycled when there are three elements present: demand from an end market buyer; proper sorting at the material recovery facility (MRF); and public education to recycle cups through residential programs. Increasingly, these factors are coming together to create recovery pathways for paper cups. The new white paper, The State of Paper Cup Recycling, provides an in-depth analysis of where we are and where we are headed.”

–Natha Dempsey, President of the Foodservice Packaging Institute (FPI), in a press release from the association, “New White Paper Examines the State of Paper Cup Recycling”

“Functionality has been the most important driver to innovation in the non-alcoholic beverages market for the past decade, and consumer demand for drinks with added benefits has only increased during the pandemic. The number of adults consuming drinks with functional claims has risen over a year ago, as has the number of benefits consumers are getting from these products. Brands that expand to offer options with benefits that appeal to a wider range of shoppers— especially older adults—will have the best chance of standing out in an increasingly competitive and blurry space.”

–Karen Formanski, Health and Nutrition Analyst for Mintel, in a press release from the company, “Functional beverages see demand increase throughout pandemic”

“We need a treaty that will quickly move us away from unnecessary plastic packaging and support the development of refill and reuse systems on a global scale. Anything less will be a missed opportunity.

In the meantime, there is no reason for big brands, big oil, and policymakers to wait for a treaty to make the right decision—our climate depends on swift action.”

–John Hocevar, Oceans Campaign Director for Greenpeace USA, in a press release from the organization, “Greenpeace calls for a global treaty to include the whole lifecycle of plastics”

“Due to the globalization of [the] food supply and attitude shift towards a healthier lifestyle and environmentally friendly food packaging, there is a need to develop biodegradable, non-toxic and smart/responsive materials to enhance food safety and quality.

Development of scalable synthesis platforms for developing food packaging materials that are composed of nature-derived, biodegradable biopolymers and nature-inspired antimicrobials, coupled with stimuli-triggered approaches will meet the emerging societal needs to reduce food waste and enhance food safety and quality.”

–Philip Demokritou, Adjunct Professor of Environmental Health at Harvard Chan School, as quoted in an article from India Times, “New Smart Packaging Keeps Fruits And Vegetables Fresh For Months By Killing Bacteria”

2/23/22 10:05 AM

_PW_Ad_PreflightTemplate_UpdatedSpecs.indd 1

2/21/22 1:57 PM

20 PW MAR2022

FIRST PERSON

Seal Integrity: A Primer from a Pro A provider of engineered solutions for the food and beverage industry for more than 40 years, Mark Green of Mark Green & Associates shares some thoughts on seal integrity testing.

Packaging World:

What’s the big-picture view of product freshness and the role played by package seal integrity?

Mark Green: Every manufacturer of food product faces the challenge of maintaining stability or “freshness” throughout the shelf life of their product. Significant investments are made in product and process design to maximize this time including producing and maintaining hermetically sealed containers. A failure to achieve package integrity typically results in spoilage and/or reduced product performance over time. For highly sensitive products, the manufacturer is faced with a potential product recall, reduction in brand equity, and lost consumer confidence.

Why not just design quality in, so that there is no need for testing?

I have long been a proponent of designing quality in as opposed to testing it out. The objective is to develop a combination of package components and closing/sealing processes to produce consistently robust packages. Having personally participated in development and validation of multiple types of these package systems, I can attest to countless hours of producing and testing samples to achieve the optimal design. Despite our best efforts in specification development and standard operating procedures, invariably at some point packages will be produced with compromised seals.

Is there any single biggest challenge facing food manufacturers in this area?

The biggest challenge we face in manufacturing is to detect the seal failures in “real time” to allow production to stop and correct the cause before producing a warehouse full of suspect product, or worse, releasing the product for distribution. Obviously, for this to be possible, the leak detection method must be non-destructive. Multiple non-destructive approaches to 100% on-line leak testing exist, but their effectiveness is limited depending on the line speed and cycle

FirstPerson_0322.indd 20

time for the leak testing. For example, a line producing 30 units/min could test 100% of production if the test cycle time is two seconds or less. Doubling the line speed to 60 units/min will cut the test cycle to 1 second or less and so on. With all types of leak testing available there is an inverse relationship between cycle time and size of leak that can be detected. Highly sensitive products generally require testing down to the equivalent of at least a 20-micron hole. The fastest known cycle time available today for this limit of detectability is five seconds. It is possible to install multiple testing units and split the production stream across them, but this is costly and requires a larger footprint.

Presumably there are times when 100% testing is not practical, yes?

Yes, and when that’s the case, a food manufacturer must still be able to develop an effective quality control program for seal integrity. Most manufacturing projects I have worked on ran at line speeds exceeding 200 units per minute, requiring us to utilize a less than 100% testing approach. Generally, the strategy is to test key package quality attributes and leak test from a statistically significant sample of the product stream. Since the package and process variables are unlikely to vary greatly over the relatively short intervals between tests, this strategy has been shown to be effective in minimizing leak integrity issues.

Is there a single best way to proceed when it comes to monitoring package integrity?

The most economical and effective solution is to implement a hybrid approach addressing the packaging components, process, and seal integrity. First, the packaging components must be produced and verified to comply with the specifications verified during the package validation process. A comprehensive quality assurance program to inspect incoming lots of materials should be sufficient to accomplish this.

Second, the process for closing/sealing the package must be verified through continuous monitoring or periodic sampling. On-line continuous process monitoring solutions are available from multiple suppliers for most processes and can usually be justified using labor savings when compared to manual testing, plus they provide immediate feedback when the process is drifting or has exceeded a specified limit. Third, the package seal integrity should be verified using a leak detection method. Depending on the application it may be feasible to utilize two levels of leak detection, gross and micro.

Generally speaking, a gross leak detection system will identify near total failures of the seal system. The most prominent application is foil seals on flexible or semi-rigid containers where squeezing the container will cause the foil to distend. A gross leak detection system will measure the distention, typically at full line speed, and reject the container if it fails pre-determined limits.

What about micro leak detection?

The traditional approaches to micro leak testing are bubble testing using a water bath or dye penetration testing, both of which are timeconsuming manual destructive tests. Depending on the acceptable

2/21/22 2:18 PM

21

quality level selected for the quality control method, the product costs for these methods could easily justify utilizing a non-destructive approach. For example, one of the manufacturing lines we installed required bubble leak testing five containers every 20 minutes. For our 22-hour x six-day work week we tested 99,000 containers over our 50 week work year at a product cost of almost $2.5 million for our $25 product. It wasn’t difficult to justify a non-destructive approach.

I’ve experimented with a few of the popular nondestructive methods and determined the most reliable and easiest to implement was one that measures a change in applied vacuum over time, known in the industry as vacuum decay. The better systems will utilize highly sensitive pressure sensors and advanced algorithms to detect non-tortuous path leaks to an equivalent hole size as small as five microns. Typically the system supplier will produce a test chamber fitted to your container to isolate the seal area for testing to minimize cycle time.

Depending on need, the unit may be supplied with multiple chambers to allow testing several containers simultaneously. It is also possible to install automatic sampling equipment on the line which will place product in the test unit and return it to the product flow post-testing. This is especially useful for lines with minimal staffing and/or in higher cost labor markets.

random sampling from pallets in the warehouse revealed leaking containers exceeding the acceptable quality level. The entire three days of production was put on hold and eventually destroyed. This was a very costly learning lesson for all parties involved and one that still resonates with me today. Whenever product integrity relies on producing and maintaining a hermetically sealed container, I always take the necessary steps to assure success. —Matt Reynolds

Any closing thoughts?

I learned the lesson of seal integrity the hard way.

When launching a new package where some of the materials were difficult to control manufacturing consistency, the quality control in-process checks were inadequate to predict seal integrity. At that time, leak testing was done at the beginning, middle, and end of the batch which was typically a shift. It wasn’t until three days of production were completed that

March 21-23, 2022 Pennsylvania Convention Center Philadelphia, PA USA

YOUR EAST COAST CONNECTION Interested in cutting-edge packaging and processing technology?

PACK EXPO East has the latest innovations in packaging and processing on display for you to see live and in person.

LEARN MORE AT packexpoeast.com

FirstPerson_0322.indd 21

2/21/22 2:19 PM

22 PW MAR2022

THE LEGAL SIDE

By Eric F. Greenberg, Attorney-at-law

Changing Landscape Changes are afoot in the world of food contact packaging regulation. That is not always the case, but it’s clear that 2022 will bring some changes and controversies. For one thing, the Food and Drug Administration is being pressed to again reconsider bisphenol A in packaging and other food contact materials.

For another, FDA has proposed a change to its process for wiping out existing clearances for food contact substances.

Yes, BPA is back in the headlines because, after years of squabbles over whether the typical exposures to it are harmful and might have endocrine-disrupting effects—which in turn led to scary publicity, then bans and restrictions on various uses—there’s now been an important recent development that is bound to keep BPA on a front burner of controversy, regardless of its outcome.

A collection of advocacy groups has petitioned FDA, asking the agency to withdraw remaining approvals of BPA for use in adhesives and coatings, based on recent findings of the European Food Safety Authority that the level of safe exposure “is more than 5,000 times below what FDA says most Americans are safely exposed to,” writes the Environmental Defense Fund, one of the petitioning groups.

They also say, “Findings from EFSA’s expert panel show that BPA’s effects are much worse than previously understood and that people are exposed at levels dramatically above what is safe. Extremely low exposures to BPA can lead to an overactive immune system producing out of control inflammation, as well as changes in the ovaries, endocrine disruption, and reduced learning and memory, according to the EFSA panel.”

Well, a not unreasonable first reaction here is how surprising it is that such a repeatedly and closely studied substance might now be the subject of a bombshell finding that is so dramatically different in scale than prior findings, even prior findings of EFSA. It will be up to FDA to look at the information presented in the petition, and at EFSA’s work, and decide whether it agrees that it’s well-founded, and then take action accordingly.

As for that proposed FDA regulation change, it’s one of those seemingly obscure bureaucratic steps whose motivation isn’t initially obvious, but which could, if finalized, make for more removals from FDA’s clearances of food contact substances.

Clearances of food additives can be based on one of several bases, including a Food Contact Notification, a food additive regulation, a threshold of regulation exemption, or a finding that the use is Generally Recognized As Safe.

The foundation of any clearance is a conclusion that the intended use is safe, that is, that there’s a reasonable certainty that no harm will result from the use, taking into consideration an estimate of the amount of the substance that will get into the average American’s diet.

It stands to reason that if, later, new information indicates the use of the substance is not safe after all, that the clearance should be reconsidered, and perhaps rescinded. And in fact, FDA has long had a regulation that says, in the case of food contact substances that are cleared via a Food Contact Notification, that if data or information comes to its attention that indicates an intended use is “no longer safe,” it can declare the FCN no longer effective. The regulation says that after FDA makes this determination, they need to give the affected manufacturer or supplier a chance to dispute the new information. (FDA has separate regulations that allow for safety-based reconsideration of food additive clearances that are via regulations and of conclusions that a use is Generally Recognized As Safe.)

The new proposed regulation would change this process in a few ways. First, it would give the affected companies a chance to make their case before FDA decides the FCN should no longer be effective, not afterwards as under the current regulation.

Second, it expands the reasons FDA could decide an FCN should no longer be effective. It would add “instances in which the production, supply or use of the food contact substance for its intended use has ceased or will cease,” or if the use of the substance is otherwise cleared under a food additive regulation or is covered by a threshold of regulation exemption. The proposal also would make changes about the confidentiality of information.

Why would FDA propose doing such things? If the current regulation didn’t allow FDA to withdraw a clearance based on new safety concerns, you could understand their wanting to add that power. But safety concerns were already in the regulation, and in fact right now, that is the only reason FDA can reconsider a clearance.

A clue could be found within FDA’s recent experience with PFAS, where FDA got “voluntary commitment letters from certain manufacturers” whose uses of PFAS were based on cleared FCNs that they’d stop using the substances in the U.S. [H]owever,” FDA noted, “these FCNs remain effective.” So now, FDA proposes allowing companies who have stopped or will stop using a food contact substance to not just notify FDA, but to ask FDA to declare the FCN no longer effective so FDA can remove the clearance from its books.

In sum, FDA’s proposal would give companies a chance to make their case before FDA makes a final decision on removing a food contact substance clearance, and would also give the agency more grounds for removing clearances from its books. It all adds up to a little more fairness for companies, but the prospect for more removed clearances.

Predictions have gotten some columnists into embarrassing situations now and then, but, lesson unlearned, I hereby predict the coming year will see important changes in the regulatory realm for food packaging substances, including but not limited to the above examples. PW

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

INFORMATIONAL ONLY, NOT LEGAL ADVICE.

LegalSide_0322.indd 22

2/21/22 1:58 PM

Our 3D vision, vis soft grasping and a artificial intelligence solutions are solving the most pressing challenges in the food processing industry— one pick at a time.

Contact us to see where we can help. www.softrob www.softroboticsinc.com o o Solutions@softroboticsinc.com Solutions@s Sol ions@

_PW_Ad_PreflightTemplate_UpdatedSpecs.indd 1

2/21/22 10:52 AM

24 PW MAR2022

THE BIG PICTURE

By Sterling Anthony, CPP, Contributing Editor

Pallet Management for Recycling: Part Two

Read Part One of Sterling Anthony’s series on pallet management.

Next comes the sorting, typically performed There is an untold number of pallet users by size and condition. The recycler should be whose supply chains are suited to white meticulous regarding defects like split boards, pallets. In the U.S., there are close to 2-billion white pallets in service. bark, rot, and mold. Unusable components can They enable the efficient handling, transportation, and storage of be repurposed through grinding or chipping, to goods and commodities. Workhorses that they are, they get damaged, make sawdust, ground cover, and the like. sometimes beyond being fit for their designed purpose. Recycling Disassembly should be performed under the objective of exacting diverts them away from landfills and incinerators, a valued service minimum damage to the components. Pallets, after all, were not in these sustainability-conscious times. In addition to benefits to the assembled to make disassembly easy, but to make them sturdy. environment, white pallet recycling benefits costs and efficiencies. To Misapplied brute force during disassembly can compromise the fitness reap them, however, white pallet recycling should be a component of of the components for incorporation into recycled pallets. pallet management.

Repairing is done in accordance with the received condition of All pallet recycling involves collecting, sorting, disassembling, and the pallet. It can be as simple as replacing deck boards or stringers repairing. There are major differences, however, between how they with like components obtained from other are performed by owners of pallet pools pallets. The result is a recycled pallet in the vs. how they are performed by white pallet All pallet recycling truest sense. This is the least expensive type suppliers. One difference is that pallet pools involves collecting, sorting, since it embodies fewer resources and less are national, centralized operations, whereas white pallet recycling is decentralized on disassembling, and repairing. time. Sometimes, however, a repaired pallet embodies one or more virgin components, a regional or local basis. Another is that There are major differences, making it a hybrid. It is more expensive than recycled pool pallets remain the property of the pool operators, whereas recycled white however, between how they a pallet having all pre-used components, but less expensive than a new pallet. pallets are resold. are performed by owners of stillTerms-of-delivery are important differAlthough recycled whites provide an pallet pools vs. how they are entiators among suppliers of recycled white opportunity for cost savings (vis-à-vis new pallets. If pallets have to be assembled per pallets), it should not be at the sacrifice performed by white order, there is a waiting period. In contrast, of consistent quality. Quality should be pallet suppliers. if the supplier maintains an inventory of the regarded as application-specific; meaning, requested pallets, they can be delivered sans the pallet is equal to the conditions imposed waiting, and the buyer receives the benefits of just-in-time (JIT). upon it. When savings and quality are combined, the result is a pallet The preceding discussions underscore the fact that recycled white that does the job, at the lowest price. Price, on the other hand, is pallets are not indistinguishable commodities. Even given a specified relative to other factors, such as the supplier’s reputation, customer size, such as 48 in. x 40 in., pallets differ meaningfully. One such service, etc. distinction is the number of deck boards, determining spacing and The purchase of recycled white pallets should be governed gaps, that affect load stability, especially involving corrugated boxes. by policy and procedures. That’s true of the evaluation of pallet Another is lumber surfaces, with some being more roughly sawed, suppliers. Those suppliers typically are located close to where white meaning more likely to give off splinters, a hazard to the load and to pallets accumulate: areas marked by manufacturing/processing, manual handlers. Yet another is lumber species, whether hardwood distribution centers, and other industrial activities. The proximity or soft wood. Hardwood has greater nail-holding capabilities but is affords the buyer with the opportunity to evaluate suppliers through more prone to splitting. One more is nail placement, in two regards. facility visits. To make such outings worthwhile, evaluations should be First, it should not be so close to an edge as to compromise holding performed on a systematic flow basis. capability or induce splitting. Also, it should not go into a hole from It starts with the supplier’s sourcing. Within the white pallet a previous assembly. A final one—although not completing an recycling industry, clients that buy recycled whites often are sources exhaustive list—is the precision of the cuts. The more automated the for the empty pallets (called cores) used for the recycling. An issue for process, the more tightly dimensional tolerances can be held. negotiation, therefore, is whether a recycler hauls away the pallets for In next month’s third and last installment, the subject will be the free or for a fee. Another source of empties is independent salvagers, roles played by non-wood pallets. PW who collect them and then sell them to the recyclers.

BigPicture_0322.indd 24

2/23/22 1:21 PM

VDG Drum Motors

Safe, Efficient & Reliable Conveyor Drive Solution.

The VDG Drum Motor with all drive components enclosed inside the drum is a safer, more efficient and space saving conveyor drive solution, reducing maintenance, operating and energy costs. Available in a range of diameter sizes, belt speeds, horsepower, face widths, and industry specific options to suit various belt conveyor applications.

Visit us at

Booth #B1413

Learn more at: vandergraaf.com/PW

Opportunities Available: Sales Personnel • Sales Representatives • Resellers Apply at: vandergraaf.com/jobs • (888) 326-1476

_PW_Ad_PreflightTemplate_UpdatedSpecs.indd 2

2/4/22 11:06 AM

VDG Drum Motors

Safe, Efficient & Reliable Conveyor Drive Solution.

The VDG Drum Motor is a robust and reliable conveyor drive with all drive components enclosed inside the drum and designed for 80,000 hours of service life before maintenance; reducing maintenance costs, downtime, and increasing production.

IronGrip™ Lagging

The all-316 stainless steel SSV Drum Motor is the most hygienic and efficient conveyor belt drive solution. With the belt profile machined directly onto the drum, it drives modular, wire mesh, and monolithic thermoplastic conveyor belts without the use of sprockets.

Visit us at

Booth #B1413 Learn more at: vandergraaf.com/PW Opportunities Available: Sales Personnel • Sales Representatives • Resellers Apply at: vandergraaf.com/jobs • (888) 326-1476

_PW_Ad_PreflightTemplate_UpdatedSpecs.indd 1

2/4/22 11:07 AM

25

SUSTAINABLE PACKAGING

By Anne Marie Mohan, Senior Editor

Dove Debuts Reusable Body Wash Packaging System In January 2021, Unilever’s Dove deodorant brand redefined reusable retail packaging, creating a sleek and sophisticated design-forward system with a refillable stainless-steel deodorant case and compact refills (see pwgo.to/7284). With its new Dove Reusable Body Wash Bottles + Concentrate Refills, the brand has taken a page from the household cleaning category by offering concentrated product refills paired with two “too beautiful to throw away” reusable bottles.

According to a Dove spokesperson, the brand currently has more than 100 different projects running across the world looking at every facet of its packaging, across the three dimensions of no/better/less plastic. “We know that reusables are of huge interest to consumers,” the spokesperson says, “and as industry leaders, it’s our responsibility to drive innovations that incentivize purchase behaviors with products that enable people to consume more consciously.”

The body wash system, which was launched in January 2022, is available in a starter kit that comes with a reusable 16-oz bottle, made from either aluminum or 100% recycled high-density polyethylene, depending on consumer preference, with a reusable plastic dispensing pump. Dove says it created the two bottle choices to help meet consumer preferences regarding price and material. “For those who would prefer to purchase the least amount of plastic, the aluminum bottle is available at a higher price point,” a brand spokesperson explains. “Alternately, the recycled plastic bottle is available at a lower price point than the aluminum bottle.”

Also in the starter kit is a 4-oz HDPE bottle of concentrated product in one of three varieties—Daily Moisture, Shea & Warm Vanilla, or Cucumber—fitted with a proprietary Quick Disconnect Cap that allows for mess-free filling of the reusable bottle. Says Dove, “The innovative technology allows the cap to easily connect and seamlessly release the concentrated formulation without pouring. The cap was designed originally by our Homecare division and is used on brands like CIF [household cleaning products] globally.”

To use the concentrate refills, the consumer begins by twisting both the refill and the cap onto the neck of the reusable bottle until they hear a “click.” This indicates the refill is now open and ready to dispense by simply squeezing the refill contents into the bottle. A view

SP_0322.indd 25

strip on the refill indicates when the bottle is empty, for complete evacuation of the concentrate. Next, the consumer fills the bottle with water and shakes the contents to mix. The aluminum container incorporates a groove to indicate the fill line, while the plastic bottle has a view strip.

Partnering with Dove, international design agency JDO was tasked with designing the reusable bottles as well as the concentrate refills and starter kits. According to the agency, the creative solution needed to embrace Dove’s iconic design principles while also conveying the innovative sustainable proposition in a clear and compelling way.

For the reusable bottles, JDO shares that it developed an elegantly modern illustration with botanical imagery to adorn the packages.

“Layered green fronds against the silver of the premium aluminum bottle give off a spa-like quality,” the agency says. “The final touch is a Dove icon in gold with the instructions, ‘Refill, Reuse, Repeat,’ an understated accent that keeps the design simple, sophisticated, and absolutely stunning.”

Comments Bronwen Westrip, Creative Director at JDO, “This innovation is so easy to use, and Dove products are so renowned for their quality that there was no need to over-clutter the bottles or the concentrate refills with too much information. This allowed us to really focus on creating a clean aesthetic that appealed to the consumer desire for more sustainable solutions as well as their desire for beautiful products. Our hope is to inspire them to use Dove’s new Body Wash Reusable Bottle & Concentrate Refills for a new personal care routine that looks good in the bathroom, feels good on the skin, and does good for the planet over time.”

The refillable/reusable system, with the aluminum bottle, is said to reduce plastic by 50% after two refills versus Dove’s standard plastic bottle. The HDPE bottle reduces plastic by 50% after four refills. In addition, the system results in 80% less water shipped per refill and 21% fewer greenhouse gas emissions from manufacturing over a year. The bottles were manufactured to be durable, and as part of Dove’s consumer promise of “buy once, refill for life,” the packages carry a lifetime guarantee. Says Dove, “We’re proud that consumers have a new, reusable option for both products without having to compromise on the product experience they expect from Dove.”

Now available at retail, the starter kit with aluminum bottle is $14.99; the kit with plastic bottle is $9.99. Refills sold individually are $6.49 apiece. PW

2/23/22 10:05 AM

Palletizing & Load Stabilization The following companies are leading suppliers of palletizing/depalletizing, and protective/transport packaging equipment. To see all product categories, please visit Packworld.com/leaders.

Palletizing/dePalletizing

Palletizing/dePalletizing

Palletizers for cases, trays, multipacks, crates, and bags

Best in class Palletizers & Depalletizers

Our compact, floor level palletizers deliver top reliability and reduce your operating costs.

Exclusive features form square pallet loads for efficient transport, and easy pallet configuration at the HMI ensures total flexibility.

Our team of experienced engineers design and build the best depalletizers and palletizers on the market. Our equipment delivers years of low maintenance and trouble-free performance, while providing the flexibility to adapt to changing demands.

Palletizing/dePalletizing

Palletizing/dePalletizing

Robotic Palletizing Bags, Bundles, Cases, Bulk Containers & More

Mid-Speed Case Palletizing

Brenton’s palletizing portfolio features solutions designed to optimize functionality and efficiency within space constraints and application requirements. End of arm tooling is selected or custom designed to fit the application.

Palletizing/dePalletizing

Maximus, our newly developed mid-speed case palletizer, meets several growing demands including state-of-the-art operator interface, compact footprint, and a vertical start-up feature....but what makes Maximus stand out is that it is 100% electric!

Palletizing/dePalletizing

Fully automatic inline palletizer

Integration Driving Productivity The HL9200 is our most advanced and highest speed palletizer. Its flexibility starts with the easy to operate Product Manager HMI where the customer can create new patterns or modify existing patterns.

Columbia/Okura LLC was an early leader, best known for our robotic bag palletizing expertise. Our experiences and capabilities have grown substantially in the last 25 years leading us into integrating over a 1,000 palletizing solutions across the globe.

Palletizing/dePalletizing

Palletizing/dePalletizing

Automatic depalletizer for full-height pallets

Scalable, integrated solutions optimizing fulfillment processes

The GR-X automatic depalletizer unloads full-height pallets of empty plastic containers, aluminum cans, and glass bottles/jars.

Discharge conveyors, decline conveyors, roller/chain conveyors, and other options are available. Learn more at grxmfg.com

LIP_Mini_PalletizingProtectiveBulk_0322.indd 26

Honeywell Intelligrated designs, manufactures, integrates and installs material handling automation solutions, incl. conveyor, sortation, palletizers, robotics, AS/RS and picking technologies — all managed by advanced machine controls and software.

2/18/22 3:14 PM

P

’S

NG WO RL AGI D CK A

Future leaders IN PACKAGING SC

H O L A R S HIP

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.

Palletizing/dePalletizing

Palletizing/dePalletizing

KPAL Series of Robotic Palletizers and Depalletizers

Heavy Duty Collaborative Palletizer

Kaufman Engineered Systems industryleading KPal series of robotic palletizers offers maximum flexibility to meet your company’s needs. Our palletizers will accommodate a wide variety of product formats including cases, trays, bundles, bags and containers.

Description: The PalletizHD is a fully collaborative, robotic palletizer that can be added to packaging lines in under an hour with no programming required!

Palletizing/dePalletizing

Palletizing/dePalletizing

Palletizing Solutions with Easy-to-Use OptiStak Software

545 Turner Dr. Ste. A, Durango, Colorado, 81301

Our palletizers incorporate FANUC robotics and are designed to be unique and flexible to meet your facility and production requirements. Our solutions adapt to layout requirements, increase safety, and efficiency.

Palletizing/dePalletizing

Ska Fab has provided over 1,000 businesses with depalletizers and other packaging line equipment in all 50 states, 7 provinces, and 23 countries. Ska Fab serves many markets to include coffee, tea, kombucha, water, orange juice, spice containers, and many others.

Protective/transPort Packaging

The #1 Selling Line of Palletizers in America • • • • • •

Integrated Stretch Wrapping All Product Types Both Conventional and Robotic Rates to 5 Layers per Minute Upper and Floor Level Infeed Smallest Full-featured Footprint

Airguard Packaging Protection by Design Airguard Packaging is the Designer and Manufacturer of a highly Innovative and Automated 3D Air Cushion Solution aimed at protecting a wide range of products during shipping & handling.

Protective/transPort Packaging

Protective/transPort Packaging

We help people make a material difference every day.

Complete Solutions for your End-of-Line Transit Journey

Jadex™ is driven to provide packaging and transport solutions that protect the health of our consumers and the environment.

LIP_Mini_PalletizingProtectiveBulk_0322.indd 27

Signode is a leading manufacturer of a broad spectrum of transit packaging consumables, tools, software, and equipment that optimize end-of-line packaging operations and protect products in transit.

2/18/22 3:15 PM

28 PW MAR2022

SUSTAINABLE PACKAGING

Pernod Ricard Commits to ‘Circular Making’ Believing that from grain to glass, there can be no conviviality in excess, the spirits giant commits to actions that move it toward a circular system for its packaging, with innovations around brands such as Absolut, Malibu, and Beefeater, among others.

WHAT YOU’LL LEARN

Circular packaging

Recycled glass

Glass to PET

Increased recycling

By Anne Marie Mohan, Senior Editor When it comes to partaking of its products, Francebased Pernod Ricard—the second-largest wine and spirits brand in the world—suggests consumers share with joyfulness, but without overindulgence.

They espouse convivialité without excess.

In fact, this philosophy guides all aspects of the company’s business. Says Pernod Ricard—whose tagline reads “Créateurs de Convivialité,” or Creators of Conviviality—“We believe that there can be no convivialité in excess and strive to be sustainable and responsible at every step, from grain to glass.”

That’s no small task for a company of its size and structure. Pernod Ricard, with 94 production sites in 24 countries, is a decentralized group that comprises a global flagship in France, autonomous affiliates, brand companies, and market companies throughout the world. Its portfolio includes more than 240 brands of premium wine and spirits distributed in 160 countries. Among some of its most well-known brands are Absolut Vodka, Beefeater London gin, Chivas Regal Scotch whisky, Jameson Irish Whiskey, Malibu rum, Martell cognac, and Mumm champagne.

In spring 2019, Pernod Ricard launched its 2030 Good Times from a Good Place: Sustainability & Responsibility (S&R) roadmap to address some of the biggest sustainability issues facing its business, its The Absolut Company achieved the goal of 50% recycled content in its iconic clear consumers, and the world. The overarching commit- glass Absolut Vodka bottle four years ahead of schedule. ment expressed by Pernod Ricard in the roadmap is related to this pillar deal with circular packaging design, single-use plasto reduce the overall intensity of its carbon footprint by 50% by 2030 tics, recycled content, and a transition to recyclable, compostable, and and reach net-zero by 2050, in line with the Science Based Targets inireusable packaging, among others. Since the launch of the roadmap, tiative (SBTi). Thirty-seven percent of the company’s footprint can be Pernod Ricard has made several notable sustainability improvements attributed to packaging. to some of its most popular brands to help meet the goals outlined unThe S&R roadmap is broken down into four key pillars that altogethder the Circular Making pillar and to contribute to its carbon emissions er set out 30 ambitious and concrete goals and targets for 2030. Guiding reduction commitment. its strategy around packaging is the Circular Making pillar. The goals

PernodRicard.indd 28

2/23/22 12:00 PM

29

Circular Making guides packaging improvements The concept of sustainability is not a new one for Pernod Ricard. As Chief Sustainability Officer Vanessa Wright shares, across all its brands and affiliates, Pernod Ricard has a strong legacy linked to sustainability.

“Our company founder, Paul Ricard, established the Paul Ricard Oceanographic Institute more than 50 years ago to advance ocean conservation.”

“Packaging is obviously hugely important to us,” Wright continues.

“We’re a consumer-centric business; packaging is the point of contact with our consumer. We know that our consumers, among other things like transparency and provenance, want to make sure they can have an impact on reducing waste. So, that’s the mindset we adopt from the very beginning, from how we make a product, right through every step of our production, and then to considering what happens to the product at end-of-life.”

Under its Circular Making pillar, Pernod Ricard is working on packaging and promotional materials, both with associated commitments. In 2021, Pernod Ricard banned all promotional items made from single-use plastic, for example, festival cups, tasting cups, plastic bags, and balloons, and by 2025, it will be using 100% reusable, recyclable, or compostable promotional materials.

Pernod Ricard is also committed to reducing the environmental impacts of its packaging and the waste it generates throughout each step of the production chain to the consumer. Through its S&R roadmap, it has set the following goals: 100% of its packaging will be recyclable, compostable, or reusable by 2025; it will pilot five new circular ways of distributing wine and spirits by 2030; and it will help increase recycling rates in the top 10 largest markets it serves that have low recycling rates by 2030.

One of the actions attached to these commitments is the adoption of eco-design principles to reduce the impact for all new product developments. In November 2019, Pernod Ricard launched new Sustainable Packaging Guidelines supported by a web-based assessment tool for all of its brands that contain detailed and exact information on what materials they can use, which ones to replace, and what they can be replaced with. Says Noémie Bauer, Sustainable Business Director for Pernod Ricard, “We want to change the mindset of our designers to make sure when they design new packaging that they use a lifecycle approach and optimize as much as possible.”

Other actions related to this goal include ensuring that 100% of the cardboard it uses by 2025 is certified as sustainable; using 50% recycled glass content by 2025; and increasing the recycled content of its PET bottles to 25% by 2030.

While these targets are certainly ambitious, Pernod Ricard is starting from a very enviable position.

Given that the bulk of its packaging is glass, which is infinitely recyclable, at 90%, followed by PET and then paperboard, 99% of its packaging is already recyclable.

Sustainability improvements in these areas include

lightweighting, increased use of recycled content, and removing plastic from its labels, caps, and secondary packaging.

But eliminating that 1% of packaging that isn’t recyclable is still “quite a challenge,” says Wright. These packages include the porcelain flacons used for whisky bottles in Asia, miniature and opaque PET plastic bottles, closures for PET bottles, gift boxes, and multilayer pouches, among others.

PALLETIZING SOLUTIONS

Simple. By Design.

® ®

Wrap

Integrated stretch wrapping saves floor space and end-of-line costs.

Safe

Demo

Controlled Entry ISO 13849-1 achieves safety standard category 3 PL-d.

Personal interactive Zoom demos are continuously available daily.

TopTier is the #1 selling line of palletizers in North America.

PACK EXPO International — October 23-26 — Chicago salesteam@toptier.com

www.toptier.com

(503) 217-6457

A ROBOPAC Company PernodRicard.indd 29

2/23/22 12:01 PM

30 PW MAR2022

Absolut success in recycled-glass content Glass is 100% recyclable and can be recycled endlessly without loss in quality or purity. That’s according to the Glass Packaging Institute (GPI). But being recyclable doesn’t always translate to high recycling rates by consumers. That’s the issue Pernod Ricard continues to face when attempting to increase the percentage of recycled content in its bottles, especially in countries where recycling rates are low. Says Bauer,

PernodRicard.indd 30

“When you want to add recycled content to clear glass, you have to have cullet [recycled, broken glass or waste glass] of good quality. In some markets, like the U.S., there’s not enough good recycled glass. Because the bottle manufacturers don’t have enough high-quality recycled cullet to put in the new glass, they use virgin materials.

“In other countries, like France and other places in Europe, we have much more recycled material. For the green glass bottles, sometimes we can reach 100% recycled content. For example, for the [green] champagne bottle, we’re using up to 85% recycled content because there is quite a lot of cullet available in these markets.”

In February 2021, Pernod Ricard celebrated a milestone when The Absolut Company achieved the goal of 50% recycled content in its iconic clear glass Absolut Vodka bottle four years ahead of schedule. In Sweden, where Absolut is produced, the glass recycling rate is exceptional, at well over 90%. Explains Tina Robertsson, Director Sustainable Performance for Absolut Vodka, “The availability of good quality PCR cullet from Swedish glass recycling company SGÅ [Svensk Glasåtervinning AB] in combination with the high competence of the Ardagh [glass supplier] glassworks in Limmared [Sweden] and a step-by-step process that allowed for continuous quality enabled us to achieve the high recycled content while maintaining the clarity of the glass.”

Robertsson adds that for every ton of PCR cullet used, Pernod Ricard eliminates the use of one to two tons of virgin glass. “With more than 50% of PCR cullet, we are decreasing the total use of virgin materials by a substantial number annually.”

Absolut’s work with Ardagh is also helping Pernod Ricard move toward its overarching goal of reducing the overall intensity of its carbon footprint by 50% by 2030 and reaching net-zero by 2050. “We have a close and long-term collaboration with Ardagh,” explains Anna Schreil, VP, Operations at The Absolut Company.

“Through weight reductions, increased use of recycled glass, and other measures, we have reduced CO2 emissions from glass production by 10% in only five years and continue to work toward improving this even further.”

Important to note, Absolut is also exploring paper bottles as an alternative to glass, an initiative it is working on with Paboco, a joint venture between paper packaging material developer BillerudKorsnäs and bottle manufacturer Alpla, and with brand partners Carlsberg, L’Oréal, Procter & Gamble, and The Coca-Cola Company.

Says Louise Werner, Program Manager Future of Packaging at The Absolut Company, “The paper bottle initiative is a step-by-step journey to reduce and replace the need for polymers. In the long term, the paper bottle will become completely bio-based and biodegradable and, if successful, is something that we hope will spark a real movement for change—not just limited to the products within our own portfolio, but extending to all brands within the spirits industry.”

S

BPA prod and cont load mac in-fe ther

W

End ind bag 2/23/22 12:04 PM

31

In the initial stages of the paper bottle project, Absolut developed a first-generation prototype that consists of biodegradable Forest Stewardship Council (FSC)-certified paper with a barrier of recycled plastic.

The two materials can easily be separated from each other and recycled separately, where facilities are available.

Investing in recycling is critical to advance goals

Absolut is exploring paper bottles as an alternative to glass, in a partnership with paper bottle company Paboco and a number of major brand owners.

Pernod Ricard has also committed to identifying the top 10 largest markets it serves that have low glass recycling rates and help increase those rates by 2030.

“We were one of the first companies to be part of Citeo, which is a recycling company created in France in the 1990s within the Extended Producer Responsibility (EPR) framework for household packaging and paper. With it, we’ve reached an 86% recycling rate” says Wright. “Basically, this concept has been spread all over Europe, where we have high recycling rates, thanks to this system.”

In another initiative, this one in Brazil, Pernod Ricard joined the government-supported Glass is Good Initiative, which engages the entire supply chain to increase glass recycling rates. In the U.S., it has strong relationships with groups that include the Closed Loop Fund, the Glass Recycling Coalition, and Keep America Beautiful, among others.

In November 2021, The Absolut Company’s rum brand Malibu announced a year-long collaboration with the social enterprise Plastic Bank to help stop ocean-bound plastic in the Philippines—the world’s third-largest contributor to ocean plastic—while improving the lives of

Scan for Video Pack East Booth 1413

BPA packs all types of products into cases and various secondary containers including loading into your hffs machines, wrapper chain in-feeds and indexing thermoform machines.

We Ask. We Listen. We Partner.

Vision Guided Robotics | Secondary Packaging | Turnkey Packaging Solutions

The Blueprint Way End of line packaging solutions for the consumer goods industry including, wrapper and tray loading, case packing, bag in bag multipacks, shelf ready solutions and more!

PernodRicard.indd 31

blueprintautomation.com

2/23/22 12:04 PM

32 PW MAR2022

Gin and champagne brands innovate

The Absolut Company’s rum brand Malibu has partnered with social enterprise Plastic Bank in a year-long collaboration to help stop ocean-bound plastic in the Philippines. the local collectors and communities where Malibu sources most of its coconuts. The initiative offers a trio of benefits: It helps stem the tide of plastic pollution to the ocean, it supports local communities, and it makes more plastic available for recycling.

The collaboration between Malibu and Plastic Bank is expected to prevent approximately 100 metric tons, or nearly 110 U.S. tons, of plastic—the equivalent of 5 million single-use plastic bottles—from entering the ocean within the next year in the Philippines.

Other recent eco-conscious packaging changes by Pernod Ricard brands include those made by Beefeater London Dry Gin and Maison Perrier-Jouët champagne.

In the case of Beefeater, the brand replaced the glass bottle’s plastic closure with a premium, embossed aluminum cap, switched from a plastic label to one made from paper, and eliminated all PET bottles, replacing them with infinitely recyclable glass.

Explains Murielle Dessenis, Global Brand Director for Beefeater, “It’s our aim to reduce the amount of plastic in our packaging as much as possible. That’s why we have stopped using PET bottles for any Beefeater, while using label paper made entirely of natural fibers sourced from FSC-certified forests.” These changes have allowed the brand to reduce the amount of

For its Beefeater London Dry Gin, the brand replaced the plastic closure with an aluminum cap, switched from a plastic label to one made from paper, and eliminated all PET bottles.

Protect your products and the planet.

Box smarter with our sustainable solutions.

Void-fill | Cushioning | Wrapping | Box Lining | Cold Chain | Automated Solutions www.ranpak.com

PernodRicard.indd 32

2/23/22 12:07 PM

33

plastic it uses by 410 tons per year, which Dessenis says is equivalent to 17 million standard plastic water bottles.

Meanwhile, France-based prestige champagne brand Maison Perrier-Jouët launched a new eco-designed gift box made from 100% natural fiber sourced from FSC-certified forests in Northern Europe. Two years in the making, the box was designed and developed in-house by the brand and merges an elegant, minimalist aesthetic with a focus on sustainability.

“Faithful to the precious heritage of its founders, Maison Perrier-Jouët has rolled out an ambitious program in recent years that has enabled it to manage 100% of its vineyard through sustainable viticulture since 2016,” says Axelle de Buffévent, Style Director for Maison Perrier-Jouët. She adds, “To accelerate its environmental commitment, Maison Perrier-Jouët started an experimental regenerative viticulture program last year in order to bring about a real transformation of its vineyard, the first results of which are expected by 2025. The House is working on considerably reducing its impact on nature at every stage of the wine-making process, from the grape to the glass, as the Ecobox beautifully illustrates. By the end of the year, 100% of the House’s gifting offer will be eco-designed.”

Used to house its classic, non-vintage champagnes, the upright, rectangular box is made from a matte,

white paperboard that de Buffévent says was inspired by the chalky subsoil of the Champagne region. The entire surface of the box is embossed with a complex pattern of Japanese anemones, which is the emblem of Maison Perrier-Jouët created for the House in 1902 by Emile Gallé, one of the pioneers of the Art Nouveau movement.

One of the goals of the redesign was to reduce the amount of ink on the box to ensure recyclability. Decorating the box with embossing,

91

97

92 PROCESSING AND PACKAGING SOLUTIONS • • • • • • • •

Food processing systems On-machine and process area seasoning application Conveying and product handling Multihead/combination scale weighing and filling Snack bagmaking and case packing Metal detection and x-ray Check weighing and seal checking Controls and information systems

98

17

34

116 We are successful when you are successful. That’s 94 32

Helping you bring your best products to market.

Delivering Results.

With Heat and Control, you have a partner with the scale to support your success, the innovation to advance your operations, and a commitment to quality that will help you offer better products for consumers.

why we apply creativity, engineering excellence, and determined perseverance to every project to help our customers get the performance their business demands—whether measured by flavor, efficiencies, sustainability, improvement, or innovation.

99

08 36 108

42 4 2

~2 ~2~

107 4 41 1 12 20

26

Mar. 21-23, 2022 Pennsylvania Convention Center Philadelphia, PA USA

France-based prestige champagne brand Maison Perrier-Jouët has launched a new eco-designed gift box made from 100% natural fiber sourced from FSC-certified forests in Northern Europe.

info@heatandcontrol.com | heatandcontrol.com

LOOKING BACK. PRESSING FORWARD. ALWAYS INNOVATING.

PernodRicard.indd 33

2/23/22 12:08 PM

34 PW MAR2022

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

3138NV-half-page.pdf

1

7/16/21

12:15 PM

Savings are just the beginning.

as well as reducing the weight of the box—it’s 30% lighter than its predecessor—both served to limit the amount of ink required. The ink and glue used for the gift box are water-based and mineral-free.

The Ecobox is available at wine retailers, e-retailers, and e-commerce platforms where Perrier-Jouët is typically sold. Says de Buffévent, “We’ve received very positive consumer sentiment in regard to the sustainable Ecobox, which we see as a strong testament to the package.”

Reuse is on the table As part of the S&R initiative’s Circular Making pillar, Pernod Ricard committed in 2019 to piloting five new circular ways of distributing wine and spirits by 2030. “We’re looking at a number of initiatives to find different ways to distribute our products in the future,” shares Bauer. “It’s a bit too early to share details, I’m afraid, but it’s something we’re working on quite quickly to see what solutions we can find.”

Currently, Pernod Ricard India is collecting from bars and restaurants 10% of all the glass it uses for packaging its products. According to Wright, this translates to 60 million bottles reused annually.

C

M

Y

CM

MY

Collaboration is key to future innovation

CY

CMY

K

The tough Label-Aire 3138-NV Printer Applicator is the industry's clear choice for the most demanding applications. Contact us to learn how our print-and-apply technology can lower your operating costs while increasing productivity for your business.

Built by the pros and trusted by the best.

Above are just some of the examples of successful packaging projects undertaken by Pernod Ricard to move the sustainability needle and meet its S&R strategy goals, but there are many more. And there will an even greater number in the future, as the group continues to innovate to find new ways to reduce the carbon footprint of its packaging while collaborating with industry organizations, brands, and suppliers.

“We don’t have all the solutions,” says Wright. “Take glass for example, although it is infinitely recyclable, its manufacturing is still very carbon intensive.” Jameson Irish Whiskey, for example, recently took part in bottle supplier Encirc’s pilot investigating new technology that could help reduce glass manufacturing emissions by up to 90%.

She concludes, “True to our vision of Créateurs de Convivialité, we strongly believe in working with others, within and beyond the industry, to learn from one another and strengthen what we do collectively.” PW

label-aire.com 888.664.8111

PernodRicard.indd 34

2/23/22 12:10 PM

Are you looking for packaging or processing solutions and you don’t know where to start?

You’re looking for...

The most reliable and complete online directory of packaging and processing technology suppliers in North America – designed from the buyer’s perspective.

Features include: • Plain-language filters so it’s easy to find what you need.

• Visual navigation by machine or desired package type.

• Type-ahead keyword search.

• Packaging-specific filters that are tailored to each product category.

ProSource.org _PW_Ad_PreflightTemplate_UpdatedSpecs.indd 1

2/24/22 5:34 AM

36 PW MAR2022

New Blow/fill Line for Israel’s Tempo Beverages A new one-way PET line for Israeli beverage producer Tempo Beverages combines a latest-generation stretch blow molding technology with a new filler.

WHAT YOU’LL LEARN

Upgrading during production

Coping with COVID

plains its longstanding relationship with KHS, the supplier of the new stretch blow molding and filling equipment recently installed. “We’ve trusted KHS for more than 35 years, and we value their technology,” says Haim Neori, Electrical and Process Manager for Tempo. “It’s undoubtedly some of the best there is for filling. However, we’re just as happy with how professionally we’re served by our KHS contacts on all levels.”

The most recent venture on which the two firms embarked centered on Line 12 in the Netanya facility. This is where Tempo fills its own mineral water and primarily Pepsi products—sugar-free Pepsi Max in particular—into non-returnable PET bottles. The line has now been replaced in two phases of construction. The first in 2017 focused on the packaging and palletizing section, during which an Innopack Kisters TSP with an integrated handle applicator and an Innopal PB palletizer with a capacity of up to 32,000 bottles/hr were installed. Then in 2020 the focus was on the blowing and filling section. A 25-yearold KHS filler with a maximum output of 18,000 bottles/hr and the old stretch blow molder from a competitor made room for the latest technology KHS has to offer: a stretch blow molder/filler block equipped with an InnoPET Blomax Series V and a modular Innofill PET DRV filler. An Innoket Neo roll-fed labeler and Innopro After initial hesitation to try something new, management at Tempo are now very pleased with Paramix C blending system are also part their Innoket Neo labeler. of the line.

Notable about the InnoPET Blomax Series V are its energy-saving The firm keeps good company, too. Since 1990 it is PepsiCo’s sole features, which reduce the carbon footprint of the bottle-making probottler in Israel. It’s also Heineken’s exclusive sales partner, and in 2005, cess. A new Double Gate heating concept based on NIR (Near Infrared) 40% of the company came under the ownership of the Heineken Group. heating technology is said to yield up to 40% in energy costs. And with Then nine years ago, the beverage producer was made a licensee of the the Duo Cooling concept, two cooling circuits with different temperaFrench spirits group Pernod Ricard. Tempo now clocks up sales of about tures are generated through an external cooler. This saves energy and $450 million, 45% of this with non-alcoholic beverages. prevents any condensation from being formed on the molds. Plus, the Predictably enough, the firm places great value on technological EcoDry air management system supplements the efficient AirbackPlus innovation when it comes to processing and packaging lines. That exAs Israel’s biggest producer of alcoholic beverages and the nation’s third-largest supplier of soft drinks, Tempo Beverages is a brand known to almost the entire Israeli population of 9.1 million. There’s hardly a household in the country without a bottle of beer, water, juice, or cola from this firm, which is based in the city of Netanya between Tel Aviv and Haifa.

Tempo.indd 36

2/23/22 10:10 AM

37

Bottles filled with sugar-free Pepsi Max are dressed with their characteristic black labels on the roll-fed labeler. air recycling system and reduces condensation on the base mold. This effectively combats the forming of condensation on the entire blow mold and helps to further improve machine hygiene. The EcoDry process also significantly streamlines the separate air drying process otherwise necessary in certain climatic conditions or does away with it altogether.

Challenging climate, limited space Neori and his colleagues at Tempo naturally had the usual demands for quality, efficiency, and performance when it came to the new line.

But there were additional challenges to be met. “It wasn’t just a matter of enabling us to fill our carbonated products at up to 32,000 1.5-liter bottles an hour,” says Neori. “A further requirement was that we could bottle at 20°C [68°F] using 9 grams [0.32 oz] of CO2 per liter.”

In view of the company’s proximity to the Mediterranean Sea, high humidity levels, and ambient summer temperatures of 30 to 35°C (86 to 95°F), the products needed to be cooled for filling and then reheated to prevent condensation being formed in the packs. Another obstacle to be overcome was the restricted space. With a ceiling just 4 m (13 ft) high, individual adjustments had to be made in order to accommodate the line and clean-room air filters and to position the cap and preform

Tempo.indd 37

2/23/22 10:11 AM

38 PW MAR2022

infeeds. What’s more, construction work in the limited area had to be reduced to an absolute minimum so as to keep interruptions to operation as short as possible. “KHS had the perfect remedy for each of these problems,” says Neori.

With its new PET line from KHS, Tempo again lives up to its role as a pioneer. The stretch blow molder/filler block is the very first to combine a new-generation KHS stretch blow molder with a KHS filler. Another new path was also trod—after some initial hesitation—when it came to labeling equipment, as the Innoket Neo roll-fed labeler is the first such system installed by Tempo.

“By quoting a number of successful reference projects involving the same labeler, we were ultimately able to convince the customer that this labeler was the way to go,” says Michael Roche, Head of Regional Center Middle East at KHS. “In the end Haim was full of praise for the Innoket Neo—he was really enthusiastic about how easy it is to operate and how smoothly it runs.”

Productive even in lockdown As in many other countries, the COVID-19 crisis threatened to sabotage the planned schedule in Israel, too. The country was one of the first to go into full lockdown—just as the engineers were about to ramp up the finished line. It quickly became clear that the KHS installation team was now stuck on site and that no new service engineers could be flown in—a situation that naturally caused some uncertainty as nobody knew how long it would last. After much consultation, the two parties mutu-

Part of the stretch blow molder/filler block is the transfer star that hands the finished bottles over to the Innofill PET DRV filler. ally decided to carry on working. Tempo went to great effort to ensure that the KHS employees on site felt safe at all times despite them having to unexpectedly extend their stay. In light of Tempo’s good care and support, the 12 people on the KHS team fully backed the aforementioned decision and made the best of the situation. For its part, Tempo used the time to have its employees trained by its guest engineers. And with the help of online courses, those employees reached a stage of development

WHEN OIL FREE AIR IS THE ONLY OPTION Count on Sullair for reliable oil free compressors that meet your highest standards for air quality, purity and performance. We also offer air dryers, filters and other products to meet your specific air treatment needs.

Learn more at Sullair.com/oilfree SRL Series

DSP Series

© 2021 Sullair, LLC. All rights reserved.

Tempo.indd 38

2/23/22 10:12 AM

39

enabling them to quickly and independently solve any problems that might arise. Once the new line had been finally accepted in June 2020, the last KHS engineers left in Netanya were able to travel back home.

Despite the adverse circumstances, production resumed on Line 12 just seven weeks after the old filling setup was shut down. The planned increase in capacity to 32,000 bottles/hr was also realized in the previously “underutilized” packaging and palletizing area, enabling the agreed-upon overall equipment efficiency of 92% to be already surpassed during the acceptance test.

Accordingly, Tempo is very much the satisfied customer and already looking to the next joint project: a KHS canning line with a maximum output of 40,000 cans/hr. When asked what else his company is planning for the future, Tempo Deputy CEO Daniel Beer replies, “We have to react to the significant changes we’re noticing in consumer behavior. We’re doing this by strengthening our core brands on the one hand and investing in innovation on the other—either by expanding our product range, introducing new brands, or coming up with new forms of presentation.”

This is a sign that, from a packaging machinery perspective, Tempo can be counted on to press the limits in the future. —Pat Reynolds

Y o u c a n’ t b e a l l th i n g s to a l l p e o p l e. t h at ’ s w h Y w e’r e a l l th i n g s l a b e l i n g.

• World’s best tabletop labeling system • Rounds from .5 - 6”diameters • Label up to 8,000 products per day • Same day shipping

Call 1-877-236-0266 Tempo.indd 39

or see videos of our machines in action and more at

universal1.com 2/24/22 4:48 PM

40 PW MAR2022

AUTOMATION

OEM APPLICATION NOTE

iCam-Based Linear Pick-and-Place Mechanism Maintains Control of Empty Cartons Transferring empty cartons from a highspeed forming machine into a smart carton identification and loading system helps to maintain control of the lightweight boxes prior to use.

WHAT YOU’LL LEARN

Precise carton handling

By Natalie Craig, Features Editor JLS Automation, a manufacturer of hygienic robotic packaging solutions for a broad spectrum of applications, including primary product handling, case packaging, and cartoning, recently added a vision-guided carton loading solution to its product offering. The patent-pending Peregrine uses JLS TRAK technology to transport cartons between grippers for robotic loading.

“We have incorporated the linear servo motion technology of the JLS Trak to manage the carton size and position within the system,” says Craig Hafner, chief technology officer, JLS. “The machine even has the capability to handle different carton sizes concurrently as the focus has been to accurately manage the cartons within a small footprint with quick and repeatable size change.”

A potential shortcoming of the approach was the transfer from the carton former into the grippers. If the cartons were dropped or handled roughly, it could create a weak link or bottleneck while transporting the cartons.

To resolve this issue, JLS designed and built a carton handling system using a two-axis linear pick-and-place mechanism. The system is lightweight and fast to meet strenuous production requirements, according to the company. To minimize the need to stock a new part for maintenance and repair of the system, JLS used similar components featured in some of its other machines. After some evaluation, designers made their selection.

OAN_0322.indd 40

JLS designed and manufactured this carton handling system for high-speed, low-noise operation.

A primary component required for this carton handling mechanism included cam followers designed and manufactured by Intech. Intech’s PowerCore concave cam followers provided a maintenance-free operation, which was necessary for the conditions that the JLS system would experience during production. Compared to metal parts, the components also operated more quietly since they didn’t require lubrication, and because of this, JLS also eliminated the possibility of contaminating the cartons with grease.

The carton handling system had to operate under loads of 5 lb vertically and 15 lb horizontally, during acceleration speeds up to 3g in the vertical direction and 1.5g in the horizontal direction. As a high-speed operation, the mechanism needed to function at speeds of more than 80 inches/sec. vertically and 20

2/22/22 2:39 PM

41

There are multiple placements for the iCams used in the JLS carton handling system. The iCams are arranged to minimize wear for both the cam followers and the rail. inches/sec. horizontally. Furthermore, the system had to operate at 60 cycles/min., where each cycle included up to 18 inches of vertical stroke and up to 2 inches of horizontal stroke.

Intech engineers worked closely with the JLS engineering team to calculate the proper specifications for the cam followers and fit the rail properly, which helped solve the challenges JLS was encountering. This team approach led to checking other details to be sure that Intech’s

custom shaft fit the precise cartridge-to-rail positioning needed in the JLS carton handling system. Using the company’s proprietary load calculations based on the specific material selected, Intech ensured that the iCams would carry the specified load easily, adding additional life to the system. The iCams were fitted with stainless steel, sealed bearings, stainless steel shafts, and were pre-lubricated for life.

The linear guide design and concave cam followers running on a round rail provide a self-cleaning operation. The self-cleaning nature of this design makes the iCams resistant to wear in box or carton handling operations where paper, dust, and other debris are present. To minimize wear, Intech engineers used a gothic concave profile, which has only two-point contact with the round rail, roughly at 11:00 and 1:00. Strong enough to carry the load, this arrangement minimizes wear for both the cam followers and the rail. The eccentric shaft in the second cam follower is used to eliminate any gap between the cam followers and the rail. A full contact of both cam followers with the rail is a must for a controlled, precise movement of the pick-and-place mechanism.

The greaseless, precision machined cam followers reduced noise and absorbed shock and vibration that is usually present during the fast, reciprocal operation. Overall, the PowerCore components allowed the machines to operate faster using less torque and energy than would have been typically needed, according to the company.

The first machines are being commissioned and several are under construction. PW

22_0318_Packaging_World_MAR Mod: January 25, 2022 9:46 AM Print: 02/10/22 4:14:53 PM page 1 v7

π LARGEST STOC F PALLETS SHIPPING FROM 12 LOCATIONS

SHIPPING SUPPL SPECIALISTS

OVER 7,900 MATERIAL HANDLING PRODUCTS IN ST

ORDER B M FOR SAME DA SHIPPING

COMPLETE CATALOG

1-800-295-5510 uline.com

OAN_0322.indd 41 22_0318_Packaging_World_MAR.indd 1

2/22/22 2:55 PM 2/10/22 4:14 PM

Visit the link below each item for more info.

42 PW MAR2022

AUTOMATION TECHNOLOGY

Enclosed Drive System Siemens launches the SINAMICS G120XE enclosed drive system designed specifically for industrial pump, fan, and compressor applications in a wide variety of markets.

Siemens pwgo.to/7374

Stepper Motor I/O Terminal IIoT-Enabling Controller Banner Engineering’s DXMR90 industrial controller is designed to process incoming signals from equipment including sensors attached to machinery.

Beckhoff’s EL7062 dual-channel EtherCAT terminal enables the direct connection of two stepper motors in the medium power range of up to 3 A and for a voltage range of 8 to 48 V.

Beckhoff pwgo.to/7492

Banner Engineering pwgo.to/7495

Photoelectric Sensors Variable Frequency Drive Nord expands the power range of the NORDAC PRO SK 500P variable frequency drive line extending its current range from 7.5 to 30 HP.

Nord Drivesystems pwgo.to/7493

Automation_Technology_0322.indd 42

AutomationDirect’s Contrinex metal M12 and M18 photoelectric sensors feature IO-Link compatibility, are IP67 rated, and available in diffuse, diffuse with adjustable background suppression, retroreflective, and throughbeam models.

AutomationDirect pwgo.to/7494

2/21/22 2:00 PM

43

SUSTAINABLE PACKAGING

New Reusable Packaging Systems Embody the ‘Beautiful Lifestyle’ With its MyKirei personal care brand, Kao Corp. brings to life its ESG strategy, the Kirei Lifestyle Plan, launching two reusable packaging systems, one featuring a counter-worthy, decorative holder and one with an inclusive container design and enchanting dispensing system.

WHAT YOU’LL LEARN

Reusable packaging

Material reduction

By Anne Marie Mohan, Senior Editor “Kirei”: In Japanese culture, the word is used to describe something that is clean, well-ordered and beautiful, all at the same time. With its MyKirei personal care brand, Japan-based Kao Corp. is bringing to life its ESG (Environment, Social, and Governance) strategy, the Kirei Lifestyle Plan, which includes commitments to make everyday life more beautiful, make thoughtful choices for society, and make the world cleaner.

MyKirei was introduced in 2019 and joins the company’s more well-known U.S. brands such as Ban, Bioré, Curél, Jergens, and John Frieda. MyKirei includes hair and body care products that are plantbased, biodegradable, and vegan-friendly. Driven by Kao’s ESG strategy, the brand is also the center of innovation for new sustainable packaging. In launching its first line of products—shampoo, conditioner, and

hand wash—the company debuted the AIR bottle, a flexible, yet rigid package that dispenses three times more product and uses 50% less plastic than a rigid-plastic pump bottle.

With its subsequent product introductions, Kao has continued that innovation with two more thoughtfully designed packaging platforms: the Bottle for Life for hand and body wash products and the Eco-Pouch and Eco-Holder system for lotion. And, the innovation doesn’t only involve the sustainability of the packaging, but the aesthetics and functionality, as well.

Read more about the MyKirei AIR Bottle

Cleanliness with simplicity and fun

Kao’s first product line was launched in the AIR bottle, a flexible, yet rigid package that dispenses three times more product and uses 50% less plastic than a rigid-plastic pump bottle.

MyKirei.indd 43

Given consumers’ amplified focus on creating cleaner and healthier environments for themselves in 2020, the second line of products launched by the MyKirei brand was its Yuzu Flower Foam Hand Wash and its Pampering Yuzu Foam Body Wash in April 2020, both in the Bottle for Life refillable, reusable bottle. For these products, both the formula and the packaging embody beauty, sustainability, innovation, functionality, and cleanliness, with a new delivery system for the hand wash that adds a touch of fun to what the company says is “now one of the most important self-care tasks of the day.”

The formulas for the “richly-textured” hand wash and the “cloudcream” body wash foam include rice water and the citrus yuzu fruit and follow the Japanese tradition of avoiding harsh cleansers for the skin and environment by eliminating parabens, phthalates, mineral oils, and dyes. The products’ advanced foam technology requires no water to lather and rinses cleanly and completely.

According to the company, the foaming body wash is inspired by the centuries-old tradition of bathing in yuzu fruit, an annual ritual that symbolizes and promotes cleanliness and good health for the year ahead.

The packaging system, designed internally by Kao in Tokyo, is intended to promote cleanliness as well—of the environment, in this case. The softly shaped, high-density polyethylene bottle, in an 8.5-oz size for the hand wash and in a 20.3-oz size for the body wash, was

2/22/22 4:47 PM

44 PW MAR2022

Hand wash in the Bottle for Life comes in two varieties: one for children that dispenses soap in the shape of a paw print and one that forms the foamy soap into the shape of a yuzu flower.

designed to be reused up to 100 times and is paired with a durable, reusable, one-hand pump dispenser. Refills are packaged in a 6.8- and a 16.3-oz flexible standup pouch, for the hand wash and body wash, respectively, that reduces plastic by more than 85% versus rigid packaging.

The refill pouch is advertised on the back panel as being “100% recyclable,” with an asterisk pointing consumers to the website of upcycler TerraCycle. From the site, consumers can download a prepaid shipping label from TerraCycle (linked through the Kao website) that they can use to ship the used packaging.

For the bottle structure, Marissa Vallillo, Brand Director at Kao USA, says designers opted for clean and simple shapes that fit with the MyKirei proposition. The hand wash bottle is more rounded, with a curved ridge feature along the top left side of the bottle. The container for the body wash has a more elongated, oblong shape. The bottles are both decorated with full-body shrink labels made from oriented polystyrene that are gravure-printed in five colors and offer a soft-touch feel with their matte surface.

According to Vallillo, the bottle and pump were also designed very deliberately to accommodate ease of use by children, the elderly, and

MyKirei’s body wash comes in the reusable Bottle for Life that, in conjunction with the refill pouch, reduces plastic by more than 85% versus a traditional rigid bottle.

MyKirei.indd 44

Refills for the hand and the body wash come in a flexible film pouch that can be mailed, postage-free, to TerraCycle for upcycling after use.

the differently abled. “During a time when hand washing became so important, we wanted to make sure we were creating something that was accessible to all different groups of people,” she says. “At Kao, one of our brand standards is to create products that are accessible to all people, and we honor this commitment with each innovation.”

As mentioned, the pump for the hand wash also offers an extra surprise. Two dispenser designs, the Yuzu Flower and the Paw Print (launched in July 2021), dispense the foam product in the shape of the Japanese flower or of a dog’s paw print, the latter style created to delight younger consumers. Shares Vallillo, “We wanted to create shapes that would excite everyone and turn a mundane task into a fun experience.”

For the proprietary new dispensers, instead of using the traditional pump shape, with the dispenser pointing downward, the Yuzu Flower and Paw Print dispensers comprise a half circle that faces upward.

When the consumer turns the bottle upside down and presses the dispenser against their hand, the product is pushed through a cutout design inside the pump that creates the desired foam shape.

Explains Vallillo of the design process for the pump, “We had clear objectives of what we wanted to achieve from a utility perspective and creating a moment of joy in the experience, so we had to keep working until we achieved these goals. It was important for the function of the pump to be for one-handed usage and easy to press down to create a favored shape.” She adds that one of the challenges was getting the shapes perfect with the pump design and the formula. “Both had to be adjusted to develop the perfect product,” she says.

The Yuzu Flower Foam Hand Wash and Pampering Yuzu Foam Body Wash products are available on the MyKirei website and on Amazon. com. Prices are $18 for the hand wash and body wash in the Bottle for

2/22/22 2:45 PM

45

Life; refills in the flexible pouch are $12.50 apiece.

Says Vallillo, “We are seeing very strong sales with our refills, and many of our repeat consumers are now just buying the refills. They are less expensive, and they do an excellent job in cutting back on plastic.”

She adds that the hand wash, with its flower and paw-print pump dispensers, are also being very well received. “The Yuzu Flower Foam Hand Wash is constantly being sold out,” she says, “and we’re seeing some great traction with the Paw Print Hand Wash.”

Decorative lotion holder taps into Japanese culture With its next product, on shelves in October 2021, MyKirei took the reusable/refillable concept to another level of counter-worthiness. The packaging system is for its new Soothing Peony Milky Lotion and comprises the Eco-Holder decorative holder and the Eco-Pouch, a flexible film pouch that holds the product and is inserted into the holder for dispensing. Together, the company claims, the holder and refill help reduce plastic by 75% versus a traditional rigid lotion package.

Like the Bottle for Life, the Eco-Holder and Eco-Pouch were also developed internally in Tokyo by Kao engineers. Says Vallillo, “Our goal was to launch this new Soothing Peony Milky Lotion in very sustainable packaging that reduces the world’s plastic footprint and makes the world more kirei. Many traditional lotions are packaged in large, single-use bottles that contribute to a lot of plastic waste. Knowing that lotions were not as refillable, we designed the Eco-Pouch refill into an Eco-Holder.”

The Eco-Holder is a tall, slender, cylindrical container made from virgin polypropylene that is designed to hold a 11.5-oz flexible pouch refill. The holder is available in two designs, decorated with traditional Japanese artwork by artists Shiori Kiuchi and Kouta Matsumoto. Bottle colors and graphic designs were done by Yusuke Taguchi.

“We wanted to show how sustainability can be beautiful by creating authentic, custom Japanese prints on the eco bottle that can be transferred from refill to refill, until eternity,” says Vallillo. “The beauty of the Eco-Pouch and Holder is that you can use this package in multiple rooms in the house, whether that be at your kitchen counter, bathroom, or bedside table. In all locations, the designs look amazing, and you are significantly reducing plastic versus a big plastic lotion bottle.”

The Eco-Holder has an opening at the back where the refill, once uncapped, is clipped into the neck of the holder, and a reusable pump dispenser (sold with the pouch) is screwed into the neck of the refill pouch.

When the pouch is empty, the consumer can recycle it through TerraCycle, with the same system that’s in place for the body and hand wash refill pouches.

The Eco-Pouch refill snaps into the back of the Eco-Holder by the neck, and a reusable pump dispenser is added.

MyKirei.indd 45

Two options for the decorative, refillable Eco-Holder for MyKirei’s new lotion were designed with artwork from famed Japanese artists.

The Eco-Holder and the Eco-Pouch for the MyKirei Soothing Peony Milky Lotion are also available on the MyKirei site and on Amazon.com. The reusable, decorative holders are sold for $18 apiece, and the refill pouch is $14.

Among the customer reviews found on the MyKirei site are a number that praise both the product and the packaging. For example, says one consumer in a review titled, “Simple. Pleasant. Peaceful.” “I like the Kirei Lifestyle philosophy. In a world of chaos, I always say, ‘Keep it simple.’ Aside from that, I love the product. What a nice way to invoke the beauty of the world with a product.” Says another, “I’ve never seen such thought go into its product and packaging. MyKirei goes the whole 9 yards to ensure sustainability. Love the holder for the refill pouch. So easy to pop on and off.”

Comments like this confirm MyKirei is accomplishing its goal of fulfilling its ESG strategy with this new brand. “MyKirei was launched to embody the Kirei Lifestyle plan that Kao promotes,” says Vallillo. “All elements of the brand are to make life more beautiful, whether that be the amazing formulas and formats or the packaging that will leave a safer footprint. Established brands can also utilize some of these packaging innovation to make the world more kirei.” PW

2/22/22 2:46 PM

46 PW MAR2022

Cheeba Chews Tackles New Markets with Swabbing Station Owners at Cheeba Chews noticed that a lot of early packaging solutions offered to the emerging cannabis market—whether machinery, materials, or child-resistance— lacked flexibility or customization, seeking instead to apply existing approaches to a fundamentally new and different market. So, they took matters into their own hands, improved their process and packaging knowledge, and came up with an equipment solution on their own.

WHAT YOU’LL LEARN

Multi-state licensing model

In-house equipment innovation

By Matt Reynolds, Chief Editor

Cheeba Chews taffies use packaging that borrow from pharmaceutical and confectionery industries, including a blister pack with a child-resistant multi-layer foil and paper lidding.

CheebaChews.indd 46

Founded in Colorado in 2009, Cheeba Chews is a long-tenured brand by cannabis standards. Founders were edibles pioneers and early adopters of accurate, consistent THC dosing in precisely sized, individually deposited taffy chews back when an edible product potency, usually in brownies or cookies, was anything but consistent or accurate.

The brand hit its packaging stride in 2014, when Colorado legalized recreational cannabis and began regulating. After a transition to meet the then new regulatory standards, Cheeba Chews settled into a child resistant-certified (CR), 10-cavity blister-pack format using a multilayer paper/foil CR lidding solution from Constantia with Klöckner Pentaplast rollstock blister forming material, and FormTight as the local thermoformer. This general format is still used today.

Each cavity in the individually portioned 10-pack (5x2 format) blister strip holds one 10-mg piece of single-dose, THC-infused taffy. Dosing and other pertinent details, varying by SKU, are printed on the pack.

The foil/paper-backed blister strip is then flow wrapped in printed film.

The whole system is dialed in for production, packaging, and distribution in Colorado and California, early markets in which Cheeba Chews played. But the recent spate of states legalizing recreational cannabis offered potential for the brand to expand outside into new markets.

“We were able to operate Colorado and California by ourselves, and we’re a small business. There are three of us at the ownership level, and we have zero debt, zero investors.” says Eric Leslie, co-owner, CMO, Cheeba Chews. “As new states began to legalize, we were able to establish more of a licensing model to operate in multiple states. This led us into is opportunities in Oklahoma, Nevada, and Massachusetts. In this licensing system, we ship our base taffy or our gummies [before adding

2/21/22 2:23 PM

47

Thermoformed trays are filled and lidded in a 12x10 format, then cut to individual pack sizes of 5x2 and flow packed into printed film.

THC extract or oils, which cannot be transported across state lines], along with packaging components and equipment knowledge, to our partners.”

Those Cheeba Chew partners are separately licensed in their own state, with their own state-licensed kitchen facilities. They then have to source their cannabis extract or oil locally.

“So, they source their oil, and we ship them the base taffy product and packaging,” Leslie says. “We set them up with a manufacturing process and machinery, walk them through training processes, and they operate their kitchen and do the infusion process in order to take it to market.”

Having started in Colorado, which is very dry climate, Cheeba Chews had developed tried and true processes and manufacturing equipment, and it made sense to license that whole package together for the new market partners. But going into a place like Massachusetts, even Oklahoma, even California, the company began to see a lot of variables across multiple kitchens. Depending on the humidity at which it was processed, taffy product sticking to blister cell walls became an issue.

“Even within the same state, different kitchens have different humidity controls,” Leslie says. “When take the same taffy manufactured in Colorado, ship it to Massachusetts, they cook it down, and then infuse it, they are doing so in a kitchen with higher humidity, so they’re collecting more moisture in the taffy process that changed the viscosity. That changed the behavior of the taffy and how it interacted with our thermoformed trays. Taffy wasn’t popping out for the consumer the same way that it was in this dry climate in manufacturing here in Colorado.”

Another challenge that revealed itself was that in some states, cannabis edibles brands are required to stamp or mark individual pieces of candy to identify them as cannabis products when they are outside of the pack. Massachusetts is one of these states. That’s easy enough with a gummy, which holds its shape out of the mold. But taffy, no matter how firm a local licensee can cook it to be, is going to slightly reshape itself, and won’t hold that symbol once it’s outside of the tray.

That meant that they couldn’t simply think about other forms of packaging outside of the individual trays.

“We really need to hold it in that tray, in that single indentation, in order to stay compliant in multiple different states,” Leslie says.

Why should you compete in the industry's most prestigious packaging competition?

See how you measure up.

Benchmark against other packaging professionals and refine your skills with thoughtful critique from industry leaders.

Showcase your talent.

Receive industry-wide recognition and valuable exposure on social media and in top digital and print trade publications.

Strengthen your resume.

Increase your marketability profile, whether in your current or next job!

Visit iopp.org/ameristar today for more information.

CheebaChews.indd 47

2/24/22 3:56 PM

48 PW MAR2022

KEEP IT CLEAN

Overhead and side external views of Cheeba Chews’ proprietary swabbing station innovation.

Automating a solution for themselves Visit Us at

Booth 113

SANITARY CONVEYOR SYSTEMS • No fasteners & tool-less disassembly • Match-marked components

The home-grown solution to the taffy sticking to trays, which came with the help New Jersey equipment partner RLS Equipment Co. Inc., is what’s called a swabbing station. In early 2020, Cheeba Chews and RLS co-developed an automated, in-line swabbing system with 12 sponges on a motorized arm. Each sponge is able to dispense, via feeder tubes, a thin layer of food-grade oiland wax-based agent. This is swabbed into the sides and bottom of each cavity, preventing taffy from sticking to the internal blister walls of the thermoformed tray.

“Whether the taffy does have some more moisture to it, depending on the location, and if it’s a little bit softer, it’s still releasing and falling out of the tray like it’s supposed to,” Leslie says.

Why 12 sponges for a 5x2 cavity pack? Keep in mind, the thermoformed blisters that will eventually be 5x2 10-packs arrive to the facility as 12x10 format, 120-count trays. They are filled with THC-infused taffy product in that larger 12x10 format via a modified Egan Food Tech chocolate depositer. Only later will they be cut into 12 separate, 5x2 10-packs prior to flow wrapping. The swabbing system covers an entire 120-cavity tray.

Given an oil- and wax-based agent was being applied to the trays, an early concern was maintenance of a solid lidding seal if the swabbing sponges left a trace amount of agent on the sealing surface rather than within the cavities. Fortunately, the lidding supplier Constantia had been working on that problem for other applications and had a new lidding product at the ready.

“While a lot of third-party solutions that are available, there’s a lot of up mark on the solution from the whoever owns the CR certification, to the material providers, to the guy selling it to you,” Leslie concludes. There’s a lot of pennies being stacked on top when you just go get a clam shell,

• Completely disassembles for COP • Fully wash-down capable for CIP

Contact Us for Details

Getting Started Guide: Designing Packaging for Cannabis Looking for information on packaging cannabis products?

This Packaging World primer will provide an overview of general cannabis market considerations, the different variety of cannabis products and potential packaging options, automation considerations, and a glossary with links to source material. Download this free PDF today at pwgo.to/7469.

www.nerconconveyors.com 844-293-2814

CheebaChews.indd 48

2/21/22 2:23 PM

49

What’s next

On a mechanical arm, 12 tube-fed sponges swab foodgrade anti-sticking agent into each individual cavity of the thermoformed tray, preventing taffy from sticking and allowing it to better hold its shape. or you get a pouch, or a jar. By working directly with an OEM, and certifying our own solution, and going through some of these painful R&D processes, we were able to keep our cost down to provide a solution that not only is cost effective, but we can scale it into any market in the U.S. and still be compliant with the state regulations.”

CheebaChews.indd 49

With its own Colorado machine up and running, Cheeba Chews has since installed swabbing stations in California and at the Oklahoma franWatch Cheeba chise. Franchisees in Massachusetts and New Jersey Chews’ are next up to adopt the swabbing station solution. swabbing But Leslie says that he realizes this suite of station in product, packaging, equipment, and IP can be a action. big investment, depending on the market. Potential licensees in big states like New York, Illinois, or New Jersey can readily justify this investment, but not all new markets can.

“We are now finalizing is a small state solution that still has the same process,” Leslie says. “You’re still going to have swab trays. You’re going to have depositing, maybe in manual capacity. Maybe you go into a pouch instead of flow wrap outer package, or a more manual process. But a [licensee in a] state like New Mexico doesn’t need a six-figure manufacturing setup in order to execute, because the demand doesn’t require that much of an investment. We’re looking at more manual processes—it’s still machinery, just more semi-automatic—where it’s going to take multiple steps to get you to that same solution. But we’re working on making sure that a small state, like New Mexico, can still operate to scale alongside a big state, like New York, that’s going to need more robust, automated systems.” PW

2/22/22 4:44 PM

50 PW MAR2022

By Anne Marie Mohan, Senior Editor

Chocolatier Radically Transforms Products & Packaging For craft chocolate maker TCHO (“cho”), a radical transformation of its products required an equally dramatic change to its packaging. Since 2007, the Berkeley, Calif., company has been committed to crafting sustainably made chocolate bars and professional baking products through its TCHO Source sourcing program, whereby it partners with cacao farmers and scientists around the world to create a better cacao bean.

Last year, the company achieved Certified B Corp status as a result of its work to improve the lives of its workers, customers, suppliers, and the local community.

In 2020, in an effort to create chocolate that further reflected its values, TCHO began the process of reformulating its products to be completely plant based. “Reducing our reliance on dairy is one of the quickest ways TCHO can lighten our impact on the environment.

While this will not be an easy transition for us, we know it’s the right one,” shares Josh Mohr, Vice President of Marketing at TCHO. “From the beginning, TCHO has been committed to working with our farming partners in the field, improving farming techniques, bettering soil conditions, and doing what we can to help minimize deforestation—all of which speaks to a plant-based model.”

The reformulation includes a simplification of the ingredient panel on all of TCHO’s dark chocolate bars and a move to sunflower lecithin from soy. For its milk chocolate bars, the company has replaced animal milk with oats, cashews, and coconut sugar. This now means that the entire TCHO retail line is Certified Fair Trade, Certified Organic, vegan, gluten free, and kosher, and is 100% made from plants. The new selection includes four delectable dark chocolate varieties and three milk chocolate selections in unique flavors such as Choco Latté, Born Fruity, and Holy Fudge.

In early 2020, TCHO approached brand design firm Super Okay to help them create a completely new brand platform to communicate the changes to its bars and tell the story of its mission. Says Mohr, “We

SI_0322.indd 50

knew we wanted to break through the sea of sameness on the craft chocolate shelf. TCHO originally launched as a very design-forward brand in the late 2000s, and we wanted to get back to that simplicity.

We also asked Super Okay to bring our personality to the forefront, captivating the consumer enough to stop and grab one to read the back of the package while in the aisle.”

Structurally, the existing chocolate bar packaging consisted of a foil wrapper and a paper envelope overwrap, which held a nine-square, 70-g bar. The transformation includes a switch to three individually wrapped, 0.83-oz, three-square bars packaged in a square, wallet-style carton that not only enables consumers to easily share and store the chocolate, but also provides an “immersive experience,” as well.

Explains Robert Medkeff, Creative Director & Partner at Super Okay, “The packaging structure was a joint collaboration between TCHO and Super Okay. The concept was to use color and messaging as the main communicator on the outside. Upon opening the product, we wanted to provide a more immersive experience with a contrasting image linked directly to the bar itself, with a short writeup of the origin and/ or flavor. This direction added an element of surprise and delight that aligns with the brand’s principles.”

On the front panel of the carton, rather than having an ingredient or a background pattern taking center stage, as was done on the previous package, Super Okay uses bold, bright color backgrounds that reflect the natural brilliance of cacao pods throughout the world. The chocolate bar variety name is front and center in an offwhite color, along with smaller copy in black that describes the bar and its ingredients. The copy uses a custom-drawn typeface that highlights the notion of craft and celebrates the legacy of wood type. “Its asymmetrical letterforms and whimsical cuts and curves provide rhythmic visual cues to entice chocolate lovers,” says Medkeff.

“The art direction is elegant and simple, championing only the very ingredients of each bar.”

2/23/22 10:06 AM

51

The brand logo, which appears at the top of the carton on the front panel, is the only element of the previous design that was retained. However, it has evolved into a more “colorful and controlled visual system,” Medkeff explains.

“We brightened the intensity of the orange [TCHO’s brand color] and boxed in the TCHO logo. This was an intentional decision. Since pivoting the brand to become extremely color forward, we wanted to find a way to ensure the consistency of the logo across all packaging and communications, regardless of other colors.”

Part of Super Okay’s design approach was to select images for the inside of each carton based on whether a bar was flavor forward or origin forward. According to Medkeff, the individual images act as a visual cue to guide the consumer and help draw them further into the story behind each bar. “With Holy Fudge, for example, the image is one we shot in Ghana with a farming partner of TCHO’s. We wanted the consumer to see the environment where the cacao beans were being grown in a very honest and authentic way,” he says. “By contrast, Toffee Time has beautiful macro photography, showcasing the raw ingredients that make up the flavor of the bar.”

Along with copy that details the background of the bar, the inside of each carton is printed with a QR code with the words, “Learn Where This Cacao Was Grown.” By using their smartphone, consumers can access a page that provides tracking information for the cacao from each bar. Explains Mohr, “We wanted to be as transparent as possible, and since the pandemic made QR codes more popular, we figured we’d provide people who purchase our bars direct access to the Google sheets we use to manage the cacao we purchase.”

Another design element of note is one that harkens back to the chocolatier’s beginning. “The original TCHO packaging was clad with a gold foil pattern that had gotten lost over the years as the brand evolved,” explains Medkeff. “The pattern represented the history of chocolate’s early days as currency in Central and South America. The subtle touch is something we wanted to bring back with the new branding.” The spirograph pattern first used by TCHO is now a concentric square pattern that is used on both the primary wrappers and the bars themselves and reinforces the company’s new strategic positioning, which is “Chocolate. Fair & Square.”

Lastly, TCHO also made sure its packaging reflected its sustainability values by using more eco-friendly packaging. The wrapper for the bar is a multilayer construction of 100% recycledcontent paper and compostable, non-GMO polylactic acid (PLA). The carton is recyclable paperboard.

The new line of chocolate bars launched in early December 2021 exclusively on TCHO’s website and will be rolled out to retail distributors and accounts in spring 2022. PW

JOIN A GREAT TEAM

DISTRIBUTORS represent

Modular Conveyor Express An industry leading company with proven conveyor systems.

• Product Flexibility: Quickly introduce new products into inventory • Process Flexibility: Modular conveyor systems with standard designs and short lead times • Cost Flexibility: Quote solutions with options for every project blueprint

Conveyors designed by Nercon

modularconveyor.com 844.293.2816

SI_0322.indd 51

2/23/22 10:09 AM

52 PW MAR2022

INDUSTRY WATCH

Companies Paxiom opened a state-of-the-art 50,000-sq-ft facility in Las Vegas.

Bartelt Packaging was named the North American distributor for Spain-based FLtècnics. ei3 completed the acquisition of Cognitive Solutions and Innovation AG (COGSI AG) of Zurich.

COGSI will assume the ei3 brand and is being rebranded as ei3 Europe.

Eastman invested up to $1 billion to accelerate the circular economy by building a material-to-material molecular plastics recycling facility that is projected to handle up to 160,000 metric tons of hard-torecycle waste annually.

Ring Container Technologies made a $1.5-million gift to the Michigan State University (MSU) School of Packaging to support renovations to its School of Packaging building.

The BoxMaker’s 62,000-sq-ft plant in Lowell, Ark., began operating this year.

Triangle Package Machinery partnered with Capper-McCall Co. to represent its Southeast U.S. territory.

Honeywell and Avangard Innovative announced a joint venture to build a recycling plant that will use Honeywell’s UpCycle Process Technology to transform end-of-life plastic waste into recycled polymer feedstock that can be used to create new plastics.

BW Packaging Systems aligned Hema with Synerlink. The alignment will allow the complementary filling and closing companies the capability to offer innovative solutions for global food and beverage markets.

Pregis’ EverTec™ lightweight, paper-cushioned mailer received independent certification of recyclability.

Scholle IPN, a supplier of flexible packaging solutions, agreed to be acquired by SIG, an aseptic carton packaging company.

May River Capital acquired Cablevey Conveyors.

Printpack announced a strategic partnership with U.K.-based Sirane.

JLS will expand its headquarters in York, Pa. focusing on expanding the production space to accommodate rapidly growing consumer demand for large automated packaging systems.

People Michelle Bryson was appointed Global Sustainable Packaging Leader for BW Packaging Systems.

Ryan Schuelke was promoted to Chief Sales Officer for Enercon Industries.

Evanesce made key appointments to its management team: Angela Rodenburgh was added as Global Vice President of Marketing, and David Chaplin was promoted to Director of Operations for Manufacturing, overseeing its South Carolina and Nevada facilities.

Karl Odegaard was named Vice President, Operations for BW Integrated Systems.

Brian Hodek was named Director of Food and Beverage for Glenroy Inc.

In Memoriam The Nalbach Group announced the passing of John Nalbach, Nalbach Engineering Co., on January 1st.

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

www.packworld.com/leaders

IW_0322.indd 52

2/21/22 1:55 PM

Visit the link below each item for more info.

53

TECHNOLOGY

Automatic Stretch Wrapper

Robot for Heavy Products

Orion Packaging offers the Rotary Tower Automatic (RTC) stretch wrapper that integrates with new or existing conveyance.

Fanuc introduces the M-1000iA robot designed to handle heavy products featuring a 1,000kg payload, a 3,253-mm horizontal reach, and a 4,297-mm vertical reach.

Orion Packaging Systems pwgo.to/7255

Fanuc pwgo.to/7479

Recyclable Packaging for Sliced Food Products Sealpac’s FlatMap® modified atmosphere packaging (MAP) is designed for sliced products such as meat, dairy, and seafood. It allows products to be placed on a flat cardboard carrier made from bleached or unbleached fiber.

Sealpac pwgo.to/7451

Sidebot for High-speed Collaborative Automation

Breathable Vacuum Packaging Film Profol Americas introduces PP-based CPVac™ coextruded breathable vacuum packaging film designed to ensure fresh red meat and produce retain their color for shelf presentation.

Track and Trace Systems, Software

Wyzo direct pick-and place sidebot works safely side-by-side with humans without protective barriers or performance compromises. It is ideal for lightweight applications with a payload up to 1.1 lb and is suitable for the food and beverage, consumer goods, pharmaceutical, cosmetics, and electronics sectors.

Mettler-Toledo launches its line of Integrated Mark & Verify systems and software to aid pharmaceutical manufacturers in fulfilling their increasing product safety and compliance requirements by making it easier to integrate code marking and verification capabilities into their production lines.

Wyzo pwgo.to/7296

Inspection System

Mettler-Toledo PCE pwgo.to/7481

For products flowing into a pipe, Eagle’s Pipeline with PXT™ inspection system meets demanding food safety and retailer specifications.

Eagle Product Inspection pwgo.to/7480

Profol Americas pwgo.to/7482

Technology_0322.indd 53

2/23/22 10:04 AM

Visit the link below each item for more info.

54 PW MAR2022

TECHNOLOGY

Recyclable Flat-Bottom Pouch ProAmpac’s QUADFLEX® recyclable flat-bottom pouch utilizes the company’s R-2000 recyclable laminated mono PE film and is available in either a side-gusseted with flat or pinchedbottom stand-up pouch.

Vibratory Conveyors Key Technology introduces Marathon vibratory conveyors with monobeam construction available in lengths from 30 to 50 ft.

ProAmpac pwgo.to/7319

Key Technology pwgo.to/7254

Semi-automatic Case Former The BEL 505 V2 semi-automatic case former from Wexxar Bel features an upgraded pneumatic system with folding mechanisms to reduce air consumption by 27%.

Wexxar Bel pwgo.to/7294

E-commerce Packaging Kit HexcelPack introduces the Store in the Box™, an e-commerce packaging kit that provides retailers with on-demand packaging supplies to allow them to bypass traditional fulfillment centers and ship orders from local stores.

HexcelPack pwgo.to/7368

Robotic Case Packer Brenton’s RT1000 compact, modular-footprint top-load robotic case packer is designed to load up to 20 cases/min with a payload of up to 7 lb.

Brenton pwgo.to/7295

Conveyor Modules Puck Stop and Puck/Package Divert Modules are available on Dorner’s FlexMove conveyor system, giving users the ability to stop pucks or packages for pacing requirements, as well as divert pucks and packages into a second lane.

Dorner Mfg. Corp. pwgo.to/7258

Technology_0322.indd 54

Recyclable, Transparent Laminate TIPA’s T.LAM 608 recyclable, transparent laminate is designed for a variety of food packaging applications, including stand-up pouches, zipper pouches, open pouches, side-gusseted pouches, and more.

TIPA pwgo.to/7369

2/23/22 10:04 AM

55

AD INDEX

Affordable, High-Quality

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

PAGE

AmbaFlex Inc. www.ambaflex.com

6

BELL-MARK www.bell-mark.com

55

BluePrint Automation www.blueprintautomation.com

31

Brenton www.brentonengineering.com

21

Dodge Mechanical Power Transmission www.dodgeindustrial.com

9

Econocorp, Inc. www.econocorp.com

37

Eriez Magnetics www.eriez.com

16

Heat and Control, Inc. www.heatandcontrol.com

33

Institute of Packaging Professionals www.iopp.org

47

Label-Aire, Inc. www.label-aire.com

30

Michelman Inc. www.michelman.com

17

Modular Conveyor Express www.modularconveyor.com

51

National Bulk Equipment, Inc. (NBE) www.nbe-inc.com

5

Nercon Conveyor Systems www.nerconconveyors.com

48

Packaging Distributors, Inc. www.pdimachinery.com

49

PFlow Industries, Inc. www.pflow.com

15

PMMI, The Association for Packaging and Processing Technologies www.pmmi.org Ranpak Corp. www.ranpak.com Robatech USA Inc. www.robatechusa.com

Easily install yourself & be running production within minutes!

Replace your CIJ printer at a fraction of the cost & without the maintenance requirements March 21-23, 2022 Philadelphia, PA USA

Join us at booth #1909 to see this printer & more!

www.bell-mark.com 973-882-0202

7 35, IBC 32 3

Serpa Packaging Solutions www.serpapackaging.com

39

Soft Robotics www.softroboticsinc.com

23

Specialty Equipment www.specialtyequipment.com

52

Sullair A Hitachi Group Company www.sullair.com

38

Syntegon Packaging Company www.syntegon.com

1

Uline www.uline.com

41

TopTier Palletizers www.toptier.com

29

Unified Flex Packaging Technologies www.unifiedflex.com

19

Universal Labeling Systems, Inc. www.universal1.com

39

Valco Melton www.valcomelton.com

10

Van der Graaf www.vandergraaf.com

24a

Westrock www.westrock.com/aps

Thermal Inkjet j Printer t

34, OBC

Mettler Toledo www.mt.com/pi

PMI KYOTO Packaging Systems www.pmikyoto.com

InteliJet TSi

CONGRATULATIONS TO READ ALLEN ON BEING RECOGNIZED IN 2021 AS AN ELITE RECRUITER IN THE PACKAGING INDUSTRY

IFC, OFC

Wexxar/BEL www.wexxar.com

11

ZSG Talent www.zsgtalent.com

55

Read Allen Vice President & Practice Leader ٢‫ה‬1‫ג‬٣ ‫חדז‬-1‫חגב‬ read@zsgtalent.com

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

www.packworld.com/leaders zsgtalent.com

March ad index.indd 55

2/24/22 4:01 PM

56 PW MAR2022

PROFESSIONAL PERSPECTIVE

By Judy Larkins, CPP

Finding Opportunity in the Project that Never Was Your big packaging project has suddenly fallen apart after all your hard work. Is it a total loss or can you somehow turn it into a win? I believe that despite the setback and disappointment, it can still present an opportunity for you—if you choose to allow it. That approach worked for me, and here is my experience.

It was close to the end of the day when I received the news that a big packaging project I had been driving was being tabled “indefinitely.” During this particular week, this was the second project to be cancelled after months of work.

We all have been there. I had felt particularly invested in my project since it was an idea that had started years back. Because of conflicting priorities, it never got the momentum to become a real initiative until very recently. I powered down my laptop feeling frustrated, disappointed, and even a bit angry. All that time and energy wasted! I would have to relay the news to the project team. And what about the packaging suppliers who had worked feverishly to develop concepts, prototypes, and supply proposals under impossible timelines?

The pivot point I decided to call my mentor—a former boss at a previous employer—to vent and complain.

He listened intently and then as he is known to do, reminded me of a similar challenge we faced when working together. He had been tasked with creating a sourcing team designed solely to find cost-saving opportunities for the medical device company where we worked. I was thrilled to be chosen for the team and together we enthusiastically set out to find savings on packaging, logistics, supply chain, etc.

As we brought ideas to the table, each was summarily shot down.

The reasons were many: not enough savings to justify the change, too much risk, insufficient resources. My boss quickly realized he needed to pivot. He restructured the team goals to recognize proposed savings, versus realized savings, as a win. He had the vision to see the company wasn’t ready to make changes, but a victory could be

defined not by executed savings but instead by the idea-generation process. By changing the definition of success, he moved the goalpost.

Both the company and our team changed the earmark of success.

With that, the team felt their efforts were validated and we set out on finding opportunities with a new focus.

A different definition of value As my mentor reminded me of this experience, I saw the parallel to my current dilemma. I was viewing a successful project only through the lens of seeing a completed product on a store shelf.

What if there were another way? What if success is about learning from the process and the experience along the way? Sometimes, it is only after you set off on a new project that you realize the existing package or process is a better fit than the one you are considering. If you hadn’t taken the time and effort to explore something different, you wouldn’t have the validation to know that what you are doing already is the best solution. There is value in trying and abandoning the idea you were chasing.

For the suppliers who worked diligently, hoping to win a contract, this isn’t necessarily an empty exercise either. Stalled projects can lay the foundation for something down the road. If nothing else, they build a bridge between the two companies.

When a future opportunity arises, they will be front-of-mind as the company to contact. It is about focusing on the long game. They, too, can learn from the process, and that could make them a better choice for the next customer/project.

I have changed my mindset. I now view every project experience as a potential for learning and growth. It is about the steps along the way. Maybe the project ends up being cancelled, but perhaps in the process, I learn a new skill in managing people or leading a team. Or I discover a new packaging innovation or technology. These learnings stay with us long after the project itself. They accumulate and make us better at what we do.

To that I say—bring on the next project! PW

The author, Judy Larkins, is Director of Corporate Purchasing at Bumble Bee Foods and an IoPP Certified Packaging Professional.

For more information on IoPP, please visit www.iopp.org.

ProPerspective_0322.indd 56

2/23/22 10:02 AM

THE INDUSTRYÕS DEFINING EVENT RETURNS!

PACK EXPO International is back in Chicago, giving you the unmissable opportunity to explore technology, materials and reinforce industry connections. Discover innovative solutions for packaging and processing, automation, sustainability, e-commerce and more at the most comprehensive packaging and processing event in the world in 2022!

ENGAGE WITH 2,000+ LEADING SUPPLIERS 40+ VERTICAL INDUSTRIES REPRESENTED FREE EDUCATIONAL SESSIONS 7 PAVILIONS including 3 new hotspots:

Register now for only $30 packexpointernational.com _PW_Ad_PreflightTemplate_UpdatedSpecs.indd 1

October 23-26, 2022 Chicago, Illinois, USA 2/20/22 6:15 AM

6000n-9x11a.pdf

1

7/16/21

11:09 AM

Preventing headaches for over 50 years.

C

M

Y

CM

MY

CY

CMY

K

For speed and reliability, the Inline 6000-N is the perfect front/back labeling solution. With its zero downtime option, labels can easily be changed without stopping production. Contact us to find out about our trouble-free labeling solutions.

Built by the pros and trusted by the best.

label-aire.com | 888.664.8111

Untitled-3 1

2/10/22 1:05 PM

P

’S

NG WO RL AGI D CK A

Future leaders IN PACKAGING SC

H O L A R S HIP

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.

More Information: packworld.com/leaders ©2022 PMMI Media Group

LIP2022_Ad_1.indd 1

1/28/22 1:07 PM

P

’S

NG WO RL AGI D CK A

Future leaders IN PACKAGING SC

H O L A R S HIP

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.

More Information: packworld.com/leaders ©2022 PMMI Media Group

LIP2022_Ad_2.indd 1

1/28/22 1:09 PM