SPN Nov 2020 by spnews.com

Nov 2020

SUSTAINABLE

PACKAGING NEWS

Taking the lead in sustainability

Trailblazers

of the recycling revolution SPN looks at the diverse and innovative approaches pioneered by companies across the globe that are setting the standards for sustainability

Covid 3-step Survival Plan

EnvoPap

We speak to CEO of EnvoPap Kaushal Shah

Elopak Thomas KĂśrmendi, CEO of Elopak, informs SPN about Elopakâ&#x20AC;&#x2122;s product developments

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WELCOME TO SPN MAGAZINE

Welcome to SPN is devoted exclusively to promoting and optimising sustainable packaging worldwide. Since the launch of our first issue we have been busy building on the publication’s enthusiastic reception and adding more up-to-the-minute news about sustainable packaging from around the globe. At SPN everything we do is dedicated to helping you to become better equipped to deal with the current market forces and the latest Covid 19 legislation. With the pandemic showing no signs of slowing down, we look at how the industry is reacting and coping with the threats posed to our industry. For example in “Covid in Context” we look at how the pandemic is impacting the industry and where the markets are now heading. In addition, in our regular “Spin Doctor’s” feature we also offer readers a 3-step survival plan as featured in a recent McKinsey report. There are plenty of other current topics too in this issue such as innovative solutions for the protection of pharmaceutical products from both extreme weather conditions and damage from sunlight. As you will see, our remit includes bringing the big-picture to companies operating across the entire spectrum of sustainable packaging. SPN is the new “tour-de-force” in sustainable packaging, working on your behalf to help you to achieve and surpass your packaging sustainability goals. Welcome aboard!

Philip Yorke ( Editor )

SUSTAINABLE

PACKAGING NEWS Nov 2020 Nov 2020

SUSTAINABLE

PACKAGING NEWS

Taking the lead in sustainability

Trailblazers

of the recycling revolution SPN looks at the diverse and innovative approaches pioneered by companies across the globe that are setting the standards for sustainability

Covid 3-step Survival Plan

EnvoPap

We speak to CEO of EnvoPap Kaushal Shah

Elopak Thomas Körmendi, CEO of Elopak, informs SPN about Elopak’s product developments

Director Editor Writer Designer

Kevin Gambrill Philip Yorke Emma Jane Batey Dom Thorby

linkedin.com/company/ sustainable-packaging-news/

news_packaging

spnews.com SUSTAINABLE PACKAING NEWS

CONTENTS

Contents

TOPICS

INTERPACK 16 Interpack 2021 returns PACKADORE 17 Packadore at Dutch Design week PROTECTION FOR DELIVERY 18 Countering extreme climatic conditions ELOPAK 20 Elopak’s latest product developments

REGULAR FEATURES SUPPLY-CHAIN SLEUTHS 6 The latest developments in supply chain management

SPN SPIN DOCTORS 10 Covid 3-step survival plan DIGITAL DIGEST 14 Creating a new digital workplace

MULTIFACETED ELECTRONICS 24 Heterogeneous integration of photo-lithography

RESOURCE EFFICIENCY 28 Phenol Phenomenon from Borealis ENVOPAP 30 The sustainable materials company INNOVATION INSIGHT 34 Bossar’s packaging machine technology RECYCLABILITY 36 The latest on Recyclability innovations RECYCLING TRAILBLAZERS 42 The global quest for efficient recycling

4 SUSTAINABLE PACKAING NEWS

Issue 1 Sep 2020

CONTENTS

34 30

SUSTAINABLE PACKAING NEWS

SUPPLY-CHAIN SLEUTHS

Supply-chain Sleuths

Wake-up call

for supply chain management

As procurement teams struggle to cope with the Covid-19 global pandemic, most have been trying to keep up with the news about global response measures and have been working diligently to secure raw materials and components and protect supply lines. However, vital information is often not available or accessible across their global teams. As a result, their response to the disruption has been reactive and uncoordinated, and the impact of the crisis is hitting many companies full-force. In contrast, a small minority of companies that invested in mapping their supply networks before the pandemic emerged better prepared. They have better visibility into the structure of their supply chains. Instead of scrambling at the last minute, they have a lot of information at their fingertips within minutes of a potential disruption. They know exactly which suppliers, sites, parts, and products are at risk, which allows them to put themselves first in line to secure constrained inventory and capacity at alternate sites.

6 SUSTAINABLE PACKAGING NEWS

Despite numerous supply-chain upheavals inflicted by disasters in the last decade — including the eruption of a volcano in Iceland, the Japanese earthquake and tsunami, Thailand floods, and Hurricanes Maria and Harvey — most companies still found themselves unprepared for the Covid-19 pandemic. Seventy percent of 300 respondents to a survey conducted by Resilinc in late January and early February, immediately following the Covid-19 outbreak in China, said they were still in data collection and assessment mode, manually trying to identify which of their suppliers had a site in the specific locked-down regions of China. There are a number of reasons for this problem — and potential solutions.

SUPPLY-CHAIN SLEUTHS

12 Resources for supply network mapping are expensive. Many companies and leaders talk about the need to do supply network mapping as a risk-mitigation strategy, but they have not done so because of the perceived large amount of labour and time required. Executives of a Japanese semiconductor manufacturer told us that it took a team of 100 people more than a year to map the company’s supply networks deep into the sub-tiers following the earthquake and tsunami in 2011. This explains why most companies are like a major South Korean consumer goods company, which recently told us it had known that it should have mapped its supply networks but has not done so because of the difficulties involved.

“ Companies will discover the value of the map is greater than the cost and time to develop it ” Consequently, many companies continue to rely on human intelligence from top-tier and a select few lower-tier suppliers.

But the information collected via personal relationships is typically anecdotal and often mere conjecture, and when procurement personnel leave, change roles, or retire, their knowledge leaves with them. It can take new employees years to get to know immediate suppliers, let alone the suppliers’ suppliers and their global footprint. Yes, supply network mapping can be resource intensive and difficult. However, there is no way around it. Companies will discover the value of the map is greater than the cost and time to develop it. The most common approach is to use the bill of materials and focus on key components. It typically starts with the top five products by revenue and goes down to their component suppliers, and their suppliers, ideally, all the way down to raw materials suppliers. The goal should be to go down as many tiers as possible, because there may be hidden critical suppliers the buying firm is not aware of. The map should also include information about which activities a primary site performs, the alternate sites the supplier has that could perform the same activity, and how long it would take the supplier to begin shipping from the alternate site.

SUSTAINABLE PACKAGING NEWS

SUPPLY-CHAIN SLEUTHS

A new breed of services companies can help acquire and analyze supply network data and organize the results in a user-friendly way. Their services typically do not map the supply networks all the way down to raw materials, but they may provide a start. A few of the companies operating in this space include Elementum, Llamasoft, and Resilinc. (Disclosure: One of us, Bindiya Vakil, is the founder and CEO of Resilinc.)

The procurement function is measured by cost savings, not revenue-assurance. Most of procurement’s activities are focused on cost savings, which means obtaining supplies at the lowest cost possible, provided they fall within specified quality parameters. When the procurement function has to resort to extraordinary measures to secure supplies on time (e.g., by expediting shipments or purchasing parts or materials at a premium), the higher costs are assigned to other parts of the organization (the logistics function in the case of expedited shipments, and the finance function in the case in the case of premium prices for raw materials and parts). Often, no one asks: Why was expediting or paying a premium necessary in the first place? People from procurement, logistics, and supply-chain financing need to come together to talk about what key gaps (tools, information, people, processes, etc.) need to be fixed to protect the company from disruptive events in the future and how to align the goals of procurement with the overall business objectives.

8 SUSTAINABLE PACKAGING NEWS

Disruption often not part of supplier-performance metrics.

When a disaster strikes, everyone suffers: buyers and suppliers alike. Therefore, it only makes sense that firms should incorporate disruptionrelated metrics in their evaluations of suppliers.

For example, when selecting a supplier and writing the initial contract, many leading companies include language that requires the supplier to participate annually in its supplychain mapping efforts. When force majeure events like the current pandemic strike, those supply maps can be used as a roadmap to solutions to the crisis. (Suppliers in China made more than 3,000 force majeure declarations during the first few months of the Covid-19 crisis.) Contracts should also spell out expected recovery times and methods during such events.

“ There will be those that don’t do anything, hoping such a disruption won’t ever happen again. These companies will be taking a highly risky gamble “ After the Covid-19 crisis dissipates, we will see companies fall into one of two categories. There will be those that don’t do anything, hoping such a disruption won’t ever happen again. These companies will be taking a highly risky gamble. And there will be firms that heed the lessons of this crisis and make investments in mapping their supply networks so they do not have to operate blind when the next crisis strikes and rewrite their contracts so they can quickly figure out solutions when disruptions occur. These companies will be the winners in the long term.

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SPN SPIN DOCTORS

SPN Spin Doctors The latest Spin from SPN

Covid 3-step survival plan As the Covid 19 pandemic continues to have a “Shock and Awe” impact on the global packaging industry, it is clear that some sectors are facing greater challenges than others. SPN reviewed the latest packaging industry report from Mckinsey, which offers vital help to packaging companies with its three-step survival plan. The latest report released in September 2020 offers a three-part plan that can provide vital insights for packaging companies. The Mckinsey report will not only help companies to mitigate the effects of the crisis, but also provide valuable advice on how to navigate them towards a strong and lasting recovery. Leaders of packaging companies could therefore consider a three-part response to the crisis as suggested by Mckinsey.

“ A key priority should be to support and protect employees’ health “ 10 SUSTAINABLE PACKAGING NEWS

Part one: Navigate the now As a first action, a packaging player can create a crisis-response nerve centre that can steer the organization and serve as the core information source. The nerve centre can manage risks and responses and align all its stakeholders. A key priority should be to support and protect employees’ health. Besides that being arguably a moral responsibility of an employer, it is also a pragmatic first line of response to maintain an enterprise’s ability to function at all. Acting on this top priority can happen in several areas.

SPN SPIN DOCTORS

The company can monitor health risks and communicate about them through updates on its intranet, postings at the entrance to its sites, and regular conduct training on how to handle them. It can also provide personal protective equipment, including masks, gloves, and hand sanitizers, and can regularly clean its buildings. It can also implement targeted processes and policies that include checklists, new travel and meeting guidelines, and the splitting of teams into shifts when operationally possible. A company can also review its production footprint and what it will need to ensure that it can keep running by creating country specific plans and clear checklists for plants. Related to this is the need to screen the supply chain to understand the risk of disruptions such as dependence on a single supplier source for raw materials or on printers that might close and then take actions to address anticipated disruptions and shortages.

Once the top priorities to maintain health and operations have been dealt with, a leadership team can set about understanding how consumer sentiment may be evolving for example, to an acceleration in e-commerce shopping and higher than-previous demand for grocery packaging and how that could make some shifts necessary in its portfolio of packaging offerings. Based on that assessment, a leadership team can review its operating model to evaluate its packaging production flexibility. For example, it can take steps to understand where demand will be temporarily high and assess its ability to shift production appropriately to fulfill new demand patterns. At the same time, the leadership team can evaluate what it needs to do to ensure the companyâ&#x20AC;&#x2122;s financial health by identifying and mitigating risks of declining demand from certain segments and by monitoring raw material pricing indexes closely to protect its margins.

SUSTAINABLE PACKAGING NEWS

SPN SPIN DOCTORS

Step two: Plan for the comeback Leadership teams in packaging companies should build a recovery strategy that will include a mix of financial resilience, operational plans, and strategic customer-focused moves (such as understanding the impact of COVID-19 on particular customers’ packaging-substrate choices). Companies can take steps to identify packaging categories that are likely to return to strong levels of demand. They can also consider the supply-chain requirements and production planning including addressing the footprint and rebalancing supply that they will need to cope with that return. They can also look out for new pockets of growth potential with different packaging end uses and different substrates. Last, companies can review the packaging product designs and associated capabilities that they would need to manage new trends in consumer sentiment and requirements, such as safety, health concerns, and more e-commerce. Based on those assessments, leadership teams can sharpen their companies’ value propositions to deliver on the next normal in demand. Such propositions could include the ability to adapt packaging designs best to the needs of e-commerce while simultaneously adhering to consumer preferences and, at the same time, always delivering greater cost efficiency.

12 SUSTAINABLE PACKAGING NEWS

“ companies need to make a regular practice of the kind of vigilance that served them well at the start of the crisis “ Step three: Shape the next normal

Packaging company leadership teams should assess which shifts are getting under way in customer and consumer sentiment and which behaviour may stick after the crisis. For example, hygiene requirements, e-commerce, and resurgent concerns about sustainability. They can also consider rethinking their business portfolios so that they can ensure the stable cash flows and healthy balance sheets that can protect their companies. Steps that packaging companies can take to this end can include narrowing the range of substrates they currently use. They can also extend to evaluating acquisition opportunities of assets in the market that could strengthen their business. And finally, companies need to make a regular practice of the kind of vigilance that served them well at the start of the crisis: thinking through the network implications for their plants and supply chains and the potential risks related to single sources of raw materials and packaging components.

Courtesy Global Editorial Services McKinsey & Company. For further details and the full report visit www.mckinsey.com

SUSTAINABLE PACKAGING NEWS

DIGITAL DIGEST

Digital Digest

Creating a new digital workplace The Covid 19 pandemic is a humanitarian crisis of unprecedented scale. Today’s top priority is to protect the health and safety of people and their workplaces. Leaders must make rapid, highly-informed decisions, and take immediate actions to protect and support their people and to ensure that critical business operations move forward in order to help societal continuity. The new elastic digital workplace created by Accenture offers a way forward. With Covid 19 continuing to spread, the time to act is now. Deferred decisions and delayed actions have immediate and longer-term business impacts. To minimise business disruption and protect employees. Organisations must take positive steps today, in order to create a digitally more efficient workplace. SPN believes that Accenture’s ‘Elastic Digital Workplace’ solution offers an answer with its highly extendable workplace environment that allows companies to quickly scale and dynamically adapt to changing business needs based on both global and local conditions.

Within 24 hours Assess your current state and analyse your current technology capabilities and your potential to scale out internally, including your current communications plan and support structure.

Within 72 hours Identify how you can leverage existing technologies more effectively.

14 SUSTAINABLE PACKAGING NEWS

Within 5 days Develop a leadership and culture awareness and change plan: Design a change management plan, including leadership communications that encourage employees to adopt key technologies that will facilitate connections to their team members and leaders in this new environment, internal meetings and even large-scale external events.

DIGITAL DIGEST

Within 2 weeks Rapidly modernise and scale your collaboration capabilities as well as your workforce engagement plans: Identify how to expand your workplace to the periphery, including a focus on home networking, broader networking, security, upgrading other tools and capabilities and helping your people learn and embrace new ways of working with each other.

Looking ahead

While Covid 19 is the catalyst for an immediate implementation of a new Elastic Digital Workplace, Accenture anticipates that the crisis will fundamentally alter how we work and engage. Leaders should therefore develop a comprehensive Elastic Digital Workplace implementation plan, focusing on 6 key dimensions. 1

1 Culture and awareness Provide technology and environment optimisation for enabling effective remote working and activate communications, plan to provide policy guidance both internally and externally. 2 Elastic Collaboration Rapidly deploy collaboration tools across the organisation and build bridges with your customers, partners and suppliers. 3 Virtual work environment Evaluate network, accelerate devices and deployment, and leverage virtual environments to support increased mobile demand

4 Seamless Networking Enable reliable network connectivity to employees homes and seamless integration with customers and partners. 5 Distributed Continuity Enhance buisness continuity plans to include reduction in workforce, travel restrictions and large scale remote working environments. 6 Adaptive Security Leverage exception-based processes, expand zero trust network access approach, and automate with endpoint management detection and response

SUSTAINABLE PACKAGING NEWS

INTERPACK

Interpack The packaging industry’s most important and prestigious trade show opens in 2021 to a growing demand for more sustainable, recyclable and biodegradable packaging. The latest developments in these key areas and how they are highlighted at Interpack will be brought to you as they happen by SPN. Interpack 2021 returns as the leading international event for the processing and packaging industry in February. After the postponement of its 2020 edition, interpack is back in 2021 for an even bigger event than ever before between 25th February and 3rd March. To make you feel completely at home at interpack, Messe Düsseldorf has developed officially coordinated hygiene and infection protection standards for all visitors, exhibitors, and members of staff – keeping safe together.

To access the interactive hall plan visit https://www.interpack.com/en/ Interactive_hall_plan

16 SUSTAINABLE PACKAGING NEWS

PACKADORE

Packadore at Dutch design week Packadore Collective have come together united by a common objective — to help brands reduce their global footprint. Each partner brings unique capabilities to the mix and will work collaboratively to help brands enhance the consumer packaging experience and, at the same time, to navigate the circular economy maze. In preparation for launch, Packadore Collective have been exploring the theme of ‘the new intimacy’ as part of this year’s Dutch Design Week and the different ways design can be used by both brands and consumers to relate to each other and the world around them. Packaging design is an invaluable tool to help create more intimate connections with consumers and can offer tangible solutions to contribute to a better world. Packadore Collective’s exhibit at Dutch Design Week, ‘Brains that buy green’ combines concept design innovation and consumer neuroscience research to generate a series of both desirable and sustainable packaging design innovations. Check out their exhibit at Dutch Design Week or get in touch with the team via their website.

About Packadore Collective Packadore Collective work collaboratively to design and implement both desirable and sustainable packaging solutions to help brands create real impact, now and for the future. We are the innovators in temptainability.

Visit us at: www.packadore.com

SUSTAINABLE PACKAGING NEWS

PROTECTION FOR DELIVERY

Countering extreme climatic conditions The need to provide optimised protective packaging has never been greater. With temperature extremes and pressure fluctuations becoming more prevalent, pharmaceutical products are more at risk than most, especially when facing an increasingly volatile environment. Pharmaceutical products represent some of the most delicate goods to be regularly shipped all over the world. Like food items and electronics, they are easily affected by moisture ingress, temperature and atmospheric changes, all of which can render pharmaceutical products useless or in the worst case, make them dangerous to use or ingest. Safe transport and storage of pharmaceutical products is an important consideration for all manufacturers. The right packaging will be able to protect pharmaceutical items from not only moisture but also from other damaging factors such as U.V. light, odour transfer, temperature changes and even oxygen ingress. Barrier foil laminates are the product of choice, eliminating all of the above while protecting the integrity of the product inside the packaging.

18 SUSTAINABLE PACKAGING NEWS

PROTECTION FOR DELIVERY

One of the world’s leading companies in pharmaceutical packaging offers a range of aluminium foil packaging solutions for pharmaceutical intermediates which have been approved to the appropriate FDA standards, ensuring that they will be suitable to protect pharmaceutical products and aid significantly in maintaining their potency.

As for the FFS process, PPL’s single-wound sheeting and tubing offers the perfect solution. Suitable for automated, high-speed production lines this continuous roll of aluminium barrier foil is available in a variety of FDA approved laminate grades. All the company’s single-wound sheeting and tubing can be manufactured to any width and length.

Protective Packaging Ltd., provide solutions that include gusseted bags, pouches, and FFS tubing, all of which have been designed as bespoke climactic solutions for pharmaceutical goods. The bespoke gusseted barrier bags are manufactured to fit the inner dimensions of an outer ‘octabin box’, corrugated box or FIBC and will accommodate all large and bulk formats of packaging. Additionally, the gusseted bags will provide extended protection to specially formulated products, ensuring that they do not compromise efficacy before reaching their final destination. For smaller volumes of product where gusseted bags will not be suitable, it is possible instead to rely on the company’s bespoke pouches. Its flat bags are custom-made to customer’s exact specifications and are available in a wide range of laminates that provide total climatic protection. Protective Packaging Ltd (PPL) have no minimum order requirement and offer short lead times.

“ designed as bespoke climactic solutions for pharmaceutical goods “ SUSTAINABLE PACKAGING NEWS

ELOPAK

Elopak A global supplier of paper-based packaging system solutions for liquid products. Thomas Körmendi, CEO of Elopak, informs SPN about Elopak’s product developments.

“ Brands are looking for packaging that reflects the ethos of their product and consumers are opting for environmentally friendly packaging. Elopak is well positioned to meet this demand. “ 20 SUSTAINABLE PACKAGING NEWS

ELOPAK

How ‘sustainability-aware’ would you say your company is and what recent measures have you taken to improve your overall contribution to the circular economy? Sustainability is at our core. It is incorporated into every aspect of our operations, from the development of new products to the way we power our factories. Elopak’s fully renewable and recyclable Pure-Pak® cartons offer a sustainable alternative to plastic bottles.

In relation to sustainability, what would you say have been your most important milestones? In 2016 we achieved carbon neutral status. Then in 2019, Elopak was one of the first companies to formally pledge to cut greenhouse gas emissions in line with new Science Based Targets initiative criteria, aiming to keep global average temperature rise below 1.5°C.

In your opinion what have been the most significant developments in terms of recycling and bio-degradable packaging? Exciting conversations are taking place on the potential for technology to support recycling, including as part of the HolyGrail 2.0 initiative that brings together actors from across the packaging value chain to drive improvements using pioneering digital watermarks.

What do you consider to be the most promising market opportunities for your company at this time?

What are the key drivers for change in your industry sector and how much is the on-going pressure for greater sustainability and recycling affecting your productivity?

We are encouraged by the trend towards conscious consumption. Brands are looking for packaging that reflects the ethos of their product and consumers are opting for environmentally friendly packaging. Elopak is well positioned to meet this demand.

There is a big drive to increase recycling of cartons. Elopak is targeting a 70% recycling rate in the EU and Canada by 2025. To achieve this we are collaborating with a host of industry players to support initiatives such as the 4evergreen alliance, GRACE and EXTR:ACT.

SUSTAINABLE PACKAGING NEWS

ELOPAK

As we are keen to understand more about the latest trends shaping the packaging industry in your sector, what do you consider to be the most significant recent developments? When it comes to sustainability the adoption of wood-based plastics has been key and enables Elopak to offer fully renewable cartons. The elimination of the plastic closure on the Pure-Pak® Imagine has also been significant, reducing plastic content by 46%.

Can you describe your product portfolio and its sustainability credentials? Studies show cartons result in more than 70% lower CO2 emissions than PET bottles for milk and juice. Our product portfolio includes several even more sustainable cartons such as those made with Natural Brown Board, renewable plastics or the Pure-Pak® Imagine carton.

22 SUSTAINABLE PACKAGING NEWS

Are you planning the launch of any new products in the foreseeable future that you can tell us about? Elopak invests heavily in innovation to drive sustainability and product improvements, increasing R&D spending by 25% between 2017 and 2019. The Pure-Pak® Imagine carton launched earlier this year is the first in a line of new sustainable openings. Watch this space.

How has the Covid 19 pandemic affected your production and manufacturing capabilities? The pandemic has highlighted the importance of agility. With more people working from home grocery sales have risen, boosting consumption of our beverage cartons. We have had to adapt quickly, not simply maintaining operations, but stepping up a gear to meet demand.

2020 PACKAGING INNOVATIONS

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CREATING VALUE | www.emeryoleo.com SUSTAINABLE PACKAGING NEWS

MULTIFACETED ELECTRONICS

Multifaceted electronics

Photo-opportunity? Heterogeneous integration of photo-lithography – a paradigm shift. As the world of packaging embraces ever more sophisticated technologies in order to improve sustainability, the options can be bewildering. Here is one example of how technology can be used to serve the best interests of companies that use photo-lithography in order to optimise their product’s sustainability and presentation.

Gareth Kenyon - a senior product engineer, and consultant to Veeco Instruments, made the following comments. “As heterogeneity increases, convergence of device, package, and PCB will increase, creating a multitude of advanced packaging solutions that have evolved to cater to specific systems.

Recently photolithography has been forced to adapt along with the development of an advanced packaging industry. As the complexity of devices evolve, pressure on device and package scaling has become intense, giving rise to a plethora of research in established industry segments seeking to develop an opportunity. The resulting technological innovation requires new or enhanced collaborations between device, package, system designers, and manufacturers, disrupting the historical boundaries between the industry segments.

For example, high performance computing (HPC) applications demand 2.5D interposer technologies for fine pitch micro-bumping and redistribution layers (RDL). In contrast, consumer mobile and IoT markets require less stringent design rules that do not incorporate an expensive interposer, choosing to embed interconnect layers in associated mold compound using high density fan out (HD-FO) packaging technology.

“ pressure on device and package scaling has become intense “ 24 SUSTAINABLE PACKAGING NEWS

Interposer (TSV) and fan-out (TSV-less) technologies are not mutually exclusive and can be combined in a single, mixed technology package. The end use case largely determines the package requirement, and therefore, defines the complexity of both the device and the package.

MULTIFACETED ELECTRONICS

Logic

Logic / Analog / RF < 40um

TSV <

bumps

Microbumps

40um

Wiring 2um lines/spaces

Interposer

TSV Wiring 2um lines/spaces

Flip Chip <

Flip Chip 80um

“For lithography, there are two paradigms: the front end of line (FEOL) and back end of line (BEOL). Metallization interconnects have traditionally been considered a BEOL domain, but as 2.5D and 3D architectures emerge, this demarcation is blurred.

(a) Bond Pad <

Metal

Dielectric

The requirement for high performance interconnects necessitated vertical electrical connections—TSV or TMV—that pass right through the silicon or mold compound, complementing and supplanting traditional wire-bond and flip-chip solutions. Via technology has become essential for implementation of high performance interconnects.

Land Pad (b) <

20 < um

Memory

100um

Microbumps TSV <

Logic / Analog / RF < 40um

Logic

Microbumps

40um

Wiring 2um lines/spaces

Interposer

TSV Wiring 2um lines/spaces

Flip Chip <

Flip Chip 80um

(a) Bond Pad

* Heterogeneous integration exhibits the TSV and interposer capabilities

SUSTAINABLE PACKAGING NEWS

MULTIFACETED ELECTRONICS

RDL and bumping challenges “As interconnect technology changes, the lithography requirement to produce it also changes. Some prior BEOL processes now run using FEOL tools, and some BEOL tools are now performing at FEOL standards while running BEOL wafers. All photolithography processes emphasize feature resolution, critical dimension (CD) control, and overlay accuracy metrics while maintaining high productivity and low cost. FEOL lithography tools that typically operate at high numerical aperture (NA) for resolution reasons are now tasked with fine line/space, via, and micro-bump patterning for initial interconnect definition. As the density of interconnect and redistribution layers increases, the challenges relating to thicker photoresist films, substrate warpage, and depth of focus become compounded and high NA lithography systems frequenting the FEOL are no longer capable of running these difficult processes. Certain advanced packaging technologies employ more difficult process flows, leading to more difficult-to-manufacture wafers. Take, for instance, die shift and wafer topography on TSVless reconstituted eWLB or fan-out type wafers, which create challenges for overlay and depth of focus, respectively, in advanced packaging photolithography process flows. This is where a different lithography approach is required, utilizing BEOL lithography tooling that has been developed to address these issues with practical yet versatile solutions.

26 SUSTAINABLE PACKAGING NEWS

The BEOL is recognized as the domain for metallization and interconnects. Next, flip-chip (C4) bumping is a well-defined and stable process that has been an industry standard for several years. Although it too has been subjected to scaling, bumping is still fundamental to advanced packaging for heterogeneous integration. Generally, bump lithography is performed with thicker photosensitive materials that benefit from tooling with a low NA and a high depth of focus to define the larger flip-chip bumps—C4 technology. However, as industry segmentation shrinks, drawing FEOL and BEOL closer together, BEOL tool flexibility has become critical. The capability to handle warped wafers, broadband exposure—GHI, GH & I-line wavelengths—for multiple film stacks, and variable NA for resolution adaptability with large depth of focus control have all proved paramount for high productivity, high yield, and good cost of ownership. This flexibility will be extremely important, especially at outsourced semiconductor assembly and test (OSAT) facilities. Versatility to match a variety of FEOL exposure field sizes, substrate sizes, and material types are also an important consideration. The requirement of improved stage precision for tighter overlay, higher throughput for greater productivity, and tighter exposure uniformity for improved CD uniformity is merging FEOL and BEOL tool performance for leading-edge heterogenous integration technology applications.

MULTIFACETED ELECTRONICS

“ As interconnect technology changes, the lithography requirement to produce it also changes “

SUSTAINABLE PACKAGING NEWS

RESOURCE EFFICIENCY

Resource Efficiency

Phenol Phenomenon from Borealis Covestro receives first delivery of certified, renewable Phenol for Polycarbonates from Borealis. This represents the next big milestone in the strategic cooperation between, Borealis, Covestro and Neste for their use of raw materials. As part of a strategic collaboration, Covestro received a first delivery of 1,000 tons of renewable phenol from Borealis, produced with renewable hydrocarbons from Neste. Neste produces these ISCC Plus certified hydrocarbons (ISCC: International Sustainability and Carbon Certification) entirely from renewable raw materials.

28 SUSTAINABLE PACKAGING NEWS

The hydrocarbons are then converted into ISCC Plus certified phenol by Borealis and finally used by Covestro to produce the high-performance plastic polycarbonate â&#x20AC;&#x201C; as a replacement for part of the phenol previously manufactured from purely fossil resources. Polycarbonate is used in car headlights, automotive glazing, LED lights, electronic devices as well as other applications.

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primary packaging. Not only saving on initial investment costs but also removing the huge loss experienced in disposing of outdated supplies when a design refresh is needed or dictated by changes in legislation. Letâ&#x20AC;&#x2122;s go one step further. With a smart design a single print run will fulfil all branding and communication needs for a full series of products. Simply print variables directly onto the band with a thermal transfer printer, such as flavours, ingredients, codes and data. And why not just print it all onto a plain bio paper?

How does non-adhesive, linerless bandingFlexible reduce so printing much packaging tonnage? while banding Bandall banding has been gaining ground in the world of packaging as a most effective and flexible labelling and bundling concept. Equally importantly, it is also one of the fastest ways to reduce packaging volumes, simply by removing the need for excess bulky and complex packaging.

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SUSTAINABLE PACKAGING NEWS

ENVOPAP

envoPAP

Creating food-grade packaging solutions Proudly labelled as ‘the sustainable materials company’, paper packaging manufacturer envoPAP develops and creates food-grade packaging solutions, using renewable sources to support a circular economy while delivering convenience to consumers. Emma-Jane Batey speaks to founder and CEO Kaushal Shah to understand how this fast-growing company is making ‘packaging materials that make sustainability the new normal’. 30 SUSTAINABLE PACKAGING NEWS

ENVOPAP

Kaushal Shah

I wanted to reduce the burden on the earth caused by paper and packaging production by connecting it with agricultural waste.”

“ Paper is widely seen as a responsible packaging material but it actually contributes to around 40% of deforestation worldwide “

Material Benefits To understand sustainable packaging innovation is to understand changing consumer behaviour. While consumers want to know that they are not contributing negatively to environmental issues, they would prefer to buy products with responsible packaging. Increased focus on plastic pollution awareness and the role of the circular economy is crucial, and so too are the alternative packaging solutions that address both environmental and practical concerns. Innovative paper and packaging products that ‘reduce waste and revolutionise materials’ are at the heart of envoPAP, a forward-thinking, London-based certified B Corporation that was founded by entrepreneur Kaushal Shah. Shah spoke to Sustainable Packaging News to share how his visionary approach has enabled envoPAP to grow quickly and purposefully. Shah says, “I identified a clear need for truly holistic, sustainable packaging as an alternative to known tree-based paper products while at the University of Southampton.

That connection between the growing demand for sustainable packaging and the existing agricultural waste from sugar cane, wheat straw and rice from parts of India is the innovation that underpins envoPAP. Shah explains, “Paper is widely seen as a responsible packaging material but it actually contributes to around 40% of deforestation worldwide. I was inspired to create a viable foodgrade packaging solution that replaces woodbased production with existing agro-waste in order to significantly reduce our environmental footprint.”

Fair and transparent Shah notes how envoPAP ‘embraces sustainability at every level of the company’, with his dynamic approach and historical understanding of Northern India and its rural economy proving a packaging that is both high quality and low environmental impact. He continues, “We buy our fibres directly from a farmers’ union in Northern India, who in turn receive a fair price. For cane sugar for example, the fibres then go to a mill to have the cane juice removed and the resulting fibres are then cooked, turned into a slurry pulp, pressed and dried. This dried pulp is then finished according to the final product demand; there’s a lot of flexibility in terms of the look and feel of the packaging. Wheat straw goes through a similar process but can be more of an emotional toll as it involved more specific harvesting that happens only once a year; the farmers’ union we work with has over 150 farmers.”

SUSTAINABLE PACKAGING NEWS

ENVOPAP

It is clear that Shah understands deeply the practical and emotional issues connected to the creation of envoPAP packaging solutions, with his dedication to ensuring the whole concept to completion process is conducted with the utmost care and respect. He says, “It is hugely important to me that envoPAP was established in such a way that we could multiply in a responsible manner. Our ‘sustainability at every level’ promise is real; we fully honour our commitment to the 2030 UN Sustainable Development Goals and we believe that envoPAP proves waste materials have the capacity and potential to enable high quality packaging alternatives.” The passion and conviction of Kaushal Shah has been recognised by a number of respected organisations, including being included in the StatMatters ‘Thirty Under 30’, EU-India featuring him as a ‘40 Under 40’, and the Sunday Times naming envoPAP as one of its ‘10 Green Tech Companies To Watch’. Shah says, “Of course it means a lot to get that recognition, but what is most important to me is getting envoPAP recognised as a viable, sustainable packaging solution for food and non-food applications. I believe that now is the right time for envoPAP as people know we cannot just keep doing what we’re doing, yet they’re not sure about what they can do differently. During the coronavirus crisis, we’ve seen that there is a real appetite for responsible packaging that still keeps products safe and protected. Our packaging is still glossy and attractive to consumers – it’s just produced from agricultural waste and the whole supply chain is transparent and responsible.”

“ envoPAP is the perfect balance of responsibility and desirability. Our beautiful packaging has a positive story to tell and it is also ideal for protecting the product within “ 32 SUSTAINABLE PACKAGING NEWS

Ecommerce partnerships Shah and his envoPAP team are actively targeting brand owners as well as packaging manufacturers as the company is able to supply its packaging at different stages of the process, including a totally finished product. It is particularly in tune with the trend for ecommerce primary and secondary packaging, and is able to provide high gloss, printed packaging for fashion brands as well as for food and on-the-go eating. With current lead times between 75-90 days due to all processing conducted in Northern India, Shah is soon to complete a European manufacturing partnership that will retain the pro-farmer values while offering far shorter lead times of just nine days within Europe. envoPAP has established its supply chain in such a way that it has capability available across its portfolio including cups, bowls, food wraps and food containers as well as hot and cold barrier packaging for food products coming in the near future. With Shah’s careful analysis of the entire supply chain it uses to produce envoPAP products, the company is able to be nimble when it comes to customising its range. With so many accolades justly awarded and a rapidly-increasing portfolio that addresses the latest ecommerce packaging trends as well as convenience food applications for food truckstyle brands, it is clear that Kaushal Shah and his team deserve the ‘one to watch’ status. He concludes, “envoPAP is the perfect balance of responsibility and desirability. Our beautiful packaging has a positive story to tell and it is also ideal for protecting the product within. We work together with our customers to develop sustainable packaging that is exactly what their product requires and fits well with the feeling of the times; nobody wants to be irresponsible, but it can be hard to know how best to be responsible. envoPAP takes the stress out of that decision by offering a broad range of effective packaging that is sustainable in the long term.”

DataLase Case Coding Unlocking environmental and operational benefits

Inkless laser printing of variable information directly onto corrugated and SRP boxes Eliminates consumables from production lines Minimal preventative maintenance servicing Laser reliability to reduce unscheduled downtime No waste disposal considerations Late-stage customisation of packaging Enhance operational efficiencies and quality with packaging automation

Eliminates Single Use Plastics Label

Thermal Transfer Ribbon

from the supply chain

150mm x 100mm

16.8

1 million shipping labels

Reduction in carbon emissions against alternative solutions*

300Km Backing Waste to Incinerator

CO2e Assessed Product

1:1 ratio labels/ribbon

DataLase.com33 SUSTAINABLE PACKAGING NEWS

INNOVATION INSIGHT

INNOVATION insight

The boss knows best

When it comes to creating the most competent response to the world’s current sustainability problems, you need look no further than to Bossar’s latest packaging machine technology.

Bossar is a leader in the design and manufacture of optimised packaging machinery that clearly addresses the world’s quest for greater sustainability and the recycling of plastic waste. The company’s latest full-servo machines offer the most advanced technology available in HFFS machinery today. These are going a long way to achieving both goals. Another of the important features of the new Bossar range is the savings they can offer on regular maintenance, as all adjustments are carried out via their crystal-clear HMI screen. This facilitates each machine’s functionality, thus making them more reliable and more user-friendly than any other such machine on the market.

34 SUSTAINABLE PACKAGING NEWS

INNOVATION INSIGHT

In addition, Bossar excels in pouch making, and in particular, spout sealing. This is due to their in-depth knowledge gained from working in close partnership with their sister company Scholle IPN. Bossar Packaging told SPN, “We have a sophisticated, high-tech laboratory where we conduct quality trials, and scientific analysis of our packaging machinery’s performance, and obtain and collect data for our on-going investment in R&D. Inevitably, a company is just made up of people, and our employees’ combined experience and passion for our mission, makes us, and our products unique. Moreover, we have multidisciplinary staff operating throughout the company. This is thanks to the fact that most of them have benefited for their experiences in other departments within our company”.

Differentiating technology

Bossar’s most recent packaging machinery offers customers the world’s most advanced technology, all of which are designed to significantly improve packaging performances and deliver more sustainable packaging. . These unique machines have built-in features that are ahead of their time and created specifically to increase recyclability and more sustainable packaging. This is especially true of Bossar’s BMS series, which are servo driven, thus outclassing the functionality of mechanical machines.

Adding value

Bossar’s unrivalled reputation for world-class engineering, is also enhanced by its dedication to innovation and close partnership with its parent company in the United States. Scholle IPN Inc. specialises in injection moulding for a diverse range of closures and components, as well as for film extrusion and lamination. However the company is most famous for its long history of bag making, including its universally recognised, ‘Bag-in-box’ series. Bossar Packaging has been in collaboration with its partners over the last few years in order to drive a number of important sustainability projects. This has been achieved by jointly supplying its products, services and technology to increase the level of added-value offered to its customers. Today Bossar and Scholle IPN, provide vertically integrated solutions for the flexible packaging market by combining the convenience and advantages of a one-stop shop.

Bossar added, “One could draw a comparison such as the difference between a new generation electric vehicles, with an older diesel vehicles. They both do the same thing, but the latter in a different and more sustainable way. Our advanced technology clearly differentiates us from our competitors and considering the importance of switching to recyclable and sustainable packaging, our offering is far better suited to the industry’s needs, as well as to that of a vulnerable world. Our passion is driven by our focus on how to solve today’s urgent need for a more sustainable and recyclable future for the packaging industry”. SPN is fully supportive of the contribution that Bossar is making towards a greener, safer and more sustainable world.

SUSTAINABLE PACKAGING NEWS

RECYCLABILITY

Covid in Context SPN looks at how the Corona virus pandemic is impacting production and demand, and where markets are likely to be headed in the future. We also pick up on the latest news on recycling cans. A recent event held to discuss recent expansion projects and trends in the recovered fibre market in the US, led to some interesting outcomes. WestRock which operates recycling programmes and paper mills saw “significant change” that demonstrated a shift away from home-fromhome packaging to at-home packaging as the pandemic took hold. The company discovered that substantially more material was now going into curb-side bins, a fact noted by Linda Leone of WestRock, who serves as VP of recycled fibre supply at the company. The shift from commercial to residential generation results in its own impacts on fibre feedstock.

36 SUSTAINABLE PACKAGING NEWS

Residential material typically includes more contamination, and the OCC often comes in the form of smaller cardboard boxes used mainly for e-commerce sales. WestRock operates a number of mills with different cleaning capabilities. Leone added that, “Flexibility was key when adjusting to the effects of the pandemic”. In a separate move, Norpac announced that it would convert some of its capacity from printing and writing papers to produce more recycled packaging. It said that packaging, tissues and towels were the only three markets that are showing significant increases, and large enough to accommodate the company’s large machine output.

RECYCLABILITY

Every Can Counts The Covid Pandemic sparks urgent action as 86% say more needs to be done for the environment. A new survey by Every Can Counts released by Brussels PR Newswire said that a vast majority of Europeans confirmed that it is more important than ever to take care of our environment. They also said that it was imperative to recycle after COVID-19 while a staggering 91% said they would like to do more, according to a survey performed in fourteen European countries by the LUCID polling agency in association with the Every Can Counts initiative that has been raising awareness about the advantages of recycling aluminium drink cans since 2009. Many proclaimed the world would be different after the coronavirus pandemic, and the results of this poll are a sign that is coming true with a growing urgency about caring for the planet. â&#x20AC;&#x153;The findings show there is a growing awareness about the need to recycle as much waste as possible, and the COVID-19 pandemic only accelerated that process. People realise how pressing this problem is and are willing to work towards establishing a true circular economy,â&#x20AC;? Every Can Counts Europe Director David Van Heuverswyn said.

Since 2009, Every Can Counts has worked to increase awareness about recycling aluminium drink cans with the vision of recycling 100% of the cans consumed in Europe. In 2017, the drink can recycling rate stood at 74.5%, but the poll showed that 90% of respondents believe their country should recycle more if not all drink cans, and a full 4 out of 10 would like to see 100% of them getting recycled. The survey polled a sample size of 13,793 people older than 16 balanced for age and gender in 14 countries where Every Can Counts had a local initiative (Belgium, Serbia, Austria, Hungary, Greece, Romania, Poland, Czech Republic, Ireland, Netherlands, United Kingdom, Spain, Italy, France) from August 5 to September 14, 2020.

To find out more about Every Can Counts, visit: https://everycancounts.eu/press/

Moreover, a total of 52% of respondents would not put the economy over the environment, despite the economic slowdown in the wake of the COVID-19 pandemic. Two out of three said recycling is an obligation for all and that there is an urgent need to tackle the problem. More than three quarters of respondents always or often recycle all types of materials while 76% of people often or always recycle their aluminium drink cans, the most recycled beverage packaging globally.

SUSTAINABLE PACKAGING NEWS

RECYCLABILITY

The largest ever UK investment in recycling technologies Four “cutting-edge” plastics recycling plants have today secured a share of £20m in funding, thus forming part of the UK’s largest ever investment in plastic chemical recycling technologies. Designed to reduce the amount of plastic sent for landfill, incineration or export to facilities overseas, the selected recycling plants will expand the range of plastic materials which can be recycled in the UK, as well as increasing capacity for processing. The £20m investment has been made available through the government’s Industrial Strategy Challenge Fund. The agency said that when combined with more than £65m of funding from industry in support of the projects, the deals represented the largest investment the UK has made in plastic packaging recycling technologies to date. Technologies supported through the funding announced today include Teesside firm ReNew’s plan to build a ‘catalytic hydrothermal reactor’ that converts 20,000 tonnes of waste plastics per year into chemicals for use in the production of new virgin grade plastics. Poseidon Plastics has also received funding to help construct a 15,000 tonnes per year PET plastics recycling facility alongside waste and plastics specialists Biffa, Alpek Polyester UK, and DuPont Teijin Films.

38 SUSTAINABLE PACKAGING NEWS

The project aims to chemically recycle plastic waste back into new consumer goods, UKRI said. Both the ReNew and Poseidon Plastics facilities are located at the same site on Teesside, where they have the potential to create around 200 local jobs, according to UKRI.