ProPack Pro June 2021

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Up the ante with full automation

www.propack.pro June 2021

A FOCUS ON:

Independence in Gallus future Gallus’ future lies as a more independent company within the Heidelberg family

A look at Australia’s recycling capability Discussions arise around novel solutions for HDPE milk bottle contaminants

AIP announces PIDA winners for 2021 Who are all the winners from the Australasian Packaging Innovation & Design Awards?

ALSO INSIDE...

2021’s top packaging tech

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AUSTRALIA’S BEST BEST TRADE TRADE PRINTER PRINTER AUSTRALIA’S

EDITOR’S NOTE HAFIZAH OSMAN

Leading with innovation Innovation in packaging is no longer what it used to be. Cost was one of the primary concerns back in the day but much has changed since then.

These days, companies are prioritising sustainability, recyclability, reusability, embellishments for capturing customers, personalisation, security, automation and other factors over costs, and the industry has made way for these changing requirements.

And keeping the end-customer in mind, manufacturers are now further innovating the products that they’re offering to be able to deliver on these customer needs. These machines now have functionalities and capabilities that can surpass a

customer’s requirements, showing industry-leading innovation beyond its years in packaging.

When discussing innovation, it is likely for the conversation to be intertwined with technology.

In the packaging industry, real innovation occurs in design.

In this issue, we look at some of the latest technologies from packaging manufacturers, examining their key features and areas of innovation. We also look into how these technologies suit the local market and areas where companies in packaging can take advantage of opportunities to play to their strengths.

We also deep dive into Starleaton’s install of two Zünd D3 2XL-3200

machines with BHS150 systems at Billboard Media – the first installation of its kind in Asia-Pacific and only the second time two units have been installed in a single business worldwide – and showcase the solution’s innovation which resulted in Billboard Media receiving immeasurable ROI, improved productivity and better automation.

One thing is clear – to stay ahead of the pack, manufacturers need to innovate, and innovate thinking of the future ahead, while packaging companies need to adopt these technologies to deliver on market needs. Otherwise, they stand a good chance in being left behind.

We hope you enjoy the read.

Hafizah Osman Editor hosman@intermedia.com.au Ph: +61 431 466 140

Stay informed… visit www.propack.pro and subscribe to receive the latest packaging industry news and views

ProPack Industry Supporters

Managing Director & Publisher: James Wells Editor: Hafizah Osman Design: Carrie Tong

Sales Manager: Brian Moore Sales Manager: Carmen Ciappara Production Manager: Jacqui Cooper

Pre-Press Manager: Tony Willson Printed by: Hero Print, Alexandria, NSW 2015 Mailed by: D&D Mailing Services

ProPack.pro is published by Printer Media Group, registered in Australia ABN 47 628 473 334. This publication may not be reproduced or transmitted in any form in whole or in part without the written permission of the publishers. While every care has been taken in the preparation of this magazine, it is a condition of distribution that the publisher does not assume any responsibility or liability for any loss or damage which may result from any inaccuracy or omission in the publication.

4 ProPack.pro June 2021

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CONTENTS

IN THIS ISSUE...

P14-15

P6-8

Starleaton delivers on automaton with largest Zünd install at Billboard Media

A low migration-enabled Labelfire hybrid press was recently demonstrated by Gallus at its High-Performance Day event

P6-8

Starleaton installs two Zünd D3 2XL3200 machines with BHS150 systems at Billboard Media - the first installation of its kind in Asia-Pacific

Leading the way with innovation

Gallus event takes the wraps off new, low migration Labelfire P16

P10-13

As businesses pivot to address a new normal, we take a closer look at some manufacturers’ innovations that help execute on customer demands

The future of Gallus P14-15 Following the failure of the Benpac acquisition, Heidelberg CEO Rainer Hundsdörfer explains that Gallus’ future lies as a more independent company within the Heidelberg family

Recycling schemes for beauty packaging P18-20 David Jones unveils its BeautyCycle beauty packaging recycling program, while Mecca formally rolls out packaging recycling following trial

And the winners of the 2021 PIDA are...

P22-24 The winners of the 2021 Australasian Packaging Innovation and Design Awards for A/NZ were recently revealed

Discussing Australia’s recycling capability P26-27 A seminar explains novel solutions for sensing and treating residual contaminants on HDPE milk bottles

P26-27

Paper is king: Two Sides packaging survey P28-29 The study, analysed by TRMC, finds that Australians want packaging solutions that are better for the environment, are recyclable, and compostable

Australia sees launch of first Industry Insight Reports for Save Food Packaging Design P30-31 In economic terms, food waste in Australia has become a $20 billion problem that sees each person waste 298kg of food a year on average

Foodtech Packtech highlights 2021

P32

The event brought industry professionals and decision makers together, providing a forum of education and knowledge

Pack Diary

P34

A guide to the upcoming packaging industry events globally

THIS ISSUE SUPPORTED BY

www.propack.pro

Pegras International is a network of Technology Professionals with extensive management and line experience in executing successful business development strategies into the Asia Pacific region. This includes business restructuring and optimisation for supply partners to extract maximum value from joint ventures.

Print Media TECHNOLOGY CONSULTANTS Market solutions delivered via multiple pathways

June 2021 ProPack.pro 5 - Digital inks - Coldset uv inks

COVER STORY

Starleaton’s largest Zünd i 1

Starleaton installs two Zünd D3 2XL-3200 machines with BHS150 systems at Billboard Media – the first installation of its kind in Asia-Pacific

S

tarleaton, the Australian agent for Zünd, has just completed the installation of two Zünd D3 2XL-3200 machines with BHS150 systems at Billboard Media – the first installation of its kind in Asia-Pacific and only the second time two units have been installed in a single business worldwide.

Billboard Media has been a Zünd customer since December 2019 and decided on the investment following a bottleneck in its workflow at the cutting stage.

The company currently operate six flatbed printers, four UV roll-to-roll and four latex roll-to-roll printers as well as a host of finishing equipment 6 ProPack.pro June 2021

1. (l-r) Starleaton’s Ben Eaton, Billboard Media’s David Langford and Starleaton’s Dale Hawkins

which includes hot air vinyl welders, guillotines, die-cutters and table cutters.

With its six large format flatbed printers running two shifts, five days a week, Billboard Media senior production coordinator David Langford said the business could print jobs within hours, but it would take several days to progress a job through its cutting department.

“We had added an auto-platen diecutter and moved a great deal of our carton work onto it but our four existing cutting tables struggled to keep up with the signage and display work,” he said.

“We were running additional shifts at night and on weekends, which incurred labour costs that we couldn’t in good faith pass onto our customers.

We have a good reputation for fast turnaround times, so we take delays in getting product out to our customers as a failure on our part. That had to be addressed quickly.”

The Melbourne-based business predominantly plays in the large format printing space and is primarily a trade printer operating large format digital printers. Its customer base includes anyone who needs printed products –

from small independent signage contractors to multi-national print management companies and retailers.

With 65 staff employed, Billboard Media works across a wide gamut of printed products – from banners and billboards to signage, display, posters, promotion, transit and corrugated carton work. It processes materials including vinyl banners, mesh, selfadhesive vinyls, paper, corflute, screen boards, aluminium composite panels, rigid substrates and corrugated boards.

So, when the requirement for augmenting its existing cutting tables arose, Billboard Media researched into what was available in the market.

“We started to examine the pros and cons of each machine we looked at and ways to improve speed, costs and workflow,” Langford said.

“We looked at as many cutting solutions that we could find and gathered as much information as we could on each machine before making enquires. We even considered larger format die-cutters as an option.

“We try to understand every aspect of a machine’s capabilities and performance before making a decision.

In this case, we narrowed it down to two options which included Zünd. www.propack.pro

COVER STORY

install at Billboard Media By the time we were ready to talk to suppliers, Zünd was already in our prime spot.”

Billboard Media’s extensive research process included speaking to some of its customers that own older-generation Zünd cutters themselves.

“We got feedback from some of our customers who owned Zünd cutters that they were excellent machines.

Additionally, a few of our staff had worked with Zünd cutters and also highly recommended them,” he said.

Support from Starleaton

Once Billboard Media set its sights on Zünd cutters as a solution, they contacted Starleaton to determine the best technology for the business.

“Starleaton came out to our plant, looked at what we were doing and the direction we wanted to head as a business. They took time to understand what we did and how best to solve our particular issues, and recommend the Zünd D3 with BHS150,” Langford said.

“Starleaton was so confident that Zünd was the right choice for us that they provided us with a smaller cutting table to demonstrate Zünd’s capabilities. We were so impressed with the demo machine that we didn’t give it back and bought it!”

Billboard Media then ordered two Zünd D3 2XL-3200 machines with BHS150 systems.

However, with the global freight delays impacting all industries, Langford said Billboard Media too faced some delays in its delivery.

“The first D3 was originally going to be flown out to Australia; however, this was constantly pushed back as flights were either cancelled or carriers gave preference to priority freight.

Eventually, the decision was made to send the machines via sea freight.

There were a couple of parts that arrived water damaged due to the sea freight but Starleaton quickly replaced the parts and the machine was in place and running in manual mode only a few of weeks after landing,” he said.

“The second D3 machine arrived as the first was installed, and the BHS150 systems arrived a few weeks later.

Shipping delays aside, once the machines arrived, installation was fast and pain free thanks to the excellent Starleaton Zünd trained technicians.”

The solution in action

Since the installation of the two Zünd D3 2XL-3200 machines with BHS150 systems, Billboard Media has improved www.propack.pro

2. The installation of two Zünd D3 2XL-3200 machines with BHS150 systems at Billboard Media is the first of its kind in Asia-Pacific 3. The Zünd D3 2XL-3200 machines feature double beams and dual handling for maximum productivity 4. The Zünd D3 2XL3200 machines set new standards in performance with their Cut Center software automation

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3

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its operations and has been able to service its clientele quickly and efficiently without having to compromise on quality.

“We have one operator running both machines. He loads a pallet of printed sheets, starts the cutting process and is then free to perform other duties while the Zünds autonomously load, cut and stack completed sheets on a pallet,” Langford said.

“The Zünd D3s are more than three times faster than our old cutting tables – that translates to a significant increase in throughput, with one D3 taking about two to three hours to do the work an old cutting table would have taken a shift to complete.

“Downtime has also been reduced as the D3s can be left to run while staff are on breaks or even left to complete jobs autonomously and unattended after hours.

“The smart aspects of the machines mean that if they encounter a stoppage, like a broken blade, they will pause the job until the stoppage is cleared and send a message to a staff member to alert them that the machines need human intervention.”

According to Langford, the units’ speeds are their best quality.

“Getting work off the floor, cut and out to customers quickly is of great benefit. Of course, speed isn’t the only thing. The cutting must be accurate and of high quality. And there is the added benefit of automation, which means we’ve increased output without increasing labour costs,” he said.

“Unfortunately, the effect of COVID19 on our industry has meant that we are yet to see just how much of an increase in productivity the D3s have Continued on page 8 June 2021 ProPack.pro 7

COVER STORY Continued from page 7

added to our capabilities. However, we are already noticing increased throughput with jobs going out to customers which are well ahead of our previous timelines.”

Langford also added that the Zünd D3 cutters will help the business expand its current display and packaging offerings.

“Billboard Media is looking to expand our corrugated board operations,” he said.

“We are looking at increasing our corrugated board printing capabilities, which will enable us with a wider market to play in.

“This would, in turn, increase our competitiveness on longer run projects and provide quicker turnaround times for our customers.

5. Starleaton CEO Ben Eaton 6. Billboard Media senior production coordinator David Langford 7. Billboard Media’s premises has six flatbed printers, four UV roll-to-roll and four latex roll-to-roll printers and a host of finishing equipment including the Zünd machines

A closer look at the Zünd D3 Cutter

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“The Zünd D3s with BHS150 systems have fulfilled our main priorities of speed and automation.

And hopefully with increased print production, there will be a need for us to increase our conversion capacity in future. Installing additional Zünd cutters would definitely be something we would be looking at in future.”

Largest Zünd installation

The Zünd D3 machines with BHS150 systems deliver on precision

With its innovative dual-beam system, the D3 sets new standards in performance. The two beams can each be equipped with up to three different modules, doubling the throughput. The cutter controller optimally allocates the jobs to each of the two beams, aiming for maximum productivity.

The D3 Cutter is designed for precision as from drive system to blade, all components are coordinated, allowing users to produce jobs at the highest quality level, economically and efficiently. It also features a modular design concept which enables users to put together a tailor-made cutting solution configured to meet specific production needs.

As for the BHS150 board handling system, it is an industrial-level manufacturing unit that uses highly automated production lines for users to produce around the clock while keeping personnel requirements to a minimum.

The BHS150 can efficiently process materials up to 110mm thick (depending on the beam height) and offers bridge-free stacking as its off-load conveyor and stacking system deposits cut sheets in a perfect stack on a pallet.

Depending on the job, this stacking method eliminates the need for bridges to hold cut parts in place. This feature also facilitates separating cut parts from waste.

In addition, the combination of 1.5m stack height, high production speeds, and extremely short set-up times is said to lead to considerable increases in productivity and profitability.

8 ProPack.pro June 2021

Starleaton CEO Ben Eaton said the Billboard Media investment marks the “largest Zünd installation” for Starleaton to date since it took over the Zünd portfolio as its local agency several years ago.

Eaton said in the past 35 years, Billboard Media has built on its reputation as a quality printer to the retail, POS, exhibitions, advertising and media industries and this deal takes their existing relationship to new heights.

As it is the first of such installations in Asia-Pacific and the second time two units have been installed in a single business worldwide, Eaton said it highlights the benefits of introducing such automation.

“At Starleaton, we have put a huge amount of focus over the last couple years promoting these semi-automated

6

and fully-automated systems from Zünd. This latest installation is one of the largest configurations of its type,” he said.

“We have got a number of these installations coming up over the course of 2021. Ultimately, businesses are either upgrading current cutting systems to add in the semi-automated systems or are looking at other fullyautomated systems to improve their overall production efficiencies.”

Eaton also mentioned that Billboard Media made the decision to purchase two of these units as it was looking to upgrade its machinery to a model that was more automated.

“They had an ageing fleet of other smaller cutting tables and were looking to introduce automation into the business,” he said.

“The Zünd D3 2XL-3200 machines with BHS150 systems appealed to them as they are end-to-end automated cutting machines.

“It enables the business to cut pallet to pallet, having material stacked up to 1.5m, with multiple pallets at the entry point. With fully automated robotics to pick up the sheets, cut them and then move them to the other end without any human touch points, this is a true ‘lights out’ cutting solution.”

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FOCUS PACKAGING TECHNOLOGIES

Leading the way with innovation As businesses pivot to address a new normal, we take a closer look at some manufacturers’ innovations that help execute on customer demands

By Peter Kohn

Bobst Group As one of the world’s leading suppliers of substrate processing, printing and converting equipment and services for the label, flexible packaging, folding carton and corrugated industries, Switzerland’s Bobst Group, is scaling up business in 2021 as the post-pandemic markets beckon with expanded activity and renewed opportunities.

A Bobst representative makes the point that unlike many suppliers, Bobst Group can rely on all technologies: flexo, all-inone and digital.

“We don’t push one technology versus another – we simply offer solutions to optimise the entire production floor.

The recently announced Bobst Master DM5, combining flexo units and the digital Mouvent technology print engine, is probably the best label press on the market, delivering all type of labels from the PDF to final rolls. Prime, print, embellish, cut – all-in-one, all-inline.

It shows that technology can co-exist and that customers’ needs will be met using the most appropriate technology,” the spokesperson said.

For example, Bobst’s Mouvent Cluster technology comprises four Fuji Samba printheads capable of printing native

The Bobst Master DM5, which combines flexo units and the digital Mouvent technology print engine

1200 x 1200dpi up to 100m/min. A stateof-the-art electronic layer drives one million drops per second, while an ink conditioning layer ensures that each individual printhead’s ink supply is close to the printhead. There is fully automated flow regulation control for each printhead, making certain that consistent print can be maintained at high speeds.

Finally, a mechanical layer and individual control of each printhead is implemented to ensure optimal alignment. In addition, with its oneINSPECTION technology, Bobst offers a smart digital visual control system to ensure that all labels are delivered with the highest and most consistent quality, for any jobs and with any operator.

“If you are using four or six colours, or if you are using white or special inks, Mouvent Cluster technology combines high quality with high speed at levels never achieved before,” Bobst said, which is also at the cutting edge in terms of white inks.

“For decades, white printing was almost taboo for digital.

“There is a perception that white is the flexo premise.

“This was partially true – the opacity and the cost in digital were indeed not matching expectations for a while.

“It took some time to deliver a solution and now we deliver white ink at 70 per cent opacity at up to 45m/min – a world record in digital printing.”

Durst Oceania Durst’s P5 WT 250 press has been billed as one of the market’s most productive water-based ink multi-pass printers for corrugated packaging.

Durst Oceania managing director Matt Ashman said the P5 WT 250 incorporates Durst Water Technology and prints from flexo quality up to premium litho quality with odourless ink.

“Durst Water Technology is highly suited for a range of corrugated packaging and display applications. Durst WT inks are completely free of hazardous labelling and comply with the strictest health and safety regulations,” Ashman said.

He explained that as a specialist shortrun device, or as a main production machine, the P5 250 WT brings corrugated digital production up-to-date, with better-than-litho quality, direct to media.

The ink system developed by Durst is fully food compliant, he noted, and the WT (Water Technology) ink, is suited to odourless, high-quality production. The press has options ranging from manual feed-and-stack, all the way to fully 10 ProPack.pro June 2021

The P5 WT 250 is said to be one of the market’s most productive water-based ink multi-pass printers as it incorporates Durst Water Technology and prints from flexo quality up to premium litho quality with odourless ink

automated stack-to-stack production, up to 2.5m wide.

“With the trend moving to print on demand and shorter runs, with multiple SKUs, the set-up time for traditional presses is becoming a cost issue for printers,” Ashman said.

“With the Durst WT technology, the set-up time and set-up costs are eliminated, while at the same time,

the press can deliver better than litho quality. Combined with our food-safe ink technology, this is an alternative for current producers or an entry point for businesses needing to enter into the shortrun packaging sector.

“Combining this technology with the Durst Smart Shop online design and order software, a business can offer one-off, on demand packaging for B2B or B2C.” www.propack.pro

PACKAGING TECHNOLOGIES FOCUS Epson Australia Epson’s SurePress translates into a revolution in label production, according to Epson Australia managing director Craig Heckenberg.

The SurePress L-6034VW digital label press features Epson’s latest heat-free PrecisionCore line inkjet printhead technology and industrial-grade Epson UV ink. It is designed for converters focused on producing quality labels with a durable finish in short-to-medium print runs.

The press is compatible with a wide range of paper and film stocks, producing high resolution output with outstanding scratch and weather resistance.

“Jobs are quick to set up and fast to complete with minimum effort and wastage. Machines are compact, costeffective to run, and can be managed by a single operator. Output is compatible with a wide range of industry-standard

The SurePress L-6034VW digital label press features Epson’s latest heat-free PrecisionCore line inkjet printhead technology, amongst other key features

finishing equipment to enable a low set-up cost with maximum production flexibility,” he said.

The new SurePress L-6534VW prints at speeds of up to 50m/min for higher productivity with improved reliability

and usability. It also uses wide-gamut CMYK inks with a high opacity white as standard, and includes an innovative inline digital varnish which delivers smooth gloss, matte and spot finishes. It also utilises single-pass high opacity white ink which provides high-density performance and is an ideal base layer for printing vivid colour on clear or metallised substrates.

Heckenberg said the press is packaged with ESKO RIP software and can be ordered with an optional X-Rite spectrophotometer for work with custom media.

“It has never been easier to go digital and you can do it with machines that are compact, offer wide media compatibility and high production flexibility,” he said.

“Jobs can be set up and completed quickly with low wastage and minimum labour. They produce output with outstanding print quality.”

Gallus (Heidelberg A/NZ) Heidelberg A/NZ offers its Gallus range of narrow-web presses as a key tool in the development of process management to avoid or minimise time loss in the pressroom during label production.

Process management ends guesswork and approximations. It performs and records calculations such as how often deviations occur in the register during automatic changeover. Heidelberg offers the Gallus narrow-web presses – equipped with UV offset printing units and configurable with additional printing and finishing units – as the tools needed to ensure a smooth, efficient workflow.

Citing one example, on the Gallus range, changing printing units can be carried out within a few minutes. The presses are versatile and open to many configurations.

For example, a flexographic printing unit can be prepared outside the press, then positioned inside the press for a coating application. German package printing analyst Dieter Finna said one of the central

Heidelberg’s Gallus narrow-web presses are versatile and open to a variety of configurations

tasks in process management is to analyse the causes of disruptive factors and to find solutions that keep the effects on the planned work procedures to a minimum.

The aim is to avoid or minimise time loss or additional effort.

“As well as analysing short-term disruptive factors, process management also pursues medium- to longer-term goals. This involves examining market

trends and their impact on the product portfolio. To ensure that equipment can be used universally, even with changes, great importance is attached to high flexibility of press systems in terms of their configurability and retrofitting,” he said.

Finna listed the pressroom tasks that process management can streamline as process changeover times, set-up times for job changes, reproducibility of orders, web transport, web paths, substrate diversity, multi-web, flying imprint, and digital hybrid solutions.

He pointed out that today’s narrow-web presses offer great operational convenience due to their modular design and high degree of automation.

“However, a more detailed analysis of the time required for individual workflow steps reveals significant differences in the set-up and changeover times of the various press systems on offer. This is why larger label and packaging printers need to carefully examine process times,” he said.

Graffica “The packaging industry is experiencing unprecedented growth and obviously, e-commerce is a big factor,” Graffica director Neil Southerington said.

He added that packaging is booming “but so is the demand for shorter runs and ‘Just-In-Time’ (JIT) manufacture”.

For Southerington, this is especially so for the corrugated box business.

“For this area, we have fully automated box forming machines capable of making a box without a forme, gluing inline with print options.

“We also have all the ancillary equipment available,” he said.

“For carton board and corrugated packaging as well as displays, our Century die cutters have been a big hit”, he noted,

Graffica also offers 1450mm, 1650mm and 1850mm machines that suit the needs of the packaging industry

starting this year with a 1650 installed in regional NSW. Add to that two fully automatic top-sheet suction feed machines for Melbourne and Auckland.

These are in addition to Graffica’s eight installations across Australia and New Zealand in the previous three years.

“Customers like the three different feeder options to choose from – which are semiauto, lead-edge and suction top-feed, ” Southerington said.

“The other thing they really like is grippers without prongs, which means solid fibre boards can be processed, as well as plastics and of course the full range of corrugated products.”

With die cutting machines starting at 1050mm and progressing through to 2,100mm, Graffica offers machines in the 1450, 1650 and 1850mm class.

“The semi-auto machines are a much better and safer option for short runs.

They can do the work of four clam-shell cutters with only the one operative,” Southerington said.

Continued on page 12

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June 2021 ProPack.pro 11

FOCUS PACKAGING TECHNOLOGIES Continued from page 11

Graph-Pak Graph-Pak offers a number of solutions from a variety of manufacturers, but in particular this year, this vendor will be focusing on automation and high output in die cutting of labels.

Graph-Pak partners with Busch, the leading manufacturer in this field, with prices of basic entry machines starting from $50,000 and full production machines from $150,000.

As far as output goes for one of these machines, one million labels per hour is not out of the question.

Graph-Pak also offers Busch’s inline banding machinery.

With the bending machinery, paper and plastic bands are easily applied to a pre-nominated number of labels for further processing and/or shipping.

Looking back at 2020, Graph-Pak said it has survived a tough year that was heavily

The Multiple Banding Machines MB 54 / 74 / 104 from Busch focuses on automation and high outputs

affected by the coronavirus pandemic.

In 2020, the pandemic stopped Graph-Pak attending major tradeshows around the world, which it depended on for its business growth.

However, the company pushed on with its goals and continued its investment in global technology by signing a four-year agreement to represent Lombardi.

Up to that point, Lombardi, an Italian manufacturer of label printing presses, had not had any exposure in Australia, which Graph-Pak is hoping to change by bringing sales of the brand to the Australian market.

A focal point of the Lombardi offering is the Synchroline, a world-class printing press that features exceptional embellishment equipment options, enabling the device to compete on more than a dozen platforms.

The Goglio Vertical Form Fill Seal (VFFS) machinery can produce and fill block-bottom gusset bags at high speed

“The capability to achieve the popular block-bottom design in a cheaper and more productive way for coffee brands is something we are very excited about.

The block-bottom design allows for improved styling of product branding, which comes at an advantage to brands wanting to stand out from others in the market,” Jet Technologies general manager Daniel Malki said.

“Until now, brand owners have needed to purchase a pre-made bag to achieve the desired block-bottom look, which is more expensive, and was typically filled either by hand or required a standalone filler, which added further overhead costs.

“Now coffee brands can use highproductivity VFFS machinery to simultaneously make and fill the blockbottom gusset bag to order and in line with demand.”

Jet Technologies Jet Technologies is now offering its latest coffee packaging innovation with the launch of the first Vertical Form Fill Seal (VFFS) machinery in the local market that is capable of producing and filling blockbottom gusset bags at high speed.

Suited to high-output coffee production environments, this feature allows roasters to produce their own block-bottom gusset bag without needing to purchase this packaging as a pre-made bag.

Manufactured by Italian packaging machinery developer Goglio, this innovation achieves the desirable blockbottom coffee packaging design at half the cost of purchasing pre-made bags. The attractive aesthetic and practical design of the block-bottom gusset bag allows products and their branding to be showcased neatly, upright and with a strong shelf presence.

Mark Andy The Mark Andy Evolution E5 was launched at LabelExpo Brussels in September 2019 and was an immediate success, says Chris Bodger, national sales manager at Graphics, a division of Aldus.

The company is the Australian distributor and supplier for Mark Andy.

“The E5’s printing and converting architecture was taken directly from Mark Andy’s flagship Performance Series P7 model,” Bodger said.

The E5 replaced the P5 model and meant that the user could benefit from a 100 per cent fully servo-driven, shaftless press platform, with scalability in configuration for a wide range of applications.

“In a cost-driven market, the E5 offered more affordability than its predecessor the P5E, and was released in 330mm and 430mm web widths. This meant that the P7E and P9E models were typically used for 12 ProPack.pro June 2021

The E5’s printing and converting architecture was taken from Mark Andy’s flagship Performance Series P7 model

wider applications up to 660mm web width where more complex applications called for true customisation,” he said.

Bodger said the Evolution E3 and the Digital Series iQ are new additions for 2021.

The Evolution E3 has been developed to offer the label industry a fully servo, shaftless printing and converting system

in a more standardised configuration to meet the majority of their pressuresensitive label needs at a most affordable price point.

Available in standard 330mm and 430mm web widths in four- or eightcolour formats, the E3 uses the same printhead technology and tooling as the rest of the Mark Andy range.

The Digital Series iQ is the latest addition to Mark Andy’s growing digital portfolio and joins the Mark Andy Digital Pro1, Pro3 and Digital Series HD platforms. The iQ is built on the Evolution E5 platform and is powered by the highly-regarded Domino N610i Digital UV Ink Jet Engine.

The iQ fits neatly in the middle of Mark Andy’s digital portfolio as a hybrid system that is fit for the production of short-run digital labels and packaging, including shrink sleeve. www.propack.pro

PACKAGING TECHNOLOGIES FOCUS

OKI Data Australia OKI has paved the way for businesses to have a unique difference in digital printing for packaging, especially smallvolume packaging, such as food pouches, paper bags, seed packets and boxes, according to OKI Data Australia channel marketing manager Michelle Rochford.

The OKI Pro 9 Series printers are specifically designed for the graphic arts market, offering outstanding print quality, the option of CMYK plus white or clear, higher print speeds, lower total cost of ownership and unrivalled media flexibility.

“With the unique option of printing with a fifth colour, you can print on demand the full range of process colours, with the addition of a fifth spot colour in either white or clear gloss,” she said.

Rochford sees OKI’s Pro9431dn-CMYK as an optimal partner for creative agencies and design teams where producing

The OKI Pro 9 Series printers are specifically designed for the graphic arts market, offering print quality

concepts that are as close to the proposed final design is essential for client approval.

The Pro9542dn- CMYK + White is ideal for printing high-density white on coloured

or transparent media, making white on colour design possibilities endless.

“Or lay white underneath CMYK colours to create high-impact ‘colour-on-colour’ designs on coloured or transparent substrates. With outstanding print quality achieved in a single pass, the Pro9542dn is ideal for proofing, light production and short-run, on demand creative printing,” Rochford said.

And the Pro9541dn- CMYK + White or Clear equally enables lay-down of white toner on its own, in unrivalled high density, on coloured or transparent media for a stunning yet simple result.

“However, where the Pro9541dn differs is in laying white or clear toner down as the last colour, allowing you to create selective spot effects or embellishment. This can be done without costly, intricate and lengthy process restrictions,” Rochford said.

Screen GP Australia Early last year, Screen GP Australia announced the global parent company’s plans to target the package printing sector as a strategic business area. The first product, scheduled for release around the third quarter of 2021, will be an 830mm-wide web digital press for flexible packaging – the Truepress Pac 830F. This new high-speed, water-based inkjet printing system is specially designed for flexible packaging and can handle media up to 830mm wide at speeds of up to 75m/ min. It is also capable of printing at a resolution of 1,200dpi using CMYK and white water-based inks that conform to relevant food safety regulations.

Screen GP Australia managing director Peter Scott explains that these features allow it to deliver both the excellent safety and rich colour expression that is essential for the food products industry.

The Truepress Pac 830F is a high-speed, water-based inkjet printing system designed for flexible packaging

“In identifying packaging print as a major growth area of the graphic arts, Screen has conducted extensive R&D to bring sustainable, digital, variable and versatile on-demand production targeting folding cartons, corrugated and flexible packaging in addition to labels,” he said.

“The Truepress Pac 830F is an all-new high-speed, water-based inkjet system specifically designed for the flexible packaging market and represents a major

move into the flexibles market, with a powerful digital solution.”

The Pac 830F encompasses Screen’s ProSPEQ total quality technology that includes wide-gamut inks and precise colour management, gleaned from Screen’s expertise in the commercial print and label markets, with fine detail text and barcodes – essential in the FMCG sector where brand integrity matters, Scott said.

“The Pac 830F is able to meet a wide variety of flexible packaging print needs.

It also demonstrates exceptional responsiveness for small-lot jobs of less than 4,000 linear metres, an area that can be problematic for conventional production, due to the long set-up time involved and the making of flexographic plates. At present, the system handles both PET and OPP media, with Screen working to further expand compatibility,” he said.

Xeikon In February last year, Xeikon launched its REX programme to support printers looking for entry-level, affordable digital production solutions, such as the Xeikon 3030REX and the Xeikon 3050REX to suit label converters looking to move into the professional and industrial space.

Flint Group and Xeikon general manager of sales Trevor Crowley noted that one of Xeikon’s successes in 2020 was its Xeikon CX300 digital label press based on nextgeneration Cheetah 2.0 technology.

Launched in April 2020, this press was designed for mass-customisation with shorter lead times and more product diversification. The press combines high production speeds and the highest possible OEE for maximum sellable output.

In June, Xeikon demonstrated the CX300 during a live broadcast on Xeikon Cafe TV to the Australian and New Zealand markets. www.propack.pro

The Xeikon CX300 digital label press is based on nextgeneration Cheetah 2.0 technology

“With food safety guaranteed with Xeikon’s dry toner technology, both the Xeikon CX300 and the Xeikon CX500 are popular choices for printers and converters working with consumer applications such as wine & spirits and food & beverage.

Safety along with creativity and highquality colour controls are key attractions for these applications,” he said.

In September last year, Xeikon launched the Xeikon FEU Fusion Embellishment Unit to meet the demands of brand owners.

Xeikon’s FEU in partnership with MGI technology aims to provide UV spotvarnish, tactile varnish, foiling, 3D textures and holograms across a wide range of substrates.

In February 2021, Xeikon launched its Xeikon CX30 and Xeikon CX50 digital label presses built on its sixth-generation platform and based on Cheetah 2.0 technology, with new generation interfaces and cloud connection.

“These two presses fit perfectly into our portfolio between the Xeikon 3030REX and Xeikon 3050REX and the higher-end Xeikon CX300 and Xeikon CX500. The two new presses are designed to suit any label printer operating on middle capacity in all end-use segments,” Crowley said.

June 2021 ProPack.pro 13

UPDATE GALLUS

The future of Gallus 1

Following the failure of the Benpac acquisition, Heidelberg CEO Rainer Hundsdörfer explains that Gallus’ future lies as a more independent company within the Heidelberg family

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ver the last year, the label industry has been avidly following the fate of Gallus, an iconic company which was one of the original founders and key innovators of the narrow web converting industry.

This story centered on Gallus’ changing relationship with Heidelberg, a leading name in the global commercial sheet-fed press market.

It begins in 1999, when Heidelberg acquired a 30 per cent stake in Gallus with a view to better understanding the narrow web label business. There was some limited technology cooperation, particularly in the development of offset printing heads for the Gallus RCS press platform, and in some parts of the world Gallus took advantage of Heidelberg’s sales and support network to bolster its global operations. In August 2014, Heidelberg exercised its option to buy the remaining shares in Gallus, and set about fully integrating the company into Heidelberg’s global sales and service network.

14 ProPack.pro June 2021

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By Andy ThomasEmans; republished from Labels & Labeling, with permission 1. Heidelberg CEO Rainer Hundsdörfer 2. Gallus label head of business unit Dr Frank Schaum

Development of the Gallus Labelfire print engine, integrating Fujifilm printhead technology, was moved to Heidelberg’s Wiesloch manufacturing site where it formed a key plank of Heidelberg’s broader tilt towards digital across its sheet-fed operations.

Then in July, Heidelberg made the startling announcement that it had sold Gallus to Switzerland-based Benpac Holding for €120 million, a deal subsequently passed by the German Federal Cartel office and due to be closed by the end of 2020.

The closing date was postponed until the end of January 2021, but when Benpac failed to make the payment on the final deadline of January 29, the deal collapsed and Gallus remained a member of the Heidelberg group.

How had this situation come about?

And where does it leave the GallusHeidelberg relationship going forward?

These were the questions put to Heidelberg CEO Rainer Hundsdörfer and Gallus label head of business unit Dr Frank Schaum.

Navigating the COVID-19 crisis

According to Hundsdörfer, the decision to sell Gallus was taken a little over a year ago, as the COVID pandemic was sweeping across Europe.

But the subject of Gallus’ place in the Heidelberg operation was already under consideration.

“We had started a restructuring program in 2019, and one of the aims was to make Gallus more independent, so Heidelberg could concentrate on its core business of sheet-fed equipment, services, software and subscriptions,” Hundsdörfer said.

“We had already tried to fully integrate Gallus into Heidelberg, because it is close to our core packaging business, but this did not prove to be the right way. We learned narrow web label is another market.

“Sheet-fed and in-mold label is not the same customer base, except maybe just at the top. Full integration had just cost time and money.

“So, we wanted to give Gallus back its management independence so it could chart its own growth in a more agile way.

“We looked for the best of both worlds – where independence was of most importance to Gallus; and where the infrastructure of Heidelberg could be used, for example in Heidelberg’s global logistics and sales service.”

The restructuring plan was finalised in March 2020. But this was swept away a few weeks later when COVID threatened the whole industry.

“The Benpac deal did not come out of a clear sky. The company had already taken on Gallus technicians from the St Gallen operation who would otherwise have been made redundant and had expressed an interest in taking on Gallus’ wider manufacturing operations,” Hundsdörfer said.

“We had other deals with Benpac, and we had to secure Heidelberg’s financial stability, so it was a welcome offer at that time. In the tight economic situation from COVID-19, it was a logical move for us to sacrifice a good piece of growth business to get us through the crisis.”

Hundsdörfer now insists that Heidelberg’s financial situation has greatly improved compared to a year www.propack.pro

UPDATE

GALLUS

ago because of the cost-cutting and rationalisation measures the company has undertaken, meaning there was no further need to sell Gallus.

“We laid off more than 1,600 people – a program we pulled forward, so saving personnel costs, and we engaged in a number of mergers and acquisitions deals instead of selling Gallus, like getting rid of operations we do not need any more like high-tech coating and chemical companies, divesting Cerm and managing our operational network and capital in a better way,” Hundsdörfer said.

“So in the end, we could afford for the deal not to go through. We can keep Gallus and we are going back to the original strategy to give Gallus more independence. We are back to square one a year later.”

Hundsdörfer said in preparation for the Benpac sale, Gallus had already moved along the road to independence.

“The focus for Gallus now will be to push its new products and become more competitive. I am optimistic about what we have already achieved.

There is a good possibility Gallus will provide significant growth and contribute nice profits to the Heidelberg group,” he said.

Towards a digital future

Looking to the future, Hundsdörfer stressed the importance of digital printing to both Gallus and Heidelberg.

“Despite the exit from Primefire, we believe that this is important for the future of Heidelberg and we will be back with new solutions. Heidelberg put a lot of effort in and this is still the best technology in the market. It is important for Heidelberg to save this investment because it will become valuable for the Group in the not too far future, and also very important for Gallus,” he mentioned.

Hundsdörfer confirmed that Gallus’ digital assets were not part of the Benpac deal – the relationship between Heidelberg and Gallus here was too strong.

“Heidelberg acts as a (digital) supplier to Gallus, but not just a supplier/customer – it’s more like

family, and we have the opportunity to develop it further. The Gallus Labelfire is not just for printing on flexible packaging materials, but also for folding cartons. Now we are closer to Heidelberg’s core business again.

So, we will keep that technology in-house and together improve the performance level,” he added.

4

From a Gallus perspective

Dr Schaum elaborated on the company’s technology roadmap, starting with digital.

Dr Schaum said the next step for Labelfire will be both a wider 430mm web and a 250mm 4-colour model.

“We are designing the Labelfire as a modular platform which can be scaled to customer needs, so the customer can build up their own digital system in terms of print speed, colors and width,” he mentioned.

In line with Heidelberg’s push towards total service offering, Dr Schaum emphasised that digital is a business model.

“You have to include a service contract and maintenance and the full range of inks. We can now provide special inks for flexible materials or low migration and we have very good digital white, and printing at 70m/min.

It’s so important to have ink R&D in-house. Having a digital machine without having ink development in-house does not make business sense.

Everything is in one hand,” he said.

Hybrid inkjet-flexo is also a major priority, according to Dr Schaum.

“A label with high coverage of ink can use flexo printing units in the Labelfire. We are fully convinced that the hybrid concept is the way to go.

Everybody is testing business models and brand owners have their own ideas facing pressure for more SKUs, marketing innovation and multiplelanguages,” he said.

At the same time, conventional print development will not be neglected, Dr Schaum insisted.

“We still have enough applications for conventional printing at the high end with high speeds and long runs.

Also for areas of high ink coverage

3. The next step for Labelfire will be both a wider 430mm web and a 250mm 4-colour model 4. As part of its new independent position within Heidelberg, all Gallus’ conventional machine-related manufacturing will now be located in Langgöns, in Hessen, Germany

which don’t make sense for digital,” he said.

The venerable RCS platform – which remains after 20 years Gallus’s high-end machine – has been refitted with a state-of-the-art electronic control system which opens up new multi-web applications.

“This is still our highest automated platform with eleven servos per print unit. We can’t add any more,” Dr Schaum quipped.

The Labelmaster remains Gallus’ ‘bread and butter’ machine and the ECS the ‘value’ machine.

“Our next step for the Labelmaster platform is adding the next level of web width. For that we now bring additionally to the existing widths of 340mm and 440mm the web width of 570mm,” Dr Schaum said.

“This new type brings the Labelmaster, on the one hand, towards being able to offer more productivity namely 200m/min on 570mm – and on the other hand, the capability for more applications such as shrink sleeves and flexible packaging.

“For applications from 670mm web width and even more Heidelberg offers solutions out of its site in Weiden, Germany [Heidelberg Web Carton Converting GmbH]. These machines are more specialised for dedicated applications like card board and can be customised to the customer’s needs very specifically.”

The 570mm Labelmaster is currently under development and the first prototype will be delivered in the next few months.

The Gallus organisation

3

As part of its new independent position within Heidelberg, all Gallus’ conventional machinerelated manufacturing will now be located in Langgöns, in Hessen, Germany. There will be no further manufacturing in Wiesloch or St Gallen.

St Gallen will now become Gallus’ sales, service, demo and digital competence centre, while Wiesloch forms the company’s digital inkjet technology centre, along with ink R&D and digital front-end development.

Continued on page 16

www.propack.pro

June 2021 ProPack.pro 15

UPDATE GALLUS Continued from page 15

Gallus event highlights low migration Labelfire A low migrationenabled Labelfire hybrid press was demonstrated by Gallus at its HighPerformance Day event

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allus ran its first ‘virtual’ live showcase in March, with 1,500 people signing up to view multiple press demonstrations at the High-Performance Day 2021 event.

Over two days, Gallus demonstrated a Labelfire hybrid press, a Labelmaster and an RCS430 in addition to three expert breakout sessions.

The main focus was on the Gallus Labelfire hybrid press printing with low migration inks. The low migration configuration includes a nitrogen inerting unit to suppress oxygen at the point of cure and a UV booster to ensure a high level of cure. Built-in sensors monitor residual oxygen levels and UV intensity.

This is a relatively new development for Gallus-Heidelberg, and there are currently three presses in the field proving the low migration concept.

Gallus digital business development manager Martin Leonhard explained how Gallus has control over all the low migration components. The ink is developed and manufactured by Heidelberg, which also controls the digital engine development and frontend workflow.

Leonhard explained the challenges involved in developing a low migration UV inkjet ink.

“UV flexo ink manufacturers tackle the issue of migration by increasing the size of the photo-initiator molecules.

But this route is not open to UV inkjet ink developers because larger molecules are more likely to block the inkjet nozzles. Achieving a low viscosity ink formulation with a low photo-initiator ratio and the smallest possible molecular components is a big challenge,” he said.

Leonhard also stressed that the press and inks are just one component of a total low migration system.

“Pre-press is also critical. We use a reduced volume approach, an algorithm which minimizes ink laydown, since what’s not on the substrate cannot migrate,” he said.

16 ProPack.pro June 2021

Thomas Schweizer, head of product management, introduces Gallus Labelfire printing with LM inks

Good Manufacturing Practice (GMP) also had to be followed, which involves all the participants in the production chain including equipment and consumables suppliers and even the print buyer. GMP means the converter needs to keep all low migration components and operations separate from conventional (non-LM) operations, and the whole process has to be documented in a form which is ‘legally robust’. Low migration procedures must also be documented throughout the distribution chain.

Digital embellishment

The Labelfire demonstration also allowed Gallus to show off the capabilities of the Labelfire’s in-line Digital Embellishment Unit (DEU).

The DEU jets at 600 DPI resolution using Ricoh inkjet heads and is a joint development with Swiss company Steinemann Technology and Schmid Rhyner. It can print variable spot matte and gloss varnishes and cold foil adhesives as well as creating a range of haptic effects. The demonstration wine label job showed simulated embossing combined with digital cold foil metallic effects.

The addition of the flexo white station allowed Gallus to demonstrate the power of the hybrid approach in extending the breakeven point of the Labelfire against in-line flexo presses.

Gallus estimates the Labelfire breakeven at 7,000 linear metres – compared to around 2,800 linear metres for a stand-alone Labelfire without the hybrid flexo units.

The Labelfire demos also showed other aspects of the tight integration with Heidelberg. The front-end (DFE-L) is built around the Heidelberg Prinect workflow, which includes data preparation and Fogra-approved colour management. The HMI handles tasks such as job queueing, all hooked up to a server network. Variable data job preparation and automatic data check is also supported.

Avery Dennison’s Vladimir Tyulpin talked through the substrate requirements for a hybrid press. He said because UV flexo and UV inkjet inks are from the same family of products, the majority of UV flexo topcoats will be compatible with hybrid printing.

The situation is different in the US, however, where top coatings tend to be optimised for the dominant waterbased flexo process. Coatings in the UK generally need to be tailored for UV inkjet.

“Uncoated papers – for wine and premium food and spirits labels for example – present more of a problem.

While UV flexo anchors well, the different ink load and non-contact nature of inkjet can present issues.

This requires the use of papers with dedicated inkjet coatings which will not affect the look or structure of the paper,” Tyulpin said.

Andy Thomas is strategic director of Labels & Labeling, a part of Tarsus Group. Previously group managing editor for almost two decades, he has extensive knowledge of the label and package printing industry, having previously edited British Printer and Packaging News magazines in the UK.

Conventional demos The Labelmaster press on demonstration was printing a shampoo label on clear PP material, and was fitted with an integrated Digital Printbar to lay down the opaque white. The Printbar lays down a 10 micron thick film at 600 DPI resolution at speeds up to 70m/min.

The Gallus RCS 430 was shown with an integrated Pantec Rhino rotary/ flatbed hot foil embossing unit.

A screen breakout session demonstrated the possibilities of metallic doming – applying a metallic foil to screen printing to create engaging 3D effects. www.propack.pro

Advancing packaging for a more sustainable world The Power of Packaging www.dic.com.au www.dic-global.com

FOCUS HEALTH, BEAUTY AND WELLNESS

Recycling schemes for beauty packaging David Jones unveils its BeautyCycle beauty packaging recycling program, while Mecca formally rolls out packaging recycling following trial

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eauty packaging can be a challenge to recycle – most items have packaging that is made up of numerous materials, which results in it being not accepted in kerbside recycling.

As such, two of Australia’s biggest retailers, David Jones and Mecca, have recently partnered with TerraCycle – an innovative recycling company that has become a global leader in recycling hard-to-recycle materials – to offer consumers with beauty recycling services.

In light of its partnership with TerraCycle, David Jones has recently launched BeautyCycle, a specialised beauty packaging recycling program that recycles what can’t be put into the kerbside recycling bin.

To ensure no returned product ends up in landfill, special ‘drop-off boxes’ are positioned instore, where customers can easily dispose of empty beauty packaging and feel assured that they are contributing to a more sustainable footprint.

The company said this way, valuable materials aren’t lost to landfill but can be recycled to make new products, in addition to transforming the way consumers think about waste so materials stay in use out of the environment. Currently available in Australian stores only, the program lets consumers bring their clean, empty beauty packaging items to designated BeautyCycle drop off boxes located in all David Jones beauty departments.

“Our partnership with TerraCycle ensures materials collected are sorted and recycled,” the company said.

David Jones BeautyCycle accepts: · Empty plastic bottles and pumps from skincare and hair care · Empty glass bottles, jars and pots · Caps and tubes in regular, travel and sample sizes · Empty foundation bottles, compacts, lipsticks and gloss, eyeshadow palettes, mascara, eye and brow liners David Jones does not accept: · Aerosol cans or perfume bottles

18 ProPack.pro June 2021

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1. To ensure no returned product ends up in landfill, special ‘drop-off boxes’ are positioned instore 2. Mecca has partnered with TerraCycle to ensure customers’ empty beauty products don’t end up in landfill 3. Mecca has rolled out its trial beauty recycling program as a permanent initiative across all Mecca stores in Australia and New Zealand 4. Pop your clean empties into a labelled bin, or pass them on to a team member at the registers at Mecca 5. David Jones now has a beauty packaging recycling program that recycles what can’t be put into the kerbside recycling bin 6. TerraCycle A/NZ general manager Jean Bailliard welcomed the partnerships 7. BeautyCycle lets consumers bring their clean, empty beauty packaging items to designated drop off boxes

· Bottles from nail polish and nail polish remover · Electrical hair and skincare devices · False eyelashes · Bags, brushes and other beauty accessories · Full bottles of product Beauty product packaging bought from non-David Jones stores can also be disposed of via the BeautyCycle drop off boxes in these stores.

David Jones general manager of beauty Rachel Duffy-Packer said, “As a community, we are acutely aware of the fragility of our planet and this is increasingly playing a role in influencing our shopping habits and what we expect from the brands that we choose to support. Our customers have responded well to our Mindfully Made shoppable edit online. We can see their values driving their shopping behaviour, and their desire to do more.

“Our partnership with TerraCycle for our BeautyCycle program will ultimately help to break the cycle of waste in the beauty industry as together, we strive to collectively contribute to a more environmentally conscious future.”

David Jones head of sustainability Eloise Bishop added that David Jones is committed to reducing its impact on the environment by investing in programs and activities that optimise its use of energy and increase diversion of waste from landfill.

“We are also committed to exploring new ways of doing business to support a transition to the low-carbon and circular economy of the future. Our new BeautyCycle initiative is part of this commitment. It is designed to help our customers dispose of used beauty

products in a convenient way and assist in creating a beauty industry that thinks full circle,” she said.

TerraCycle A/NZ general manager Jean Bailliard said the collaboration with David Jones supports TerraCycle’s mission to move waste from a linear system to a circular one.

“The BeautyCycle initiative will educate customers on a mass scale and provide a simple solution for a busy consumer,” he said.

“Sustainable shopping has to be our future and with the support from a major retailer like David Jones, there is no limit to what we can achieve.”

As for the partnership between TerraCycle and Mecca, it branches from a trial collaboration that started within a selection of Mecca stores in October 2019, which has now been rolled out across more than 100 of its stores. Mecca said a total of 1,024kg of beauty waste was returned during the trial, enabling the business to divert 10,240 empty beauty containers from landfill during the 14-month trial alone. Now, the trial has been rolled out as a permanent initiative across all Mecca stores in A/NZ. “Rather than throwing away your already-loved bottles, pots, tubes, and palettes, TerraCycle’s recycling program lets us send back your beauty waste, ready to be sorted, processed, and transformed into something new (and just as beautiful),” Mecca said.

“Next time you have squeezed as much as you can out of your favourite beauty product’s packaging, give your local Mecca a visit and pop your clean empties into a labelled bin, or pass Continued on page 20 www.propack.pro

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FOCUS HEALTH, BEAUTY AND WELLNESS Continued from page 18

them on to a team member at the registers – we’ll take care of the rest.”

Any brand of cosmetic, hair care or skin care packaging that is empty can be put in a Mecca TerraCycle beauty waste bin, such as: · Shampoo bottles and caps · Conditioner bottles and caps · Hair gel tubes and caps · Hair spray bottles and triggers · Hair paste plastic jars and caps · Lip balm tubes · Face soap dispensers and tubes · Lotion bottles, tubes, dispensers, and jars · Shaving foam tubes (no cans) · Lip gloss tubes · Mascara tubes · Eye liner pencils and cases · Eye shadow tubes · Concealer tubes and sticks Items that can’t be deposited include: · Aerosol cans · Perfume bottles · Nail polish bottles and nail polish remover bottles · Electronic items such as blow dryers and straighteners · Any bio-medical or bio-hazardous waste or · Any contents of packaging such as nail-polish, lotion, soap or ointments

Attention SELF ADHESIVE LABEL SUPPLIERS FOR SALE Unique domain name available instantlabels.com.au Call 0408 005 034 for all enquiries

Everything collected from David Jones and Mecca is then sent to TerraCycle to be sorted and processed into raw materials that can be reused instead of being sent to landfill.

Plastics: Plastics are separated by number, melted down, and turned into pellets that can be moulded and extruded to produce new products.

Metals: Metals are separated by type and smelted into ingots for reuse.

Glass: Glass is cleaned and sorted by colour for processing. It is then crushed and melted to be used in new glass products.

Bailliard said the move tackles the problem of waste on behalf of the entire beauty industry.

“Beauty products are often made from complex materials that aren’t accepted in kerb side recycling. To make an impact, the problem of waste needs to be addressed by the beauty industry as a whole. We’re excited to support Mecca in taking a remarkable step forward in reducing the environmental impact of beauty packaging by providing a free recycling solution for A/NZ consumers,” he said.

Mecca said TerraCycle has received more than 40 tonnes of beauty waste across all beauty care recycling programs globally and that it is thrilled to support TerraCycle’s mission to eliminate the idea of waste.

“Mecca is proud to be partnering with TerraCycle to ensure our customers’ empty beauty products don’t end up in landfill. Rather than throwing away already-loved bottles, pots, tubes and palettes, TerraCycle’s recycling program allows Mecca to collect beauty waste, ready to be sorted, processed, and transformed into something new and just as beautiful,” the company said.

What is TerraCycle?

TerraCycle is a social enterprise that aims to eliminate the idea of waste. In 21 countries, it tackles the issue from many angles. TerraCycle has found that nearly everything we touch can be recycled and thus, collects typically non-recyclable items through national, first-of-theirkind recycling platforms.

Leading companies work with TerraCycle to take hard-torecycle materials from its programs, such as ocean plastic, and turn them into new products, and its Loop platform aims to change the way the world shops with favorite brands in refillable packaging offered with convenience and style.

Packaging developments in beauty...

Couleur Caramel raises the bar

Couleur Caramel developed new packaging using Polylactic Acid (PLA) and Forest Stewardship Council-certified wood. PLA is a bioplastic that is fully biodegradable and can also be recycled or used as compost.

Lumson offers PCA Glass

Lumson is now offering PCA Glass for use across the beauty industry. The move was triggered by increasing consumer demand for sustainable packaging options and the company’s commitment to ethically and economically sustainable solutions.

Wrinkles Schminkles rebrands

In celebration of its 16th birthday, Wrinkles Schminkles has conducted a rebrand involving a packaging facelift.

Packaging and ingredient reformulations were a direct response to the decision to refresh the brand’s positioning with a more contemporary look and feel.

Davines’ packaging innovation

Be quick, this won’t last long!

20 ProPack.pro June 2021

Davines recently launched its ‘SU’: before and after sun products. The multi-purpose products designed for hair and skin use the brand’s sustainability ethos to create product that’s ingredients and packaging are biodegradable. www.propack.pro

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FOCUS PACKAGING INNOVATION AND DESIGN AWARDS

And the winners of 1

The winners of the 2021 Australasian Packaging Innovation and Design Awards (PIDA) for Australia and New Zealand were recently announced at a virtual ceremony

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he Australian Institute of Packaging (AIP) has revealed the winners of the 2021 Australasian Packaging Innovation and Design Awards (PIDA), which was recently held on the 25 and 26 of May as a virtual awards ceremony.

O F Packaging, a Melbourne-based packaging company that produces and delivers top-quality flexible solutions for Australia and around the globe, came out tops, winning three gold awards at the ceremony.

The full list of winners are as follows:

Food Packaging Design of the Year

Gold award: Brookfarm (O F Packaging) The high barrier monopolymer 22 ProPack.pro June 2021

1. The gold award winners of the 2021 Australasian Packaging Innovation and Design Awards

pouch for Brookfarm (O F Packaging) was created as a more sustainable alternative to its previous metallised multi-laminate structure – all the while, keeping its existing brand heritage and pack style.

Despite being monopolymer and made entirely from PE, the pack still contains the functionality of the original, with use of a resealable zipper closure and tear notches. The main benefit of the redesign also revolves around its Recycle Ready feature and the elimination of complex laminate structure in lieu of the high-barrier recyclable alternative.

Silver award: Chobani (PakPot) Bronze award: Oasis Spice Shaker (Oasis and Qdesign Enterprises) High commendation: MasterFoods Herbs and Spices (Mars Food Australia and Cormack Packaging) High commendation: Nature’s Way SlimRight (Zipform Packaging)

Beverage Packaging Design of the Year

Gold award: Sipp Instant (Sipp Instant) As a premium instant coffee company, Sipp Instant want to be accountable for the future of the planet along with producing the best functional beverages on the market.

It has created a different product to the traditional instant category, which is totally organic and fair trade.

The new Sipp Instant packaging was designed to elevate the functionality

of the brand and features an ABAcertified home compostable internal film. The principal raw material for its cellulose is a renewable raw material from eucalyptus trees in South America. The cardboard exterior packaging is made of 100 per cent recycled cardboard and non-toxic inks.

Silver award: Flexi-Hex Sleeve and Pinch Mailer System (Macher Australia and Flexi-Hex) Bronze award: Podpress Capsule System (Reflo) High commendation: Schulz Organic Dairy (Schulz Organic Dairy and Rhima Australia)

Health, Beauty and Wellness Packaging Design of the Year

Gold award: Lovekins (Impact International) The Lovekins range has been developed as a pure and natural brand that harnesses the native flora that Australia has to offer.

The new packaging has been shifted to tubes for ease of use and without having to waste product.

The tubes are also more sustainable and locally manufactured – the Impact International range contains sugarcane derived PE and recycled PE. Gold award: Vaccine Protector (Planet Protector Packaging) The Vaccine Protector is a sustainable alternative to EPS for the transport of frozen vaccines, with all components fully recyclable or compostable. The packaging design www.propack.pro

PACKAGING INNOVATION AND DESIGN AWARDS FOCUS

the 2021 PIDA are…

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consists of three key components – a wool NOP liner encased in a metallised PE film as well as a corrugated carton.

Silver award: SolvEasy Tinea (Ego Pharmaceuticals – SolvEasy) Bronze award: rPump (Zipform Packaging)

Domestic and Household Packaging Design of the Year

Gold award: Zero Co (O F Packaging) Zero Co set out to reduce the large amount of unnecessary single-use plastics that household products typically use, and at the same time, clean up the plastic floating in the oceans. It created an innovative reuse and refill option that is made from ocean plastic and recycled plastic.

The dispensers are made from plastic rubbish that have been pulled out from the ocean, beaches and landfill. So far, it has removed over 6,000kg of plastic rubbish from the ocean. Consumers then refill their dispensers using a reusable, refill spout pouch.

Silver award: Cove (Natures Organics) Bronze award: Ikea (Packsize Australia and Ikea)

Labelling and Decoration Design of the Year

Gold award: Brookfarm (O F Packaging) This packaging is the first to market not only for the roll and recycle program but for any type of kerbside www.propack.pro

recyclable flexible packaging format made from soft plastics.

The addition of the callouts on the front of the pack communicates to consumers the new feature of this recyclable pouch.

The roll and recycle feature allows the pouch to be processed through kerbside recycling infrastructure, rather than having consumers return the pack to store for disposal.

Silver award: Pana Organic (Zipform Packaging) Bronze award: De Bortoli Petit Moscato (Cutler Brands) Bronze award: UV22 QR Print (Danone SN – Mark Purdy)

Outside of the Box Design of the Year

Gold award: rPump (Zipform Packaging) The rPump is a world-first in combining a recyclable composite paperboard pack with a reusable closure and pump in response to the recyclability and reusability challenge presented by existing wellness products. The rPump packs are manufactured with over 90 per cent fibre content and over 60 per cent PCR paperboard.

The packs are also deemed recyclable through the prep tool as a result of the high fibre content, ability to crush the pack flat, and the use of water-based adhesives to laminate the layers.

Silver award: Ventx Unico (Omni Group)

2. The gold award winners of the 2021 Australasian Packaging Innovation and Design Awards

Marketing Design of the Year

Gold award: Oasis Spice Shaker (Oasis and Qdesign Enterprises) The high polished finish to the recyclable rigid container of the Oasis Spice Shaker showcases the kaleidoscope of colours that the middle-eastern spice range offers to the consumer. Apart from the style and brand cues, mirrored across both structures and formats, the one key link is the newly created circular economy brand mark of Oasis Loop.

This mark has been used as a key vehicle to educate Oasis’ customer base of the system it promotes at checkout by encouraging refilling of the shaker containers with the large format bags.

It is the combination of these two packaging formats, and using the brand mark as the link, that lays the platform for the next development of its reuse scheme.

Silver award: Cutri Fruit (N.A.V.I Co Global) Bronze award: KitKat ‘Give the planet a Break’ wrappers and soft plastics promotional packs (Nestle Australia)

Save Food Packaging Design of the Year

Silver award: Junee Lamb (Junee Lamb and Sealed Air for cryovac brand total bone guard for agriculture) Silver award: Edgell Supa Crunch (Simplot Australia for food service) Continued on page 24 June 2021 ProPack.pro 23

FOCUS PACKAGING INNOVATION AND DESIGN AWARDS Continued from page 23

Bronze award: Southern Fresh Foods (N.A.V.I Co Global) High commendation: George Weston Foods (O F Packaging) Certificate of merit – Retail: Simson’s Pantry Wraps (True Foods and Result Group)

Sustainable Packaging Design of the Year (General)

Silver award: Kapiri Bros Tomato Punnet (BioPak) Bronze award: Nescafe Blend 43 Lid and Cap (Nestle Australia) High commendation: Blue Harvest Oyster Tray (BioPak) High commendation: Linerless Closures for Oil-Based Dressings (Wellman Packaging) High commendation: Lightweight Fliptop (Wellman Packaging)

Sustainable Packaging Design of the Year (Recycled Content)

Gold award: Squeezepak Squeezy Sauce Bottle (Wellman Packaging) The Squeezepak Squeezy Sauce Bottle with 100 per cent food grade recycled PE, is believed to be a first of its kind in the region and is part of Wellman Packaging’s overarching

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24 ProPack.pro June 2021

13. The PIDA winners were announced virtually over two days 14. The PIDA is organised by the Australian Institute of Packaging (AIP) 15. The PIDA aims to commemorate innovation and design

strategy to become better than carbon-neutral and convert all feed stocks to 100 per cent recycled or renewable content by 2025.

In addition, the bottle’s packaging features improved hot filling performance and bottle stability, about 12 per cent increased top load strength, an eight per cent possible reduction in bottle weight, an approximate 10 per cent larger brimful volume, about seven per cent larger label panel area and a multi-layer extrusion technology for reductions in pigment use by 50 per cent.

Silver award: The Collective (Pact Group) Bronze award: Colgate Palmolive (Wellman Packaging and Colgate Palmolive) High commendation: Dove (Pact Group)

Sustainable Packaging Design of the Year (Reuse)

Sustainable Packaging Design of the Year (Closed Loop)

Gold award: Oasis Spice Shaker (Oasis and Qdesign Enterprises) A newly created circular economy brand and mark of Oasis Loop was envisaged as a return to store deposit scheme. But this had to change with the emergence of COVID-19 as a result of the negative impact on returnable packs and consumer panic of hygiene and secondary use of packaging.

The mark is now used to educate Oasis’ customers of the refilling option for the shaker containers with the large format bags.

It is the combination of these two packaging formats, and using the brand mark as the link, that is said to lay the platform for the next development of its reuse scheme.

Sustainable Packaging Design of the Year (Industrial)

Gold award: Cove (Nature’s Organics) Cove is an innovative, reusable cleaning system designed to reduce waste and lessen the environmental footprint of cleaning in the kitchen, bathroom and laundry. The three key components to the Cove system are: reusable bottles, refillable pouches and plant-based ingredients.

The aluminium bottles are designed for continued reuse and durability.

The Cove refill pouches use at least 80 per cent less soft plastic compared to conventional cleaning products.

The pouches are compact, recyclable and made from soft plastic that is readily recyclable through the RedCycle program.

Silver award: Podpress Capsule System (Reflo) Bronze award: Schulz Organic Dairy (Schulz Organic Dairy and Rhima Australia)

Gold award: Ventx Unico (Omni Group) Ventx Unico’s stretch wrap is 100 per cent recyclable and the 15um film can be dispensed through the Unico ropers, reducing stretch wrap usage by over 50 per cent. The solution requires fewer wrapping rotations and significantly decreases pallet wrapping costs by halving film usage.

The stretch wrap also increases load ventilation, to help prevent moisture build-up so that goods can remain fresh and condensation free, therefore extending shelf-life and reducing damaged produce.

Silver award: 1/6 Pallet Retail Ready Platform (Chep Australia) Silver award: NZ Post Jiffy Recycled Shurtuff (Sealed Air and NZ Post – Jiffy Recycled Shurtuff) Bronze award: Polyrok (Replas) High commendation: Telstra (Birdstone Collective – Telstra)

Sustainable Packaging Design of the Year (Recycle)

Young Packaging Professional of the Year

Gold award: Melbourne Coffee (Cyclpac) The Melbourne Coffee concept evolved from a desire to challenge the space of flexible packaging and create a mono structure material for coffee. The innovative solution is a recyclable and sustainable solution for coffee, that also offers barriers to oxygen and vapour.

The packaging features include: 90 per cent LDPE, a technical barrier to gas and vapour, a mono structure lamination, BOPE, seven-layer high barrier co-extrusion with EVOH, and is reverse or surface printed.

Silver award: Woolworths Meat Tray (Woolworths Group) Bronze award: Coles Hot Smoked Salmon (Coles Supermarkets) Bronze award: Flexi-Hex Sleeve and Pinch Mailver System (Macher Australia and Flexi-Hex)

Winner: Nina Nguyen (Founder and CEO of Pakko)

Industry Packaging Professional of the Year

Winner: Alan Adams (Sustainability Director – APAC of Sealed Air)

Australasian Bioplastics Association (ABA) Scholarship Program

ABA Diploma in Packaging Technology winner: Karunia Adhiputra (Packaging Specialist at Nestlé Australia) ABA Certificate in Packaging Scholarship winner: Maria Becerill Roman (Packaging Technologist at Coles) AIP President’s Scholarship winner: Libby Treves (Packaging Technologist at Frucor Suntory) www.propack.pro

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FOCUS WASTE AND RESOURCE RECOVERY

Research and industry discuss A A seminar has brought together research and industry to explain how they developed novel solutions for sensing and treating residual contaminants on HDPE milk bottles

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esearch and industry experts recently gathered at a Towards a Waste Free Future: Technology Readiness in Waste and Resource Recovery seminar in Sydney, co-hosted by the NSW Smart Sensing Network (NSSN) and Australian Academy of Technology and Engineering (ATSE).

The seminar convened a team of research and industry partners that have banded together to enhance Australia’s recycling capability.

Brought together by the NSSN, researchers from the University of Sydney, University of Technology Sydney (UTS) and University of New South Wales (UNSW) have collaborated with major Australian companies to develop novel solutions for sensing and treating residual contaminants on HDPE milk bottles.

Project partners and industry experts involved include Labelmakers Group, Dairy Australia, Bega, Lactalis, as well as Saputo.

Led by PEGRAS Asia Pacific, the industry-driven collaboration aims to support the transition towards a thriving circular economy.

PEGRAS director and technology consultant Ian Byrne said the partnership took roots in 2017 when the Labelmakers Group approached PEGRAS about the glue used in labels and the impact they may have on recycling milk bottles.

“The problem relates to the glue sticking the labels to the milk bottles made out of HDPE. The label is only about the thickness of a strand of hair and consists of five separate layers.

About 12.5 per cent of the milk bottle surface is covered with label material that is stuck on with pressure sensitive adhesive. The glue is very hard to wash off when the milk bottle is being recycled as if we try to wash the adhesive off the flake, the adhesive permeates the entire system,” he said.

26 ProPack.pro June 2021

1. Jessica Walters (Labelmakers), Graeme Lang (Labelmakers), Dr Thomas Maschmeyer (University of Sydney) and Ad van Dijk (Bega)

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2. A Prof Yansong Shen (UNSW), A Prof Brian Hawkett (University of Sydney), Dr Melita Jazbec (UTS), Ian Byrne (PEGRAS) 3. Hugh Donnelly (FPC Food Plastics), Dr Stephanus Peters (PEGRAS), and Graeme Lang (Labelmakers) 4. Prof Benjamin Eggleton (NSSN, University of Sydney), Dr Donald McCallum (NSSN), Charles Watson (TRMC), Ivan Chua (NSSN), and Dr Tomonor Hu (NSSN)

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5. Gabrielle Upton (NSW MP) officiated the event

As such, Byrne said a QC method that yields an accurate measure of glue contamination was needed, in addition to finding a way to get rid of the glue before it permeated the system. The aim of the research project was to increase the recycling of plastics by sensing and treating label contamination.

Fast forward four years and the partnership has developed a world-first for sensing residual glue levels on recycled HDPE, involving HDPE with labels and glue attached put through an impact delamination process to remove the labels and glue from the surface.

A new chemical washing technology has also been developed to remove most residual glue from a commercial HDPE feed.

The new QC method was then used to determine the glue content of the final HDPE. This method takes into

account the non-uniform nature of the recycled flake.

A provisional patent covering this technology is being prepared.

“Reaching this target requires an ongoing collaboration between industry, government and academia.

Labelmakers has since designed four trial variations, printed 80,000 labels, and used over 4,000L of wash solution to remove them,” Byrne said.

“But the speed of design upcycle needs to be increased. Labelmakers will be transferring testing to a project test read, currently under construction.”

A new mechanical separation technology is also under development, based on impact delamination, to remove most of the labels and glue without washing.

Labelmakers Group technical manager Graeme Lang said making www.propack.pro

WASTE AND RESOURCE RECOVERY FOCUS

Australia’s recycling capability any serious inroads towards a truly circular economy requires improving the detection of the individual component parts and their separation.

“We need to design materials that lend themselves to separation within the existing infrastructure,” Lang said.

“It’s really advanced technology that’s going to allow us to separate materials, verify their integrity, and then allow them to be recycled. We can’t rely on humans to do this [task] with the accuracy level and at the volume that is needed.”

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Packaging in focus

Parliamentary secretary to the NSW Premier Gabrielle Upton, who officiated the event, said there is now a stronger understanding by government that as a country, we need to own our waste.

“Having a circular economy underscores the work done here. It’s not easy and does challenge local and federal councils and government, but putting waste into landfill must be the last resort,” she said.

“Plastics, in particular, is a wicked problem that we have.

Plastics have been a ubiquitous commodity in our lives but with the National Recycling targets, we now have realistic goals to achieve by 2025 in the recycling of these materials, including HDPE milk bottles.”

Dairy Australia program manager for innovations sustainability Ian Olmsted said it was only until recently that packaging discussions were off the table.

“It was seen as too competitive and too commercially sensitive,” he said.

“However, with the rise of the National Packaging Targets, this has changed. The targets have created momentum and a level playing field for companies to address packaging challenges and move towards more sustainable packaging outcomes.

“Dairy brands are working hard to address the challenges in sustainable packaging and through this network, we are now able to collectively work on a dairy packaging roadmap to 2025.”

Some of these projects include improving recycled content of HDPE milk bottles and to trial packaging lines which improve the recyclability of material and reduce waste in production.

PEGRAS Asia Pacific managing director Dr Stephanus Peters said plastics and bottle recycling is still in its early stage of development in Australia.

“Only a small portion of used plastics are recycled back into re-usable materials. Currently, most of these plastics are downcycled or send overseas,” Dr Peters said.

“By investing in systems designed for Australia’s unique geographical circumstances, we can stop the plastic stream from going into landfill or even worse, into the ocean.”

NSSN development manager Dr Don McCallum said the event is an excellent demonstration of utilising the research and development capabilities of NSSN member universities to tackle a complex industry problem.

“Sensing is the fundamental science to efficient sorting of waste. Sensors can help identify materials and detect toxins,” Dr McCallum said.

“The NSSN and the project partners are keen to build on the success of the current HDPE recycling project and scale the developed solutions to other recyclables. We think we’ve got a method of attacking the fundamental science problems, we’ve added to that the engineering scale-up, and we’ve got an understanding of the entire circular economy.

“We hope it’s something that can be used industry-wide and for the benefit of the whole country.” www.propack.pro

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June 2021 ProPack.pro 27

UPDATE THE REAL MEDIA COLLECTIVE

Paper is king: Two Side The study, as analysed

by TRMC, finds that Australians want packaging solutions that are better for the environment, are recyclable, as well as compostable from homes

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he Two Sides Global Survey exploring packaging preferences across Australian consumers illustrates how far we have come and the growing opportunity for fibre-based packaging across the country.

Surveying 1500 Australians across all age-groups in line with the Australian Census population mix recently in February, the survey aimed to understand consumer preferences across packaging with considerations of usage, environment and brand responsibility undertaken.

The survey was conducted across the world with participating countries including the UK, Spain, Italy, The Netherlands, The Nordics, the US, Brazil and Australia. Australian consumers responded similarly with the UK and European citizens mostly, with a key awareness of the environmental credentials of paper packaging products.

The Real Media Collective (TRMC) has historically surveyed consumer preferences across reading and habits with paper.

However, this year we have added packaging as a key growth sector of our membership. The findings demonstrate very clearly that Australians want packaging solutions that are better for the environment, are recyclable and compostable from our homes.

Key findings of the recent survey are as follows:

Better for the environment

Respondents selected paper packaging as the top substrate that is ‘better for the environment’ and ‘easier to recycle’.

They ranked packaging substrate over all other materials including glass, metals and plastics.

28 ProPack.pro June 2021

Kellie Northwood 1. Paper packaging was the top substrate that is ‘better for the environment’ and ‘easier to recycle’ 2. Paper/cardboard was the best fit for packaging 3. Paper/cardboard was the packaging material that is better for the environment and is easier to recycle 4. Paper/cardboard picked for its home compostable ability 5. Supermarkets are said to be doing enough to introduce sustainable packaging

With 58 per cent of Australians stating paper packaging is better for the environment and 51 per cent saying that it is easier to recycle, the nearest other substrate identified as ‘better for the environment’ and ‘easier to recycle’ was glass at 30 per cent and 26 per cent respectively.

We know that paper is the highest recycled household waste in the country and people understand how to recycle paper products, especially packaging. From paper boxes to now more sustainable solutions across food containers and wrappings, paper is being used more and more in homes and people are responding very well to the substrate.

This was further supported by the latest Australia’s State of the Forests Report, which was released in 2018, which reported that 1.7 million tons of recycled paper were used for domestic paper and paperboard production in Australia, contributing to 53 per cent of paper and paperboard produced.

This number, given the increase in paper packaging moving through households is expected to be much

higher present day with a new report pending release.

Compostable and recyclable equally ranked

In the Two Sides packaging study, paper products were considered able to be composted in the home and this ranks as highly as the perception of paper’s recyclability.

Whilst this may not be applicable to all paper substrates or those with embellishments, the perception is clear with 72 per cent of Australians stating that paper products are home compostable, as compared to the next nearest substrate being plastics at 11 per cent.

Compostable papers and substrates are a newly sought-after environmental condition, which consumers are keen to explore. Whilst studies show consumers are less likely to compost than recycle, it appears that there is a strong interest and possible indicator of future trends and a possible consumer demand moving forward that packaging manufacturers need to be mindful of. www.propack.pro

THE REAL MEDIA COLLECTIVE UPDATE

des packaging survey Key statistics at a glance: · Paper is a renewable resource, with the majority of paper produced for the Australian market coming from sustainably forested plantations, certified forests (83 per cent) or ISO14001 or EMAS certified (91 per cent). · Paper is 100 per cent recyclable and its recyclability is key to the ongoing supply of pulp in an industry facing global pulp shortages (Two Sides, 2019). · Paper recycling rates in Australia are amongst the highest in the world with over 87 per cent of all paper and paperboard consumed being recovered. · Australia’s only local newsprint producer recycles 100,000 tons of old newspapers and magazines each year as part of its production of newsprint (CEPI Sustainability Report, 2018). · In 2015-16, 1.7 million tons of recycled paper were used for domestic paper and paperboard production in Australia, contributing to 53 per cent of paper and paperboard produced. · A total of 1.4 million tons of recycled paper were also exported in 2015-16. · Altogether, in 2014-15 Australia recycled 60 per cent of the 5.3 million tons of paper and cardboard waste generated (Australia’s State of the Forests Report, 2018).

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Both government and individuals have a role to play in achieving sustainable targets

The study also found that consumers believe it is up to the government and brands to do more to achieve sustainable packaging targets.

On a 1:4 index, Australians reported that the government is most responsible at 2.8 and individuals at 2.5. However, they identified that brands are doing their fair share.

According to Australians aged 35-44, 74 per cent agreed that brands are doing enough to promote sustainable packaging. A well-won perception war for brands and retailers with the banning of plastic bags has also shifted to more awareness in store on packaging and environmental messaging across supply-chains, which is directly influencing consumer consciousness.

Fibre-based or paper packaging solutions is recognised as holding strong environmental credentials as paper packaging is 100 per cent recyclable, can be compostable and is a lightweight and convenient solution.

We only need to look to McDonalds and other food chains moving from plastic to paper straws, Starbucks to 100 per cent paper cups, Woolworths’ offering paper bag alternatives to plastic and other brand endorsed solutions.

This is a strong turning curve for the paper packaging industry as we have long argued for the environmental attributes of paper products and now are being heard, which is an excellent outcome for industry and the environment.

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Kellie Northwood is the CEO of The Real Media Collective, an industry Association representing the paper, print, mail, publishing and distribution companies across Australia and New Zealand. Northwood also holds the executive director position for the Australasian Paper Industry Association (APIA).

For more information contact: 03 9421 2296 or hello@thermc.com.au. www.therealmediacollective.com.au www.propack.pro

June 2021 ProPack.pro 29

UPDATE AUSTRALIAN INSTITUTE OF PACKAGING

Australia’s first Industry Insight Repo In economic terms, food waste in Australia has become a $20 billion problem that sees each person waste 298kg of food a year on average

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ustralia needs to build a sustainable food system that delivers food security, considers social, economic and environmental impacts and no longer sees food waste heading to landfill.

This is where innovative Save Food Packaging (SFP) Design has a role to play within the food system.

Sadly, Australia is one of the worst offenders for food waste and loss in the world, with a staggering 34 per cent (2.5 million tonnes) of all food wasted in the household, followed very closely with 31 per cent (2.3 million tonnes) in primary production.

In economic terms, food waste in Australia has become a $20 billion problem that sees each person waste 298kg of food a year on average.

Add to that the environmental impacts that sit behind food production including water, land, energy, labour, capital and the fact that far too much food waste is heading to landfill and creating greenhouse gas emissions.

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Nerida Kelton, AIP

1. SFP uses innovative design features to contain and protect, preserve, extend shelf life, easily open and reseal, and provide consumer convenience and portion control 2. Approximately 30 per cent of stakeholders are unwilling to redesign a product’s packaging to save on food waste 3. Shelf life of a product is the first and most important consideration within NPPDs 4. Greater SFP adoption within the food industry requires leaders to promote and give ‘case study’ examples of SFP value

What is SFP?

SFP uses innovative and intuitive design features that can contain and protect, preserve, extend shelf life, easily open and reseal, provide consumer convenience and portion control; all the while meeting global sustainable packaging targets.

To embed SFP Design into businesses, we first need to understand whether manufacturers consider food waste and loss, how packaging technologists are designing food packaging, if marketing are ensuring that on-pack communication provides the best messaging to consumers and what the barriers are to implement SFP strategies.

As a core participant of the Fight Food Waste Cooperative Research Centre, the Australian Institute of Packaging (AIP) SFP Design project has released two stakeholder industry 30 ProPack.pro June 2021

insight reports that will help to set a baseline for current design practice and enable a path forward for areas of improvement.

The SFP Consortium is made up of the AIP as project lead, and RMIT as the research partner, while project contributors include Zipform Packaging, Sealed Air, Multivac and APCO, and project partners including Plantic Technologies, Result Group and Ulma Packaging.

The Extension Network consists of the Australian Food Cold Chain Council (AFCCC), Australian Food and Grocery Council (AFGC), Australian Institute of Food Science and Technology (AIFST).

The consortium is made up of experts who work in SFP Design to ensure that the project develops

practical guidelines that are suitable for the industries they will serve.

The two reports are called 1.

Industry Insights Report: Stakeholder Online Survey of Product-Packaging Design Processes and 2. Industry Insights Report: Stakeholder Interviews of Product-Packaging Design Processes.

As Australia’s first industry insight reports for SFP, these reports represent the current landscape of the food and packaging industry regarding perceptions and practices of food waste and SFP. Key insights include: 1. Key executive and management levels are unfortunately not claiming responsibility for food waste reduction with marketing standing out as the least invested. www.propack.pro

AUSTRALIAN INSTITUTE OF PACKAGING UPDATE

orts for Save Food Packaging Design

2. Food waste mitigation considerations are mostly made in the early stages of the new product development (NPD) process and significantly less in the later stages.

3. Approximately 30 per cent of stakeholders are unwilling to redesign a product’s packaging to save on food waste.

4. Terminology and definitions of SFP Design features are still unclear, and not fully recognised within the industry.

5. Active and Intelligent Packaging and Controlled Dispensing are the areas that underutilised.

6. Greater SFP adoption within the food industry requires leaders to promote and give ‘case study’ examples of SFP value.

7. The greatest perceived barriers www.propack.pro

to SFP adoption is that it adds cost and time to production and organisations lack resources.

8. Sustainability is also perceived by industry to be a SFP function.

In Industry Insights Report 2: Stakeholder Interviews of ProductPackaging Design Processes, a food manufacturer mentioned that “...if there’s some training involved and gets more people to understand the importance of considering that save food packaging design criteria really early in the process, then I think that will be beneficial.”

This insight report further reviews the expert knowledge and perceptions from stakeholder interviews, representing a range of organisations from the Australian food industry, evaluating current SFP Design and system implementation techniques.

Other insights include: 1. Considerations of SFP are currently occurring primarily at the beginning of the new product packaging development (NPPD) process.

2. Shelf life of a product is the first and most important consideration within NPPDs. 3. Consumer food waste data is relatively unknown within the industry, relying heavily on feedback and complaints for packaging design improvements.

4. Consumer demands and trends change quickly, making it difficult for the food industry to design appropriate products.

5. There is a need for enhanced consumer education on food waste versus packaging waste.

6. Organisations were divided in their marketing of SFP to consumers; some deeming it unnecessary and others essential by others.

7. Trade-offs between achieving the 2030 Food Waste Targets and the 2025 National Packaging Targets.

8. Case studies and training modules for roles and sectors were identified as the most appropriate form of SFP design criteria to be implemented into organisations. These are being developed by the AIP. As such, the AIP looks forward to working with food and beverage manufacturers to design innovative SFP solutions that offer the lowest environmental impact and minimise food waste wherever possible.

In addition, we encourage everyone to access these reports and consider utilising some of the recommended SFP design features into your packs.

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Download the reports from: http://aipack.com.au/wp-content/ uploads/FFWCRC121_SFPDC_ OnlineSurveyReport_final-25.11.20_ v3.pdf and http://aipack.com.au/ wp-content/uploads/FFWCRC121_ SFPDC_InterviewIndustryReport_ V2_reduced.pdf Nerida Kelton is the executive director of the Australian Institute of Packaging (AIP) and vice-president – sustainability and save food of the World Packaging Organisation (WPO).

June 2021 ProPack.pro 31

FOCUS EVENTS

Foodtech Packtech highlights 2021

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oodtech Packtech (FTPT) was held successfully in Auckland at the ASB Showgrounds from 13 to 15 April. The event brought industry professionals and decision makers together, providing a forum for education, discussion and the sharing of knowledge and expertise, critical in the sustainability and growth of the industry.

The event also provided visitors with the opportunity to come faceto-face with the experts and discover the freshest ideas, latest technologies and the newest developments entering the food and beverage manufacturing and packaging technology industries.

FTPT is New Zealand’s largest food manufacturing, packaging and processing technology trade show, which has been going strong for over 20 years. Featuring excellent seminars as well as the Materials Handling & Logistics Expo, the event attracted over 200 local and international exhibiting companies and some 4000+ qualified visitors.

It was a must attend event for anyone involved in one of New Zealand’s fastest growing industry sectors.

For more information visit https://www.foodtechpacktech.co.nz/

Oji Fibre Solutions discusses its solutions with some of the attendees

The Packaging Forum offered a seminar and useful information at the event

The Eurotec team at Foodtech Packtech were all smiles

Visy’s packaging solutions were on display at the technology tradeshow

Integrated Packaging share knowledge and expertise with the attendees of the event

32 ProPack.pro June 2021

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• 1050/1300/1450/1650/1850/2100 – and now a NEW size for POS/POP a whopping big 2,300mm x 1,520mm. 2,500 sheets per hour. Does the work of FIVE Clam shell hand fed cutters or cutting tables with one operative!

• Flute and sold fibre • Corflute polypropylene etc • Full and Semi Auto – Various feeding options – Top sheet suction feed. Lead edge feeder. Lead edge suction feed and semi auto.

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• Litho Laminating machines. To 1650.

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PACK DIARY

UPCOMING EVENTS Fujifilm Virtual Exhibition

ProPak Myanmar 2021

June 24-July 9 2021 Virtual event believinginprint.fujifilm.com/eu/en/

December 8-10 2021 Yangon, Myanmar propakmyanmar.com/

ProPak Vietnam 2021

Labelexpo Southeast Asia 2022

July 28-30 2021 Ho Chi Minh City, Vietnam propakvietnam.com/

May12-14 2022 Bangkok, Thailand labelexpo-seasia.com

INDOPLAS, indopack and indoprint 2021

Label and Packaging Expo 2021

August 11-14 2021 Jakarta, Indonesia indoprintpackplas.com

September 28-October 1 2021 Melbourne, Australia labelandprintpackagingexpo.com.au/

PacPrint 2021

ProPak India 2021

September 28-October 1 2021 Melbourne, Australia pacprint.com.au

September 30-October 2 2021 Mumbai, India propakindia.com/

AUSPACK 2022

May 17-20 2022 Melbourne, Australia auspack.com.au interpack 2023

May 4-10 2023 Düsseldorf, Germany drupa.com

Got an event? Send an email to hosman@intermedia.com.au with all the details and we will put your event on the page.

Technology Solutions for Business and Industry About us

PEGRAS is a Technology Solutions Consulting company operating in the associated fields of chemistry, print media, industrial equipment and manufacturing sectors. We deliver our services by leveraging from our international network of technology professionals who have extensive management and line experience in executing successful business development strategies into your region.

This includes business restructuring and optimisation for supply partners to extract maximum value from joint ventures. PEGRAS established its roots in Europe, and over many years developed a deep understanding of Asian business cultures.

In Australia, PEGRAS is a business partner of NSSN which connects NSW universities with industry.

PEGRAS PEGRAS International Technology Solutions Consulting

pegras.com

34 ProPack.pro June 2021

Our expertise

• Business partnership identification • Business partnership negotiations • Business financial turnaround strategies • Marketing and brand management • Government relations • Media and communications strategy • Environment solutions • Advice on cultural implications and regulatory environments effectiveness and sustainable energy concepts

Our services

Print and Recycling Within the print media environment, PEGRAS has access to a network of technology professionals with extensive experience across a broad range of print consumables and production processes. Driven by a concern for the environment, this has progressively evolved into developing solutions for the circular economy needs of plastic packaging.

Industrial Services PEGRAS Industrial Services concentrates on custom-made production technologies for goods procurement, automation, evaluation, logistics and concept.

Renewable Energies PEGRAS offers renewable fuel project management, from concept to production and final sales. PEGRAS can assist in calculating tax concessions resulting from CO2 reductions.

International Relations Over the last 30 years PEGRAS has developed a large network servicing international organisations and governments. Engaged in cultural, economic and historical studies, PEGRAS provides analysis and information to multinational companies, government as well as non-government organisations.

PEGRAS Asia Pacific Pty Ltd Level 9 Avaya House 123 Epping Road Macquarie Park, NSW 2113 AUSTRALIA PEGRAS Ltd Level 29, The Offices at Centralworld 999/9, Rama I Road Pathumwan, Bangkok 10330 THAILAND

PEGRAS, Taylor-Made-Solutions e.K. Ziegelstadelstr. 3 Elsendorf, 84094 GERMANY PEGRAS International Ltd 8 Finance Street Level 19, Two International Finance Centre Central, Hong Kong CHINA

www.propack.pro

GRAPH-PAK

Since 2006 GRAPH-PAK PTY LTD has delivered high quality products and services to the printing and packaging industries in Australia & New Zealand.

Our mission is to continue to provide advanced, reliable and functional equipment and engineering solutions and services that enable our customers to maximise their business potential.

SUPPLIER PROFILE

SERIESDIE DIECUTTER CUTTER SERIES SERIES SERIES DIE DIE CUTTER CUTTER See us at

on stand D08 The Insignia is a sheet-fed, rotary, The Insignia is a sheet-fed, rotary, The Insignia aadiesheet-fed, rotary, flexo magneticisisdie cutterdesigned designed The magnetic Insignia sheet-fed, rotary, flexo cutter flexo magnetic die cutter designed SHEETFED CONVERTING for production-driven operation at magnetic die cutter designed forflexo production-driven operation at Die-Cut, Kiss-Cut, Strip and Deliver at for production-driven operation an affordable price point. production-driven operation at anforaffordable price point. an affordable price point. an affordable price point.

INSIGNIAS W/ WASTE STRIPPING UNIT

A TRUE GUIDE & GRIP REGISTER A TRUE GUIDE & GRIPSHEET-TO-SHEET REGISTER SYSTEM ENSURE SYSTEM ENSURE SHEET-TO-SHEET AACCURACY. TRUE GUIDE GRIPGUIDE REGISTER SIDE&PULL IS ACCURACY. PULL GUIDE IS ENSURE CAPABLE OF PULLING EITHER ASYSTEM TRUE SIDE GUIDE & SHEET-TO-SHEET GRIP REGISTER CAPABLE OF ENSURE PULLING EITHER ACCURACY. SIDETOPULL GUIDE IS LEFT OR RIGHT MATCH PRESS SYSTEM SHEET-TO-SHEET LEFTACCURACY. OR RIGHT TO MATCH PRESS IS CAPABLE PULLING REGISTEROFEDGES. SIDE PULL EITHER GUIDE REGISTER LEFT OREDGES. RIGHT TO MATCH PRESS CAPABLE OF PULLING EITHER REGISTER EDGES.TO MATCH PRESS LEFT OR RIGHT REGISTER EDGES. A TOP SUCTION AIR FEEDER A TOP SUCTION AIR IS POWERED VIAFEEDER A BUILT IS POWERED VIA A BUILT AINTOP SUCTION AIRINFEEDER BLOWER PUMP THE IN BLOWER PUMP INAIR POWERED ATHE BUILT MACHINE. ANVIA OPERATOR CAN AIS TOP SUCTION FEEDER MACHINE. AN OPERATOR CAN IN BLOWER PUMP THE INDEPENDENTLY IS POWERED VIA ADJUST AINBUILT INDEPENDENTLY ADJUST MACHINE. ANPUMP OPERATOR VOLUMES BOTH & IN BLOWEROF INBLOW THECAN VOLUMES OF BOTH BLOW & CAN INDEPENDENTLY ADJUST SUCTION TOANADJUST FOR THE MACHINE. OPERATOR SUCTION TORANGE ADJUST FOR THE & VOLUMES OF BOTH BLOW WIDEST OFADJUST MATERIALS INDEPENDENTLY WIDEST RANGE OF MATERIALS SUCTION ADJUST FOR THE POSSIBLE.TOOF INDEPENDENT VOLUMES BOTH BLOW & POSSIBLE. WIDEST RANGE OF SUCKERINDEPENDENT HEADS CANMATERIALS BE SUCTION TO ADJUST FOR THE SUCKER HEADS CAN POSSIBLE. INDEPENDENT ADJUSTED TO SHEET SIZE. WIDEST RANGE OFBEMATERIALS ADJUSTED TO SHEET SIZE.BE SUCKER HEADS CAN POSSIBLE. INDEPENDENT ADJUSTEDHEADS TO SHEET SIZE. SUCKER CAN BE ADJUSTED TO SHEET SIZE.

Make your mark with packaging, cartons, promotionals, ID cards, postcards and more when you offer in-house die cutting.

With Insignia your customers will appreciate the quality and fast turnaround on their high-value products.

INSIGNIAS W/ WASTE STRIPPING UNIT DELIVERY OPTIONS:W/ Shingle conveyor, STRIPPING smart stacker or in-line with INSIGNIAS WASTE UNIT folding gluing unit.

INSIGNIAS W/ WASTE STRIPPING UNIT

FEATURE-PACKED: Die-cuts, kiss-cuts, cut-scores, embosses, creases, perforates and hole punches—all with automatic waste removal.

FAST, FLEXIBLE & EASY-TO-OPERATE: Simple, fast changeovers using flexible dies and speeds up to 5,000sph. Handles substrates up to 30pt thickness. Runs in-line with a folder/gluer for a complete production line.

FOUR SIZE MODELS (in inches) : 20x15, 20x20, 24x24, 30x24

Affordable, endless die-cut possibilities.

The shape of things to come.

A RECESSED SCRIBE LINE ON A RECESSED SCRIBE LINE ON SINGLE MAGNETIC MACHINES SINGLE MAGNETIC MACHINES AALLOW RECESSED SCRIBE LINE ON FOR FAST, CONSISTENT ALLOW FOR FAST,SCRIBE CONSISTENT MAGNETIC MACHINES DIERECESSED MOUNTING & ENSURES ASINGLE LINE ONDIE DIE SINGLE MOUNTING &FAST, ENSURES DIE & ALLOW FOR CONSISTENT TOOLS ARE HUNG PARALLEL MAGNETIC MACHINES TOOLS ARE HUNG PARALLEL & DIE DIE MOUNTING ENSURES CENTERED. ALLOW FOR FAST,& CONSISTENT CENTERED. TOOLS ARE HUNG& PARALLEL & DIE MOUNTING ENSURES DIE

INSIGNIAS W/ RECEDING STACKER INSIGNIAS W/ RECEDING STACKER INSIGNIAS W/ RECEDING STACKER

INSIGNIA SERIES ROTARY DIE CUTTER

The Insignia is a sheet-fed, rotary, flexo magnetic die cutter designed for production-driven operation at an CENTERED. TOOLS ARE HUNG PARALLEL & affordable price point. Maximise your business potential and profits.

CENTERED. A PIN MOUNT machines SYSTEM ON DUAL This labour saving machine can withstand materials of density and tremendous forces, theA PIN Insignia MOUNT SYSTEM ON ENSURE DUAL MAGNETIC MACHINES are capable of applying up to 1,360kg of downward force directly to the cutting station to MAGNETIC ensureMACHINES the flexible ENSURE ATHEPINALIGNMENT MOUNT SYSTEM DUAL OF THEONPAIRED dies can cut through whatever it is being asked to do.

THEAMAGNETIC ALIGNMENT OFSYSTEM THECYLINDERS PAIRED ENSURE SET DIEMACHINES TOOLS. PINOFMOUNT ON DUAL SET MAGNETIC OF DIE TOOLS. CYLINDERS THE ALIGNMENT OF THE PAIRED ALSO HAVE BUILT-IN MICROMACHINES ENSURE INSIGNIAS W/ WASTE STRIPPING UNIT INSIGNIAS W/ RECEDING STACKER ALSOTHE HAVE BUILT-IN MICROSET OF DIE TOOLS. ADJUSTMENT CAPABILITIES TO ALIGNMENT OFCYLINDERS THE PAIRED ADJUSTMENT CAPABILITIES TO ALSO BUILT-IN MICROENSURE MATING. SET OFHAVE DIE TOOLS. CYLINDERS ENSURE MATING. ADJUSTMENT CAPABILITIES ALSO HAVE BUILT-IN MICRO-TO ENSURE MATING. ADJUSTMENT CAPABILITIES TO ENSURE MATING. HYDRAULIC PRESSURE HYDRAULIC PRESSURE ASSEMBLIES ARE ADJUSTED EASILY ASSEMBLIES AREPRESSURE ADJUSTED EASILY HYDRAULIC VIA THE BLACK WHEEL. INFINITELY Available Sizes See us at VIA ASSEMBLIES THE BLACK WHEEL. INFINITELY ARETOADJUSTED ADJUSTABLEPRESSURE UP 3,000 PSIEASILY OF HYDRAULIC ADJUSTABLE UP TO 3,000 OFEASILY VIA THE BLACK WHEEL. INFINITELY CUTTING PRESSURE IS PSI AVAILABLE. ASSEMBLIES ARE ADJUSTED • 510 x 380 CUTTING PRESSURE ISOPERATOR AVAILABLE. ADJUSTABLE UPWHEEL. TO 3,000 PSITOOF GAUGES ENABLE VIA THE BLACK INFINITELY • 510 x 510 GAUGES ENABLE OPERATOR TOPSI OF CUTTING PRESSURE IS AVAILABLE. DETERMINE MINIMUM PRESSURES Now in 4 Sizes ADJUSTABLE UP TO 3,000 on stand D08 • 760 x 610 MINIMUM PRESSURES Available in DETERMINE single and GAUGES ENABLE OPERATOR TO TO EXTEND DIEdual LIFE. CUTTING PRESSURE IS AVAILABLE. • 510 x 380 TO EXTEND DIE LIFE. magnetic cylinder drums also all in TO • 510 x 510 DETERMINE MINIMUM PRESSURES GAUGES ENABLE OPERATOR

• 610 x 610 • 760 x 610

Scan to watch the Insignia6

one hybridDETERMINE TOmodels EXTEND DIE LIFE. PRESSURES MINIMUM TO EXTEND DIE LIFE.

FOR FURTHER INFORMATION PLEASE CONTACT OUR HEAD OFFICE

Specialising in Capital Equipment PLEASE Sales, Service, Engineering FOR FURTHER INFORMATION CONTACT OUR HEAD OFFICE Specialising in Capital Equipment Sales, Service, Engineering Solutions and Consumables.

Solutions and Consumables.

FOR 1/44 FURTHER INFORMATION PLEASE CONTACT OUR HEAD OFFICE Head Office: Office: 1/44 President Avenue Caringbah, NSW, 2229, info@graph-pak.com.au Head President Avenue, Caringbah, NSW, 2229, email: email: info@graph-pak.com.au info@graph-pak.com.au SpecialisingEnquiries: in Capital Equipment Sales, Service, Engineering Enquiries: info@graph-pak.com.au FOR FURTHER INFORMATION PLEASE CONTACT OUR HEAD OFFICE Solutions and Consumables.

Specialising in Capital Equipment Sales, Service, Engineering

Unit 1G, 1-3 Endeavour Road, Caringbah NSW 2229, email: info@graph-pak.com.au Unit 1G, 1-3 Endeavour Road, Caringbah NSW 2229, email: info@graph-pak.com.au Toll Free: 1300 885 550 NSW www.graph-pak.com.au Unit Toll 1G, 1-3 Endeavour 2229, email: info@graph-pak.com.au Free: 1300Road, 885Caringbah 550 www.graph-pak.com.au Enquiries: info@graph-pak.com.au Solutions and Consumables.

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