Sustainable Packaging Africa Magazine March 2023

AFRICA Packag ng SUSTAINABLE

IN THIS ISSUE

COUNTRY FOCUS: ETHIOPIA

INDUSTRY FOCUS: TRENDS IN PHARMA

PACKAGING

PACK MATERIAL: BEER PACKAGING

MARKET TRENDS: LIGHTWEIGHING

PACKAGING INDUSTRIES LIMITED

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TAPING SOLUTIONS

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FLEXIBLE PACKAGING

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Statpack Industries Limited

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COMPANY FEATURE: Packaging Industries Limited

Carving a Niche in Sustainable Flexible Packaging

42

COUNTRY FOCUS: Ethiopia

As Ethiopia positions itself as a manufacturing hub in Africa, investment opportunities abound in the packaging sector

REGULARS

6 News Updates:

• Dow appoints Sami Mainich as President for Africa to accelerate regional operations

• Phatisa acquires minority stake in subSaharan African print and packaging firm

MHL International

• Ardagh Glass Packaging completes refinancing of South African debt facilities

• Canada imposes strict deadline on singleuse plastic products elimination

• Zaidi Recyclers launches digital platform for collecting dead car batteries for recycling

24 Suppliers News:

• Mondi, Heiber & Schröder develops eComPack machine for automated packaging

• BASF partners StePac to develop sustainable packaging for fresh produce

• Ishida Europe launches VFFS bagmaker to optimize productivity

• Liquibox launches two new automatic bagin-box filling equipment

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INDUSTRY FOCUS: Trends in Pharma Packaging

56

PACK MATERIAL: Glass persists as the material of choice in Beer Packaging

30

NEW PRODUCTS

Coca-Cola European Partners: Pet Bottles with Tethered Caps | Nestle: Recyclable paper packaging for KitKat : PepsiCo | Refillable glass bottles for Pepsi Sodas : Kellogg | Cereal packaging to help visually impaired customers

: Mars | Paper-based wrappers for its chocolate bars : Nespresso | Home-compostable coffee capsules

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MARKET TRENDS:

Lightweighting, an industry’s response to the plastic packaging problem

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FOUNDER & PUBLISHER

Francis Juma

SENIOR EDITOR

Paul Ongeto

JUNIOR EDITOR

Alphonce Okoth

BUSINESS DEVELOPMENT DIRECTOR

Virginia Nyoro

BUSINESS DEVELOPMENT ASSOCIATE

Hellen Mucheru

HEAD OF DESIGN

Clare Ngode

VIDEO & DESIGN ASSISTANT

Newton Lemein

ACCOUNTS

Jonah Sambai

Published By: FW Africa

P.O. Box 1874-00621, Nairobi Kenya

Tel: +254 20 8155022, +254725 343932

Email: info@fwafrica.net

Company Website: www.fwafrica.net

TO THE INAUGURAL ISSUE OF SUSTAINABLE PACKAGING AFRICA MAGAZINE

Welcome to the inaugural issue of our sustainable packaging Africa magazine! We are excited to be launching this publication at a time when sustainable packaging has become an increasingly important topic of discussion and action.

As we all know, packaging plays a crucial role in the transportation, preservation, and protection of goods. However, the packaging industry has also been a significant contributor to environmental pollution, particularly in the form of plastic waste. As the world continues to grapple with the consequences of climate change and pollution, it is becoming clear that the packaging industry must evolve to meet the challenges of sustainability.

Our magazine aims to be a comprehensive resource for all those involved in the packaging industry, from manufacturers and suppliers to retailers and consumers. Through our articles, interviews, and case studies, we will explore the latest trends, technologies, and innovations in sustainable packaging.

examine glass as sustainable packaging in beer and also the latest trends in pharmaceutical packaging.

Furthermore, we feature Packaging Industries Limited (PIL), a leading supplier of flexible packaging who has successfully implemented sustainable practices in its operations.

As we continue to publish our magazine, we hope to provide valuable insights and information to our readers that will inspire them to take action towards a more sustainable future. We also welcome feedback and suggestions from our readers on how we can improve our content and coverage.

Together, let us work towards a packaging industry that is not only functional but also environmentally responsible.

part of the contents without written permission from the editor is prohibited. All information is published in good faith. While care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of any action taken on the basis of information published.

In this first issue, we delve into the concept of lightweighting in plastic packaging and whether it’s a sustainable move or not. We also

Thank you for joining us on this journey.

Paul Ongeto

Editorial Lead, FW Africa

Sustainable Packaging Africa (ISSN 2307-3535) is published 6 times a year by FW Africa. Reproduction of the whole or any

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Dow appoints Sami Mainich as President for Africa to accelerate regional operations

AFRICA – Dow, one of the world’s materials science companies, has appointed Sami Mainich as the President of its Africa operations, effective immediately.

Mainich had previously served as the Managing Director for Dow North and West Africa.

In his new role, Mainich will be accountable for capitalizing on market opportunities, working closely with the businesses to drive and implement accelerated growth strategies across the region.

Neil Carr, President Dow Europe, Middle East, Africa, and India described Mainich’s appointment as a testament of Dow’s commitment to the continent.

“Sami has been a vital business leader in the company. His leadership qualities and experience fit handin-glove with the envisaged growth

opportunities in the African region,” said Carr.

“As President, Mainich’s new role will be vital in driving critical enterprise-wide initiatives to provide solutions that accelerate the continent’s industrialization and sustainability agenda.”

Mainich joined Dow in 2011 and has served in various leadership roles including Regional Director for Morocco and Algeria, and Sales Director for the Packaging & Specialty Plastics business across Middle East, Africa and Turkey region.

In 2020, Mainich was appointed Chair of the Dow Africa Steering Committee (ASC), leading a team of cross-functional leaders to boost market participation, create business synergies and drive growth.

Commenting on his appointment, Mainich said: “Africa’s path to

KENYA – US-based packaging provider NEXGEN Packaging is set to erect a new US$2 million (Sh245.5 million) plant in Nairobi to begin operations in April 2023.

The factory, to be domiciled within the Export Processing Zone at Athi River, promises at least an additional 50 direct jobs for locals on top of tilting favor for indirect investments into the region.

In addition, the investment will bolster the company’s operations in Ethiopia, Egypt and West Africa.

The facility will also expand Nexgen’s product offerings into the African market, with a focus on

industrialization requires global trade linkages, enhanced productivity, and adaptation to evolving scientific and technology trends.

“We leverage our science and technology to address today’s most pressing challenges and enable sustained and inclusive economic growth.”

sustainable solutions.

The company aims to make Kenya its primary production location in Africa.

In partnership with Contech Container Technology Ltd., Nexgen is establishing a sustainable footprint in Kenya by using “upcycled” shipping containers as the base of three facilities being constructed.

Within these facilities, Nexgen will have the ability to produce and/or deliver packaging products including care labels, heat transfers, variable data products (including RFID tags and stickers), brand identification products, woven labels and other packaging offerings.

Rwanda unveils US$221M circularity action plan for African waste

RWANDA – The government of Rwanda has unveiled a 14-year US$211.3 million circular economy action plan for African waste management at the 6th World Circular Economy Forum (WCEF).

On the first day of the event, Rwanda published its first Circular Economy Action Plan and Road Map, providing 17 concrete policy interventions and a clear direction to achieve carbon neutrality and climate resilience.

“Enabled through the financial support granted by the UN

Development Program, the Ministry of Environment is proud to present the National Circular Economy Action Plan for Rwanda,” the action plan outlines.

The action plan envisions that by 2035 Rwanda’s economy will have placed circularity at its core, ensuring the retention of resources and eliminating waste and pollution while regenerating natural systems.

“Investing in the circular economy is an investment in climate action, biodiversity protection, supply chain security, innovation as well as job

INVESTMENT

Nexus Circular secures US$150M to expand its advanced recycling process

US – Polyolefins producers Nexus Circular has raised US$150 million in seed funding to expedite the growth of advanced recycling solutions for plastics.

The funding round was led by Cox Enterprises, a private broadband company based in Atlanta, Georgia, becoming the majority owner.

Nexus will use the funds to fulfill recycled-plastic commitments by accelerating the development of its advanced recycling methods.

The company plans to build more facilities to address the growing demand for recycled plastic products. These facilities will have a total annual processing capacity of more than 250 million pounds of used plastic.

Nexus Circular CEO Jodie Morgan

said: “With this funding, our team and partners can more rapidly execute the next phase of growth, accelerating the circular economy for plastics.”

Based in Atlanta, Nexus manufactures and sells high-quality circular products certified according to ISCC PLUS standards.

The company uses landfill-bound plastics to make its products, which are claimed to have diverted more than seven million pounds of waste to date.

creation and skills development,” says Jeanne d’Arc Mujawamariya, Rwanda’s minister of environment.

WITH THIS FUNDING, OUR TEAM AND PARTNERS CAN MORE RAPIDLY EXECUTE THE NEXT PHASE OF GROWTH, ACCELERATING THE CIRCULAR ECONOMY FOR PLASTICS.

Jodie Morgan, CEO, Nexus Circular

Smurfit Kappa invests US$6.54M in solar panels at its Spanish mill

SPAIN – Irish corrugated company, Smurfit Kappa has invested US$6.54 million (€6m) at its Sanguesa paper mill in Spain, which will see the construction and installation of up to 12,000 solar panels on land adjacent to the mill.

Smurfit Kappa says that solar panels will reduce CO2 emissions by over 3200 tonnes annually and provide significant cost savings.

Once operational, it is estimated that the panels will generate more than 10 GWh of power annually which will reduce the current external electricity consumption and dependency by 7%.

Phatisa acquires minority stake in subSaharan African print and packaging firm MHL International

The Spanish solar energy project is the latest for Smurfit Kappa which has launched similar initiatives in other plants in Spain, Colombia and Mexico to generate sustainable energy.

The mill at Sanguesa is one of Smurfit Kappa’s key facilities that produce light MG kraft paper, a packaging solution widely used across industrial and consumer markets in products such as grocery bags and wrapping paper. Its customer base includes some of Europe’s largest brands.

AFRICA – Sub-Saharan private equity investor, Phatisa, has acquired a significant minority stake in MHL International Holdings Limited (“MHL”), a printing and packaging provider with strong exposure to the food and beverage sector.

MHL is a subsidiary of The Manipal Group, an India-based conglomerate with interests in printing and technology, which operates in SubSaharan Africa through subsidiaries in Kenya and Nigeria.

Manipal’s range of products cut across flexible packaging and selfadhesive labels and support a wide variety of industries, including the food, beverage and agriculture sectors.

The investment will mostly be used as expansion capital and is the fifth investment in Phatisa Food Fund 2.

Wilfrid Korsaga, Partner at Phatisa, said: “In partnership with The Manipal Group, our expansion capital aims to support the consolidation of MHL’s current market position, whilst facilitating product and geographic expansion to serve the growing printing and packaging sector in Africa.”

MHL plays a pivotal role in the East

and West African region, producing a wide variety of self-adhesive labels, shrink sleeves, and printed and packaging materials, particularly into the food, beverage, and agriculture markets.

Its packaging solutions preserve product quality and shelf-life (for consumers), whilst MHL’s in-house R&D team work closely with corporate customers to provide innovative solutions to protect their

OUR

Wilfrid Korsaga, Partner, Phatisa

brands from counterfeit labels.

Founded in 1941, The Manipal Group employs over 7,000 people spread across four continents and seven countries across the globe.

EXPANSION CAPITAL AIMS TO SUPPORT THE CONSOLIDATION OF MHL’S CURRENT MARKET POSITION, WHILST FACILITATING PRODUCT AND GEOGRAPHIC EXPANSION.

Danone to invest US$65M to establish new bottle production line in Florida, US

efficiencies.

Shane Grant, Group Deputy CEO, North Americas said: “This investment will allow us to capitalize on consumer demand in key beverage categories including coffee creamers, plant-based creamers, and ready-to-drink coffee, while also supporting our long-term growth agenda.

food to as many people as possible through purpose-driven, marketwinning growth.

As a Certified B Corp™, Danone North America leverages its business as a force for good to build a more inclusive and sustainable economy through its family of brands.

USA – Food and beverage company

Danone North America has announced that it will invest up to US$65 million over the next two years to create a new bottle production line in Jacksonville, Florida.

The investment will support Danone North America’s long-term growth strategy and will deliver key benefits across the U.S. business, including advancing operational excellence, enabling flexibility in bottle design, accelerating the company’s sustainability goals, and driving cost

“It will also help us keep our products on our customers’ shelves and give more American consumers the Danone products they love.”

According to Danone, the expansion will create up to 40 new full-time jobs with competitive wages and benefits.

New employees will be eligible for Danone North America’s parental bonding leave policy, enabling all manufacturing employees with one year of tenure to take up to 18 weeks of paid time off after the birth or adoption of a child.

Danone North America is committed to bringing health through

EGYPT – Egypt’s agrifood group Haj Arafa has announced plans to build a US$4 million date packaging unit next year in the Siwa oasis, west of Egypt.

The project will be implemented in collaboration with date producers in the region who will supply it with raw materials.

According to Al Attar, the new facility will provide, among other things, fruit sorting, cleaning and packing services.

The facility is expected to have a thermoforming packaging machine that allows dates to be packed in flexible

THIS INVESTMENT WILL ALLOW US TO CAPITALIZE ON CONSUMER DEMAND IN KEY BEVERAGE CATEGORIES INCLUDING COFFEE CREAMERS, PLANT-BASED CREAMERS, AND READY-TO-DRINK COFFEE.

Shane Grant, Group Deputy CEO, North Americas

film or rigid film, automatically.

The firm says that the production of the factory will be mainly reserved for the African and Asian markets.

It should contribute to supporting the ambitions displayed by the local industry, which wishes to increase its export revenues to US$100 million by 2024 against an envelope of around US$40 million in 2021.

The new packaging facility comes as a boost in date production in the country. According to the Food and Agriculture Organization of the United Nations (FAO) report, Egypt’s annual production of dates surpasses 1.7 million tonnes.

Egypt’s agrifood group Haj Arafa to build US$4M date packaging facility

AFMASS COMPETITIONS

• The AFMASS Cake Decoration Competition is a new initiative by the organisers of the AFMASS Food Expo that is mainly focused on promoting excellence in cake making and decoration, advancing the pastry and baking profession in Africa and to create vibe and celebration at this pan-African Expo.

BARISTA COMPETITION

• The AFMASS Cocktails Competition at the AFMASS Food Expo promotes excellence and creativity in the art (and science) of cocktails making and thereby advancing the cocktail making profession in Africa.

• The AFMASS Barista Competition at the AFMASS Food Expo promotes excellence and creativity in the art of coffee making and thereby advancing the barista profession and coffee industry in Africa.

FOUR PAVILLIONS THAT COVER THE FOOD INDUSTRY FROM A-Z

FOOD EXPO INGREDIENTS AFRICA

FOOD AFMASS DRINKS

MARKET

PACK

AFRICA EXPO Process &

Canada imposes strict deadline on singleuse plastic products elimination

Competition Tribunal blocks merger between Neopak and Corruseal

SOUTH AFRICA – The Competition Tribunal has issued an order prohibiting the proposed merger between paper and packaging company Corruseal Group and recycled containerboard and paper company Neopak Holdings.

CANADA - The government of Canada has laid out a mandatory timeline for industries to phase out and ultimately eradicate single-use plastic products throughout the country.

According to the authorities, six items are being prohibited: checkout bags, cutlery, foodservice ware made from hard-to-recycle plastics, ring carriers, stir sticks and straws.

Each item has been selected because they are commonly found in the environment, harmful to wildlife and wildlife habitat, difficult to recycle and have readily available alternatives, according to the Canadian government.

As of December 2023, all sales of those items will be prohibited. The manufacture and import for sale of these items were already banned last month.

The Canadian government says that ring carriers and flexible straws packaged with beverage containers will be prohibited in June 2024. All items sent for prohibition will also be outlawed for export sales in 2025.

The Single-use Plastics Prohibition Regulations were made under the authority of the Canadian Environmental Protection Act, 1999 (CEPA), following the addition of “plastic manufactured items” to Schedule 1 of the Act in May 2021.

The Tribunal has stated that the merger is likely to result in a substantial prevention of competition in the upstream and downstream markets.

“The Commission found that the merged entity will have the ability to act unilaterally by, for example, raising the prices of recycled containerboard, refusing to supply competitors of Corruseal who also rely on Neopak for recycled containerboard, or supplying downstream competitors on poor terms,” said the Tribunal in a statement.

The commission said the investigation revealed that the merger would result in the merged entity

The Commission said it further found that barriers to entry into the upstream market were high.

“There has been no significant production capacity installed in the upstream market for at least the last five years,” it added.

“Moreover, the Commission found that the supply of recycled containerboard paper from the upstream market to the downstream market is tight.”

Corruseal and Neopak had approached the Tribunal with a request for consideration after the Competition Commission (“the Commission”) prohibited the proposed transaction on grounds that it would likely result in a substantial prevention or lessening of competition.

having high market shares irrespective of whether production capacity, production volumes or domestic sales volumes are used to measure their size.

In their request for consideration to the Tribunal, Corruseal and Neopak sought to have the proposed merger unconditionally approved by the Tribunal or, alternatively, approved subject to conditions.

THE TRIBUNAL HAS STATED THAT THE MERGER IS LIKELY TO RESULT IN A SUBSTANTIAL PREVENTION OF COMPETITION IN THE UPSTREAM AND DOWNSTREAM MARKETS.

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Castel acquires Alver glass factory to bolster sustainability drive of reducing plastic usage

Castel has signed a letter of intent with Condor Electronics for the acquisition of 100% of the capital of Alver spa.”

“This operation confirms Castel’s desire to develop its activity in Algeria, where it already has 3 industrial sites while working to reduce the use of plastic.”

Based in Oran for over 70 years, Alver is one of the leading manufacturers and marketers of glass products in Algeria, focusing on glass bottles and jars for the local beverage and food market.

Castel said it will start to invest in modernizing the industrial facility and developing the skills of its workforce to support its long-term growth, once the transaction is approved by authorities in charge of the competition.

In line with its goal of promoting economic self-sufficiency in the regions where it operates, the French giant noted that the factory will primarily use locally sourced materials, particularly sand.

ALGERIA – French beverage company, Castel, has strengthened its diversification strategy by developing green and local production with the acquisition of a 100% of the share capital of the Alver glass factory, a subsidiary of the Condor group based in Oran.

In a statement, Castel said: “Present in Algeria for nearly 20 years and a major player in beverages in Africa,

The Alver glass factory was acquired in 2018 by Condor Electronics from the Italian subsidiary of the French group Verallia.

According to the French group, this investment responds to its desire to promote the independence of its activities concerning imports of inputs and packaging and to reduce the share of PET (Polyethylene terephthalate, a plastic oil-based) while helping to develop returnable and recyclable glass.

INDIA – The United Nations Development Programme (UNDP) has partnered with Hindustan Unilever (HUL), on a plastic circularity initiative dubbed Inclusive Circular Economy.

The initiative focuses on the end-to-end management of plastic waste by promoting the segregation of waste at source, collection of the segregated waste, and setting up Material Recovery Facilities (MRFs) for recycling all kinds of plastic waste along the value chain.

Under the partnership, the two

firms will promote waste segregation at its source and the collection of segregated waste.

UNDP and HUL will also develop material recovery facilities (MRFs) that can accept all kinds of plastic waste along the value chain.

In addition, the project aims to promote the social inclusion of wastepickers, locally known as Safai Saathis, in India’s waste management sector.

The project is a scale-up of existing partnerships under UNDP’s flagship Plastic Waste Management Programme.

CASTEL WILL START TO INVEST IN MODERNIZING THE INDUSTRIAL FACILITY AND DEVELOPING THE SKILLS OF ITS WORKFORCE TO SUPPORT ITS LONGTERM GROWTH.

UNDP India partners with HUL to drive plastic circularity in India

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CONFIRMED SPEAKERS

ASHISH PANDE Country Head, Olam Agri, Nigeria

ESSAM EL-MADDAH HR & General Secretary Director, Danone Egypt & North East Africa

JUSTIN ARCHER COO East Africa & Group Head of Sustainability, Sucafina SA

CLAUDIA CASTELLANOS Managing Director, Black Mamba

STEFFANY BERMUDEZ Policy Analyst, Sustainability Standards International Institute for Sustainable Development (IISD)

MILLICENT A. ADOBOE Co-Founder, Achiever Foods Ghana

Paloma Fernandes, OGW CEO, Cereal Millers Association, Kenya

SAINT-FRANCIS TOHLANG Corporate Affairs Director, Nestle East & Southern Africa

GAURAV VJ CEO, 260 Brands

BRETT THOMPSON Co-Founder & CEO, Mzansi Meat

YEMISI IRANLOYE Founder/CEO, Psaltry International

MICHAEL CHORSKE Operating Partner, Pegasus Capital Advisors / Sustainable African Foods, Mali

JOHN MWENDWA Public Affairs & Communications Director, Coca-Cola Beverages Africa

DAVID KAMAU Managing Director, Fortified Whole Grain Alliance

NDIDI NWUNELI Executive Chairman, Sahel Consulting & Co-Founder, AACE Foods

DAVE OKECH OKECH Founder & Chief Imagination Officer, Aquarech

MATTHIAS GRABE Managing Director, Buhler East Africa

HARRISON JUMA General Manager, Tunga Nutrition (Unga Group)

TUMISANG MATSHEKA Vice President, Supply Chain, PepsiCo South Africa

STANLEY MWORIA CEO, Aquaculture Association of Kenya

PAUL BARTELS CEO, Mogale Meat

CLAIRE VAN ENK CEO, Farm to Feed

MICHAEL ORANGI Country Director, Kenya & Tanzania, Rainforest Alliance

WILLIAM KAPFUPI Managing Executive, CCB, National Foods

TALASH HUIJBERS CEO & Founder, Insectipro

JOACHIM WESTERWELD Executive Chairman, Bio Food Products

VAISHALI MALDE Sales & Marketing & Sustainability Manager, PIL

CAESAR ASIYO Chief Development Officer, Victory Farms

NICO ROOZEN Honorary President, Solidaridad Network

ROZY RANA Managing Director, Dormans Coffee

PepsiCo to introduce recycled plastic bottles across AMESA by 2023

AMESA - PepsiCo has announced plans to introduce bottles made from recycled plastic in several markets of Africa, the Middle East and South Asia (AMESA) across beverage brands like Aquafina and Pepsi.

With only 1 country in the region allowing the use of recycled plastic in food and beverage packaging in 2020, PepsiCo continues its journey of policy unlocks aiming to introduce recycled bottles across 10 AMESA countries by 2023.

PepsiCo aims to continue its progress towards expanding plastic collection programs to 14 AMESA markets by developing recycling infrastructure through advocacy and partnerships by 2023.

The reiterated sustainability commitment comes as PepsiCo marks one year of its strategic, endto-end transformation, called pep+, which puts sustainability at the center of the company’s growth and value.

From sourcing ingredients to making and selling its products more sustainably, pep+ connects the future of its business with the future of the planet.

Envisioning a world where packaging never becomes waste, PepsiCo’s pep+ ambition aims to design 100% of its packaging to be recyclable, compostable, biodegradable or reusable by 2025.

TANZANIA – Zaidi Recyclers, a Tanzanian recycling firm has launched a digital platform (NiBOOST integrated into the Zaidi App) for collecting dead car batteries for recycling, saving the environment and humanity from harm.

The new digital platform has been put into use in the city of Dar es Salaam and is expected to expand to many localities in the near future.

According to Zaidi Recyclers CEO and founder, Allen Kimambo, customers can request the NiBOOST service by sending SMS or WhatsApp messages or calling through the Zaidi App.

The company says that they not only collect waste batteries but also provide new batteries to serve customers.

Zaidi Recyclers said they are looking for partners to expand its waste battery collection program, thereby raising people’s awareness about the dangers of batteries when thrown indiscriminately into the environment. both collect and recycle this type of waste.

Specifically, with the waste batteries

collected, Zaidi Recyclers has an agreement with professional recycling companies in Tanzania to recycle without harming the environment and people.

“When handled with the appropriate expertise, dead car batteries can be safely recycled to prevent these challenges and to encourage a circular economy approach to all material types,” said Allen Kimambo, CEO and Founder of Zaidi Recyclers.

Zaidi Recyclers launches digital platform for collecting dead car batteries for recycling

ZAIDI RECYCLERS HAS AN AGREEMENT WITH PROFESSIONAL RECYCLING COMPANIES IN TANZANIA TO RECYCLE WITHOUT HARMING THE ENVIRONMENT AND PEOPLE.

UK Government to roll out deposit return scheme in 2025

discarded in England, Wales and Northern Ireland by 85% within three years of launch.

The proposed scheme will include reverse vending machines installed at designated sites, where people can deposit plastic bottles and cans in return for cash.

The government will work with the devolved administrations and industry to begin implementing the program.

shortly after the UK announced plans to ban single-use plastic plates, trays, bowls, cutlery, balloon sticks, expanded and extruded polystyrene food and drinks containers, including cups in England from October 2023.

UK – The Department for Environment, Food and Rural Affairs (Defra) has announced plans to introduce a deposit return scheme in 2025 to improve the recycling of plastic bottles and drink cans.

The DRS aims to reduce the number of drinks containers being

UK Environment Minister Rebecca Pow said that the decision to introduce the DRS was made following a consultation, in which 83% of respondents voted in favor of the new system.

The introduction of a DRS has been planned since 2018 and was initially due to be launched in 2023, but this was delayed until late 2024 and now 2025.

The announcement also comes

Amcor acquires Chinese medical device packaging firm MDK

CHINA – Global packaging company, Amcor has announced the acquisition of Chinese medical device packaging firm MDK expanding its healthcare platform in the APAC region.

Based in Shanghai, MDK supplies paper-based packaging and coating capabilities for companies in China’s medical device sector.

The firm generates annual sales of approximately US$50 million and is a leading provider of medical device packaging, a key priority growth segment for Amcor.

MDK’s coating capabilities, medical paper-based packaging offerings and customer base complement Amcor’s existing portfolio, further enhancing its leading position in the Chinese medical device packaging market.

The addition of MDK also strengthens Amcor’s leadership in the broader Asia Pacific medical packaging segment, which now comprises four manufacturing sites serving China, India, Japan and Southeast Asian markets.

The deal is expected to close around March 2023 if it receives all customary regulatory approvals. The financial terms of the transaction have not been disclosed.

Ron Delia CEO of Amcor said: “As Amcor continues to sharpen its focus on higher growth priority segments, the addition of MDK will enhance our already strong healthcare platform in the Asia Pacific region.

THE PROPOSED SCHEME WILL INCLUDE REVERSE VENDING MACHINES INSTALLED AT DESIGNATED SITES, WHERE PEOPLE CAN DEPOSIT PLASTIC BOTTLES AND CANS IN RETURN FOR CASH.

WHAT’S ON SHOW AT THE EVENT

Mondi, Heiber & Schröder develop eComPack machine for automated packaging

GERMANY – Paper and packaging company, Mondi has partnered with German machine producer Heiber + Schröder to develop eComPack, an automated packaging machine for e-commerce.

The new eComPack machine is designed for mid to large-size eCommerce operations seeking efficiency and reliability.

It can process up to 500 parcels per hour thanks to an automated erecting, filling and closing process.

The technological expertise of paper and board packaging automation expert Heiber + Schröder forms a perfect synergy with Mondi’s innovative packaging solutions.

The resulting high-output eComPack can automatically process a wide scope of goods using one heightadaptable packaging design that is available in varied sizes.

According to the partners, the

needles

equipment stands out for its compact floor space requirement and simplicity in operation and maintenance.

The launch comes at a time when the eCommerce market has grown significantly in recent years, accounting for approximately 20% of global retail sales in 2021, according to Statista.

This means a wider variety of goods is being distributed, which increases packing complexity and

GERMANY – Munich-based provider of functional labels for the healthcare industry, Schreiner MediPharm has developed NeedleTrap, a unique label with integrated needle protection.

Needle-Trap indicates whether a prefilled syringe has been previously opened, helping protect the integrity of its contents until final use, notes the company.

Due to its integrated plastic trap, the Needle-Trap needle protection label poses special challenges to a firstopening indication feature.

Before injection, the needle trap is first folded sideways, as usual.While the cap is being pulled off, a perforation automatically activates the label-

requires versatile packaging solutions of different sizes and shapes.

At the same time, with the rising cost of labor, the desire for packing machines in eCommerce is more prominent than ever before.

To help customers tackle these challenges, eComPack provides a solution dedicated to the automated packaging of Mondi’s corrugated eCommerce solution EnvelopeMailer.

integrated seal, which irreversibly indicates the label’s initial opening.

Special security cuts prevent undetected removal of the seal. For authenticity verification, overt authentication features such as a guilloche pattern or covert security features can be added.

The addition of the new feature provides pharmaceutical manufacturers with a multifunctional and cost-efficient solution.

It combines the protection of healthcare staff against needlestick injuries with first-opening indication ensuring the integrity of the prefilled syringe on a unit level. Product and patient safety are enhanced, according to Schreiner.

Schreiner MediPharm develops tamperevident seal for syringe

THE NEW ECOMPACK MACHINE IS DESIGNED FOR MID TO LARGESIZE ECOMMERCE OPERATIONS SEEKING EFFICIENCY AND RELIABILITY.

Century installs Mark Andy Digital Series iQ press to scale operations

BASF partners

StePac to develop sustainable packaging for fresh produce

COLOMBIA – German chemical company BASF has partnered with functional packaging provider StePac to develop sustainable packaging for the fresh produce sector.

US – Century Printing & Packaging (CP&P), a label converting company, has invested in one of the newly launched Mark Andy Digital Series iQ digital hybrid presses, to grow its digital capacity.

The Digital Series iQ press is said to combine the servo platform and technology from Mark Andy’s Evolution Series with the Domino N610i UV-inkjet engine.

Mark Andy said that the press is targeted at the intermediate segment of the label market and provides the ideal balance of speed, print quality, and cost-effectiveness.

The newly installed press at Century Printing & Packaging features a four-color digital capability with three flexo units along with Mark Andy’s QCDC die-cutting equipment.

Mark Andy said that the press can print at a resolution of 600 x 600dpi across a 13″ (330mm) web at a production speed of up to 230ft/ min (70 m/min) in high-speed mode and 164 ft/min (50 m/min) in highquality mode.

The new press is said to enable Century Printing & Packaging to increase its production volume and

variety through the fast turnaround of high-quality labels with minimal waste and downtime.

Founded in 1997, Century Printing & Packaging converts labels for different markets including newspapers, chemical, nutraceutical, and the food and beverage sectors.

The label converting company now has five Mark Andy flexo presses, which include three 10” 2200 models and a 13” Performance Series P5, in addition to the latest Digital Series iQ.

BASF says it will supply StePac with its Ultramid Ccycled product, a chemically recycled polyamide 6 that will provide StePac with greater flexibility to advance contactsensitive packaging formats to a higher sustainable standard within the circular economy.

StePac, which specializes in developing packaging, says it is pioneering the use of chemically recycled plastics for the packaging of fresh perishables.

The company’s two brands, Xgo and Xtend are based on MAP technology with built-in humidity control that slows respiration inside the packaging, delays the aging process, inhibits microbial decay and preserves the quality and nutritional value of the product during prolonged storage and long-haul shipm ents.

As part of the partnership, 30% of Xtend and Xgo packaging will be made from Ultramid Ccycled, with plans to increase the content in the future.

The packaging’s MAP properties are designed to slow the ripening process and maintain the quality when in transit from Colombia to Europe.

THE NEWLY INSTALLED PRESS AT CENTURY PRINTING & PACKAGING FEATURES A FOURCOLOR DIGITAL CAPABILITY WITH THREE FLEXO UNITS ALONG WITH MARK ANDY’S QCDC DIECUTTING EQUIPMENT.

Harpak-ULMA introduces TFS 216 thermoforming machine for fresh food packaging

waste.

The cardboard base material can be printed on both sides with product or marketing information and is registered.

The use of transport chains, a design common in most conventional thermoformers, requires that part of the original reel width be discarded as scrap.

US – Harpak-ULMA has unveiled the ULMA TFS 216 thermoforming machine, which is designed to offer more sustainable packaging for fresh food products.

The TFS 216 takes ULMA’s pursuit of sustainable packaging solutions a step further by offering a new model

of thermoforming machine designed to package fresh products in vacuum skin packs on a flat cardboard base.

The TFS 216 uses cardboard roll stock to produce the flat, nonthermoformed base of the packaging – eliminating the need for a plastic tray while generating zero cardboard

In contrast, the TFS 216 is equipped with an innovative bottom film traction system without chain, so the LeafSkin packaging produced retains all of the base material, regardless of its width.

This TFS 216 is part of the ULMAweCare range of solutions, which target more sustainable packaging with a smaller environmental impact.

EUROPE – Ishida Europe has launched a new INSPIRA Box Motion vertical form fill seal (VFFS) bagmaker to facilitate a lower-cost and flexible operation process for snack manufacturers.

According to Ishida Europe, the new VFFS utilizes 17% less energy in operation and 25% less on standby than previous models.

Capable of operating in both continuous and intermittent motion modes, the machine features box motion technology that allows for the sealing jaw motion to operate in both vertical and in/out horizontal planes and apply more uniform pressure over the entire area of the jaws.

As such, the bagmaker can produce such pack formats as pillow packs, side gussets, block bottoms, chain packs, and flat bottoms.

Operators can switch between continuous and intermittent motion using the machine’s pre-settings, with no part changes required.

Other automated features for centering film, managing air fills, and adjusting tensions are also expected to cut down on human error and production waste, as well as maintain consistency in packaging production.

Meanwhile, its new splice table light bar is reported to complete a

film splice cycle in 20 seconds and allow for the management of more machines per head – increasing speed and efficiency in the automatic film splicing process.

This is expected to lower operational costs, lessen the challenges of manual intervention, and improve the speed of previous models by 30%.

Ishida Europe launches VFFS bagmaker to optimize productivity

ACCORDING TO ISHIDA EUROPE, THE NEW VFFS UTILIZES 17% LESS ENERGY IN OPERATION AND 25% LESS ON STANDBY THAN PREVIOUS MODELS.

Sidel to install EvoBlow blow molder at StrongPack facility, Nigeria

into the still-water co-packing market.

StrongPack is one of the biggest producers by volume of Royal Crown (RC) Cola worldwide and is also the biggest and the most diversified copacker in Nigeria.

The company is co-packing products such as malt drinks, teas, regular carbonated soft drinks, fruit juices, juice nectar, and fruit-flavored drinks, including some nitrogenpressurized packaging for major global brands.

the elimination of intermediary conveying.

Eric Thibault, chairman of StrongPack Nigeria, said: “We have partnered with Sidel right from the start of our operations and we are very

THE NEW 86,000 BOTTLES PER HOUR

NIGERIA – Sidel, a global provider of packaging solutions is set to install its 1000th EvoBlow blow molder as part of a high-speed PET water line at StrongPack in Nigeria early this year.

The new 86,000 bottles per hour (bph) high-speed line will be the fastest in Africa, the company said in a statement. It marks StrongPack’s entry

StrongPack’s new water line will combine an EvoBlow regular blowmolding machine with filling and capping equipment, integrating these production phases into one compact Combi SF100 solution.

The integrated solution includes a water treatment room and automated cleaning-in-place (CIP), ensuring hygiene and food safety.

StrongPack’s choice of Combi set-up offers material savings, with bottle lightweighting opportunities through bottleneck handling and

SLOVAKIA – Print company

Tlačiareň Bardejov has bought a fivecolour Rapida 76 with an inline coater and an Omega Allpro 90 folder-gluer technologies from Koenig & Bauer to scale operations.

According to Koenig & Bauer, by investing in a five-color Rapida 76 with inline coater, together with an Omega Allpro 90 folder-gluer, Tlačiareň Bardejov has boosted its production capacities in preparation for new and future market demands.

The highly automated Rapida 76 in B2 half shape was built exclusively for Tlaiare Bardejov’s product line,

(BPH) HIGH-SPEED LINE WILL BE THE FASTEST IN AFRICA, THE COMPANY SAID IN A STATEMENT. IT MARKS STRONGPACK’S ENTRY INTO THE STILL-WATER CO-PACKING MARKET.

happy to have had the same trusted execution project manager, Yasser Seffo, throughout.”

Koenig & Bauer said.

It will help Tlačiareň to produce packaging for wines and spirits as well as for e-commerce and print boards up to a thickness of 0.8mm.

Spot colors (Pantone, HKS, metallic inks) can be used with the fifth printing unit which ensures that the products can be printed and finished in a single pass, which eventually lowers production costs.

In addition, the Rapida 76 has an integrated high-flow coater unit that handles simple inline dispersion coatings, and in combination with the last printing unit can deliver special multiple finishes.

Tlačiareň Bardejov opts for Koenig & Bauer’s print and packaging technologies to scale operations

EQUIPMENTS

Shawpak introduces new Rigid Blister Machine for pharma applications

UK – Medical packaging machinery company Shawpak has launched its new Shawpak Rigid Blister Machine for the pharma industry.

The Shawpak Rigid Blister Machine can create die-cut rigid blister packs of up to a maximum size of 600 x 280mm giving a web width of 620mm and an index length of 300mm, notes the company.

A single blister can be produced at the maximum size or any combination of blisters to make up the 600mm width.

Shawpak says that narrower materials can be loaded onto the machine down to a minimum width of 250mm.

According to the company, the machine gives medical device customers full flexibility, making packaging on demand from roll stock,

rather than relying on supply chains.

The tooling can be quickly changed to give full control and allows customers to make trays ahead of time, preventing the need to store a surplus inventory of stock for months taking up space and tying up cash.

In addition, this machine can help integrate a company’s supply

SWITZERLAND – Swiss multinational plant equipment manufacturer, Bühler has partnered with Pellenc ST on a front and backend solution for PET bottle and flake sorting.

The two companies are hoping to improve and future-proof PET recyclers’ processing activities with a new Demo and Applications Centre opening in November.

Combining Bühler’s PET flake sorting solutions – the SORTEX N PolyVision and the SORTEX A GlowVision – with Pellenc ST’s Mistral+ Connect bottle sorter, the companies have recently signed a North America agent agreement and anticipate that a joint Demo and Applications Centre utilizing the SORTEX A GlowVision sorter will

chain and allow them to control serialization and inspection as packs are made, allowing better quality control.

Understanding customer struggles with supply chains and limitations in the current standard market solutions was key in the development of Shawpak’s Rigid Blister machine.

open there next month.

It is hoped that this development will make a contribution to a circular economy in PET production, as well as allow the companies to make further investments in R&D.

It is claimed that 5% of Bühler’s annual turnover goes into R&D investment and that 35% of Pellenc ST’s total staff headcount works in R&D.

Carlos Cabello, Sales Director of Digital Technologies and lead of Bühler in Northern Europe, says: “This alliance has been set up to streamline the sorting process for PET plastics recyclers, providing one port of call for our companies’ collective customer base. We look forward to the collaboration between the teams on both sides.

Bühler, Pellenc ST partners on new center for PET bottle and flake sorting

Gerresheimer partners Merck to develop digital twin packaging solution

GERMANY – Global packaging supplier Gerresheimer has partnered with pharmaceutical company Merck to develop a digital twin solution to further ensure traceability and trust in the pharmaceutical supply chain.

Under the partnership, the two companies have developed a Proof of Concept (PoC) to provide primary packaging with a unique ID to access its own trustworthy digital twin.

The PoC aims to transform the pharmaceutical supply chain by creating digital twins for primary packaging.

The automated process will result in full traceability and digital trust, resulting in cost savings, improved quality and even new business models through a single interconnected network.

Gerresheimer said that by using the

jointly created solution, the physical primary packaging for Gerresheimer is given a dependable ‘key’ that grants access to its digital twin.

The primary packaging which includes syringe and vial are connected to their individual ID to travel across the whole supply chain, from production to the point of care, linking and gathering data.

They turn into the key to unblocking data from multiple digital ecosystems, enabling more effective communication between diverse supply network firms.

According to Gerresheimer, the innovative approach enables physical objects to be securely anchored in the digital world using a blockchainbased platform and multi-patent authentication technologies created by Merck.

EQUIPMENTS

Liquibox launches two new automatic bag-in-box filling equipment

US – Global leader in liquid packaging and dispensing, Liquibox has unveiled two new bag-in-box filling machines for safer, easier, and more efficient bag-in-box filling.

The latest modular design platforms include automatic A-Series and semi-automatic S-Series machines.

Liquibox said that the machines can fill a broad range of liquid products, including liquid food, beverages and non-food.

They can also be easily adjusted and customized to work with different fitments, taps, and bag sizes for different beverages to cleaning products.

The Liquibox A-Series filler is said to be totally automatic which makes high-speed filling a simple operation. It is made to be easy to use, adaptable for bag loading, and quick to switch

between bag sizes.

In comparison to other filling equipment, the A-Series has a small footprint, allowing for more bags to be filled per square inch of the manufacturing floor.

It is also ESL capable and has a redesigned sterilizing kettle and chamber design, making it perfect for filling items with a longer shelf life,

the company said.

The semi-automatic Liquibox S-Series is an accessible and userfriendly bag-in-box filler with superior production efficiency. It can be configured with a single head or two heads, allowing the producer to increase output as necessary, Liquibox claimed.

COCA-COLA EUROPEAN PARTNERS PET Bottles with Tethered Caps

Coca-Cola is rolling out PET bottles with tethered caps for its carbonated soft drinks in Europe. The tethered caps supplied by Berry are designed to remain intact with the bottle – making it less likely to be littered and more likely to be recycled. They feature tamper-evident band that, once broken, does not impact the closure’s ability to remain attached and is positioned out of the way for drinking but can easily be reclosed. When open, it provides a wide angle for easy access to the beverage and comfortable on-the-go drinking.

PEPSICO Refillable glass bottles for Pepsi Sodas

Malta-based PepsiCo partner and Pepsi-Cola portfolio bottler Simonds Farsons Cisk has launched a new refillable glass bottle for the beverage company’s flagship brands.

The single-serve bottle will be rolled out for Pepsi-Cola and Pepsi Max, 7up and 7up Free and Mirinda brands. The new bottle features a twisted and etched bottom for an improved visual and tactile experience with the packaging. It also features a swirl design and elevated profile intended to appeal to younger consumers by encapsulating the brand’s ‘youthful spirit.

The latest bottle introduction is the company’s first redesign since 1996.

Nestlé’s KitKat, one of the world’s most popular confectionery products, is introducing recyclable paper packaging in Australia on a pilot basis. According to Nestlé Australia, the recyclable paper packaging will be available for a limited time for its four-finger bar in Australia, across Western Australia, South Australia and Northern Territory.

The pack has a QR code that people can scan to have their say and give valuable feedback on the new paper packaging.

NESTLE

Recyclable paper packaging for KitKat

KELLOGG

Cereal packaging to help visually impaired customers

Kellogg has incorporated NaviLens technology to improve the shopping experience for its visually impaired customers.

NaviLens’ optical smart code, consisting of high-contrast, multicolored squares on a black background, will feature on the front and side of its Kellogg’s Corn Flakes, Special K Original, Rice Krispies and Crispix cereal brands. Consumers can use this function to locate the boxes from several feet away, navigate to them, and hear their names, package sizes, and nutritional information in up to 36 languages.

MARS

Paper-based wrappers for its chocolate bars

Confectionery giant Mars has announced plans to switch to new recyclable packaging for its chocolate bars in Australia and New Zealand.

Mars, Snickers and Milky Way chocolate bars will have biodegradable brown paper packaging, designed to be more environmentally friendly, in Australia in April 2023 and New Zealand the following month.

Mars said the wrappers on its chocolates would be able to be put in the recycling bin from June 2023. This will be followed by the rollout of sustainable packaging for Milky Way in 2024. The paper-based packaging will be available on 47g and 64g Mars bars, as well as 44g and 64g Snickers bars.

NESPRESSO

Home-compostable coffee capsules

Nestlé’s Nespresso in collaboration with Huhtamaki has unveiled a new range of home compostable coffee capsules.

The paper-based capsules are touted as a breakthrough in packaging technology after three years of R&D. Developed as an alternative for those who prefer and have access to compost, the innovation will widen the sustainable choices already offered to Nespresso consumers through its aluminum capsules.

The product is certified for composting, both home and industrial, by TÜV Austria, an international certification body.

Nespresso says the new range will pilot initially in France and Switzerland on the Nespresso Original system. It will be further launched in several other European countries within a year.

With more than 35 years of experience in flexible packaging, Packaging Industries Limited (PIL) prides itself as a leading provider of high-quality, sustainable flexible packaging for food, beverage, healthcare, agriculture, home and personal care. The company specializes in extended shelf-life packaging, giving products longer life and reducing food waste.

“Our packaging is designed to cater for our client's requirements and is customized to their needs. Our products are practical, affordable, and most importantly, environmentally sustainable,” says Vaishali Malde, Sales, Marketing and Sustainability Manager at Packaging Industries Limited (PIL).

From its operational base in Nairobi, Kenya with 300 staff, the company serves its clients across East and Southern Africa with exports to the European market.

“We believe that our agility and ability to optimize the full operating model across strategy, structure, processes, people, technology, development, and innovation by going after flat and fluid structures built around a high-

performing cross-functional team while instituting more frequent prioritization and resource allocation processes is our strength,” adds Vaishali.

According to her, the company has established a paradigm shift away from multilayered reporting structures, rigid annual budgeting, and a separation of business and technological innovation. She observes that the discontinuity and change of this magnitude has given them a competitive advantage. She adds that this transformation has improved efficiency, customer satisfaction, employee engagement, and operational performance with a turbocharged innovation.

AWARD WINNING INNOVATIVE PACKAGING PRODUCTS

Vaishali Malde, Sales, Marketing, & Sustainability Manager, PIL

OUR PRODUCTS ARE PRACTICAL, AFFORDABLE, AND MOST IMPORTANTLY ENVIRONMENTALLY SUSTAINABLE

PIL has won the Packaging innovation awards for 3 years consecutively.

In 2020, PIL won Gold award for their Mama Silage bag, an innovation developed to allow fodder storage for small-scale dairy farmers for up to 2 years without deteriorating its nutritional quality. As part of its strong collaboration with various actors in the dairy value chain, PIL says it is committed to providing localized, innovative and sustainable solutions for improved dairy farming across the region.

In 2021, they also won a Diamond finalist award for the Mavuno Bora Hermetic bag - a sustainable and responsible packaging solution to ensure food security.

“With the adoption of Mavuno Bora hermetic bags, farmers can store their harvests

for extended periods and utilize them during critical seasons rather than selling their yields immediately after harvests for fear of associated postharvest losses,” she explains.

The other accolade was the Gold award in 2022 for a Lightweight Nutra-milk Flexible pouch in Collaboration with 260 Brands in Zambia. Their collaboration partner, 260 brands, was looking to provide a nutritious non-dairy product to improve consumer health, combat hunger, and reduce food waste.

The packaging designed for this product needed to support the extended shelf life and withstand long road transits to reach developing communities.

“This rural reach had limited infrastructure development, and refrigerated storage wasn't an option. We then had to put together a solution that is a lightweight barrier pillow pouch with excellent mechanical performance and supporting extended shelf life. The packaging has been designed to transport and store without refrigeration, overcoming cold chain logistics challenges,” she adds.

For an industry in a developing country, their recognition with Packaging Innovation awards affirms that innovation doesn’t have to come from first-world countries for adoption in the developing countries, where in many cases, it fails to work as it is not localized.

“The award gives us the positivity to keep developing sustainable solutions that are localized for our markets and sustainable for the environment and the awards spotlight our actions and the sectors we represent in Africa.”

OVERCOMING PLASTIC BAN IN KENYA

The Plastic Bag Ban with a 6-month allowance for Kenyans to transition to alternatives, announced by the Kenyan Government in 2017 was a big threat to the business founded some 35 years ago by Mr. Navin Raichand Haria.

Limited information on the notices, which were restricted to 120 words led to a chaotic understanding of the legislation with interpretation of banned plastic bags restricted to a few words, which many ordinary users could not understand, assuming a blanket ban

ABOVE: THE TEAM BEHIND PIL'S AWARD WINNING PACKAGING SOLUTIONS

on all packaging yet the scope was only on carrier bags, flat bags used in non-industrial settings, and waste garbage bags.

The prevailing attitude towards the legislation was that it was written in stone; however, following numerous interactions and lobbying with the authorities, they found some clarification on the ban and invested in technologies to manufacture alternatives to the scope of the ban.

“We believe that the environmental legislation must be alert to new challenges and opportunities and be amendable to face them as the authorities’ work on ensuring the development of infrastructure to support the segregation, collection, sorting, and recycling of waste,”

She adds that a successful address of plastic pollution would need a regional level of legislation through synchronization of our environmental policies with the East African community to ensure the circulation of banned items through the porous borders stops.

INNOVATIVE PRODUCTS TO REDUCE FOOD WASTE

With the ever changing consumer tastes and preferences, PIL has designed product categories to fill this gap with specific emphasis on packaging designed to reduce food waste. “Food packaging is often viewed as having a negative impact on the environment. However, packaging can protect food, prolong shelf life, and reduce environmental impact by reducing food waste.

She adds that consumer knowledge and levels of awareness, interests, and appreciation of these packaging functions are significant factors in their refusal or acceptance of emerging packaging technologies, whether those technologies are directed explicitly at reducing food waste or not and that consumers' complex relationship with food packaging creates a barrier to food-saving practices.

Vaishali says that in as much as the current global trend is to have recyclable packaging, at Packaging Industries Limited, they often prioritize packaging design to reduce food

BELOW: MAMA SILAGE BAG, ANOTHER AWARDING WINNING INNOVATION FROM PIL

waste before considering its recyclability.

“We focus on innovation that tackles both problems of packaging sustainability and food waste prevention in tandem.We design beyond merely getting the product to the consumer and instead embrace taking responsibility for consumers' climate impacts from downstream food waste,” she adds.

She further explains that educating consumers on the tradeoffs between packaging sustainability and food waste is often difficult adding that on average, only 3-3.5% of the climate impact of packaged food comes from the packaging itself – the rest comes from producing, transporting, storing, preparing, and potentially disposing of the food.

This proportion she says can be significantly higher for certain kinds of foods and formats, but ultimately, packaging “pays off” if it helps to reduce waste of the food it contains by at least 4%.

That means that companies should prioritize strategies that reduce food waste even when packaging creates climate impact. Alongside designing out waste, they work on the opportunity for the packaging designed for recyclability.

“We intensely focus on developing packaging to prevent food waste, meet climate goals, and integrate features that consumers value and appreciate.”

On their circular packaging designs, she says that more and more people seek a greener, environmentally friendly, sustainable, and circular packaging design that will not end up in an ocean or landfill.

One after another, she says that companies have declared plans to cut waste and move toward the ultimate goal: recyclable packaging.

“Our research and development team engineer solutions to drive this shift without compromising on processors’ other priorities for product quality, product shelf life, manufacturing efficiency, packaging mechanics and more.”

EXTENDING SHELF LIFE OF HIGHLY PERISHABLE FRESH PRODUCE

Packaging Industries limited has worked with various perishable food packers across the

Vaishali Malde, Sales, Marketing, & Sustainability Manager, PIL

WE INTENSELY FOCUS ON DEVELOPING PACKAGING TO PREVENT FOOD WASTE, MEET CLIMATE GOALS, AND INTEGRATE FEATURES THAT CONSUMERS VALUE AND APPRECIATE.

ABOVE: VAISHALI MALDE, SALES, MARKETING & SUSTAINABILITY MANAGER, PACKAGING INDUSTRIES LIMITED

for several decades and has since developed a specialty in designing packages to increase the shelf life, prevent discoloring, and preserve freshness and flavor, all while ensuring an aesthetically pleasing shelf appeal.

Its expertise is on Modified Atmosphere Packaging (MAP) which alters the atmosphere inside packaging containing perishable foods (for example, fresh vegetables, meat, and fish to increase the shelf life of the product contained.

The technology works by reducing the amount of oxygen (which supports lipid oxidation reactions and high respiration rates) and replacing it with other gases, reducing and delaying unwanted reactions.

“We focus on designing packaging for fresh produce based on the desired shelf life, quantity of a product, and the harvesting, transporting, storing, and shelf life temperatures to ensure minimal waste.”

PIL also offers Cryofrozen Fruit Packaging technology which extends shelflife of produce for up to 1 year under low temperature storage conditions. Cryofreezing is becoming a popular preservation and export method for many fruits in Kenya such as berries and avocadoes. Cryonics is used to freeze the fruits and is an innovative and effective method of safeguarding the supply of these seasonal fruits.

CHANGING CONSUMER TRENDS

Vaishali notes that consumer trends for effective packaging solutions have drastically changed over time and that sustainability agendas are being focused on globally.

‘There is immense interest in transitioning of other packaging formats to flexible packaging as they are designed to minimize the use of packaging materials, highly customizable, lightweight, and boast a low product-to-packaging ratio.

“Flexible packaging provides sustainability benefits and significant value to producers, consumers, and retailers and these packaging solutions call for less transportation and storage space than their counterparts, reducing fuel consumption and toxic carbon emissions.”

Flexible packaging demand 40% less shipping space than rigid alternatives when empty and requires less landfill space when they end up in the environment.

The increase of environmental concerns and increasing sustainability awareness has also drawn more global attention to the use of water-based inks in flexographic printing.

“We will be focusing on shifting to water-based inks that consist of much less organic solvent with lower Volatile Organic Compound (VOC) emission issues.”

She explains that as PIL works around designing for recycling, they are looking at investing in an in-house recycling facility to recover their process wastes as they keep the loop closed for the post-industrial waste.

The company also has systems in place to ensure no contamination of this waste, PIL can easily recover the material and use it in producing packaging for non-food contact applications. This she says would also help reduce the virgin plastic they use in some

ABOVE: STATE OF THE ART PACKAGING MANUFACTURING EQUIPMENT AT PIL FACTORY IN NAIROBI

FOOD AFMASS

MARKET

applications and have an overall lower carbon footprint.

INVESTING IN RESEARCH & DEVELOPMENT

Vaishali Malde who joined the company in 2016 as a sales representative and later made the Sales and Marketing Manager says that the path to the perfect package design is best taken as a team, with experts in machine, material, and process, each leading the way through their specialty.

“Our process includes Packaging Development Manager(s) who specialize in packaging designs and are up on current trends in the packaging industry globally and guide the entire packaging design. They also collaborate with our supply chain partners to bring you new ideas and cutting-edge technology,”Vaishali explains.

The vastly experienced flexible packaging industry expert adds that their Research and Development team creates customerfocused innovation by continually testing new materials, inks, coatings, adhesives, and more and once they determine the best material and specifications for our client’s requirements, they continue to provide field support throughout the development, market entrance and transition.

“As we engineer for recyclability, we constantly advocate for light weighting to reduce the amount of plastic used by our brand

owner.We also work on ensuring the functional features of the packaging are designed to minimize the environmental impact of our packaging.”

A CHAMPION FOR EXTENDED PRODUCER RESPONSIBILITY

However, a detailed analysis of the Act has revealed that it has not effectively dealt with the issues of plastic waste and its associated problems and the Act does not specifically address the issue related to plastic waste management. According to Vaishali, the failure to incorporate a long-term solution to address the problem of plastic waste has been the key limitation of existing policies on Waste management and as a result, addressing the littering of plastic bags and plastic bottles and as such has been difficult and there is no longterm solution to the problem.

She explains that specific steps to advance waste management in Kenya have already been taken by both the private and public sectors with the most notable development being the initiation of a system of Extended Producer Responsibility (EPR).

This EPR system is currently supported by upcoming public and private-sector regulations, most prominently through the Kenya Extended Producer Responsibility Organization (KEPRO), focusing on all plastic

FLEXIBLE PACKAGING DEMAND 40% LESS SHIPPING SPACE THAN RIGID ALTERNATIVES WHEN EMPTY AND REQUIRES LESS LANDFILL SPACE WHEN THEY END UP IN THE ENVIRONMENT.

waste fractions.

Despite certain challenges and the requirement to further develop the policy framework, the EPR regulations represent the most promising approach for addressing current deficiencies of the Kenyan waste management sector and all these actions need to be considered as pieces of a wider puzzle.

“At Packaging Industries Limited, we actively participate and interact with other platforms and policy bodies. We share our opinions, intelligence and knowledge with policy and regulatory bodies through their public participation and workshops to highlight our recommendations in their frameworks.”

She adds that building a holistic and robust waste management framework and hence effectively mitigating the problem of littered plastics is a cross-cutting task that involves policymakers on all levels of government, businesses, and civil society all at once.

“Next to a continuous improvement and development of the regulatory framework, actions to improve ease of waste management may also be taken specifically to plastic fractions and items prevalent in Kenya.”

She goes on to say that authorities could consider various ways of addressing the policy and regulatory loopholes by investing in waste management infrastructure to curb the adverse effects on the waste management system and

the environment.

“For plastic packaging, the authority should give clear guidelines on changes in design for increased recyclability and eliminate the chances of it ending up as litter in the environment. Nevertheless, particularly the further operationalization of the EPR system is supposed to play a key role in enabling the successful and efficient advance of these strategies and reducing the adverse effects of waste management practices.”

SUSTAINABILITY INITIATIVES

Vaishali says that the company’s focus was on designing for recyclability and a circular economy. However, challenges are abounding.

“It may seem an obvious fix to move to recyclable packaging, but putting this into practice is far more complicated. There are lots of decisions to be made throughout the supply chain that can turn redesigning packaging into a time-consuming process.”

She adds that from production lines to design, it can take years for a brand to finalize a sustainable packaging strategy, making progress seem slower than it is. In addition, the financial and time costs of revamping a packaging strategy from top-to-bottom is incredibly high. “Massive investment is needed. While larger companies may have the funds to do this, smaller players struggle, particularly after many suffered significant economic hits from the pandemic.”

Vaishali explains that sustainable and recyclable packaging is more in demand than ever, yet the packaging industry on a global scale is at a crossroads. While the traditional practices and old packaging design are effective in protecting food and getting it to the consumers, avoiding the circular economy is not a viable plan for the long term.

“A combination of redesigning packaging and technological advancement can make a big difference. It doesn’t have to be a radical overhaul overnight, but with constant improvement in design, we can provide sustainable solutions for the long-run. We have embraced design for recycling for a circular economy and we hope our peers can join us in this journey as we make packaging environmentally friendly.”

BELOW: LIGHT WEIGHT FLEXIBLE POUCH FOR PLANTBASED MILK DEVELOPED IN COLLABORATION WITH ZAMBIA'S 260 BRANDS

IN NUMBERS THE NUMBER OF YEARS THAT PIL HSD BRRN IN THE FLEXIBLE PACKAGING BUSINESS

ETHIOPIA:

AFRICA’S UNTAPPED PACKAGING INVESTMENT DESTINATION

By Alphonce Okoth

As Ethiopia positions itself as a manufacturing hub in Africa, investment opportunities abound in the packaging sector

With about 123 million people (2022), Ethiopia is the second most populous nation in Africa after Nigeria. The Eastern African nation is also among the fastest-growing economies in sub-Saharan Africa. According to Prime Minister Abiy Ahmed, Ethiopia’s economy will grow to 7.5% in the 2022-2023 financial year. The IMF, on the other hand, projects Ethiopia to surpass Kenya as the largest economy in Eastern Africa in 2023. The multilateral lender expects the Ethiopian economy to expand by 13.5 percent to reach US$126.2 billion, about US$8.6 billion ahead of Kenya’s US$117.6 billion. The rapidly expanding economy is creating new opportunities for the packaging Industry. A recent study by Manufacturing Africa noted that there is an unmet and growing demand for packaging products in Ethiopia. The study funded by the UK’s Foreign, Commonwealth & Development Office (FCDO) that supports investment into the manufacturing sector noted that Ethiopia will have a packaging manufacturing opportunity worth US$971 million by 2030, with more than 50% of the potential lying in packaging for the food and beverage sectors. Currently, about 20% of packaging is imported into the country this could expand further if investments in local manufacturing are not ramped up to meet

demand.

INVESTMENTS DRIVE NEED FOR PACKAGING

Ethiopia’s manufacturing output doubled in over the past five years and is expected to expand at 13% annually. The food processing sector in Ethiopia is by far the largest manufacturing industry in Ethiopia. The food and drinks sector collectively represent about

BELOW: MINUT MAID, ONE OF THE FRUIT JUICES TO BE PRODUCED IN NEWLY COMMISSIONED COCA-COLA FACTORY IN ETHIOPIA

half of the total demand for packaging (about US$333 million of US$649 million), as cited by Ethio12 news. Several notable investments have gone into the sector, creating a need for more packaging. Last year, multinational soft beverage company Coca-Cola Beverages Africa (CCBA) inaugurated its US$100 million factory. Completion of the bottling plant brings CCBA’s production capacity in Ethiopia to more than 100 million cases a year and will enable the company to integrate the production of inputs such as preforms, closures and other materials, as well as the local production of new products such as Minute Maid Juice.

In November last year, Pepsico invest US$40 million in its Ethiopian subsidiary Senselet Food Processing to increase crips production in the country. This means that as the production of the crips increases so as the demand for their packages. Similarly, UK-based consumer goods company Unilever, in August last year announced plans to invest in food processing in Ethiopia. The new investments will add to Unilever’s local footprint that includes an oral care factory that was commissioned in 2019 and soap, detergent and Knorr manufacturing plants inaugurated by Unilever in 2016 and

2017 respectively. Ethiopia’s Oromia Industrial Parks Development Corporation signed an agreement worth Birr 7.8 billion (US$193.6m) to construct a food processing park in Oromia. The new park, which will process coffee, tea, edible oils, grains, dairy, meat and honey products, will come on stream in 2024. When complete, the project is set to have packing suppliers for its products.

Aside from food, Pharmaceutical manufacturing is emerging as a major industry in Ethiopia driven by the country’s ambition to become a pharmaceutical manufacturing hub in Africa by 2025. In 2020, the Ethiopian pharmaceutical market was estimated to be valued at US$905 million and is expected to grow at a CAGR of 15% to reach an estimated US$3.662 billion by 2030, according to UNIDO. To make this goal a reality, the government, with funding from the world bank, set up the Kilinto Industrial Park (KIP) to specialize in pharmaceutical manufacturing. The park has already attracted investments from Africure Pharmaceuticals which intends to produce 1 billion oral solid and liquid dosages annually. The facility will join the Sansheng Pharmaceuticals Plc facility that was commissioned in 2018 and others by SinoEthiopian Sunshine Pharmaceutical PLC and Humanwell Pharmaceutical Ethiopia Plc. As more pharmaceutical industries trickle into the country, the need for more packaging will arise further creating opportunities for packaging manufacturers.

LOCAL PACKAGING INDUSTRY STIRS TO LIFE

Between 1994 and 2017, there have been 198 licensed investment projects in the Ethiopian packaging industry. Just over three-quarters of the investments were from domestic sources, 17.2% originated from abroad and 6.1% were joint investments from local and foreign sources. The highest proportion of foreign investments was from China and India, followed by the USA.

Growth of the sector has however not been fast enough to meet demand. “Even though agro-processing has been growing rapidly in the past few years, the packaging industry is

ABOVE: COCA-COLA BEVERAGE AFRICA BOTTLING FACILITY IN ETHIOPIA

lagging,” notes Mebratu Meles, State Minister of Industry. As a result, most manufacturers have been forced to rely on imports for packaging.

To bridge this gap, the country in 2017, initiated a plan to help it shift from importing to exporting plastic products. The move triggered increased interest from both foreign and local investors in plastic products manufacturing, said the Ethiopian authorities. This led to substantial capital investment in the sector, with Ethiopia importing US$39 million worth of packaging machinery in 2017 - a CAGR of 48% from 2012 - making it the second-largest importer in East and Central Africa, according to AsokoInsights.

“The number of both foreign and local investors in plastic manufacturing has been increasing every year. Currently, there are a total of 350 plastic manufacturing companies in Ethiopia producing 12 categories of products ranging from the automotive tire to the latest wood and plastic blend home partitions and PVC-made tiles and small household furniture,” said Eng. Yonas Abate, Plastic and Rubber Industries Development Director at the stateowned Ethiopian Chemical and Construction input Industries Development Institute.

To take advantage of the expanding pharmaceutical sector, Prime Point Packaging is establishing a new facility in the Kilinto Industrial Park to be manufacturing packaging materials for pharmaceuticals. Roshan Packages, a leading manufacturer of corrugated and flexible packaging has also expressed keen interest to invest in Ethiopia to meet the demand for packaging. Even as more investments come online, the study by Manufacturing Africa detailed various opportunities that

manufacturers could tap into. According to the report, there exists a US$95 million market opportunity in the supply of PET bottles. Flexible plastic packaging (US$200 million), and cutting plants for tubes for toothpaste (US$8 million), are other opportunities that investors could tap into.

MANAGING PLASTIC PACKAGING THROUGH RECYCLING

Ethiopia is the second largest importer of plastic raw materials from east and central African countries. Due to a lack of technology, investment, and experience only 30–40% of the 386,000 tonnes consumed yearly is recycled, according to the African Association of Entrepreneurs (AAE). Only ten plastic bottle recyclers and only two of them are using the hot wash processing that obtains a higher quality of flakes, according to the association. With plastic increasingly becoming an environmental nightmare, opportunities exist for manufacturers to explore plastic recycling. According to Manufacturing Africa study, a US$30 million market exists for recycled plastic to replace imports for local producers to use as feedstock or for gasification (fuel). Recently, an Indian and Mauritian joint venture in Ethiopia started the production of

THE FOOD AND DRINKS SECTOR COLLECTIVELY REPRESENT ABOUT HALF OF THE TOTAL DEMAND FOR PACKAGING - ABOUT US$333 MILLION OF US$649 MILLION.

fuel from waste plastics using new technology. The company has built a factory on 15,000 square meters in Akaki/Sebeta sub-city and the fuels, which can be produced from waste plastics, are being used for various applications including jet fuel. Additionally, a further US$30 to US$40 million opportunity exists to recycle PET plastic to converted polyester fibre for textile sector, the study highlights.

OPPORTUNITIES IN ECO-FRIENDLY PACKAGING

As plastic packaging takes its toll on the environment, manufacturers could explore opportunities in eco-friendly packaging. The presence of multination consumer goods companies from PepsiCo to Coca-Cola and Unilever further incentivizes investments in this area as all of them need sustainable packaging to meet their ambitious net zero carbon goals. According to Manufacturing Africa study, a US$120 million opportunity exists in the production of bio-plastics from sugar cane to reduce environmental impact of plastic use. Investors could also explore forest-certified bamboo wood pulp for paper packaging producers, local production of corrugated paper (US$70 million), metal cans production for food and beverage (US$70

million) and glass packaging production for beverages (US$70 million).

GOVERNMENT INCENTIVES

Investors in packaging could exploit various incentives provided by the Ethiopian government to manufacturers. For instance, the government is currently constructing or has commissioned 15 industrial parks as part of a plan to turn the country into a light manufacturing hub in Africa. The parks offer Serviced land with common infrastructure such as wastewater treatment plant, regular water supply, and dedicated power substations. Other incentives include duty and other tax exemptions on inputs and Zero tax on exports. Relevant regulatory and supporting institutions will be located in the park to provide services, such as fast tracked registration.

For pharmaceutical packaging the government further offers corporate income tax exemptions up to 8 years.To bridge the skill set gap, Ethiopia also offers manufacturers long term visas and personal income tax exemption of 5-10 years for expat employees. Further, the

THE GOVERNMENT IS CURRENTLY CONSTRUCTING OR HAS COMMISSIONED 15 INDUSTRIAL PARKS AS PART OF A PLAN TO TURN THE COUNTRY INTO A LIGHT MANUFACTURING HUB IN AFRICA.

government also offers 25% price preference and 30% prepayments for firms manufacturing in Ethiopia and Potential for long-term procurement guarantee. Where exports are involved, Ethiopia promises manufacturers more accessible and competitive logistics as well as information consolidation and market linkages.

Ethiopia is currently implementing its Second Growth and Transformational Plan (GTP II), which sought to transform the country and place it on a path toward becoming a middle-income economy by encouraging a shift to high-productivity industries, especially manufacturing.The policy has emphasized development of manufacturing through industrial parks, encouraging foreign investment, and attracting and supporting small- and medium-sized enterprises (MSEs). This has likely contributed to the country's growth in manufacturing value-added goods, although growth in manufacturing sector employment has been much slower.

CHALLENGES TO GROWTH

In Ethiopia, the cost of labor is relatively low, which does help to reduce costs, but the flip side is that the country’s relatively weak labor law system and its lack of a minimum wage are challenging factors for workers and are a constraint on the development of a strong and skilled industrial labour force.

The Government does, however, recognize the importance of strengthening the skills of the country's workforce and has invested in

technical training institutes, such as the Adama Technical University and several regional vocational colleges. The attractive incentives for manufacturers to bring in expats also helps to bridge the skillset gap as the country grows its own local expertise.

Another challenge for the economy, in general, and specifically for industrial and manufacturing development, is the country's relatively underdeveloped infrastructure. This includes roads, transport systems, electricity, supply chain logistics, water and sanitation facilities, mobile and internet communication services. These factors make it difficult to access many parts of the country, import and export goods, and overall makes the country less competitive from a global investment perspective. A related issue is the relative lack of industrial information for the country, including research studies that would assist (and attract) investors.

A MUST REVIEW INVESTMENT DESTINATION

With Ethiopia set to overtake Kenya as the largest economy in Eastern and Central Africa, investment opportunities in the packaging industry are bound to expand even further. Multinational food companies are aggressively expanding their capabilities to meet demand from the Ethiopian market which boasts of a population of more than 120 million people. This is an opportunity that packaging suppliers could tap into to reduce the country’s reliance on imports which will definitely go up if local production does not expand,

A wider government strategy to position Ethiopia as a leading manufacturing hub inAfrica by 2025 further creates more opportunities for packaging manufacturers. Attractive incentives including competitive tax and duty exemptions from the government make Ethiopia an attractive destination as it lowers the cost of doing business for both manufacturers and packaging producers. Challenges still abound in terms of infrastructure and access to highly skilled labor, but make no mistake, Ethiopia is rising as an economic powerhouse in subSaharan Africa and with it many opportunities for packaging investors to exploit

ABOVE: UNILEVER SOAP MANUFACTURING FACTORY IS ONE OF THE BIGGEST CONSUMERS OF PACKAGING IN ETHIOPIA

AUTOMATION, ROBOTICS & Sustainability drive PHARMA PACKAGING

By Alphonce Okoth

Pharmaceutical packaging is a critical segment of the healthcare industry as it secures, stores, and protects drugs when transporting and storing drugs. Poor quality packaging can impact a drug’s efficacy, affecting patients’ outcomes in the process. It is for this reason that pharmaceutical packaging is highly regulated over the world to protect medicines from physical damage and external influences that might lead to contamination.

Nevertheless, pharma packaging has been rapidly expanding in the recent past due to the rising demand for pharmaceutical drugs and medicines. Fortune Business Insights estimates that pharma packaging market to be worth US$101.59 billion in 2022 and forecast the market to grow at a compound annual growth rate (CAGR) of 5.8% to reach US$150.78 billion by 2029.

As the market grows, packaging providers are innovating to keep up with new demands in the healthcare industry. From the need for sustainable packaging to the incorporation of artificial intelligence in production processes, a

lot is happening in the industry at the moment and is certainly poised to radically change the pharmaceutical packaging landscape.

A SECTOR RELIANT ON ARTIFICIAL INTELLIGENCE (AI)

According to a report by Grand View Research, the global AI healthcare market size will reach a staggering US$31.3 billion by 2025, growing at a Compound Annual Growth Rate (CAGR) of 41.5% in this time. This just shows how AI is becoming increasingly pivotal in healthcare delivery.

When it comes to pharmaceutical packaging, AI pill inspection systems are already being deployed as an effective way to help pharmaceutical companies avoid defects. With AI pill inspection, it is possible to increase the speed at which solid oral doses travel through a packaging line. This could dramatically decrease manufacturing time and the number of pill defects that occur. This technology also helps pharmaceutical companies maintain better quality standards for their pill packaging.

In addition, AI inspection helps

manufacturers maintain the correct number of counts in each container by keeping track of pill orientations and pill positions within a package or bottle. This is adding consistency not only across packages but also throughout each container, which leads to more effective pharmaceutical packaging overall.

ROBOTICS TAKE OVER MANUFACTURING PROCESSES

The adoption of robotics, collaborative robots (cobots) is steadily increasing in pharma packaging. It brings with it the benefits of increased efficiency, boosted productivity, scalability and increased speed.

Previously, robots were often used for lifting heavy items and they used to work in dangerous areas. Nowadays, robots can be found everywhere because of their flexibility for different products and formats. For instance, robots are now being deployed to load products and packaging material on the lines, the picking and placing of products into the packaging as well as labeling and assembling too.

Gerhard Schubert, a developer of modular packaging machines for the pharmaceutical industry has introduced its flexible, robotbased top-loading packaging technology (TLM). Utilizing simple mechanics, intelligent control technology, and high modularity, the technology can also integrate into the packaging machines diverse additional functions such as labeling, inserting instructions for use, or prescribed quality controls. The modular machines by the firm can package pharmaceutical products of all kinds in a wide variety of dosage forms.

Another robot in the market is Marchesini Group’s Integra 720V. The robot is an integrated, robotic line for packaging blisters in cartons, and is characterized by very high speeds. The compact multilane blister line comprises two sections: a blister packaging machine that forms the blisters and places the products for packaging in their cavities, and a cartoning machine that packages the blister in its carton.

The two sections are connected by Robocombi, a three-axis robot fully

integrated with the line and created entirely by the firm’s R&D departments. This solution can produce up to 720 blisters and up to 500 cartons/minute, delivering easy cleaning and size change since the product loading area is separated from the electrical and mechanical parts.

ECO-FRIENDLY PACKAGING

A significant portion of pharma packaging is plastic in nature, therefore, making it a problem for the environment. Pharma packaging manufacturers like their peers in food, homecare, and beauty are also on the lookout for alternatives to plastic to cut down on their carbon footprint.

“The market is currently looking for alternatives to plastic," says Francesco Stanzani, Commercial Director, Marchesini Group.

Those that find viable alternatives end up having an edge over their competitors. “We have had great success with our solutions such as the MA 80 cartoner, which is designed to place products in paper trays, as well as the FB220 thermoforming machine with ecofriendly materials such as Polylactide (PLA),” Stanzani confirms.

Packaging equipment supplier Ima is also promoting eco-friendly plastic substitutes for

the packages manufactured on its machines. An example of this is Ima Safe’s ‘Paper tray packaging line’ which packages a wide range of parenteral products and medical devices on paper trays inside cartons, creating 100 % paper-based packaging which is easy to recycle, has low energy requirements and is biodegradable.

Sustainability can also be applied to the manufacturing process. Thomas Fricke, Commercial Director of Ima Pharma, Ima Group adds, “There have been significant movements in containment technology for capsule filling which reduces the use of disposables – often in plastic – and of water, thus generating significant energy savings and economic benefits.”

When it comes to producing sustainable packaging materials collaboration is key. For instance, Bosch’s Syntegon, one of the leading global process and packaging technology providers, collaborated with the Finnish packaging material manufacturer Huhtamaki to develop a sustainable paper alternative to plastic blisters for tablets and capsules.

Matthias Klauser, Sustainability Expert at Syntegon states in a release, “Thanks to the combination of our TPU 1000 form, fill and seal machine for paper packaging; the

3D formable Fibreform paper from Billerud Korsnäs; and the sealable barrier coating from Huhtamaki, we have succeeded in forming paper with the geometry required for tablets in cavities of three to four millimeters.”

One emerging trend in pharma is the concept of quality by design (QbD). This initiative ensures that medicine is administered to patients as intended and nothing environmentally harmful escapes the packaging. Antibiotic environmental contamination is and has been a big problem in recent years and QbD can help curb this. In addition, recycling also continues to trend in a positive direction in all packaging formats. This even includes flexible plastic packaging, which is becoming an easily recyclable packaging format. There is also a push to find solutions for single-use plastic, but in the medical field, that presents a particular challenge. Therefore, single-use plastic continues to be utilized, while other types of plastic are evaluated for its replacement.

SINGLE-USE PROCESSES

More pharma companies are embracing singleuse technology (SUT) in their manufacturing process. This shift is ongoing as more industry players are becoming aware of the incredible advantages of this technology.

With reduced maintenance processes, pharmaceutical companies already using SUT report quick turnaround and development

times and simplified operations. Also, the technology supports the manufacture of more reliable products, eliminating the need

ROBOTS ARE NOW BEING DEPLOYED TO LOAD PRODUCTS AND PACKAGING MATERIAL ON THE LINES, THE PICKING AND PLACING OF PRODUCTS INTO THE PACKAGING AS WELL AS LABELING AND ASSEMBLING TOO.

to sterilize containers. Equipment running on SUT is easy to set up, taking one or two hours compared to stainless setups which can take a couple of days.

In addition, system maintenance is straightforward, with no need for sterilization validations, annual cleaning, and minimum monitoring. Single-use processes reduce the risk of product cross-contamination, making it easy to maintain a sterilized production environment.

While SUT is a modern technology, its benefits are far-reaching, making it impossible for pharmaceutical companies to ignore.

AUTOMATED SHRINK WRAPPING PROVIDES PRECISE OUTCOME

The pharmaceutical industry embraced shrink wrapping to protect drug packaging from tampering. This process was however tedious, particularly when it comes to vertically oriented products which required manual handling to ensure the whole process was effective.

To avoid the added labor and expense from conventional horizontal shrink wrapping systems, manufacturers are now turning to

automation.

With automation, multipacks of bottles can be wrapped directly from the fillers with the product standing upright with no need for

ABOVE: MA 80 CARTONER IS DESIGNED TO PLACE IN PAPER TRAYS

THERE HAVE BEEN SIGNIFICANT MOVEMENTS IN CONTAINMENT TECHNOLOGY FOR CAPSULE FILLING WHICH REDUCES THE USE OF DISPOSABLES.

Francesco Stanzani - Commercial Director, Marchesini Group

manual re-orienting of the products before wrapping, which was the case in conventional horizontal wrapping systems.With automation, containers can now go directly from filling to wrapping, and to palletizing and distribution in-line, without interruption.

One such system is the 914 Orbital Vertical System (OVS) from Texwrap, which designs and manufactures fully-automatic shrink wrapping systems. The system not only automatically wraps bottles while in vertical positions, but the wrapper trims the film above or underneath the package, where it is hidden from view.

With automation, a multipack of verticallyoriented bottles can be automatically arranged with the labels facing precisely in the same direction while standing upright, before shrink wrapping. Additionally, it has now become possible to cover the barcodes of the individual bottles so that the package can be identified as a multipack and not as individual units.

A SECTOR ON THE RISE

Pharma packaging depends primarily on the prevalence of communicable and noncommunicable diseases. Although efforts have been made on the disease war front,

communicable and non-communicable diseases continue to impact health systems leading to a rise in demand for drugs and extension-appropriate packaging.

The Covid-19 pandemic for instance reminded the globe that we are far away from completely eradicating communicable diseases and put stress on the entire pharma manufacturing industry on a scale never seen before. Non-communicable diseases such as cancer and diabetes also create a huge demand for drugs that need to be packaged in a safe and secure manner.

The global Oncology Cancer Drugs market alone was valued at US$147.2 billion in 2021 and it is expected to hit around US$289.2 billion by 2030 with a CAGR of 8.4% during the forecast period 2022 to 2030. This just shows how much potential lies in the pharma packaging industry and its critical role as an enabler of healthcare delivery.

While the market for pharma packaging is thriving and continues to grow, players in the sector have to continuously adopt new ways of processing to align with the specific needs of the industry while at the same time enhancing the efficiency, safety, and sustainability of their operations

GLASS PERSISTS AS THE MATERIAL OF CHOICE IN BEER PACKAGING

By Alphonce Okoth

In the beer market, glass has maintained its position as the preferred packaging material for many decades. “I have been told by customers that the first chilled sip of beer, including the bottle feeling on the lips, can be the favorite part of a day,” says Mark Comline, Senior Global Procurement Director for Cans and Glass at Carlsberg. In addition, many consumers also feel that glass packaging is more attractive than aluminum cans or other options.

But the preference for glass in beer packaging far transcended the purported experience it gives to consumers. Glass means sustainable, innovative, healthy, reusable, and infinitely recyclable packaging – that’s what makes it a true champion of circularity, for policymakers, brands, and consumers alike. Glass is virtually inert and impermeable, making it the most stable of all packaging materials. With no risk of harmful chemicals getting into the drinks that are packed in glasses, no additional barriers or additives are needed.

BENEFITS OF GLASS OVER OTHER MATERIALS

Glass has kept its role in beer packaging throughout the years despite the many innovations in materials and packaging forms that have happened around it. This is only partly due to its sustainable credentials. Glass

is fully recyclable and can be reused many times without compromising its integrity or capabilities. “Glass is 100% recyclable and customers know that,” says Greg Bentley, Global Packaging Innovation Director at Anheuser-Busch InBev (ABInBev). “Glass goes back into glass. Glass bottles are made from glass bottles. Furthermore, you can break it and melt it using significantly less energy than it would take to make new glass from raw materials.” Many consider this as a major plus that plastic cannot offer. While versatile and durable, plastics are not always recyclable or reusable, and it is usually not a straightforward process when they are.

Another benefit of glass is that it preserves the freshness of beer. Glass acts as an effective barrier against external influences. “With glass packaging, nothing gets into the drink and nothing gets out,” observes Bentley. This prevents the aromas from escaping while shielding your drink from interacting with oxygen. It’s this interaction with oxygen that can make your drink go stale. As glass is natural and inert, it prevents any transfer of flavors into or from the beer. It’s a single-layered material that doesn’t require any chemical liners that could interact with the beverages. “With the amber colour added to the glass the beer is also protected from UV light, which can damage it,” Bentley adds. The quality of the packaging

ON THE LEFT: GLASS MEANS SUSTAINABLE, INNOVATIVE, HEALTHY, RESUSABLE, AND INFINITELY RECYCLABLE PACKAGING

also remains the same, no matter how many times it is recycled, making it the most stable packaging material.

Above all, it is a material that has strong associations in the minds of consumers. Glass brings a premium feel to the packaging that other types of packaging cannot offer. With its heavier weight and more vintage look, it tends to evoke a very different image: one that can inspire the right retro vibe when paired with a colorful logo for craft beer. This is what most brands seek to exploit when they want to communicate a certain image and feeling to their customers. For some, that means offering a heightened sense of luxury with a premium feel whenever a buyer picks up their goods.

Glass can also be designed in different shapes to connect with the history of a product or to send a specific message. Looking beyond the label, the bottles allow for special brews and pints to be packaged in a variety of shapes, sizes and colors – leading to unique, eye-catching designs that match the originality of the brew and the brand. That’s what adds to the thrill for many beer lovers who collect and display their favorite bottles from around the world at home.

WHATEVER ITS COLOUR, GLASS IS ALWAYS GREEN

In the early years of glass packaging, drinking beer and soda from returnable bottles was

commonplace. The bottles could be refilled and reused many times, but the practice of returning bottles became less familiar with the introduction of steel and then, later, aluminium cans. Now, there is a steady resurgence in returnable bottles, at least in some markets.

Belgium is one of the European markets where the practice or returning bottles to be reused and refilled is on the rise. In the US, ‘bottle bills’ are being reintroduced in some areas, mandating refundable deposits on beer and soft drink containers. “Returnable glass bottles are designed slightly differently to be able to be used multiple times, in line with sustainable practices,” says Mark Comline, Senior Global Procurement Director for Cans and Glass at Carlsberg. “However, in countries such as Denmark, where deposit rates are above 90%, breweries, producers and importers choose themselves the type of bottles to use for their brands but the law requires that a deposit be charged on all bottles no matter the colour, shape or form.”

LIGHTWEIGHTING

Although glass is popular among beer producers, its greatest disadvantage is only its high weight. In direct comparison, PET bottles can be as much as 90% lighter than the multiple use variety made of glass. To counter this, manufacturers of glass packaging are working

GLASS BOTTLES ARE MADE FROM GLASS BOTTLES. FURTHERMORE, YOU CAN BREAK IT AND MELT IT USING SIGNIFICANTLY LESS ENERGY THAN IT WOULD TAKE TO MAKE NEW GLASS FROM RAW MATERIALS.

FGreg Bentley, Global Packaging Innovation Director at Anheuser-Busch InBev

BELOW: GLASS CAN BE DEISGNED IN DIFFERENT SHAPES TO CONNECT WITH THE HISTORY OF A PRODUCT

on weight reduction, such as using tempered, lightweight glass. Reusable bottles produced this way are not only as much as 30% lighter than the standard variety but they are also more resistant to abrasion, which can turn them into a real alternative both economically and ecologically. Lightweight glass further allows thin-sided glass containers to be made, which are just as capable as traditional glass packaging when it comes to strength and durability. Lightweight glass is also 100% recyclable and is completely neutral in relation to the contents. With lighter bottles, the weight of stacking the product is much less likely to cause damage and will also lead to more products being delivered. A decrease in the weight of bottles and other glass packaging leads to savings, due to the need for fewer raw materials. Lightweight glass is also environment friendly. For instance, alcoholic beverage giant AB InBev achieved 17% CO2e emissions reduction per bottle by just decreasing the weight of the standard longneck beer bottle from 180 to 150 grams.

DRAWBACKS OF GLASS PACKAGING

Despite having benefits and being preferred for a long time in beer packaging, glass also has a few downsides that come along with it. Cost is one of the factors that every company must consider throughout every aspect of their business is cost. One of the flaws of utilizing

glass packaging is that it tends to be more expensive than its plastic counterparts. This is partly due to the higher amounts of energy required to manufacture glass products and the increased shipping rates tied to its heavier weight and more delicate nature.

The fragility of glass packaging is something that must also be considered. A plastic bottle will not break when dropped, but a glass bottle is more likely to shatter. This causes problems at all points in the supply chain – for the manufacturer, handlers, shippers, retailers, and end users. A broken glass container means a useless product, making it a total loss and waste of money.

While glass offers the major benefit of being fully recyclable and reusable, it’s not the perfect fix to all of our packaging sustainability woes.The manufacturing process for glass takes up quite a higher amount heat and energy than that of many plastics, which causes its carbon footprint to be sizeable. According to the International Journal of Life Cycle Assessment, a 0.75-liter glass container must be used at least three times to bring its carbon footprint in line with a half-liter plastic bottle and the United States EPA says that only about 1/3 of all glass containers ever even make it to the recycling bin.

PROSPECTS AND CONCLUSION

The increased consumer awareness and call for sustainable production have given rise to innovations and development in the entire value chain. Many companies have set net zero emissions and are striving to beat the target without altering the quality of the glass used. with so many benefits from reuse to recycle to customized designs, glass offers the best material for beer packaging.

One of the main reasons why brewing experts prefer the bottle is mainly that it enables exhaustive control over the final product by controlling the beer’s carbonation levels. Some brewers prefer to use secondary fermentation, with natural carbonation and that fine layer of yeast sediment on the bottom of the bottle. Drinking beer from a can is about the beer. Drinking beer from a glass bottle is about savouring the experience

WITH LIGHTER BOTTLES, THE WEIGHT OF STACKING THE PRODUCT IS MUCH LESS LIKELY TO CAUSE DAMAGE AND WILL ALSO LEAD TO MORE PRODUCTS BEING DELIVERED.

LIGHTWEIGHTING: AN INDUSTRY’S RESPONSE TO THE PLASTIC PACKAGING PROBLEM

By Alphonce Okoth

In 1800 as history puts it,the first manmade plastic was unveiled by Alexander Parkes at the Great International Exhibition in London. This material, dubbed Parkesine, was derived from cellulose and could be molded when heated and retained its shape when cooled. It was however not until 1950s that commercial plastic packaging was widely adopted in various sectors including food, pharma, electronic goods, among other uses. Its success came from the simple fact that unlike many other forms of packaging, plastic is highly flexible, resists most chemicals, and is impervious to air and water. Seven decades after its introduction, plastic packaging has grown to

be a menace to the environment. It’s a great eyes in many landfills, it clogs our waterways, pollutes once pristine ocean beaches, and litters oceans all over the globe impacting marine life.

An estimated 300 million tonnes of plastic are produced every year, eight million of which end up in our oceans, reports the international environmental watchdog, IUCN. Although useful to many industries from food and beverage to pharmaceutical manufacturing, plastic has long lost its glory as the solution to all packaging problems. With many alternatives still far from possessing the qualities that we all love in plastics, innovations to make plastic less injurious to the planet are becoming

popular. Lightweighting is one such innovation that holds the promise of better-for-theenvironment plastic packaging and it is being explored by manufacturers in various ways.

USING LESS MATERIALS

The most common approach to lightweighting is to replace heavier materials with less dense and/or stronger materials and components. By moving to an alternative lighter material, such as flexible pouches, there is greater benefits in terms of saved energy and CO2 during manufacturing and transportation. For instance, Carex’s Eco pouch refills use 75% less material than 2 equivalent bottles. Colgate

Palmolive’s Sta Soft fabric Softener and Procter and Gamble’s Downy Fabric Softener are another example of brands with pouch refills that are significantly lighter compared to rigid PET bottles. Love, Beauty, and Planet have launched concentrated shampoo and conditioners which provide the same number of uses as a regular-sized bottle and use 50% less plastic, saving resources and waste. The company is also aiming to use 25% recycled content in its packaging by 2025, supporting its bid to reduce the use of about 100,000 tonnes of virgin plastics.

Technology is also playing a role in reducing the weight of plastic. Unilever implemented

ABOVE: LIGHTWEIGHTING IS SEEN BY SOME AS ONE OF THE SOLUTIONS TO THE PLASTIC WASTE PROBLEM

injection compression technology for some food tubs in Europe in 2015, saving 21 tons of plastic in 2017 without compromising the quality of packaging. They also redesigned some of their pouches and sachets, combining a durable polymer with a thinner polyethylene layer, ultimately reducing their polymer usage by some 1,400 tons.

Through various lightweighting technologies, Coca-Cola Europacific Partners has reduced the weight of its 500ml PET bottles by 30%, from 28.9g to 19.9g since 2008. The company has further introduced a new lighter-weight neck design that will remove a further 1g of plastic per bottle, totaling 6,800 tonnes of plastic by the end of 2024.

Reducing the amount of plastic used in packaging sometimes means creating a whole new product line. PepsiCo designed a line of beverages called Drinkfinity, a direct to consumer subscription model that ships flavored pods and a reusable 20oz bottle. Instead of grabbing a drink on the go, using Drinkfinity results in using 65% less plastic.

REMOVING UNNECESSARY PARTS

Given the economies of scale for major consumer brands, even shaving a few grams of plastic from a bottle can reduce a large amount of plastic from ever making it into supply stream and ultimately into landfills and oceans. Diageo is a perfect case study when it comes to product redesign to remove unnecessary

parts. The company has redesigned its 1.75L Smirnoff bottle by removing the handle. This simple change shaved 137g off their packaging. With 8.7 million bottles sold, the resulting savings in packaging material is the equivalent in weight of 7 Boeing 747 jets.

Nestlé has also started to remove unnecessary plastic lids, accessories, layers, and films to reduce the carbon print of its packaging. In Egypt, Nestlé has eliminated plastic bottle cap tear-off bands from Nestlé Pure Life water bottles – which means 240 tonnes less plastic

BY MOVING TO AN ALTERNATIVE LIGHTER MATERIAL, SUCH AS FLEXIBLE POUCHES, THERE IS GREATER BENEFITS IN TERMS OF SAVED ENERGY AND CO2.

every year. And the company is eliminating close to 10 times that amount of plastic by removing over-cap lids from Gerber baby food.

All these light-weighting initiatives not only reduce the amount of plastic used in packaging, but they also decrease the amount of fuel and greenhouse gases used in the distribution of products. Lighter goods weigh less, and that means less fuel to transport. If light-weighting also makes an overall product package more compact, it also lessens the number of vehicles required to ship the same amount of product.

LIGHTWEIGHTING IS NOT AN ANSWER TO PLASTIC POLLUTION

Lightweighted packaging configurations are often marketed to consumers as being more affordable, more convenient and making less of an environmental impact by taking up less volume. However, the trade-off of a lighter package is often one that is neither reusable nor recyclable, destined for landfill or incineration and the inevitable pollution of our natural ecosystems.

For example, in many cases, a lightweighted package, like a juice pouch, is multicompositional in nature and not recyclable in the current waste management infrastructure. The multi-layer films from which most

pouches are comprised are often made up of several different plastics, which are difficult to recycle because these components require separating. Further, the waste created by the various fitments that give lightweighted items high functionality (such as straws, caps and spoons) are also not recyclable through curbside collections due to their small size. These loose add-ons fall through the screeners at municipal recycling facilities and are missed for recovery.

In addition, reduction in the weight of plastic packaging does not influence the likelihood that it will end up in the ocean. If the lighter packaging enters the environment after usage, it will, in fact, break down into smaller pieces more quickly than packaging that is thicker and stronger. Additionally, if less plastic is used per package — for example thinner PET water bottles — it does not mean that the producer will use less plastic in total. On the contrary, as these companies strive to increase their sales, the number of packaging units is likely to increase. The biggest problem here is caused by mini-packages.

In countries where consumers have less buying power, companies like Unilever and Danone sell small packages with a very small amount of a given product (e.g., shampoo, body wash, washing powder or coffee) inside. Whatever the product may be, there is proportionately a lot more packaging material used compared to when larger or ‘bulk’ product sizes are used, even if it is lightweight plastic.

Overall, The biggest problem with lightweighted packaging is that producers and manufacturers of these items have not designed end-of-life solutions into their packaging innovations. Where items like pouches and sachets bring down costs, we see packages with decreased recyclability in largely inefficient waste management infrastructures, compounding the issue of their pollution.

ALTERNATIVE BIO-BASED MATERIALS ON THE RISE

Understanding that reducing overall weight of plastic does not solve the problem, manufacturers and co-packers are now shifting towards biodegradable raw material to make new packages that have the same properties as

BELOW: THE MOST COMMON APPROACH TO LIGHTWEIGHTING IS TO REPLACE HEAVIER MATERIALS WITH LESS DENSE ALTERNATIVES

plastics. London-based startup called Notpla, developed a range of grease and water-resistant packaging formats – with a plastic-free barrier made from seaweed. The company is making three basic products: seaweed-coated cardboard boxes for food retailers, seaweed film for wrapping food or cosmetics, and small sachets containing a drink, like water, alcohol or fruit juice. The seaweed itself has been rendered tasteless, but it’s perfectly edible, notes the company.

Seaweed isn’t the only alternative to plastic. UK-based brand, 4eco uses starch from the cassava root vegetable to produce its zeroplastic alternative. This method can be used to make plastic bags, as well as other items like cutlery and straws which are also often made from single-use plastic. Crucially, the bags are able to carry the same weight as their plastic counterparts and are dissolvable in water, leaving behind a liquid that is harmless to the environment.

Meanwhile Panda Packaging uses bamboo to do the job of single-use plastic. Using a proprietary technology, the company takes natural materials like bamboo and feeds them into a machine which can produce packaging like take-away boxes, plates and wrappers

on and used. However, Hubbub’s Rosie Sharp says there remains a considerable uphill journey ahead. “A big struggle for these packaging companies is the behavior change needed on both sides of the debate,” she says. For manufacturers, the fact remains that plastic is by far and away the cheapest and easiest material to use when packaging food and drink. Meanwhile for consumers, sticking with what you know ensures you’re never disappointed.

Avoiding single-use plastic would be the ideal solution to preventing the material from ending up in landfills and oceans, but ultimately brands and manufacturers have to balance consumer demands, retailer considerations, and the safety of food and other products when creating a sustainability plan.

after breaking it down. The main focus of the company is customizability, with the main aim to make it just as easy as working with plastic. These are just a few examples of bio-based alternatives to plastics.

Notpla,4eco, Panda Packaging and more demonstrate there is no shortage of sustainable packaging alternatives currently being worked

Ultimately, light-weighting is just one method for reducing the number of plastics that end up in the environment. Brands should reevaluate their packaging and task their designers and engineers with finding ways to replace or decrease the amount of plastic used in their products. Managers and marketers should be mindful that the pressure to reduce the use of plastic packaging is not just coming from environmentalists, but also from consumers and even shareholders. Moreover, the clock is ticking, and at our current rate, the plastic will eventually outweigh fish in the world’s ocean by 2050

ABOVE: PHARMACEUTICAL SOCIETY OF KENYA JOINS KABARAK UNIVERSITY SCHOOL OF PHARMACY IN A WALK TO HONOR WORLD

THE BIGGEST PROBLEM WITH LIGHTWEIGHTED PACKAGING IS THAT PRODUCERS AND MANUFACTURERS OF THESE ITEMS HAVE NOT DESIGNED END-OF-LIFE SOLUTIONS.

TWO-STEP MOLDING CAN HELP

up to 20% Lower package part cost up to 20% Minimized package weight up to 9% Improved uptime Reduce initial CAPEX