Canadian Packaging September 2014 by Annex Business Media

SEPTEMBER 2014 | $10

www.canadianpackaging.com

TOAST OF THE TOWN Packaging automation upgrade gets to the crust of the matter

Publication mail agreement #40069240.

Story on page 12

FUEL FOR THE ROAD 

Page 22

IN THIS ISSUE: CANADIAN CONVERTING • PRODUCT ID NOW • CORRUGATED PACKAGING p OFC cpac sept 2014 OFC CVR NL p OFC.indd 1

14-09-22 11:47 AM

Delivering End-to-End Packaging Solutions xpedx and Unisource Worldwide recently merged to form Veritiv – a new distribution company leading the way in packaging. Whether you’re in need of a more cost-effective packaging option, better speed-to-market capabilities or new innovative package designs, Veritiv will help shape success for your business.

p IFC cpac sept 2014 IFC AD p IFC.indd 2

14-09-05 11:22 AM

With its breakthrough design, the 9550 applies labels directly onto packs without the need for an applicator, while self-adjusting label placement accommodates varying line speeds, throughput and package sizes. Revolutionary Intelligent Motionâ&#x201E;˘ technology targets zero unscheduled downtime as it precisely and automatically controls the entire system. See the Videojet 9550 in action at PackExpo 2014 in Chicago.

Intelligent MotionTM

p 01 cpac sept 2014 AD p 01.indd 1

14-09-05 10:59 AM

Watch it!

= Retail Innovation

Conair and Add Ink teamed up to develop a virtual video display printed right onto an in-store display. Now customers can use their smart phones to directly engage with Conair’s new Even Cut display and watch the grooming tool in action. AR technology activates virtual video on the display or on the front panel of the product package.

Virtual Video Display

Try it and see for yourself

1. Download the Conair for Men App 2. Launch the 3D Product AR 3. Select the ‘display’ option 4. Hover your camera over this Virtual Video Player and watch the Video

Virtual Video Display (VVD) Benefits: • Replaces costly display-mounted LCD screens • Easy set-up - no power cords or batteries required • VVD is printed onto the display and/or product packaging; activated using AR technology • Measurable ROI via real-time reporting - track downloads • Works with iPhone and Android devices • Enhanced customer experience • Perfect for new product launches

To learn more about virtual video display technology, contact us. We’d love to hear from you. n display

desig Custom

Innovative Packaging and Retail Displays

(416) 298.8101 • (800) 268.5620 • www.addink.ca www.conaircanada.ca

p 02 cpac sept 2014 AD p 02.indd 2

Add Ink is a division of Atlantic Packaging Products Ltd.

14-09-05 10:59 AM

UPFRONT

WASTE NOT WANT NOT 2.0

SEPTEMBER 2014 VOLUME 67, NO. 9

SENIOR PUBLISHER Stephen Dean • (416) 510-5198 SDean@canadianpackaging.com EDITOR George Guidoni • (416) 510-5227 GGuidoni@canadianpackaging.com FEATURES EDITOR Andrew Joseph • (416) 510-5228 AJoseph@canadianpackaging.com ART DIRECTOR Sheila Wilson • (416) 442-5600 x3593 shwilson@bizinfogroup.ca PRODUCTION MANAGER Barb Vowles • (416) 510-5103 BVowles@bizinfogroup.ca CIRCULATION MANAGER Anita Madden • 442-5600 x3596 AMadden@bizinfogroup.ca EDITORIAL DIRECTOR Lisa Wichmann • (416) 442-5600 x5101 LWichmann@canadianmanufacturing.com EXECUTIVE PUBLISHER Tim Dimopoulos • (416) 510-5100 TDimopoulos@bizinfogroup.ca

BIG MAGAZINES LP Vice-President of Canadian Publishing • Alex Papanou President of Business Information Group • Bruce Creighton

HOW TO REACH US: Canadian Packaging, established 1947, is published monthly by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. 80 Valleybrook Drive, North York, ON, M3B 2S9; Tel: (416) 442-5600; Fax (416) 510-5140. EDITORIAL AND ADVERTISING OFFICES: 80 Valleybrook Drive, North York, ON, M3B 2S9; Tel: (416) 442-5600; Fax (416) 510-5140. SUBSCRIBER SERVICES: To subscribe, renew your subscription or to change your address or information, contact us at 416-442-5600 or 1-800-387-0273 ext. 3555. SUBSCRIPTION PRICE PER YEAR (INCLUDING ANNUAL BUYERS’ GUIDE): Canada $72.95 per year, Outside Canada $118.95 US per year, Single Copy Canada $10.00, Outside Canada $27.10. Canadian Packaging is published 11 times per year except for occasional combined, expanded or premium issues, which count as two subscription issues. ©Contents of this publication are protected by copyright and must not be reprinted in whole or in part without permission of the publisher. DISCLAIMER: This publication is for informational purposes only. The content and “expert” advice presented are not intended as a substitute for informed professional engineering advice. You should not act on information contained in this publication without seeking specific advice from qualified engineering professionals. Canadian Packaging accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. Canadian Packaging receives unsolicited materials, (including letters to the editor, press releases, promotional items and images) from time to time. Canadian Packaging, its affiliates and assignees may use, reproduce, publish, republish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. PRIVACY NOTICE: From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1-800-668-2374 Fax: 416-442-2191 Email: privacyofficer@businessinformationgroup.ca Mail to: Privacy Office, 80 Valleybrook Drive, North York, ON M3B 2S9 PRINTED IN CANADA PUBLICATIONS MAIL AGREEMENT NO. 40069240, ISSN 008-4654 (PRINT), ISSN 1929-6592 (ONLINE) We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage for our publishing activities. Canadian Packaging is indexed in the Canadian Magazine Index by Micromedia Limited. Back copies are available in microform from Macromedia Ltd., 158 Pearl St., Toronto, ON M5H 1L3

ackaging rarely gets the credit it deserves in the court of public opinion for all the wonderful things it does to help people go about their daily lives in relative comfort and safety. Taken for granted at best and scorned as a necessary evil at worst, packaging is the first thing to get the blame whenever consumers have a hard time opening a product package or the milk in the fridge turns sour just before this morning’s coffee. And while most right-thinking people would agree that a world without modern consumer packaging would be a pretty grim place, bashing packaging as a major contributor to some of the word’s gravest ecological and societal challenges seems to have become a brave new pastime among the millennial generation empowered by social media and general disdain for anything pre-Internet in general as, well, just being so 20th Century, dear God! But that’s no reason for the packaging industry to stop striving to develop better, more effective and more engaging packaging formats that will ultimately help change the public’s largely cynical take on its contribution to the greater societal good, despite a plethora of existing credible evidence to the contrary. It would also do the industry well to take a more active role in educating the public on the multitude of practical benefits that a well-designed package inherently brings to their daily existence— especially when it comes to food packaging. While enhancing product protection and shelflife is the obvious no-brainer, there are many other reasons why, according to the industry’s conservative estimates, the food product waste that this packaging prevents from taking place is at least 10 times greater than the waste it creates. This mighty multiplier effect has profound significance for Canada and the U.S., with consumers in both countries estimated to throw away about 40 per cent of all the food produced there each year—translating into about $27 billion in Canada and some US$162 billion south of the border, or six million and 35 million tonnes respectively. So how can packaging be used to cut that waste down in a meaningful way?

According to a recent position paper from AMERIPEN (American Institute for Packaging and the Environment), packaging can be effectively used to reduce this staggering mountain of food waste by: • Maintaining longer freshness, nutritional value and safety. Rather than acting as mere oxygen barriers, “The latest packaging innovations even include technologies that prevent or reduce contaminants—increasing shelf-life and product safety, while maintaining nutritional value,” the study points out. • Providing critical storage and usage information, thereby increasing the amount of food that is actually consumed, rather than thrown away due to spoilage. • Delivering effective portion control. “Individually-wrapped chicken breasts, squeezable yogurt tubes, and cheese sticks are much more than conveniences,” according to the study. “They ensure that the portions not eaten remain fresh and protected, ready for use at a later date [and] they help you from inadvertently serving to your family more than they can finish.” • Providing more pre-cut and pre-washed food options. Bagged pre-cut carrots and celery, jarred sauerkraut and canned artichokes reduce waste by “delivering only the parts of these products that can be eaten,” without all the stems, peels, husks and stalks that have to be disposed of. Instead, all these ‘edibles” can be composted by farmers and food processors before packaging to create natural fertilizer and soil condition right where they’re needed in the field. Says AMERIPEN’s executive director Donna Dempsey: “To most people, the fact that packaging plays a very positive role in our efforts to reduce food waste is counterintuitive, as they usually think about a package when it comes time to put it in the recycling or trash bin. “What they don’t realize is how that little bit of packaging saves a significant amount of food, along with the related economic and environmental resources from being thrown away.” One way or another, it’s time for everyone to start doing their part to help make that realization sink in where it really counts.

COVER STORY 12 TOAST OF THE TOWN By Andrew Joseph

Innovative Quebec breadmaker making the most of its recent packaging automation investment with optimized productivity and vastly improved line efficiencies. Cover photography by Pierre Longtin

DEPARTMENTS & COLUMNS

3 UPFRONT By George Guidoni 4-5 NEWSPACK Packaging news roundup. 6-7 FIRST GLANCE New packaging solutions and technologies. 8 ECO-PACK NOW All about packaging sustainability. 10 imPACt A monthly insight from PAC, Packaging Consortium. 32 PEOPLE Career moves in the packaging world. 33-34 NOTES & QUOTES Noteworthy industry briefs. 35 EVENTS Upcoming industry functions. 36 CHECKOUT By Paul Pethick Joe Public speaks out on packaging hits and misses.

FEATURES 18 RAPID PROGRESS By Andrew Joseph A new printing press installation is a powerful morale and performance booster for venerable Ontario foldingcarton stalwart. 22 LIVING IN THE FAST LANE By Andrew Joseph A labeling system upgrade keeps leading producer of household and automotive chemicals in pole market position.

28 FOUR WAYS TO PROSPER By Nick Griffin Ontario boxmaker scaling new heights of productivity and production flexibility with a new state-of-the-art folder-gluer.

SEPTEMBER 2014 • CANADIAN PACKAGING WWW.CANADIANPACKAGING.COM • 3

p 03 cpac sept 2014 mh-upfr p 03.indd 3

14-09-05 2:09 PM

NEWSPACK

NEW WINE LABELS PAY A FITTING TRIBUTE TO FALLEN CANADIAN WAR HEROES

With the summer commemorations of 100-year anniversary of the start of World War I providing a timely sobering reminder of the ultimate sacrifices by thousands of young Canadians who perished in the brutal four-year conf lict, Ontariobased Diamond Estates Wines & Spirits is keen to keep that sense of patriotic pride alive for years to come with the release of two new wines paying fitting homage to the country’s war-time efforts. Launched last month across Ontario, Manitoba and Alberta, the 750-ml bottles of 1914 Honour white and 1914 Valour red varietals represent a somber departure for one of the province’s leading winemakers—operating several large wineries and vintners in the Niagara region—which is betterknown for its celebrity-endorsed vintages such as Dan Aykroyd and NHL Alumni wine series. “These new wines were developed specifically to recognize and celebrate the achievements of the generations who served and continue to serve in Canada’s military,” says Diamond Estates president and chief executive officer Murray Souter. Paying a tribute to both the 100th anniversary of the Great War and the 150th Anniversary of Confederation—initiated by the historical 1864 Charlottetown Conference that paved the way to Canadian Confederation in 1867—both wines are

currently available in 750-ml glass bottles, sporting elegantly attractive labels designed by the Torontobased graphics agency Brand Muller (pictures below) and in the nine-liter bag-in-box packaging formats for the foodservice industry. Diamond Estates says it will donate 50 cents from the sale of each bottle sold through LCBO (Liquor Control Board of Ontario) and other

provincial liquor boards to the True Patriot Love Foundation, with the aim of raising $50,000 by the upcoming Remembrance Day celebrations on November 11, 2014. Established in 1955, the not-for-profit organization funds a variety of programs in mental health, physical rehabilitation, family support and veteran transition that address the unique challenges related to the impact of military service.

“The LCBO has always been a great supporter of charitable causes and they were very receptive to helping us promote this effort and the many promotional activities leading up to Remembrance Day,” Souter states. “We will be working tirelessly to get these wines into the hands of Canadians in every province.” According to Diamond Estates brand marketing manager Peter Toms, the company plans to make both labels a permanent part of its product portfolio, rather than a one-off, limited-time release. “This is a whole new brand that we are very proud of and that we feel has real staying power to it,” Toms told the Canadian Packaging magazine. “We are confident that all Canadians who try it will appreciate it both for its message and its approachable taste profile that can be enjoyed at any occasion,” says Toms, noting that the company fully intends to extend the brand’s geographic reach nationwide. Adds Diamond Estates vice-president of winemaking Tom Green: “The 1914 Honour is a refreshingly crisp white wine, while the 1914 Valour is a bold and mouth-filling red [and] either wine can be readily enjoyed either on their own or with food.”

DON’T JUST GUESS... KNOW YOUR CUSTOMERS ARE SAFE!

MDB3113 Metal Detector Simple Controls with conveyor and built-in rejection system for food processors, pharmaceutical, or chemical industries. The XtraVac MDB3113 accurately inspects food or non-food products, bulk powder or granular materials.

Call or Email XtraVac Today!

A DIVISION OF

877-435-4555 · Sales.Canada@XtraVac.com

4 • WWW.CANADIANPACKAGING.COM

p 04-05 cpac sept 2014 Newspack p 04-05.indd 4

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 2:39 PM

NEWSPACK

RECYCLING SCHEME A BIG GREEN PERK FOR OFFICE COFFEE-LOVERS

Widely loved by consumers for their convenience, large sizes, with the final price of each option and just as widely reviled by environmentalists for ($52.99, $96.99 and $136.99 respectively) also covtheir allegedly excessive carbon footprint, the sinering the cost of a pre-paid shipping label to send the gle-serve coffee capsules—still commonly referred filled boxes directly to TerraCycle for processing. to as K-Cups after (See full pricing and purchasing information at their original inventor www.officemaxcanada.com/terracycle) Keurig—have the cofSays TerraCycle Canada’s general manager Nina fee industry working Purewal: “TerraCycle is thrilled that OfficeMax furiously to develop a Grand & Toy has partnered with us to launch Canada’s workable end-of-life first K-Cup Packs retailer recycling program. solution to prevent “Their leadership in helping us eliminate waste these hard-to-recycle, speaks to their commitment to sustainability. multi-material mini“We are excited to be able to offer a recycling solupods from ending up at tion to this wastestream problem to Canadian conlandfills across North Resembling a compact-footprint filing cabinet sumers,” says Purewal, adding that a successful pilot America in their mulin shape and size, the TerraCycle K-Cup Recycling project in southern Ontario would set stage for the tiple billions year after year. System boxes are available in small, medium and program’s nationwide rollout. And while it may not quite be the green silver bullet the coffee industry would love to see right now, a new pilot recycling initiative just launched by TerraCycle Canada and leading office supplies distributor OfficeMax Grand & Toy is certainly a step in the right direction. Under the program—for now limited to a trial run in southern Ontario—OfficeMax Grand & Toy will offer its customers one of three specially-designed recycling boxes to collect all the discarded K-Cup capsules at their offices and ship the filled boxes directly to TerraCycle. Widely acknowledged as one of the world’s leading “upcyclers” of waste products, TerrCycle uses a proprietary process to separate all the K-Cup components (cup shells, lidding, filters, etc.) to make the leftover materials suitable for manufacturing a broad range of useful new products—from plastic carry bags and pencil cases to park benches and outdoor garbage bins. “At OfficeMax Grand & Toy, we believe that each and every person has a responsibility to do their part to better the natural environment that we all share,” says OfficeMax Grand & Toy’s sustainability manager Serguei Tchertok. “In line with this philosophy, we embrace environmental responsibility across every facet of our business, MachineStruxure maximises your business and machine and we foster it through unique, progressive programs such as this,” says performance through flexible and powerful control solutions Tchertok, adding that K-Cup Packs are one of the company’s most popuMachineStruxure is a complete machine automation Grow your business while reducing costs solution with benefits all through the machine life cycle. lar coffee products. With MachineStruxure you’ll get to market faster thanks to intelligent, easy-to-use “We launched this program based Four flexible and scalable development software and ready-to-use applications and function blocks. More 1 control platforms on the stakeholder feedback that we importantly, you’ll improve your bottom line with all the embedded features and single software 2 One received from our associates, supplienvironment functions in our new, highly-efficient line of flexible and scalable controllers. Even tested, validated, ers and customers, who have identi3 Ready-to-use machine integration and maintenance is easier, delivering unmatched connectivity and documented architectures fied waste and recycling as our most motion for superior lifecycle support. 4 Embedded and safety important sustainability issue,” he application development adds, pointing out that OfficeMax 5 Expert MachineStruxure, the intuitive choice. and technical support Grand & Toy, an affiliate of global office products provider Office Depot, Inc., is the first retailer in See how easy and intuitive machine Canada to get involved in the recycautomation can be! ling of K-Cup capsules. Download a FREE brochure, and enter to win a Samsung Galaxy Note™ 3!

Now, intuitive machine automation is just a click away ™

Visit www.SEreply.com Key Code g442u

SEPTEMBER 2014

©2014 Schneider Electric. All Rights Reserved. Schneider Electric and MachineStruxure are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. All other trademarks are the property of their respective owners. • www.schneider-electric.com • 998-1207451_CA-GB_Note3

CanadianPackaging_0901_g442u_CA.indd 1 p 04-05 cpac sept 2014 Newspack p 04-05.indd 5

7/29/14 12:01 PM 14-09-05 2:39 PM

PERSONAL SAFETY

FIRST GLANCE

E EN GI HY

TO OF TAL OW CO NE ST RS HIP

WLX

CODE OF CONDUCT The new model 1050 thermal inkjet printer from Markem-Imaje is designed to produce highresolution serialized data and complex linear and 2D (two-dimensional) barcodes on fast-moving production lines in the food, beverage, pharmaceutical and other industries, according to the company, while also excelling in case-coding applications in dusty, humid or corrosive environments. Incorporating a high-precision, f lexible printhead capable of generating text, logos and high density graphics up to two inches in height in 600-dpi (dots per inch) resolution on highspeed packaging lines, the 1050 is easy to maintain because it features ink cartridges that combine the printhead and ink—meaning no moving parts—with the snap-in/out cartridges facilitating uninterrupted operation. Well-suited for creating customized product promotional coding in short-run production, the 1050 thermal inkjet printer incorporates a user-friendly, seven-inch touchscreen interface with intuitive WYSIWYG programming, along with full compatibility with the company’s powerful CoLOS coding software for centralized network control of all the MarkemImaje printers. Markem-Imaje 401

CLEAN, SAFE CONVEYING, ADVANCED PERFORMANCE

Designed for maximum available production time and operating convenience, the new modular belt conveyor in stainless steel is robust, safe and easy to clean. The standardized design and modularity make changes of the production line easy. It’s the smart, long-term investment in your ATX Montreal bottom line and Booth 1107 your operators!

PRESSING THE ISSUE Designed to offer label and packaging converters faster turnaround times through automated color management, a wider frame and new ink capabilities for expanded applications, the new rollfed HP Indigo series WS6000 digital printing press from Hewlett-Packard Development Company, L.P. is outfitted with a new inline spectrophotometer utilizing closed-loop control to eliminate the need for manual color calibrations and adjustments—thereby reducing time spent preparing color profiles and PANTONE color matching

by up to 75 percent, according to the company. Boasting an expanded 320-mm frame width for higher press output, the new press also incorporates an Enhanced Productivity Mode (EPM) option to enable label converters to produce up to 131 linear feet per minute in full color. Powered by Esko’s Packaging Workflow Suite 4.1 and the HP SmartStream Labels software, the WS6800 press also boasts proprietary ElectroInk Silver technology to enrich the labels’ appearance with a metallic look similar to UV f lexo silver inks, which can be used as a spot or base color on a range of label applications, including paint, automotive, household chemicals, nutraceuticals and soft-drinks, with high-def resolution of up to 223 lines per inch. Hewlett-Packard Development Company, L.P. 402

HIP TO BE SQUARE The new patented Square Bag f lexible packaging solution from Mondi Americas incorporates advanced packaging films with a variety of spouts, closures and handles to provide a reliable and effective alternative for packaging of liquid food, wine, laundry detergent, pet food, motor oil and other liquid products in up to 1.5-gallon volumes, as well as powders and granular materials weighing up to 10 pounds. Easily adaptable to most common filling lines without specialized filling technology, the versatile Square Bag can be fitted with a spout, zipper, slider, and hook or loop openings, with label handles on different panels that can be constructed from up to three different materials. Mondi Americas

Sarong S.p.A. Italy Expands Offices to North America Sarong S.p.A., the worldwide leading manufacturuer of thermoforming fill and seal packaging machines, superior packaging materials and exceptional contract packaging, for food, pharmaceuticals and household products, has opened a new location in Mississauga, Ontario, Canada.

explains, “It makes perfect sense for us to have a domestic location in North America servicing the Canadian and US market. We offer innovative packaging solutions and can’t wait to demostrate our capabilities to small and large organizations in this region.” In November 2014, for the first time, Sarong S.p.A. will be exhibiting at the Chicago Pack Expo show Nov 2-5 and will also be presenting on the innovation stage lecturing on thermoforming packaging for single dose.

Specializing in single dose packaging, Sarong recognizes the importance of expanding this concept throughout North America where unit dose serving in packaging is becoming the packaging solution of the future.

Be sure to visit the Sarong S.p.A booth #1022 located in the Pharma Expo section.

For years, the single dose packaging concept has been the norm throughout Europe where family homes have smaller storage spaces that demand smaller packs for food and household products. On the other hand until recently, consumers in North America commanded large family size packaging for their favorite consumer products. Today the North American consumer is changing, demanding more sustainable packaging and less food wastage, therefore, vastly receptive to unit dose packaging solutions.

www.ﬂexlink.com

Flexlink_Sept14.indd 1

6 • WWW.CANADIANPACKAGING.COM

p 06-07 cpac sept 2014 First Glance p 06-07.indd 6

403

For Sarong, expanding its locations to North America was a strategic move. Mr Alberto Bartoli, Vice President of Sales & Marketing with Sarong S.p.A.

14-09-04 2:33 PM

For more information please contact: Rachel Gualtieri rachel.gualtieri@sarong.it Cell: 647-448-9124 Sarong North America Inc. Offices: 2470 Stanfield Rd., Unit C, Mississauga, Ontario L4Y1S2 Office: 905-272-3699

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 11:00 AM

North kaging e

me, the and ovation

FIRST GLANCE INTEGRAL BENEFITS The new turnkey Integra 320 robotized blister line from Marchesini Group features a new machine pitch control system combined with high-speed carton opening and product insertion systems to reach output levels of up to 320 blisters and more than 260 cartons a minute. Boasting a small-footprint design, the Integra 320 line smoothly integrates blister thermoforming and carton packaging

and quadruple suction pads that can be used for handling wooden panels, metal sheets and other large workpieces; and a sack gripper for safe and reliable transport of plastic and paper sacks. J. Schmalz GmbH

406

SOMETHING IN THE AIR

phases in a compact system utilizing a three-axes Robocombi robot with a sucker pick-up head that connects the two stations and minimizes size changeovers. Equipped with a servooperated film unwinder that stops automatically when the material runs out, the line features an integrated forming material splicing table with automatic vacuum system that blocks the film in the correct position. Marchesini Group

Storopack’s newly upgraded line of AIRplus air cushioning now includes three new types of film to expand the application range of the company’s on-demand AirPlus machine—set up directly at the packing station—to offer a cost-effective alternative to the use of conventional, pre-inf lated bubble

wrapping materials. Now available in both a standard width of 400-mm (Bubble 29b) and a larger width of 700-mm (Bubble 53b) for packing small items such as cellphones or cosmetic products, the new protective packaging options also include the AIRplus Cushion material with 28 chambers per perforated section (Cushion 28b)—engineered for the wrapping of larger items such as laptops, as well as for the wrapping of individual products in a package where sensitive items inside need to be protected from damage by other packaged goods. Storopack North America

407

404

MAXIMUM SAFETY Developed by Constantia Flexi bles, the new Safemax container is a deep-drawn aluminum container for pharmaceutical devices—featuring innovative construction whereby aluminum is laminated to poly-

prolypene and then combined with a lidding foil to ensure optimal seal integrity and provide convenient peel-off lidding foil that is safe and easy for end-users to open, while providing reliable, highly-hygienic protection against moisture ingress for the medical devices inside. Constantia Flexibles

405

UPLIFTING FEATURES With payload capacity of up to 50 kilograms, the new JumboFlex 50 vacuum tube lifter from J. Schmalz GmbH features a new operator handle with a redesigned button—along with larger soft-touch inserts on the control handle—that can be controlled with either one or two fingers by either right- or left-handed operators. Employing an energy-saving electrical pump to generate optimal suction power and lifting speeds of up to one meter per second, the JumboFlex 50 lifter comes with a variety of different quick-change suction pads to suit a broad range of demanding applications: including the round suction pad for barrels and buckets; double

SEPTEMBER 2014

p 06-07 cpac sept 2014 First Glance p 06-07.indd 7

14-09-05 11:00 AM

ECO-PACK NOW

INSULATED CARRIERS HIT THE GREEN PACKAGING SWEET SPOT Autumn holiday orders are the lifeblood of many smaller artisan bakeries specializing in creating memorable pumpkin, key-lime, apple, cherry, pecan and blueberry pies that often travel vast distances to arrive just in time for special occasions in immaculate shape and condition. This makes the delivery of such hand-crafted pies, cheesecakes and layer cakes a trickier packaging challenge than some may think—both in terms of product freshness and the environmental footprint. But not too tricky for the Norfolk, Neb.-based Thermal Packaging Products, whose new Pie and Cake Shippers were designed specifically to offer online fine-food purveyors a clever and environmentally responsible way to protect temperature-sensitive pies and cakes during mail

order delivery to customers across the continent. According to the company, the cotton-en hanced insulating materials used in the Pie and Cake Shipper carriers provide soft cushioning and thermal protection for the package contents via the use of special insulating cotton padding made from a select blend of recycled f locked cotton fibers that provide ‘super-absorbent’ properties for effective containment of undesirable condensation or accidental spills, while also incorporating a time-sensitive,

EPA-approved antimicrobial additive for crosscontamination prevention. “This unique combination, when used with gel packs or other refrigerant, provides the superior thermal protection necessary for temperature control during shipments,” the company says. The reversible two-part insulation liners also allow for frozen shipments utilizing dry ice film on one side, according to Thermal Packaging, or the perforated film for refrigerated shipments using frozen gel packs that often condensate during the thawing process. The tiny perforations in the film allow for any spills or unwanted condensation from gel packs to be wicked away from the product and be absorbed into the insulation fibers, according to the company.

A FLAKY TAKE ON CLEAN PET At Sealed Air Food Care, we deliver measurable business results to our partners by focusing on four drivers for purposeful innovation so that together we can share in the value created.

DISCOVER EFFORTLESS SAFETY. As a processor, you know how important food and worker safety are to your operation. That’s why Sealed Air’s Food Care Division offers packaging solutions like Cryovac Grip & Tear® vacuum bags that boost Food Safety. This easy-open package requires no knives and helps prevent worker injuries, and reduce product damage and cross-contamination. See how this packaging innovation - and others - can deliver measurable results to your business.

While the solid growth in recycling rates for PET (polyethylene terephthalate) beverage containers is great news on the surface, things look less rosy when one considers that up to one-third of the collected bottles ultimately can’t be recycled as intended due to contamination from labeling materials and adhesives. According to recycling industry sources, out of the 1.5 million pounds of PET collected across the U.S. for recycling in 2010, yield losses from contamination traced to direct printing, paper labels and standard pressure-sensitive labels ranged from 24.4 to 32,2 percent—amounting to a loss of over 40 million pounds of bottles. With these numbers in mind, it’s hard to understate the promising potential of the CleanFlake portfolio of adhesives developed by the Glendale, Ca.-headquartered labeling manufacturer Avery Dennison, which recently picked up the coveted Top Product of the Year honors in this year’s Environmental Leader Product & Project Awards competition. In a nutshell, the patent-pending CleanFlake adhesives are speciallyformulated to prompt them to literally “switch off ” when submerged in a recycling bath to enable labels to separate cleanly from the PET f lakes. “Although these labels adhere firmly to PET containers during use, they detach readily in a conventional recycling facility and f loat to the surface of the bath, allowing clean PET f lakes to sink to the bottom for easier reclamation,” explains Don Nolan, president of Avery Dennison’s Materials Group business.

Find out more by visiting gripandtear.com today.

8 •

File Name: 14SAC200A_G&T_PROC_ENG_CanadPack_v2 p 08-09 cpac sept 2014 ECO p 08-09.indd 8 Client: Cryovac

Live: 7 in (w) x 10 in (h) Trim: 7.875 in (w) x 10.75 in (h)

Color: 4C Process Built @: 100%

SEPTEMBER 2014

Delkor-Can 14-09-05 11:01 AM

You can change over a Delkor Trayfecta in the time it takes to read this ad. ®

SEE US AT PACK EXPO International ADVANCING

PROCESSING & PACKAGING

November 2 - 5, 2014

McCormick Place Chicago, IL, USA

Booth S-3834

Stop by our booth # S-3834 to see our Trayfecta® former in action!

Three minutes! That’s all it takes to change over a Delkor Trayfecta former – no tools required. It doesn’t matter whether you’re going from a lockstyle paperboard carton to a glued corrugated case. The Trayfecta even handles shelf-ready applications such as Delkor’s new, patentpending Cabrio Case®. Once the changeover is complete, you can immediately start high-quality production. With product-specific tooling, there is no need to make multiple adjustments that create

material waste. Trayfecta formers come in single- to four-headed units to meet the widest range of line speed requirements. It’s no surprise that plant managers are calling it “the best and most versatile machine” in their packaging lines. Stop by our booth # S-3834 at Pack Expo International in Chicago or visit our website today to see how the Delkor Trayfecta former can help you meet today’s – and tomorrow’s − packaging challenges.

PACKAGING INNOVATION AT WORK delkorsystems.com | 800-328-5558

Trays

Delkor-Canadian Packaging Sept 2014.indd 1 p 08-09 cpac sept 2014 ECO p 08-09.indd 9

Cartons

Cases

9/3/14 8:53 AM 14-09-05 11:01 AM

The vital partner and catalyst for the packaging value chain

Founded 1950

ACCESS THE GLOBAL PACKAGING NETWORK

PAC launches interactive site featuring PACit! MEMBER LOGIN

The Vital Partner and Catalyst for the Packaging Value Chain

Join PAC MEMBER LOGIN

HOME

ABOUT

PACsecure The Vital PACedPartnerPAC NEXTCatalyst MEMBERS EVENTS COMMUNICATION and for the Packaging Value Chain

HOME

ABOUT

PACsecure PACsecure

PACed

PAC NEXT NEXT

MEMBERS

EVENTS

COMMUNICATION

GOVERNMENT

CONTACT

Join PAC

Knowledge Center GOVERNMENT

CONTACT

Knowledge Center

PRODUCT PORTFOLIO PRODUCT PORTFOLIO

Start of Life

PACsecure is protecting products at the Start of Life. The product portfolio includes IFS PACsecure, the of Life most trusted and comprehensive global packaging standard. And PAC FOOD WASTE is AStart Catalyst for Food Waste Packaging Solutions. PACsecure is protecting products at the Start of Life. The product portfolio includes IFS PACsecure, the most trusted and comprehensive global packaging standard. And PAC FOOD WASTE is A Catalyst for Food Waste Packaging Solutions.

Throughout Life

PAC Members

PACed is continuing packaging education Throughout Life. The education product portfolio includes inclass and on-line specialized packaging training program. Throughout Life

PAC Members

PACed is continuing packaging education Throughout Life. The education product portfolio includes inclass and on-line specialized packaging training program.

Into Next Life

< >

PAC NEXT takes packaging into its Next Life. Our vision is A World Without Packaging Waste and our goal is to minimize recovery system costs, while maximizing recovery rates of discarded packaging. Into Next Life

Surveys < >

PAC NEXT takes packaging into its Next Life. Our vision is A World Without Packaging Waste and our goal is to minimize recovery system costs, while maximizing recovery rates of discarded packaging.

EVENTS

Surveys Packaging has an important role - what should its priority be? Designed for optimization

NEWS EVENTS

Ensuring food safety Food waste reduction

NEWS

Made from renewable materials Performance and cost in use Product protection Recyclable Vote now

Terms & Conditions

839 followers

Terms & Conditions

839 followers

New Features: Survey - Important market research, weekly updates IFS PACsecure and PAC FOOD WASTE - product safety and protection solutions

PACed - check out our 8 in-class and 15 on-line courses PACit - Knowledge Center to view 500+ papers and to post your papers Videos - real people talking about PAC value added products

www.pac.ca For more information contact Lisa Abraham at labraham@pac.ca pac0599 september CP page.indd 1

10 • WWW.CANADIANPACKAGING.COM

p 10-11 cpac sept 2014 imPACt p 10-11.indd 10

04/09/2014 10:58:30 AM

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 10:59 AM

10:58:30 AM

WORK SMARTER

RockTenn’s precision mandrel-forming technology forms cases around a fixed mandrel, minimizing case-skew and maximizing structural integrity, resulting in cases that outperform standard RSC’s in production efficiency and stacking strength. Meta® Systems’ unique case forming process offers the ultimate in flexibility and enables improved box performance in your production line and distribution system. Why work harder when you don’t have to?

Visit us at PACK EXPO International, Booth #S-2122 To learn more about our precision mandrel-forming technology, contact RockTenn Automated Packaging Systems at 407.843.1300. ©2014 Rock-Tenn Shared Services, LLC. All rights reserved. ROCKTENN, the stylized R, and META are trademarks of Rock-Tenn Company and its subsidiaries and affiliates.

SEPTEMBER 2014 • CANADIAN PACKAGING WWW.CANADIANPACKAGING.COM • 11

p 10-11 cpac sept 2014 imPACt p 10-11.indd 11

14-09-05 10:59 AM

COVER STORY

MOST DARING ADVENTURE

Quebec bakery’s automation investment hits the packaging line efficiency sweet spot

Dare Foods’ Saint-Martin facility maintenance manager Matthew Beauchamp holds semi-finished boxes constructed by the high-speed Delkor Trayfecta S4 1502 carton former.

ANDREW JOSEPH, FEATURES EDITOR PHOTOS BY PIERRE LONGTIN

o manufacturer of global renown has ever gotten to be that way without daring to set high goals for itself, and Kitchener, Ont.-headquartered Dare Foods Limited is as fine a testament to the virtues of dreaming big and reaching high as any major Canadian food producer out there—even after more than 120 years in the highly competitive baked-goods business. Founded in 1892 by Charles Henry Doerr under the name of C.H. Doerr Company, the family-owned business that rose to iconic prominence as a manufacturer of delicious, high-quality cookies is nowadays also a major North American player in the market segments for crackers, fine breads, candies and other baked goodies and treats that busy modern-day consumers can’t seem to get enough of—including the very popular line of snack-bread products produced at the company’s highly-automated, 140-employee breadmaking facility in Saint-Martin, Que. One of six manufacturing plants operated by Dare Foods in North America—employing over 1,300 people in total—the Saint-Martin plant is home the company’s very popular line of Boulangerie Grissol brand portfolio purchased by Dare Foods in its 2001 acquisition of the cookie and fine breads business of the Montreal-based Culinar Inc. Housing two baking lines and three packaging lines,

12 • WWW.CANADIANPACKAGING.COM

p 12-17 cpac sept 2014 DARE cvr sty p 12-17.indd 12

the busy plant turns out the full range of Boulangerie Grissol brand products, including the perennial bestseller Melba toast, Canapé, Bread Sticks and Baguette Bites, along with the recently-lunched new favorites such as Morning Thins, thin crispy slices of bakerystyle loaves with seeds, fiber and fruit for on-the-go mornings; Sweet Thins, a sweet calorie-controlled snack; and Artisanal Baguettes, a line of premiumquality, oven-baked baguettes made under authentic recipes and using fresh natural ingredients like black olives, cinnamon and raisin, or cranberry and figs.

Lead Role “We are a leading Canadian fine bread manufacturer,” says Saint-Martin maintenance manager Matthew Beauchamp, noting the company considers itself to be one of the leading players in the fine bread market segment across North America, despite growing competition from both imports and private-label store brands. “Increased competition is a reality for us,” Beauchamp told Canadian Packaging in a recent interview, “but we constantly strive to remain competitive by launching new and innovative products. “We also look at our bottom line results with the realization that by constantly updating our manufacturing equipment, we will not only improve our production line speed and efficiency, but will also reduce our manufacturing costs,” says Beauchamp,

citing four major facility expansions and innumerable equipment upgrades taking place at the SaintMartin factory since it first started producing the venerable Boulangerie Grissol products back in the 1940s under previous owners. As the plant’s maintenance manager, it is Beauchamp’s job to ensure the plant’s production and packaging lines are always running up to snuff, which is no easy task for a plant “producing on three shifts a day, covering the entire week—with regularly scheduled sanitation—24-hours-a-day and seven-days-a-week.” Despite the plant’s high-throughput rates and growing volumes, Beauchamp says the facility does not take any shortcuts that would in any way undermine the final quality of the product manufactured at Saint-Martin. “After fresh ingredients are mixed in batches to produce dough, we process it into various pans, and bake it in large ovens,” he relates. “After depanning, the cooked loaves are placed onto large wheeled racks and are refrigerated for several days to ensure most of the humidity is removed. “Removing it from the refrigerated section, we slice the now-dry bread, and further toast it on a processing line specific to the type of cut and packaging required,” Beauchamp expands. “After packaging—either semi-automatically or fully-automatically—the packaged products are palletized and immediately placed into vans for

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 2:27 PM

COVER STORY shipment to our distribution center which will then ensure our products go to the proper destination.” For a company that is often credited with rewriting the book on cookie packaging in Canada, having borrowed a trick from coffee packaging and introducing the tin-tie strip to cookie packaging in 1954 to make it a new de facto cookie industry standard, the performance of packaging machinery and equipment at the Saint-Martin facility naturally get all the close scrutiny and attention it duly deserves, according to Beauchamp. “When I became the maintenance manager for the Saint-Martin plant last year, I noticed early on that an existing carton former that was in use on one of our major line was not up to par,” he says. “Relative to our needs, it was a poor design that featured overly complicated changeovers and adjustments that, quite frankly, caused us a lot of unnecessary downtime. “Back in the summer of 2011, I was looking for a simple, robust, yet high-performance design with a high level of performance and efficiency, and I found one that offered all of that in one,” relates Beauchamp. “We found that at Delkor.” Delkor Systems, Inc., a St. Paul, Minnesotaheadquartered designer and manufacturer of packaging machinery, installed a brand-new Trayfecta S4 1502 model case, carton and tray former at the Saint-Martin facility. According to Beauchamp, it was when he worked

for Dare’s engineering department that he first considered them for a project. “I was impressed by the equipment that they offered, but unfortunately, that project fell through,” relates Beauchamp. Delkor sales manager Fred Sowa says that for the latest project Dare Foods was looking for a new tray former, but that “the actual carton matrix they presented was a bit unique in that they had a large format that ran quite slow and that the other smaller formats required speeds up to 90 cartons per minute.”

Head Start According to Sowa, the Trayfecta S4 1502 was the best possible solution for Dare Foods, allowing it to utilize two heads for the higher rate, while only one head would be required for the slower rates, a f lexibility offered by the machine that is considered to be unique in the business. “We actually design and manufacture three other carton formers, with another having four heads allowing for forming speeds over 200 cartons per minute, but the 1502 matched so perfectly for this mix of size and rate required, that it was a no-brainer for us to recommend it to Dare Foods,” advises Sowa. He adds that since Dare required a nominal rate of 78 with a surge rate of 90 cartons per minute for their fastest requirement. Delkor was aware that the speed on these machines

Pre-printed box flats ready to be placed into the Trayfecta S4 1502 carton former, to be glued into shape with the Nordson ProBlue 7 hot-melt adhesive applicating system.

The Delkor Trayfecta system utilizes the Nordson ProBlue 7 hot-melt adhesive dispensing and applicating system for forming the paperboard cartons at high throughput speeds.

is dictated by the carton size and style, “But on the 1502, we can mechanically operate at 60 cycles per minute so the machine is not being stressed.” Key features of the Trayfecta S4 1502 include: • A tool-less changeover that takes three minutes per head thanks to three servo motors that actually do most of the work automatically; • Fixed tooling sets that are simple to install, enabling instant startup on the first cycle for immediate formation of quality cartons, with less costly carton waste; • Changeovers that are easy for operators of all skill levels, via an HMI (human-machine interface), that is very intuitive with easy-to-follow procedures; • Provide a thorough training and support for independent operation by the plant. • Ability to run three materials: paperboard, corrugated and microf lute materials with just a minor tooling change. “You might note that Delkor seems to be a wee bit obsessed with the number three—but when we are talking about the Trayfecta series, it is by design, as it is a play on the word ‘trifecta’, bringing the power of three to the forming applications,” reveals Sowa. “The Trayfecta can also run three different package formats—cartons, cases and trays, and handles glued, locking and fold-over lock designs,” he expands.

Flat paperboard sheets being pneumatically transferred inside the Delkor Trayfecta carton former to be glued and then assembled at high speeds.

A close-up of the Trayfecta carton forming machine shows cavities being formed in the cartons to make just the right amount of space for the packaged product.

SEPTEMBER 2014 • CANADIAN PACKAGING WWW.CANADIANPACKAGING.COM • 13

p 12-17 cpac sept 2014 DARE cvr sty p 12-17.indd 13

14-09-05 2:27 PM

COVER STORY “Should you require it, it could form a paperboard carton on one lane, while at the same time form a corrugated case in the other lane,” states Sowa. “It’s just that impressive.” To handle rough going at Dare Foods, the Trayfecta S4 1502 boasts a robust construction with fixture head slide guides that maintains a stroke tolerance within 0.008-inches for repeatable and close tolerance motion. The Trayfecta S4 1502 utilizes a Rockwell Automation Allen-Bradley brand PanelView Plus 700 for easy operator interaction, and a ProBlue 7 hot-melt adhesive system to seal the cartons, cases and trays, manufactured by Nordson Corporation. Now using the Trayfecta S4 1502 for cartoning of the Melba toast products, and the new Sweet Thins and Morning Thins products, Beauchamp is quite cartons exit the Trayfecta S4 system via conhappy with the whole project. Fabbri_2013Feb_MeatPkgAd_Sausage_CP_Layout 1 2/8/13 11:13 AM PageFormed 1 veyor to be filled with product. “Everything worked out very well,” he begins.

E 1 The Markem-Imaje 6064 thermal ink coder and the Loma IQ 2 metal detection system pair up for optimal product coding and quality assurance.

N O T H I N G S AY S

F R E S H like FABB R I PAC KAG ING Fabbri Automatic Stretch Wrappers produce highly attractive packages that make your products look fresh and “just packed”. Fabbri Stretch Wrappers use stretch film to package fresh sausage in preformed trays to provide an in-store wrapped appearance. They employ four-way stretch technology to produce tight, over-the-flange, wrinkle-free packages with securely sealed bottoms and a superb case presentation. And here’s something you might find even more attractive: Fabbri Stretch Wrappers can help increase your profitability. Fabbri packaging is produced using low-cost packaging materials. And when you factor in its Best in Class low cost of ownership, the Fabbri Stretch Wrapper is your most economical and affordable packaging solution. Compact and robust servo-driven Fabbri packaging machines are built for speed, versatility and the highest levels of productivity. Fabbri Stretch Wrappers can handle a wide range of tray sizes with no changeovers, producing up to 62 packs per minute. All models feature a user-friendly full-size control panel for easy operation and maintenance. Test the Fabbri at our Reiser Customer Center and see for yourself how it can improve your packaging. Contact Reiser today.

“The machine was up and running in no time, and it passed all the SAT (site acceptance test) and commissioning at a 99.5 per cent efficiency. “We went from a two-hour changeover that took another two hours to fine-tune in production with our old machine, to a less than 10-minute changeover that generated perfect cartons in the first cycle after startup,” recalls Beauchamp. Sowa concurs, noting that Delkor performed substantial testing prior to the customer’s factory acceptance test. “Once their team arrived, we followed Dare’s extensive protocol to prove the machine,” says Sowa. Beauchamp says he was also happy about the fairly simple training for Dare Foods’ operators. “After only about 12 hours of training, a new operator could run and perform changeover with the Trayfecta within the required time,” Beauchamp says, noting that Delkor’s assembly technicians also serve as the installation service support. “As such, when we do our extensive training with the customer in our facility, and follow through at the installation with the same technicians, we can provide a training service that is perfectly in tune with people who are familiar with not only the tray former, but also Dare’s requirements,” relates Sowa. Other key equipment installed at the Saint-Martin facility include: • a Bosch Packaging Technology robotic top-loading system; • a Markem-Imaje model 6064 thermal inkjet coder; • a Loma Systems model IQ 2 metal detection system; • f lexible stand-up pouch packaging machinery for the new Boulangerie Grissol Artisanal Baguettes products. Beauchamp says he is convinced that the bakery will continue to move forward to be the best in the market segment. continues on page 16

Reiser Canada 1549 Yorkton Court #4, Burlington, ON L7P 5B7 • (905) 631-6611 Reiser 725 Dedham Street, Canton, MA 02021 • (781) 821-1290 www.reiser.com/fabbrisausage

Leading the food industry in processing and packaging solutions.

SEPTEMBER 2014

2013

p 12-17 cpac sept 2014 DARE cvr sty p 12-17.indd 14

14-09-05 2:27 PM

I w

274.6375x403.225

EXPERTFOLD 170 / 230 / 300 / 350

Itâ&#x20AC;&#x2122;s mId-range, but way above average As a mid-volume corrugated box manufacturer, you need equipment that sets and runs quickly, gives you great box quality, and can be adapted to future changes in your markets.

Available in four widths and three configurations, EXPERTFOLD has been specifically designed with mid-volume production in mind, whatever your markets. EXPERTFOLD : The right tool for the job.

Right in the middle of the BOBST range is the new EXPERTFOLD, a specialty folder gluer which gives you exactly that.

www.bobst.com

p 12-17 cpac sept 2014 DARE cvr sty p 12-17.indd 15

14-09-05 2:27 PM

COVER STORY continued from page 14

Dare Foods employs a robotic top-loading system to execute gentle and efficient placement of packs of Melba toast in the outer boxes.

Machine operator using the Allan-Bradley PanelView Plus 700 terminal to monitor and CANPACK-MicrositeSept-14.pdf 1 8/29/2014 9:39:03 AM control operations of the Delkor Trayfecta S4 model 1502 carton former.

DARE FOODS TIME-LINE The humble start to the Dare Foods empire began when Doerr began making and selling hand-made cookies at his own grocery store located in Berlin, Ont.—a predominantly German community now known as Kitchener, about an hours drive west of Toronto. By the time World War I had ended, the company a locally well-known and fairly successful cookie and candy business. Unfortunately, Doerr’s son Webourne and daughter-in-law Irene both died of the Spanish Flu of 1918, but he carried on by running the business and raising his infant grandson, Carl. By 1933, Carl began working at the family business and took over at the age of 24 when Charles passed away in 1941. After the factory burned down in 1943, the business-savvy Carl bravely proceeded to rebuild and modernize the factory, and change his family name. Perhaps because his family name was of Germanic-origin, and Canada was at war with Germany, Carl surmised that a name change might be good for business, proceeding to change both his surname and company name to Dare, and soon after starting to ship product to all regions of Canada. Not content with just producing food products, the company also took an active role in its food packaging. In 1954, Dare Foods took a coffee packaging concept and introduced cookie packaging to the tin tie-strip. The new format allowed consumers to reseal the bag to better maintain the product’s freshness, ultimately becoming the de facto standard of cookie packaging in Canada. By 1956 the company had penetrated into the lucrative U.S. market, and in 1983 introduced the popular Breton cracker line, which became a bestseller in both Canada and the U.S. Other key expansions include: • The construction in 1989 of a fully-automated soft-candy manufacturing plant in Milton, Ont., bringing the European style RealFruit Gummies to North America; • The building of a cracker bakery on a 33-acre Greenfield site in Spartanburg, S.C., which helped Dare become more of a major presence in the North American market; • A 1999 acquisition of the 134-year-old Bremmer Biscuit Company of Denver, Co. adding Bremmer Wafers to its line-up; • A 2001 acquisition of the cookie and fine breads business of Culinar Inc., adding the BearPaws, Whippet, Wagon Wheels and Viva Puffs brands, as well as the classic Melba toast, Canapé and Bread Sticks products, sold under the Boulangerie Grissol brand name; • Being chosen by the Girl Guides of Canada as the exclusive supplier of their cookies in 2002; • In 2003 it became one of the first companies in North America to turn all its facilities peanut-free in response to public concerns over nut-based allergies. Manufactured in Canada and the U.S., Dare Foods has a wide range of cookies, crackers, fine breads and RealFruit candy all of which are available throughout North America and in more than 30 other countries around the world.

16 • WWW.CANADIANPACKAGING.COM

p 12-17 cpac sept 2014 DARE cvr sty p 12-17.indd 16

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 2:27 PM

COVER STORY DARING ADVENTURE continued from page 14

An SEW-Eurodrive motor powers the conveyor line leading cartons to the product handling robotic station, where the wrapped products are placed inside cartons formed by the Trayfecta S4 model 1502 system.

“We will continue to improve our line efficiency and performance for our existing products to maintain our strong market position, involving integrating new technologies and workplace practices,” sums up Beauchamp. “We will also continue to be a leader in innovation by launching new and delicious products that fit well with our core business and values.” As for Dare Foods’ continued commitment to proactive capital investment, Beauchamp proclaims: “It’s a credit to the Dare family, and their foresight, for empowering the company to not merely be viable financially, but to be a successful business now and for the long-term future.”

For More Information: Delkor Systems, Inc.,

460

Rockwell Automation

461

Nordson Canada, Limited

462

Bosch Packaging Technology

463

Markem-Imaje Inc.

464

Loma Systems (Canada) Inc.

465

Sonoco Products Company

466

SEW-Eurodrive 467

SEPTEMBER 2014 • CANADIAN PACKAGING WWW.CANADIANPACKAGING.COM • 17

p 12-17 cpac sept 2014 DARE cvr sty p 12-17.indd 17

14-09-05 2:27 PM

CANADIAN CONVERTING

RAPID PROGRESS

New printing press propels Ontario boxmaker to the next level of technical prowess

In May 2014, Ingersoll Paper Box president Sarah Skinner purchased the first Koenig & Bauer Group KBA Rapida 106 seven-color press in Canada.

ANDREW JOSEPH, FEATURES EDITOR PHOTOS BY COLE GARSIDE

ost people may think that a box is just a box just a box, but most people out there do not make their living in the modern boxmaking business—like the venerable family-owned folding-carton converter Ingersoll Paper Box Co. Limited, where quality has been a well-entrenched part of the working vocabulary for over 90 years. Started up in 1922 by Robert Skinner to make ice cream-cones, Ingersoll Paper Box has happily been toiling away as a local, but successful player in the production of paperboard packaging and folding cartons for local CPG (consumer packaged goods) and industrial customers across southwestern Ontario. “Because the cones we made needed boxes for protective packaging, we decided to go into the paper and paperboard business ourselves,” Ingersoll Paper Box president Sarah Skinner told Canadian Packaging during a recent visit to the company’s remarkably tidy, 85,000-square-foot facility built atop the original site’s f loor in Ingersoll, Ont., about a two-hour drive southwest of Toronto. As the great-granddaughter of the company’s founder, Skinner readily acknowledges the burden of carrying on a very long and proud manufactur-

18 • WWW.CANADIANPACKAGING.COM

p 18-21 cpac sept 2014 Ingersoll-KBA p 18-21.indd 18

ing legacy, but she is confident that a series of wellexecuted major capital investments carried out by the company in recent years perfectly positions it to keep thriving a very competitive and hotly contested marketplace. “While a rush order in 1922 is the same as a rush order in 2014, we have always sought to implement the latest technologies here at Ingersoll Paper Box to ensure our customers receive the best quality product,” says Skinner, who initially joined the family business in 1994 as part of the sales, marketing and management teams. It has only been in recent years where she has taken over leadership of the company and played a key role to the recent growth and upgrades at Ingersoll Paper Box. “Our own efforts at continuous improvement, as well as customer requirements, have helped build this company over the decades, and I am sure that it will continue to drive our future as well.”

TOP SUPPORT This corporate culture of continuous improvement has been well supported over the years under the leadership of her father David Skinner, she relates, who made many keen purchases and capital upgrades that have kept the company viable and profitable, while continuously investing in new machinery to remain highly competitive.

Employing about 70 people, Ingersoll Paper Box producing a multitude of straight-line boxes such as reverse tuck, straight tuck and universal bottom; automatic bottoms also known as ‘crashlock’; fourand six-corner boxes; and blister cards. “We also offer services like CAD (computeraided design), printing, embossing, folding and die-cutting,” says Skinner, citing the company’s wide-range of customers involved in the food, healthcare, pharmaceutical and automotive industries. This past spring, the company made a serious declaration of intent with the announcement that it had just completed the installation of a brand new KBA Rapida 106 7+L ALV2 seven-color, 41-inch fully-automatic printing press, said to be the first press of its kind to be installed in North America. “It was a multimillion-dollar purchase,” Skinner points out. “And we are confident that over the next three years it will pay for itself, thanks to the KBA’s laborsaving properties, its speed, and quality of its print.” Skinner says that in addition to making everyone in the boxmaking industry take notice, the new press installation not only benefited its customers, also had a great positive impact on the staff morale by demonstrating the management’s commitment to ensure a successful future.

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 11:28 AM

CANADIAN CONVERTING

The KBA live-image QualiTronic ColorControl wall screen provides the Rapida 106 press operators with a visual inline color measuring system to ensure print integrity is maintained throughout the run. Photos by Andrew Joseph.

As the oldest press manufacturing company in the world, German-based press Koenig & Bauer Group (KBA) custom-builds each press to customer specifications to ensure they get the machine best-suited for their unique processes and their customers. Accordingly, this particular The KBA Rapida 106 —a seven-color printing press featuring a coater and UV (ultraviolet) dryer—was completely custom-built for Ingersoll Paper Box’s exact needs and application requirements. Some of the special options on Ingersoll’s new press include a kit just for packaging printers, nonstop operation for longer runs, inline quality measuring systems and special fast cleaning system which are perfect for running spot colors and special coatings. Being able to measure density, spectrally, LAB values (to define absolute colors), dot gain and other key variables makes it a perfect fit for the boxmaker’s high expectations of product quality. Says KBA North America, Inc.’s vice-president of marketing and product management Eric Frank: “In my opinion, it gives Ingersoll Paper Box a unique advantage in the marketplace—it is exactly what they need today and in the future in terms of press speed, number of printing units and automation. “It certainly enables Ingersoll Paper Box to be able to address the packaging needs of customers in today’s market place,” Frank states. “This is a tremendous example of how a customer’s future needs can be analyzed and then be manufactured as press specified, designed and built to address a certain need.”

BUILT FOR SPEED The KBA Rapida 106 boats speed rates of 18,000 sheets per hour—or a blistering five sheets a second—which Frank says actually exceeds the customer’s current requirements. “The print quality on the press is the best for difficult forms that have heavy solids, fine screens and forms that tend to ghost. The ink train is very reactive so this reduces waste and ensures consistent color during the run,” mentions Frank. The new inf lux of automation brought by the KBA Rapida 106 has enabled Ingersoll to have extremely short make-ready times, as the press essentially utilizes a one-button set up system, not

to mention presets, fast-washing cleaning systems, and a host of simultaneous processes. That one-button set-up system is done via the Rapida 106’s ErgoTronic console, whereby an ergonomic touchscreen provides easy access for the press operator to manipulate all press functions. As well, KBA added a very large visual screen of its own manufacture, so that operators can easily see what is going on in the Rapida 106. The screen also features what KBA calls a liveimage QualiTronic ColorControl—an inline color measuring system to ensure print integrity is maintained throughout the print run.

BETTER VIEW The QualiTronic ColorControl utilizes a camera visual system that is integrated directly into the press using LED illumination to allow the operator to check in-time ink density measurements in control strips, which can be positioned at either the front or center of the paperboard sheet. When the printing starts, the control strips are scanned directly in the press, and the measured solid densities are presented on the screen in a live graphic display. These measurements are used as a basis for fast, dynamic inline color correction. After the measuring system is set up, all measuring patches are scanned on every printed sheet, right up until reaching maximum production speed. The first setting corrections are realized immediately after the job start—with a control cycle measuring every single sheet and then adjusting every 10th sheet to ensure a perfect print run. At the other end of the Rapida 106 lie the feeder and infeeder sections, which, along with everything else on the press, made a big impression on Skinner. “We purchased the optional automatic skid/pallet changer with light curtains,” says Skinner. “While it doesn’t save us any time, it does actually save on worker ergonomics, meaning we have healthier employees.” After the blanks on pallets are placed within the DriveTronic feeder that is controlled via four servo-motors, the continuous, stepless pile lifting of the blanks into the press is performed smoothly thanks to automatic: speed compensation; format setting; pile side-edge alignment; pile-height sens-

ing and skew-sheet correction at the feeder head; and anti-static sheet loosening via air separation. Electronic sheet deceleration ensures optimum sheet arrival speed is achieved at the front lays of the infeed section. “The swing infeed accelerates the sheet smoothly in towards the feed drum, while the DriveTronic Infeed provides motorized remote adjustment for the complete infeed system,” explains Frank. Other main features on the Rapida 106 printing press include: • Patented KBA DriveTronic SIS (sensoric infeed system) that electronically controls the lateral sheet alignment; • Patented Venturi system to provides smooth sheet infeed; • U ltrasonic double-sheet detector; • Optical skew-sheet sensors; • Optical front lay sensors with electropneumatic overshoot blocking; • Manual non-stop system with individual rods for

With maximum throughput of 18,000 sheets per hour, the KBA Rapida 106 seven-color printing press with a coater and UV dryer was custom-built to Ingersoll Paper Box’s exact specifications.

SEPTEMBER 2014 • CANADIAN PACKAGING WWW.CANADIANPACKAGING.COM • 19

p 18-21 cpac sept 2014 Ingersoll-KBA p 18-21.indd 19

14-09-05 11:28 AM

CANADIAN CONVERTING uninterrupted production during pile changes; • Fully-automatic non-stop system with sensormonitoring rake for logistics operation; • J ob Access software program for automatic job pre-setting; • Remote register setting; • The LogoTronic professional management system that not only provides prepress setting, order management, but can also provide graphic representation of the production process as well as management of all quality reports; • Double-size impression cylinders and transfer systems on the printing unit for reliable sheet travel, regardless of substrate; • Continuous gear-train for smooth running and high precision; • Corrosion-free cylinder surface finish;

High Impact Corrugated Boxes

Ingersoll added the optional automatic pallet changer with safety light curtains for the feeder section of the Rapida 106 printing press.

• Universal gripping system for maximum holding force. “It really is an amazing press—so much so that days after our open house event celebrating the Rapida 106 at Ingersoll Paper Box, we had customers knocking on our door to do business with us, and more continue to follow,” Skinner recalls.

Visit #N-6106 at Pack Expo

A few months before the KBA press was installed at Ingersoll Paper Box, the converter purchased a new platesetter system, the model Avalon N8-22 and Elantrix 125 SX, from Agfa Graphics. “We used to purchase plates externally until six months ago,” says Skinner, “and then we’d have to store them. “But now we no longer have to store plates and we have total control over the plate manufacturing—not to mention the time we save by doing it ourselves—plates which we use on the KBA Rapida 106.” In May of 2011, Skinner made a significant purchase from BOBST, installing a new BOBST EXPERTFOLD 110 A-2 high-speed folder-gluer that Skinner says replaced some older antiquated equipment, while significantly increasing throughput capacity. To better optimize the EXPERTFOLD 110 A-2’s performance, Ingersoll Paper Box purchased a BOBST Handypack GT semi-automatic collection table for collecting and packing cartons, along with a VCX Gluing and Quality Assurance glue system option from Valco Melton—ensuring optimal quality control for the glue patterns and application of the Resicol X-697 Blue adhesives supplied by Halltech Inc. Even three years later, Skinner is still quite excited about the EXPERTFOLD’s unique capabilities,

Live Demo: Complete inline palletizing system

• Retail Ready Packaging • Award Winning Flexographic PrePrint • Solution Based Structural Design • Vendor Managed Inventory Solutions • Point of Purchase Displays • Club Store Packaging • Flexible Manufacturing Capabilities

High Speed, Inline Palletizer > Safety: Industry-leading category 3 safety system with fully integrated guarding and dual latching hoist pin system* > Flexibility: Add or modify patterns through the HMI using the adjustable programmable laner (standard) > Performance: 75 to 120 cases per minute and “Zero Time” changeover from one pattern / SKU to another > More standard features included from the industry’s largest palletizing solutions provider * Patent applied for

www.ptibox.com Tel: 905-738-8226 • 1-800-303-5883

20 • WWW.CANADIANPACKAGING.COM

p 18-21 cpac sept 2014 Ingersoll-KBA p 18-21.indd 20

www.palletizing.com 1-800-628-4065

Scan to learn more! > > > > >

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 11:28 AM

CANADIAN CONVERTING

Ingersoll Paper Box president Sarah Skinner (left) chats with employees amongst rows of completed print jobs.

notably the BOBST AccuBraille application system that can add Braille to the on-package information to be read by visually-challenged customers. The Braille messaging on the cartons is created when a metal band with raised nodules is added to the EXPERTFOLD to apply pressure to the metal band as each paperboard carton passes by. After each carton has the Braille messaging applied, a Valco Melton CaptorT system verifies the information, using high-speed CCD (charged-coupled device) camera technology and custom lighting to produce over 10,000 images per second of the carton area.

THE RIGHT IMAGE The image analysis algorithms and system software evaluates the image instantly, identifying defects like faulty cartons, incorrect Braille messaging, or improper adhesive application. Valco Melton’s OT-120 control package touchscreen data entry system uses simple pictograms and market-specific program symbols for fast set-up and changeover on the EXPERTFOLD machine. The BOBST EXPERTFOLD folder-gluer utilizes a Schneider Electric power and control panel, Baumüller servomotors, and Festo pneumatic components. Other key equipment at the Ingersoll plant includes: • a BOBST HandyPack Alpina 110 folder-gluer;

• t wo BOBST SP 102-SE die-cutters; • a BOBST SP102-E Autoplatine automatic f latbed die-cutter; • t wo manroland 700 printing presses; • four 3M-Matic case-sealing systems from 3M; • a Phoenix Innotech stretchwrapper; • a Marsh PatrionPlus large-character inkjet printers from Videojet Technologies Inc.; • a Mx12 ink formulation and dispensing system manufactured by GFI Innovations, Inc. and maintained by Sun Chemical via Sun’s GFI ink dispensing program, with Ingersoll being the first sheetfed printer to sign up to the program. • the MK420Q MINI high-speed/precision carton inspection system from Masterwork Graphic Equipment which uses four high-resolution CCD cameras for the detection of defects down to 0.2x0.2-mm at speeds of 80,000 units per hour. “There’s that old adage that ‘sometimes you have to spend money to make money’, and that’s true to a certain extent,” Skinner ref lects. “I think it’s imperative that when money is being spent, it should be well-spent on things that will not only improve the quality of life for the employees, but also enable the company as a whole to create something that separates us from the competition,” she asserts. “I think that our recent capital expenditures have really done that for us,” Skinner concludes. “Now we have to use our forward momentum to ensure a successful future.”

For More Information:

The EXPERTFOLD 110 A-2 high-speed folder-gluer manufactured by BOBST utilizes the unique AccuBraille application system to apply the Braille language codes onto the paperboard packaging.

Ingersoll Paper Box Co. Limited 468 KBA North America Inc. 469 Agfa Graphics 470 BOBST 471 Valco Melton 472 Halltech Inc. 473 Schneider Electric 474 Baumüller Nürnberg GmbH 475 Festo Inc. 476 Manroland Canada Inc. 477 3M Canada Company 478 Phoenix Innotech Inc. 479 Videojet Technologies Inc. 480 GFI Innovations, Inc. 481 Sun Chemical Corporation 482 Masterwork Graphic Equipment 483

SEPTEMBER 2014 • CANADIAN PACKAGING WWW.CANADIANPACKAGING.COM • 21

p 18-21 cpac sept 2014 Ingersoll-KBA p 18-21.indd 21

14-09-05 11:28 AM

PRODUCT ID NOW

LIVING IN THE FAST LANE Thriving manufacturer of automotive fluids and household chemicals fine-tunes its production capabilities with new cutting-edge, high-throughput labeling technologies

Weber Marking Systems Canada specialist Fred Moore (left) and Recochem Consumer Division central region plant manager Larry Funnell in front of the Model 5300 label printer-applicator system manufactured by Weber.

ANDREW JOSEPH, FEATURES EDITOR PHOTOS BY COLE GARSIDE

or every car, truck and motorcycle traveling the busy Canadian roads and highways, there are multitudes of different products available in the marketplace to ensure their optimal performance on a daily basis, just as there is a strong possibility that many of those essential auto-care products were manufactured by Canada’s remarkably successful specialty chemicals producer Recochem Inc. Founded over 60 years ago in Montreal, Recochem is a chemical manufacturer of household products and automotive f luids, featuring a global recognition for quality products and outstanding customer service. When the Austrian-born Joseph Kuchar and family emigrated from Czechoslovakia to Montreal, he quickly embraced the Canadian immigrant dream of a better life, and formed Record Chemical Co. Inc. with his wife. He later shortened the company moniker to Recochem, which initially became involved in the export of bulk chemicals to Europe and South America, as well as to a fast-growing Chinese market. Over the following six decades, the Kuchar family and its long-serving team members built the company into a well-respected multinational producer and packager of specialty chemicals. Via its Consumer Division (Americas), Recochem produces, formulates, contract packages and wholesale distributes household chemicals and automotive f luids from five Canadian locations,

22 • WWW.CANADIANPACKAGING.COM

p 22-27 cpac sept 2014 Recho-Weber p 22-27.indd 22

including Saint John, N.B., Montreal, Toronto, Edmonton and Vancouver. The company’s most famous sought-after product at one time was naphthalene—more commonly known as mothballs—and while it still processes and packages the pungent product for its customers, it’s no longer the chief revenue generator. “Nowadays, our Canadian consumer division, supplemented with U.S. contract packaging alliances, has helped us successfully grow our business in

the household, automotive and paint sundry chemical business,” Recochem’s Consumer Division, central region plant manager Larry Funnell told Canadian Packaging during a recent visit to the company’s 170,000-square-foot, state-of-the-art facility located in Milton, Ont., about 40 minutes drive west of Toronto. “I’d bet that most people in Canada have at least one of our products in their home.” The licensed brands made by Recochem are: • Armor All care for cars; • Liquid-PlumR for drain clogs; • Poly-Care hardwood and laminate f loor cleaner; • Preston and STP antifreeze/coolant for vehicles; • R ain-X windshield wiper liquid; • Varsol paint thinner; • Windex glass cleaner. Along with the licensed brands, which make up about 35 per cent of its core business, about 25 per cent of its production is for its own brand of products called Turbo Power washer f luid. The brands seven products include: Windshield Washer –35°C; Windshield Washer –40°C; Premium Washer Fluid and De-Icer –45°C; Bug Wash; BioGreen Ethanol-based Windshield Washer; Windshield Washer Concentrate; and All Season Windshield Washer. The remainder of Recochem’s production comprises third-party manufacturing for Walmart, Esso, Petro Canada, Husky and Canadian Tire. “We produce around 500 different SKUs (stockkeeping units) here at the Milton facility,” Funnell relates. “Each one is a different recipe, of course, and we can create an individual product recipe for any customer that request it.” Funnell continues: “Our plant’s blowmolding capabilities for different sizes, along with our inhouse graphic design and regulations team are added ways in which Recochem will work with a customer to not only design your packaging, but to also ensure that all regulatory compliances are followed.

One of the workhorses on the main packaging line at Recochem’s Milton facility is the new Model 5300 label printer-applicator system purchased from Weber Marking Systems Canada, capable of reaching speeds up to 50 boxes per minute.

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 2:38 PM

PRODUCT ID NOW

The Weber 5300 Label Printer-Applicator utilizes easy-to-use computer software, simplifying product changeover, and real-time alterations or adjustments to label data.

“All of the sites across Canada produce their own HDPE (High-density polyethylene petroleum-based) plastic bottles in a number of sizes, including our proprietary multi-layer co-extruded solvent bottles,” adds Funnell. “We offer liquid-filled containers from as small as 50-ml bottles all the way up to tanker trucks and train cars.” Funnell notes that all Recochem sites are highlyautomated with a plethora of machinery, including blowmolders, filling lines, palletizers and robotic case-packers, which allows it to provide 24-hour operation and a rapid response to any client requests, while maintaining its nationwide ISO standards of product quality. “When we moved into this facility in 2009, we essentially doubled the size in total land space, manufacturing capacity, inventory storage area and office space, and expanded to where we now have about 104 employees,” Funnell relates. While Recochem certainly needed more space to increase its production thanks to the popularity of its products, Funnell was adamant the company would also take an even more stringent look at safety requirements, noting that the manufacture of chemicals can indeed present a hazardous working environment. “We spent about $750,000 on safety features here at the Milton facility,” notes Funnell, adding it fully follows CSA (Canadian Standards Association) standards, and all PSR (Pre-start Health and Safety) requirements. The filling room, as expected, is highly-ventilated, and is continuously automatically monitored for LEL (lower explosive level) possibility. “Recochem is extremely serious about the volatility of its products and for the safety of our employees, as such when the LEL monitors reach the 10 per cent level, an alarm will go off, and we will monitor the situation to see where the problem is,” Funnell relates. “Should it reach 30 per cent, we immediately shut the equipment down.” In the event of the worst-case scenario, the facility can utilize an advanced multiple high-=capacity sprinkler system consisting of water, foam and ESFR. All in all, the plant is doing a very healthy business, as it also makes its own bottles, fills and labels them and ships them out seven-days-a-week, 24-hours-a-day.

Using air-blow tamp configuration where the label is blown onto the carton, the model 4300 label printer-applicator from Weber normally runs at a rate of 25 labels per minute.

Funnell says that when it moved into the Milton plant five years ago, Recochem upgraded each of its five blowmolding machines, adding that the plan is to “hopefully expand” in that area of production soon. “At our Milton facility here, we do all the one-, four- and 10-liter containers, as well as the 1,000liter totes, 215-gallon drums and also full loads for tanker trucks for certain customers,” Funnell says.

Cool Runnings The Milton facility currently houses five liquidfilling lines, two powder-filling lines and has some manual filling capacities. Its main production line, aptly named Line No. 1, boasts a capacity of filling, capping and labeling some 650,000 liters of liquid product every 24 hours, according to Funnell. Further downstream, Recochem places a product label onto each carton by its label printer-applicator supplied by Weber Marking Systems Canada. “Fairly recently, we had a customer request for scanable bar codes, and although we had some great help from Atlantic Packaging who supply us with the corrugated, the customer said they needed us to provide a high-speed capacity of up to 50 boxes per minute with great print quality,” explains Funnell. “Although we already had excellent printers capable of doing one or the other, we needed to upgrade if we wanted to do business with them.” Recochem looked at three different companies, but selected Weber owing to what Funnell says was

“the best price, along with them giving us the confidence level to achieve our requisite speed levels.” All in all, Funnell and Recochem were sufficiently impressed with the label print-and-apply technology of the Weber system, purchasing and installing eight machines in March of 2014 at its Milton and Montreal facilities—seven Weber model 4300 units, and one model 5300 system. Weber labeling systems specialist Fred Moore says Recochem purchased five units for the Milton plant: • One 5300 with a stand and alarm light system used on the Milton No. 1 Line; • Three model 4300 units with a stand and alarm light system; • One 4300 systems with an integrated conveyor, stand and alarm light system; • All units equipped with print engines manufactured by Zebra Technologies. The three Weber units in Montreal are: • Three 4300’s with a stand and alarm light system, featuring 12-inch stroke and variable stroke sensors; • Fitted with wireless Zebra print engines.

Supplied by agent Alex E. Jones & Associates, a model 28V09 filling and capping system from Pacific Packaging Machinery filling four-liter plastic containers with windshield washer fluid at Recochem’s Milton facility.

SEPTEMBER 2014 • CANADIAN PACKAGING WWW.CANADIANPACKAGING.COM • 23

p 22-27 cpac sept 2014 Recho-Weber p 22-27.indd 23

14-09-05 2:38 PM

PRODUCT ID NOW

The Columbia Machine HL6000 series high-level palletizer manufactured by Columbia Machine easily loads over 60 cases of product per minute onto the signature blue wood CHEP pallets.

You want that feeling of security. You require uninterrupted production. We bring you safety and reliability.

WE ARE THE ENGINEERS OF PRODUCTIVITY.

Says Moore, “The speed of these Weber units is variable, depending on how fast the customer wants to run it. “While the 5300 can print up to 50 labels per minute at 203-dpi (dots per inch), the 4300s are all capable of printing at a rate of 25 labels per minute.” Funnell points out that the model 4300 is a low-speed label printerapplicator system, which the Milton facility only tends to run at a comfortable rate of eight to 10 boxes per minute. “We generally run the Weber model 5300 at around 35 to 40 cases per minute, but for that one client who wants it, we can easily hit its target speed of 50 units per minute,” Funnel relates. The Weber model 5300 label printer-applicator is also very versatile— offering customers a wide range of high-quality print engines with an equally wide range of optional print resolutions and label dispensing rates. Significantly, Weber has now made it available with an upgradeable RFID (radio frequency identification) print encoding ability, though Recochem did not purchase that option. “With the 5300 we can print and apply labels with barcodes onto a wide range of surfaces, such as the plastic containers, corrugated cases, or even on the various formats of pallets, if we chose to,” says Funnell, adding the adhesive labels can be applied in a variety of manner: top, bottom, sides, and even across corners for whatever happens to provide best scanning performance. Other formidable examples of the 5300’s versatility include the myriad number of ways it can be configured depending on the user’s labeling requirements: tamp-blow; air-blow; direct-tamp; swing-tamp; corner-wrap; dual label; and electric tamp-blow. All of the label printer-applicator purchased by Recochem employ the air-blow method, whereby the label is blown onto the product from a fixed distance—without utilizing a pneumatic cylinder. “The 4300 models generally have a three- to eight-inch stroke length, while the 5300 in Milton has a one-inch stroke,” explains Moore. “The shorter the stroke, the quicker the label application.” Moore says that rather than having to purchase a whole new label application system, a user only needs to purchase a new tamping tech. “The reconfiguration can address any future printand-apply labeling requirements, a modularity that saves money.” Other value-added features of the 5300 system include a microprocessor controller and downloadable firmware capabilities, plenty of different inputs/ outputs, and a robust construction to withstand harsh industrial environs. Standard features include a remote locatable controller connected via a 15-foot cable, which allows the operator more convenience when monitoring the label printer-applicator’s workf low, such as label application, pad sensor settings, alert lights, or the status of the label roll or printer ribbon. Moreover, companies like Recochem are able to easily monitor the full operational status and configuration of the 5300 unit, by simply logging into a Web page unique to each individual 5300 system. The unit also features an intelligent computer-controlled unwind and

Security Simplicity Efficiency Competency www.festo.ca Why Festo_SecurityPillar_CP.indd 1 p 22-27 cpac sept 2014 Recho-Weber p 22-27.indd 24

04/09/2014 2:42:28 PM

SEPTEMBER 2014

14-09-05 2:38 PM

PRODUCT ID NOW

A Foxjet inkjet printer supplied by Harlund Industries applies large-character product codes to the cartons.

Other equipment and suppliers utilized by Recochem at its Milton facility include: •H itachi PB and Foxjet inkjet printers supplied by agent Harlund Industries Ltd.; •A esus bottle sleever; • Italian-made Comag SLC-300 over-the-top sleever utilizing an SEW-Eurodrive motor and Siemens Simantic touch panel for user programmability; • Sleeves from Pro-Pals Industries; •P acific Packaging Machinery Inc.’s 28V09 filler and capper supplied via the agent Alex E. Jones & Associates featuring an Allen-Bradley PanelView Plus 1000 touchscreen interface; •P earson Packaging Systems’s case erector and filling system; •H artness International Inc. Model 835 case-packer, also supplied by Alex E. Jones & Associates;

rewind function that ensures the labels match the ribbon supply at the same rate, thereby avoiding the double downtime possibility for changeover. “Also helpful to us, owing to the different-sized products and the different all-round products we place through Line No. 1, is the fact we can easily store our printing requirements in the 5300’s memory, making it very easy for the operator to select the requisite job from the applicator rather than having to download it from the computer,” Funnell relates. Funnels adds that while he is extremely pleased at how well the Weber printerapplication units are working at both facilities, he says he was equally impressed by how quickly Recochem was able to take possession of the systems. “It really was a quick turnaround, and I think it surprised all of us here at Recochem,” recalls Funnell. Another key piece of technology utilized at Recochem, is the HL6000 series high-level palletizer designed and manufactured by Columbia Machine, Inc. which is capable of palletizing 60 or more cases per minute while providing a tight, square and stable load. Says Funnell: “We installed the Columbia HL6000 in 2009 and we have been very happy with it from the outset. “Although we have had a few normal wear and tear issues, in the past five years we have had nothing out of line.” The Columbia HL6000 palletizer comes standard with such controls as the Rockwell International’s AllenBradley Compact Logix PLC (programmable logic controller), a PanelView Plus 600 Color touchscreen interface and Columbia’s own Project Manager software, all of which help make it easy to control and care for. Funnell says that the folks at Columbia Machine continue to be very easy to work with whenever called upon, and the fact that they are very knowledgeable and offer reasonably priced parts is a bonus. “One day when we did have an issue, it was quickly resolved as they were able to help us troubleshoot the HL6000 over the telephone, as well as by connecting into the PLC,” Funnell relates. After palletizing by the HL6000 is completed, the product is conveyed to an overhead stretchwrapper manufacMultivac Canada Inc. tured by MJ Malais/Wulftec.

A Baldor motor helps ensure smooth-running operations for conveyor lines at the Milton plant.

• Several Nordson ProBlue 10 hot-melt adhesive applicating systems to seal the cases; • Corrugated cartons from Atlantic Packaging Products; • Various Baldor motors to power the conveyor lines;

Toll Free: 877 264 1170 ca.multivac.com

SEPTEMBER 2014

p 22-27 cpac sept 2014 Recho-Weber p 22-27.indd 25

14-09-05 2:38 PM

PRODUCT ID NOW

A Model 835 case-packer manufactured by Hartness International was purchased by Recochem from Canadian agents Alex E. Jones & Associates.

An SEW-Eurodrive motor helps smoothly propel a conveyor line carrying large plastic containers of plumbing antifreeze to the line’s cartoner.

machines have been working very well for us and I know everyone involved is quite happy with its performances,” he concludes. “Just as everyone seems to be generally happy bout the consumer industrial products we produce.”

For More Information:

One of several Nordson ProBlue 10 hot-melt adhesive applicating systems used to seal corrugated cartons.

Atlantic Packaging Products supplies the corrugated cartons to pack the containers of consumer chemicals at Recochem.

•C HEP-supplied pallets for national and international transport of product. Funnell says that the recent capital expenditure moves by Recochem are indeed a great sign for the company’s long-term future, showing that workplace safety is deemed as important as being profitable. He adds that the company is also aware of its environmental responsibilities locally, and has gone to great lengths when designing the facility to ensure that when it comes to its water usage, it actually recycles and reuses it. “Nothing is ever dumped down the drains,

because we have a closed drain system in place,” he states. Summing up, Funnell recalls that when Recochem first moved into the Milton facility, and that despite the production f low working smoothly, it still took about a year-and-a-half for the stress level to leave the building. Notably, none of that stress came back with the introduction of the Weber label equipment, he points out. “I think there’s still a learning curve for the operators on these machines—as we continue to experiment with ways to make our unique situation even more efficient—but so far, the Weber

Weber Marking Systems Canada Zebra Technologies Corporation Columbia Machine, Inc. Rockwell Automation Inc. Hitachi America, Ltd. Harlund Industries Ltd Aesus Systems Comag srl SEW-Eurodrive Co. of Canada Siemens Canada Ltd. Pro-Pals Industries Ltd. Pacific Packaging Machinery Inc. Alex E. Jones & Associates Ltd. Pearson Packaging Systems Hartness International Inc. Nordson Canada Limited Atlantic Packaging Products Ltd. Baldor Electric Company CHEP Canada Inc.

440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458

ABB Robotics. The broadest portfolio of high speed picking robots in the industry.

The new 6 kg and 8 kg IRB 360 FlexPickers handle higher payloads with greater working depths, and are able to pickand-place up to 500 products per minute. Along with the 1 kg and 3 kg FlexPickers, all variations are available in sanitary models, ideal for direct food handling or pharmaceutical applications, including a hygienic design for wash down applications and an IP69K rated stainless model. Learn more at www.abb.com/robotics ABB Inc. 905-460-3418 www.abb.com/robotics

26 • WWW.CANADIANPACKAGING.COM

CANADIAN PACKAGING • SEPTEMBER 2014

10750_PE p 22-27 cpac sept 2014 Recho-Weber p 22-27.indd 26

14-09-05 2:38 PM

Produced by:

Encounter Innovation

Find the advanced solutions you’re looking for — and more.

PACK EXPO International 2014 is a place of possibilities. Discover countless ways to improve production, with 1,800+ exhibitors and education sessions right on the show floor. It’s the event that defines the future of processing and packaging. Be sure to attend.

Co-locating with PACK EXPO International advancing the pharma, biopharma and medical device industry.

10750_PEIL14_GEN_ad_CP.indd 1 p 22-27 cpac sept 2014 Recho-Weber p 22-27.indd 27

8/15/14 8:29 AM 14-09-05 2:38 PM

CORRUGATED PACKAGING

FOUR WAYS TO PROSPER Boxmaker’s customer service and technical excellence keep it on solid growth path

Gerrity Corrugated Paper Products founder and chief executive officer Tom Gerrity proudly poses with the brand new, state-of-the-art EXPERTFOLD 230 A-4 folder-gluer, manufactured by BOBST, recently installed at the company’s boxmaking facility in Concord, Ont.

BY NICK GRIFFIN PHOTOS BY COLE GARSIDE

ehind every successful company lies a set of core principles that have helped guide that company to its current market prominence and renown—whatever the industry. For Gerrity Corrugated Paper Products, Ltd. of Concord, Ont., those basic tenets can be boiled down to four core competencies: remarkably quick turnaround times; innovative software management of every aspect of their business; continual reinvestment in the latest finishing equipment; and, above all else, hard work. Along with his sons Blaine and Scott, company founder and chief executive officer Thomas Gerrity operates a classic, single-location ‘mediumto large-sized sheet plant’ to serve a customer base he deftly describes as, “Broad to the point of doing everything for everybody. “If it is made of corrugated, we can do it,” says Gerrity, a high-energy 82-year-old who still personally oversees the entire plant f loor operation with the youthful drive and enthusiasm of someone half his age. Upon first arriving to Canada more than 60 years

28 • WWW.CANADIANPACKAGING.COM

p 28-31 cpac sept 2014 Gerrity-Bobst p 28-31.indd 28

ago, Gerrity initially took a job operating an overhead crane at a corrugated box plant, “Because I needed a job, any job,” he explains. “Very quickly I learned how to operate their corrugator,” Gerrity recalls, “so that when their existing corrugator supervisor was about to go on holidays, the company asked me if I could operate it during his absence and I said, ‘Sure, nothing to it.’ “It was a brand new, 96-inch Langston, a beautiful machine, and I was put in charge of the nine people it took to operate it,” he recounts. “While I was running it I doubled the supervisor’s production output and cut down on scrap, so when the regular supervisor came back the boss told him that he didn’t know what to do with him because of the improvements made in his absence. “They allowed him to work under me as second operator,” Gerrity relates, “and he was grateful for that and worked for me for the next four years.” Gerrity then took on a job as a corrugated foreman with another company where he would spend the next 16 years, during which he rose to become a vice-president and general manager. “When I left there I approached a large integrated company with a plant that has now become known as a sheet feeder,” he recounts. “They were

intrigued, but due to other commitments at the time, they had to wait to put the plan in action. “So they offered me a position as a troubleshooter—going between their plants and coming up with solutions for the various issues they were facing. “Unfortunately, I found myself spending most of my time sitting around waiting for the phone to ring so I could go somewhere to solve a problem,” Gerrity continues. “After three weeks I went back to my new employers and, even though they had

Head operator Danny Buttigieg monitors EXPERTFOLD’s performance at the machine’s touchscreen control panel.

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 2:40 PM

CORRUGATED PACKAGING increased the pay, I told them that it simply wasn’t working out. “I couldn’t stand doing nothing: I hated it, I needed to work.” Having just celebrated his 45th birthday, Gerrity decided to take the big plunge and start up his own business. As he recalls, “With nothing more than a slitter and a band-saw I got from my brother, I leased a vacant 9,000-square-foot building, we got sheets into the place, and with my wife sitting at a desk in the office and me in the plant, we soon started getting our first orders. “As I would feed the sheets through the slitter my wife would catch them on the other end, after which I would strap them up, load up the truck and deliver the job. “That’s how we started—making just pads, dividers, and in some cases using the band-saw to cut off the corners for cutout wraps,” says Gerrity, relating that the f ledgling startup managed to turn a profit in only its third month of operation. After finishing school about six months later, the couple’s older son Blaine happily joined the growing family business. “We had him get a haircut and a new suit and sent him out selling,” he recalls. “He quickly built up a good deal of business: Within a few months he was selling $50,000 worth of pads. “Everybody at the time said we were stupid and couldn’t possibly do what we said we could—buying full sheets from a corrugator in different cutoff lengths and different grades of board. “Then we’d get calls from area sheet plants asking for orders as small as 50 pieces of one grade of board. They’d ask, ‘When can we get them?’, and we’d answer, ‘When do you want them? Send your truck over and they’ll be cut and ready.’” After about two years Gerrity concluded that despite the volumes increasing month after month, the family business had to try something different. “We couldn’t get enough business

In addition to high throughput rates, the EXPERTFOLD folder-gluer is capable of gluing a six-corner box, ensuring optimal flexibility and performance in short and mid-sized runs of complex box shapes.

our metal detectors are always supported We continue to provide complete support for our existing systems with readily available parts and a global service team.

Our latest technology can quickly and economically be field installed in a detector built over 17 years ago, so you stay up to date with food safety initiatives without purchasing a new detector.

CMY

CUSTOMIZED METAL DETECTION We custom design and manufacture our affordable equipment to suit your needs, specifications and product, thereby ensuring optimal metal detection within your facility. Not sure if you’re getting the most out of your metal detection system? Speak with a representative at 1-888-220-8737 / sales@fortresstechnology.com Booth 1749

The STREAMPACK batch collector installed at the end of EXPERTFOLD line.

SEPTEMBER 2014

p 28-31 cpac sept 2014 Gerrity-Bobst p 28-31.indd 29

www.fortresstechnology.com

Simple Operation. Outstanding Reliability. Exceptional Performance.

14-09-05 2:40 PM

CORRUGATED PACKAGING

The newly-installed EXPERTFOLD folder-gluer from BOBST has enabled the Gerrity plant to run a broader range of complicated and narrow box designs at very robust throughput speeds of up to 6,000 boxes per hour.

this way to keep growing in a meaningful way, so we added a simple die-cutter so we could make cartons, while adding more people both in the office and the plant,” he relates. “The former plant manager from my early employer came to work for

us and when Scott, our younger son, left school, he also came on full-time.” As Scott Gerrity recalls, “Even when I was in school I was working in the plant 35 to 40 hours a week, which frequently included weekends. “One weekend when we needed extra help I persuaded some friends to come in and help out in exchange for a case of beer,” he chuckles, revealing solid people skills and work ethic that spans generations. According to Tom Gerrity, the first major new piece of equipment to arrive to the plant was an S&S partition slotter, soon joined by a die press. “One day Blaine came in with an order for 30,000 taped boxes and we knew we couldn’t do that by hand, so we made our own taper,” he recounts. “Those days we got away with a lot of things that would be unimaginable today,” he chuckles. “So much of our work is based on the premise Whether you're a manufacturer shipping to Vancouver or a retailer of immediate turnreceiving products from Newfoundland, you can be certain that around, that we would CHEP Canada has the equipment and network to cover it all. do whatever it took to Combine this with three proven pallet options, a dedicated service achieve it.” rep for your account, and over 35 years of unparalleled experience throughout Canada, and you can trust that CHEP will be your Adds plant manager supply chain partner today and in the years to come. Scott Gerrity: “Even today, we take orders To learn how CHEP can help you, visit www.chep.com for our slitter jobs that we have out the door the very same day. “We really pride ourselves on our turnaround, whereby 50 to

CHEP CANADA CAN

30 • WWW.CANADIANPACKAGING.COM

p 28-31 cpac sept 2014 Gerrity-Bobst p 28-31.indd 30

60 per cent of all our business is booked today and shipped tomorrow.” This consistent ability to complete even the most demanding jobs within a day or two of receiving them has clearly payed off for the family business in a big way—enabling it to take on many last-minute projects that few other plants have the capabilities to execute. On some of the simpler orders, according to Tom Gerrity, jobs are completed in less than two hours from receiving the order. Nowadays this core competence is greatly enhanced with the ever-growing array of stateof-the-art production machinery assembled at the Concord facility over the years. “We have everything and then some,” Gerrity enthuses. “We duplicate our processes because it’s our business to always be on time. “For example, we have eight similar machines in a row so that machines are always waiting for the work—not the other way around,” he explains. “We even have complete redundancy with our baler system, so that if one baler breaks down, we simply hit the switch and the parallel baler comes online.” Scott Gerrity says the extremely f luid day-today nature of the business makes this f lexibility a priceless core competency for the company. “It is second nature for us to switch quickly from one type of product to another,” he states. “One day the folder-gluers are running every minute of our two shifts, while most of the die-cutters and flexos sit idle. “The next day it can be the exact opposite.” Today the Gerrity plant also boasts specialized expertise in inline specialty folding and gluing, which is especially beneficial when dealing with the smaller, very narrow and hard-to-handle boxes, as well as those with multiple gluing points. This has been enabled in large part by the recent purchase of a state-of-the-art EXPERTFOLD 230 A-4 folder-gluer with a STREAMPACK semi-automatic batch collector from global converting machinery manufacturer BOBST. “Since we purchased the EXPERTFOLD, the difference that it has made for our plant has been extraordinary. “It has brought a lot of business our way,” states Tom Gerrity, saying the new equipment has attracted a lot of work bypassed by other boxmakers who either can’t or don’t want to get involved in small-run production. “They want the really big orders, but because they don’t want to turn anything down from a customer, they send those orders through us,” he explains, adding that installing major new pieces of equipment is a regular occurrence at the plant. “Every year we add to or upgrade one major machine, and this year it was upgrading from an older BOBST Domino folder-gluer to their EXPERTFOLD 230 A-4 with a batch collector,” he says, adding the Domino machine is now used primarily to run the larger, less complicated boxes. “The other folder-gluer doesn’t have the finesse of the EXPERTFOLD, which can glue six points at one time,” Gerrity states. “There’s also a big difference in speed. “Instead of 2,000 boxes per hour on our older machine, running that same box on the EXPERTFOLD makes 6,000 boxes per hour a reasonable target. “That’s triple the production, sometimes even more,” Gerrity enthuses, while lavishing praise on the quality, reliability and high performance capabilities of BOBST machinery.

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 2:40 PM

CORRUGATED PACKAGING “My youngest son Scott went around and looked at everything out there and determined that this EXPERTFOLD folder-gluer was exactly the machine that we wanted,” he relates. “Moreover, the semi-automatic STREAMPACK batch collector at the end of the line adds a high degree of f lexibility with its ability to be adjusted to collect all the types of boxes that the line can produce. “The EXPERTFOLD costs a little more than the other machines we looked at, but its capabilities far exceeded the others,” says Gerrity, adding any difference in the machines was quickly offset by its productivity levels and the quality of final product. “In addition, BOBST had a guy in here for more than two weeks, showing our lead operator all of the things that the machine can do that we never even knew about,” Gerrity states. “They’ve also been coming back and showing us more ways the machine can be configured to make any number of products.” To complement its manufacturing prowess, the company has also developed solid in-house expertise in the development of software used to operate its box plant, with many advanced features and functions not available on vendor-offered software. According to Blaine Gerrity, “We started by getting a real computer whiz-kid named Darren Ramsay to program and develop the software. “The original computer system started with a single module, but today our system is fully mature with everything from purchasing, docket control, pricing/estimating, scheduling, order tracking, shipping and invoicing, as well as account management. “In recent years we’ve extended the system, giving our customers online pricing and ordering, job tracking and other features. “Customers can know down to the minute when a job has been shipped,” he states, noting that Gerrity’s software has also been sold to many of the company’s locally competing plants. This software proficiency helps the Concord plant to maintain a large inventory of stock sheets of virtually every type and quality of corrugated, as well as all full corrugator widths by various cutoff lengths—including specialty sheets like two-sided oyster and E-flute. “Tell me who else you can ask for a thousand boxes by tomorrow morning and have them delivered,” Tom Gerrity points out. “The customer can order 20,000 boxes, and because we already have the stock on the f loor, we can run them right away. “We also keep track of all the cutoff leftovers from a job in a computer program, utilizing them for small orders. “This way we don’t waste any material,” he states, pointing out that the plant often has well over 100 different cutoff sizes in stock at any one time. In conclusion, Gerrity sums up the business as not just highly cus-

An inline MOSCA strapping machine (left) makes the compressed bundles of corrugated boxes coming off the STREAMPACK batch collector ready for shipment.

tomer-centric, but also well-planned and expertly managed. “We get orders today and some of them are to be shipped this afternoon,” he says. “Most are for

makes

look you good

SEPTEMBER 2014

p 28-31 cpac sept 2014 Gerrity-Bobst p 28-31.indd 31

tomorrow, and very few will be for the day after, but the point is that people like to order from us because they know we can ship it to them in timely fashion. “That’s the biggest single growing trend I see in the modern corrugated business—the JIT (just-intime) inventory and Kanban scheduling systems. They enable us to hold finished products for customers so they’re available immediately and in the quantities they want. “That’s our forté: That’s what we do best, and do it better than anyone else.”

For More Information: Gerrity Corrugated Paper Products 490 BOBST 491 EAM Mosca Canada Ltd. 492

How do we do that? By printing the labels that make your

products look spectacular. And make them stand out from the others in a busy marketplace. To do just that, we’ve put together a team of professionals whose efforts are dedicated to turning out labels that really are awesome in every way. Since great labels begin with a great design, our graphics group can take your art file – or help you create one – and make certain your label will showcase your brand. We help your product stand out from the pack. We’ll also help you select the right label material and pressure-sensitive adhesive from literally hundreds of combinations to ensure they’re perfectly compatible with your brand’s package. By using clear labels, metallic materials and other treatments, we can make your label jump off the shelf. Then our experienced press operators use the latest digital or flexographic printing technologies and quality assurance standards to print exactly the labels you want. That’s how we provide the most awesome labels you can get. And, if you also need to apply the labels yourself, we manufacture a complete line of precision high-speed label applicator systems as well as industry leading print and apply solutions.

www.webermarking.ca cpac@webermarking.ca T: 1 800.265.9974 905.564.6881 F: 905.564.6886 6180 Danville Rd. Mississauga, ON. L5T 2H7

To get a closer look at our awesome labeling solutions visit us online or contact us at:

www.webermarking.ca cpac@webermarking.ca 1.800.265.9974

14-09-05 2:40 PM

PEOPLE  The Toronto-headquartered Food Industry Association of Canada has selected Marc Guay, president of leading snack-food manufacturer PepsiCo Foods Canada, and Louise Wendling, country manager for Club Store retailer Costco, as recipients of the organization’s 2014 Golden Pencil Award honors in recognition of their professional contributions to the Canadian food industry.  The Canadian Plastics Industry Association (CPIA), Mississauga, Ont.-headquartered national trade organization for the plastic industry’s processors, material suppliers, equipment manufacturers and brand-owners, has appointed Aiñe Curran as director general for issues.

Curran

 Electric motors and drives manufacturer Baldor Electric Company of Fort Smith, Ark., has appointed Greg Hewitt as engineering manager for mounted bearings, and Galen Burdeshaw as power transmission components engineering manager—responsible for the company’s Dodge and Maska brands of power transmission product lines—with both to be based at the company’s design and production facilities in Greenville, S.C.

 Bottling line equipment supplier Krones Inc. of Franklin, Wis., has appointed Hector Takahashi as regional sales manager for the U.S. northeastern and mid-Atlantic region, with responsibilities for sales development and support in the states of West Virginia, Virginia, North Carolina, South Carolina and Maryland.

Hewitt

 Cincinnati, Ohio-headquartered automated material handling systems manufacturer and integrator Intelligrated has appointed Mario Rodriguez as general director of the company’s Mexican operations—to be Rodriguez Vega based in Mexico City—and Carlos Vega as senior sales manager for its western regional operations, working out of Roseville, Ca.

Burdeshaw

 Branding and package design services provider SGK, Inc. of Des Plaines, Ill., has appointed Andrew Flynn as vice-president of brand strategy.

 Japanese-based industrial control and electronics manufacturing group OMRON Corporation has appointed Nigel Blakeway as chief executive officer of the company’s Omron Automation and Blakeway Safety business for the Americas region, headquartered in Hoffman Estates, Ill.

find it Is the cart full of smiles too? Thermo Scientific solutions help you protect your brand. Find foreign objects to ensure safety. Verify product integrity and

 The board of Naperville, Ill.headquartered World Packaging Organisation (WPO) has unanimously elected Thomas Schneider to serve a second term as the group’s president for 2015-2017.

control under and overfills to manage costs and comply with regulations. Deep expertise and application insights developed over decades and tens of thousands of installations are always part of the package. Our industry-leading service and support help maximize uptime and protect your investment.

before someone else does

 Lincolnshire, Ill.-headquartered industrial and consumer electronics manufacturing group Honeywell has appointed Sach Sankpal as president of Honeywell Safety Products, a division of the comSankpal pany’s Honeywell Automation and Control Solu tions life safety business.

Visit us at Pack Expo-Booth #S-2514 • thermoscientific.com/packexpo2014CPS

Your partner in product and process improvement Versaweigh Checkweigher

 Plastics process ing equipment group Graham Engineer ing of York, Pa., has appointed Robert Deitrick as vice-president of global sales.

X-ray Inspection

Metal Detection

US and Canada 800.227.8891

 Israeli-headquartered industrial vision systems manufacturer Advan c ed Vision Tech nology (AVT) Ltd. has appointed Windell McGill as president of the Americas region, to be based at the company’s regional offices McGill in Atlanta, Ga.

sales.packaging.us@thermofisher.com

Thermo Ad Full Line - PackExpo - 7.875x10.75.indd 1 p 32-34 cpac sept 2014 ANN-PEO p 32-34.indd 32

Deitrick

SEPTEMBER 2014

8/14/14 6:10 PM 14-09-05 11:21 AM

NOTES & QUOTES  Australian food packaging systems group TNA Australia Pty Ltd. (tna) has completed the acquisition of FOODesign Machinery & Systems, Wilsonville, Ore.-based manufacturer of fryers, ovens, seasoning and coating machines, bulk handling conveyors, and other cooking and baking equipment for the meat, poultry, seafood, bakery, confectionery and snack-food industry applications. “This FOODesign president Joseph Mistretta (left) and tna chief move underlines executive officer Alf Taylor our commitment to shake hands on the deal. servicing our customers’ growing needs for f lexible and efficient turnkey solutions,” says tna managing director APPOINTMENT

Vin Faherty Appointed National Sales Medical/Industrial In his new role, Vin will pursue his long-time passion for providing cutting edge packaging solutions to the medical and industrial market segments in North America. Vin will be working closely with the HarpakULMA sales team to support customers in the nonfood and specifically medical packaging segments for packaging and automation solutions. Vin has been with the company since 1981 in the role of Product Manager for packaging and has extensive experience in the area of medical packaging.

Michael Green. “The acquisition gives tna access to all the necessary skills, networks, market knowledge and relationships to provide customers with a new choice in processing equipment—from fryers and feed systems through to packaging and controls—so that we can add value to our customers’ entire line and achieve significant economies of scale.”  German protective packaging products and equipment group Storopack has completed the acquisition of CleanPak Products, Tampa, Fla.based supplier of loose-fill materials and other protective packaging products such as bubble wrapping, bubble-lined mailers and rolled foam (see picture) to continue the company’s strategic expansion in the Florida and other U.S. markets. Earlier this years, Storopack acquired a majority interest in two other Florida-based companies—Action Corrugated Supply LLC and Specialty Converting LLC—which have since been merged into a new corporate entity called Action Specialty Packaging LLC. Operating manufacturing facilities in Tampa and Opa-Loka, SEW-StaffTeaserManny4x7.pdf 1 8/5/2014 12:24:03 PM Action Specialty provides a comprehensive range

of protective packaging products such as singleface corrugated and paper rolls, along with corrugated boxes, bubble wrap and bubble-lined mailers. “The partnership will enable Storopack to even better serve its distributors and customers in key business areas and to further develop business opportunities in the Florida market and beyond,” says Daniel Wachter, president of Storopack North America in Cincinnati, Ohio.  Belcamp, Md.-based Independent Can Company has picked up the coveted Grand Award in the annual awards competition of the International Metal Decorators Association (IMDA)—held a few weeks ago in Chicago—for the superior print quality of the Natura Tapered Pet Can specialty metal package (see picture) produced for Natura Pet Products, Inc. of Santa Clara, Ca. Selected from over 180 entries submitted by companies around the world. This year’s award marks the third time in the past eight years that Independent Can has won IMDA’s Best of Show honors—as selected by an impartial panel of global graphic arts professionals on the basis of the quality of printing, the degree of difficulty, the appearance of coating finishes, registration and technical expertise.

Diana Duryea, Marketing Manager Harpak-ULMA Packaging, LLC 175 John Quincy Adams Road Taunton, MA 02780

Ph: (800) 813-6644 Fax: (508) 884-2501 Cell: (781)690-3141

www.harpak-ulma.com APPOINTMENT

Dave Favret Appointed TFS Product Manager David Favret has joined Harpak-ULMA as Product Manager for the ULMA TFS Thermoform line. David is a seasoned industry veteran who has spent the last two years as Product Sales Manager of Tray Sealing Systems for Ross Industries. Prior to that he held a progressive series of positions over a 25 year career with GEA Convenience Food Technologies, most recently as Product Sales Manager of Packaging. David is a resident of the town of Sandwich on Cape Cod and is based out of Harpak-ULMA’s Taunton office.

CMY

Diana Duryea, Marketing Manager Harpak-ULMA Packaging, LLC 175 John Quincy Adams Road Taunton, MA 02780

Ph: (800) 813-6644 Fax: (508) 884-2501 Cell: (781)690-3141

www.harpak-ulma.com

SEPTEMBER 2014 • CANADIAN PACKAGING WWW.CANADIANPACKAGING.COM • 33

p 32-34 cpac sept 2014 ANN-PEO p 32-34.indd 33

14-09-05 11:21 AM

NOTES & QUOTES  Industrial automation technologies group Yaskawa America, Inc. has announced the opening of a new facility in Queretaro, Mexico, to serve the local operations of the company’s Yaskawa Motoman division, a leading manufacturer of industrial robotics headquartered in Dayton, Ohio. Currently employing six fulltime staff, the new 5,000-square-facility (see picture)—the company’s third in Mexico—is intended to be primarily used for sales, training, parts warehousing and robot demonstrations. “With the recent growth of our customer base in the region, we knew that we needed to expand our support team and have a more local presence,” says Yaskawa

Motoman’s vice-president of customer satisfaction Doug Schenher. “We will now be able to provide more local training, service and parts fulfillment, and we also have ample, high-bay shop f loor space available for robot demonstrations to show potential customers and local integrators.”  Philadelphia, Pa.-headquartered Packaging Coordinators, Inc. (PCI) says it has completed the expansion of its packaging facilities in Rockford, Ill.— one of its three U.S.-based manufacturing operations—to accommodate continued growth in the company’s contract packaging services for the pharmaceutical and healthcare industries. According to PCI, the 20,000-square-foot expansion has enabled the plant to acquire new secondary and tertiary packaging capabilities such as cartoning, overwrapping, heat-seal carding and compliance-prompting packaging, as well as sup-

porting packaging for biotech delivery forms such as secondary packaging for injectable vials, syringes, devices and transdermal products. “The facilities expansion we have undertaken in Rockford is the latest in a series of investments we have made to enable continued growth and at the same time continue to provide our customers the extraordinary service they have come to expect from us,” states PCI president and chief executive officer Bill Mitchell. “We are committed to providing an unparalleled customer experience with our clinical and commercial services, which require world class facilities, and we are very excited about what these investments bring to our expanding business and our ability to support our clients.”  Leading Finnish meat packaging products group ViskoTeepak has completed the acquisition of Vista International Packaging, LLC, Kenosha, Wis.based food packaging supplier to the U.S. meat and poultry industries, as well as the exclusive U.S. distributor of fiberous casings—widely used in the production of dry and semi-dry sausages—manufactured by ViskoTeepak. “This is a winwin for everybody because it creates an opportunity for ViskoTeepak to enhance a strong supply base of fibrous, tubular plastic and cellulose products here in the U.S., while Vista becomes an integral part of a global organization with access to world-class research and development and support services,” says Vista’s vice-president of sales and marketing Ron Ramsey. “This will significantly strengthen our competitive position by improving upon our ability to offer the most innovative and effective casings solutions in the market,” says Ramsey, adding that the actual converting of ViskoTeepak’s fibrous casings—along with the Wienie-Pak range of cellulose casings (hot dogs and frankfurters) and the Nova brand tubular plastic casings (deli meats and specialty dairy products)—for the U.S. market will remain at Vista’s existing Kenosha manufacturing facility.  TimBar Packaging & Display, Hanover, Pa.-based manufacturer of corrugated containers, retail-packaging and POP (point-of-purchase) displays, has completed the acquisition of Hanover Packaging, also of Hanover, for an undisclosed amount. “Hanover Packaging has built an outstanding reputation for service and quality over its 89 years in business,” says TimBar president and chief executive officer Matt Heleva. “This purchase provides us with an immediate and exciting growth opportunity based on the ability to better service our customers and markets by expanding our retail packaging offering to include folding cartons, rigid boxes and plastic boxes, while also providing the opportunity for Hanover Packaging’s customers to consolidate vendors and purchase a fully-integrated merchandising solution from TimBar that includes displays, fulfillment and retail packaging—all from one source.”

p 32-34 cpac sept 2014 ANN-PEO p 32-34.indd 34

SEPTEMBER 2014

14-09-05 11:21 AM

EVENTS Sept. 28 – Oct. 1

Nov. 4-6

Chicago: CPP EXPO 2014, converting and package printing expo by H.A. Bruno LLC. Concurrently with Graph Expo. Both at McCormick Place. To register, go to: www.cppexpo.com

Cologne, Germany: Polymer Foam 2014, international conference on thermoplastic, thermoset and physical foam processing technology by Applied Market Information Ltd. (AMI) At Maritim Hotel. To register, go to: www.amiplastics.com/events/

Sept. 30 – Oct. 2 Toronto: A Day in the Life Symposium, sustainable packaging conference by PAC, Packaging Consortium. At Steam Whistle Brewery (Sept. 30 and Oct. 1) and Real Sports Bar & Grill (Oct. 2). Contact PAC at (416) 490-7860; via email packinfo@pac/ca, or visit the website at: www.pac.ca

Nov. 10-14 Jacksonville, Fla.: AME International Excellence Inside, annual conference by the Association for Manufacturing Excellence (AME). At Hyatt Regency Jacksonville. Contact Jodi Talley at (224) 387-3367; or go to: www.ame.org

Oct. 7-10

Nov. 12

Tokyo, Japan: Tokyo Pack 2014, packaging technologies exhibition by Japan Packaging Institute. At Tokyo Big Sight. To register, go to: www.tokyo-pack.jp/en

Brampton, Ont.: Paper Fact & Fic tion, conference by PPEC (Paper and Paperboard Packaging Environmental Council). Contact Catherine

Oct. 14-15

Ashworth of PPEC at (905) 458-0087, via email cashworth@ppec-paper.com, or go to: www.ppec-paper.com

Nov. 17-20 France: Emballage, international packaging exhibition by Comexposium. Concurrently with the Manutention material handling exhibition. Both at Paris Nord Villepinte. To register, go to: www.all4pack.com

Nov. 19-20 Montreal: PACKEX Montreal, packaging technologies exhibition by UBM Canon. Concurrently with Expoplast, Design & Manufacturing Montreal, Automation Technology Expo (ATX) Montreal, and Powders & Bulk Solids exhibitions. All at Palais des congrès de Montréal. To register, go to: wwwe.UBMCanonEvents.com/Montreal

Optimize Your Packaging

Princeton, N.J.: Barrier Pharma Packaging 2014, global conference on barrier packaging for pharmaceuticals and biologics by Applied Market Information LLC. At Hyatt Regency Hotel. To register, go to: www.amiplastics-na.com

Oct. 14-16 Cologne, Germany: Multilayer Packaging Films 2014, international conference on packaging technology, materials and markets by Applied Market Information Ltd. (AMI) At Maritim Hotel. To register, go to: www.amiplastics.com/events/

EXPOSITION: November

19–20, 2014

Palais des congrès de Montréal | Montreal, Canada

Oct. 19-22 Myrtle Beach, S.C.: FlexPackCon 2014, f lexible packaging conference by the Society of Professional Engineers (SPE). At Marriott Grand Dunes. Contact Sue Wojnicki of SPE at (203) 740-5420, or via email swojnicki@4spe.org

Just a Few Reasons to Attend: Explore an exhibit hall ﬁlled with top suppliers, advanced technologies, and new products and services Engage in educational sessions tackling critical concepts

Oct. 20-22 Tokyo, Japan: COSME Tech 2014, international exhibition for cosmetic ingredients, machinery and packaging by Reed Exhibitions Japan Ltd. Concurrently with the COSME Tokyo 2014 cosmetic products exhibition. Both at Tokyo Big Sight. To register, go to: www.cosmetokyo.jp

Hear from industry insiders, watch live product teardowns, and more at the NEW Tech Theater Trigger fresh ideas, identify new options, and expand your network

Nov. 2-5 Chicago: PACK EXPO International aging technologies and 2014, pack materials exhibition and conference by PMMI-The Association for Packaging and Processing Technologies. Con currently with Pharma Expo processing and packaging conference and trade show and the AIPA World Congress by the Active and Intelligent Packaging Industry Association. All at the McCormick Place fairgrounds. To register, please go to: www.packexpo.com

p 35 cpac sept 2014 Events p 35.indd 35

—Jean Francois Durette, President, Oculo-Plastik Inc.

29015_CN_PAX14

SEPTEMBER 2014

“I was able to make unexpected discoveries, ﬁnd new suppliers, get inspired, make networking connections and learn many things to apply back at the oﬃce.”

CONNECT WITH OUR COMMUNITY:

Get Your Badge Today!

PACKEXmontreal.com/cp

14-09-05 11:21 AM

A TOAST TO SPARKLING PACKAGING MOMENTS

ne look at the average North American kitchen quickly reveals that we, as a culture, are obsessed with culinary contraptions. Whether you need it cracked, cut, mashed or crushed, the likes of Pampered Chef or Kitchen Stuff Plus have you covered with an ever-growing array of gizmos—in at least eight designer colors of your choice. Having been long fascinated by the so-called ‘time savers’ like chocolate fountains, bread-makers and Slap Chops—albeit on other people’s counter-tops—I used to take special pride in my relatively gadgetfree lifestyle, having gotten through life this far without even a microwave oven. But you could say my life has taken on a sparkling quality since I picked up a home beverage carbonation system—made by Israelibased SodaStream International Ltd.—that turns ordinary old tap water into an extraordinarily refreshing club soda filled with sizzling sparkling bubbles to make each sip a reinvigorating beverage experience. For those with a sweet tooth, there are plenty of f lavored syrups available—including cola, lemon-lime and my own favorite Dr. Pete (a less-than-subtle facsimile of Dr Pepper)—to make your own fizzy favorites that could give national brands a good run for their money in a blind taste. The whole system consists of just three main components—a canister of CO2 to generate the bubbles, a novel carbonation delivery system and a bottle full of H2O—that are all ready to go with a simple push of the button. If there is a ‘catch,’ it’s the fact that you need to use the patented SodaStream bottle, whose nice, large mouth enables a super-tight connection to the CO2 delivery system to form the necessary seal. While the starter kit I bought came with a one-

liter bottle, I ended up purchasing an auxiliary set of two BPA-free 500-ml bottles for their extra portability. The add-on set includes one green and one red SodaStream bottle—featuring branded cartoon characters intended to appeal to both the child and the inner child—with both container lids boasting spectacular hermetic sealing performance to keep the contents effervescent for days at a time.

While extolling the virtues of my soda epiphany at work, an office colleague turned the discussion to the ongoing revival of mixology: the age-old art (and mad science?) of preparing mixed alcoholic drinks. For those quick to dismiss mixology as glorified bartending, the error of this line of thought is self-evident when you ask them to serve up something as advanced as sweet basil soda syrups or candy cap mushroom infused bourbons, which requires good understanding and apprecition of botanical bitters. As a relative newbie to these dark arts, I started out with a 100-ml bottle of Toronto’s very own Bar 40 Bitters Sour—an infusion derived from various herbs and spices steeped in high-proof alcohol. As one of four gustatory Bar 40 Bitters f lavors that also include Sweet, Salt and Umami, the Sour is a perfect match for my penchant for whiskey sours—blended with my own soda, of course. Measuring only 100-ml, what these aromatic bitters may lack in stature is amply compensated by the intense f lavor that actually requires the use of a lid dropper—something right out of a 1940s apothecary—to achieve precise measurement and dispensation for the intended end result. This extra bit of faux alchemy makes the entire experience of mixing a fancy old-school cocktail a much more visceral and inspired bit of mischief all around, which is precisely the point.

ADVERTISERS’ INDEX ADVERTISERS’ INDEX

For more information on Classified Advertising please contact: 416-510-5198

BEYOND THE CUTTING EDGE · POUCHES · SHRINK BAGS · THERMOFORMING FILM · TRAY LIDDING FILM · SKIN FILM ·

Print IT Bag IT Form IT Wrap IT Seal IT Shrink IT Preserve IT Sell IT XtraPlast.com Sales.Canada@XtraPlast.com • 877-435-4555

36 • WWW.CANADIANPACKAGING.COM

p 36 cpac sept 2014 Checkout p 36.indd 36

Page

ABB Robotics 26 Atlantic Packaging Products Ltd 2 Balluff 21 BOBST Packaging Technology 15 CHEP 30 Columbia Machine 20 Delkor Systems, Inc. 9 Emerson Industrial Automation IBC Festo 24 Flexlink, A Company of Coesia Group 6 Fortress Technology Inc. 29 Harlund Industries Ltd. 4 Harpack-UMLA Packaging, LLC 33 KBA North America 34 Multivac Canada Inc. 25 PMMI Packaging Machinery Manufacturers Institute 27 Packaging Technologies Inc. 20 RockTenn Automated Packaging Systems 11 Robert Reiser & Co. Inc 14 Sarong Machinery & Packaging Materials 6, 7 Schneider Electric 5 Sealed Air Food Care 8 SEW-Eurodrive Co. of Canada 17, 33 Thermo Scientific 32 UBM Canon 35 Unisource Canada IFC VC999 Packaging 4, 36 Videojet Technologies Canada 1 Weber Marking Systems Canada 31 WeighPack Systems Inc. OBC

I’m not sure how former U.S. president Ronald Reagan’s favorite candy treat came around to making a move into the kitchen gadgetry market, but suffice it to say that my recent purchase of the Jelly Belly Ice Shaver snow-cone maker— manufactured by the California based Jelly Belly Candy Company—has more than earned its keep during some of this past summer’s more hot-andhumid days. Boasting its own accessory line of Jelly Belly-branded snow-cone Cups & Straws—cleverly packed inside a see-through paper-plastic box bursting with fun candy colors—this is one utensil that’s guaranteed to bring any summertime party or barvbeque’s to life with its nostalgic throwback look and a joyful visual presence.

Photos by Paul Pethick

CHECKOUT PAUL PETHICK

If making your own brain-freezing slushies is not your cup of tea, you’ll find a little more mature sense of joy in the new Mike’s Hard Lemonade Frozen f lavored malt beverages marketed by Canada’s own pre-mixed cocktails pioneer Marc Anthony Group Inc. of Vancouver. Proudly standing out on the liquor-store shelf in 296-ml f lexible stand-up pouches adorned with vibrant colors set against a black background, this adult treat packs a perfect mix of chills and thrills once it’s taken from the freezer’s icy cold and squeezed into your favorite glass to serve up a tasty, ice-cold refreshment that would make many a bartender feel as proud as punch. Paul Pethick is a technical writer and editor living in Toronto.

FREE

PRODUCT INFORMATION

SEPTEMBER 2014

CIRCLE THE R.S. NO. THAT MATCHES THE NUMBER ON THE ADVERTISEMENT OR ARTICLE OF INTEREST. FAX THIS BACK TO US AT (416) 510-5140 Name Title Company Name Address City Prov. P/Code Telephone Fax Email Address

CANADIAN PACKAGING • SEPTEMBER 2014

14-09-05 2:41 PM

What

Happens

When We Don’t Conserve The Earth’s Resources?

Reducing water usage is an important goal for the Beverage Industry around the world. Eliminating water and lubrication from conveyor systems is a proven method of achieving this goal! Contact System Plast at 866-765-8744 PowerTransmissionSolutions.com/Beverage Visit us at Pack Expo 2014 in Chicago Booth #N6132

p IBC cpac sept 2014 IBC AD p IBC.indd 39

14-09-05 11:22 AM

STAND-UP POUCHES HAVE TAKEN OVER

POWDER FILLING The Star Auger is designed to weigh/fill powders, granules, spices, and more.

info@weighpack.com

p OBC cpac sept 2014 OBC AD p OBC.indd 40

STAND-UP BAGGING The Swifty Bagger is engineered to open, fill, and seal a wide variety of pre-made bags.

1.514.422.0808

CASE ERECTING The Boxxer T-12 is one of the most economical and compact erectors on the market.

SEE IT LIVE AT PACK EXPO CHICAGO NOV 2-5, 2014 BOOTH S-1548

FROM PRODUCT TO PALLET WeighPack Systems and Eagle Packaging team up and deliver a complete system designed to fill & seal stand-up pouches, erect, load & tape cases, then place on pallets.

CASE PACKING Automatic accumulation loading and sealing for a variety of pack patterns.

PALLETIZING Use the Z.Zag to automatically pick and place cases onto a pallet.

info@eaglepm.com

1.305.622.4070

14-09-08 3:49 PM