Canadian Packaging October 2023 by Annex Business Media

AUTOMATE NOW Page 25

SUSTAINABILITY Page 31

SHOW PREVIEW PACKEX Toronto Page 38 SERVING CANADA’S PACKAGING COMMUNITY SINCE 1947

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PRESSING THE POINT Corrugated packaging stalwart leaps into the digital age Story on Page 17

FROM LEFT: ANTHONY MEMME, DIGITAL PRINT MANAGER; ANDREW TUCKER, VICE PRESIDENT SPECIALTY GROUP; ADAM PAUWELS, VICE PRESIDENT OF SALES CORRUGATED DIVISION ONTARIO, ATLANTIC PACKAGING PRODUCTS LTD.

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October 2023 Vol. 76, No. 8 canadianpackaging.com

COVER STORY

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17 ABOVE BOARD

A new production-scale digital printing press enables venerable Toronto corrugated packaging producer to continue its trailblazing ways with commanding technological leadership.

FEATURES

25 Form and Function 25

West Coast manufacturer of tray forming equipment leverages advanced servo control technology for optimized machine flexibility and throughput.

31 The Future of Fiber

How paperboard packaging fits into the accelerating global shift towards the Circular Economy business model.

35 What Happened in Vegas DEPARTMENTS

COLUMNS

NEWSPACK 6-8 Packaging news round-up.

FROM THE EDITOR 4 George Guidoni Why hammer policies are a wrong path to meaningful plastics reduction.

NOTES & QUOTES 10-11 Noteworthy industry briefs. ECO-PACK NOW 13-14 Sustainable packaging innovations. IMPACT 15 A monthly insight from PAC Global.

CHECKOUT 44 Julie Saunders Joe Public speaks out on packaging hits and misses.

Recapping some of the most memorable highlights and talking points of the recent PACK EXPO Las Vegas packaging extravaganza.

38 Show and Tell

A brief preview of the upcoming biennial PAC EX Toronto exhibition at the Toronto Congress Centre next month.

EVENTS 42 Upcoming industry functions. PEOPLE 42 Career moves in the packaging world.

ISSN 0008-4654. Canadian Packaging is published 10 times per year by Annex Business Media. Canada Post Publications Mail Agreement No. 40065710. Return undeliverable Canadian addresses to: Circulation Department, 111 Gordon Baker Rd., Suite 400, Toronto, ON M2H 3R1. No part of the editorial content in this publication may be reprinted without the publisher’s written permission. © 2023 Annex Publishing & Printing Inc. All rights reserved. Opinions expressed in this magazine are not necessarily those of the editor or publisher. No liability is assumed for errors or omissions. All advertising is subject to the publisher’s approval. Such approval does not imply any endorsement of the products or services advertised. Publisher reserves the right to refuse advertising that does not meet the standards of this publication. Printed in Canada. CANADIANPACKAGING.COM

ON THE COVER Anthony Memme, Andrew Tucker and Adam Pauwels of Atlantic Packaging Products strike a confident group pose in the reception area of the company’s Tiffield Road retail packaging plant in Toronto’s east end. Cover photo by Naomi Hiltz. October 2023 · CANADIANPACKAGING

FROM THE EDITOR

Why hammer policies to reduce plastic waste may be a waste of time

40%

Estimated share of the total volume of fresh produce sold in Canada that is pre-packed in plastic

ith demonization of all things plastic seemingly becoming a full-time occupation for public figures in government and activist circles, saying anything in defence of the one-time miracle material defense runs the risk of being branded a heretic or a climate change denier. That does not seem to bother Martin Gooch, chief executive officer of the Value Chain Management International (VCMI) think-tank in Oakville, Ont. Well-known in industry circles for producing several authoritative reports on the economic and social impact of global food waste, VCMI’s fundamental position on the need for a cautious and largely voluntary approach to reducing plastic packaging solution may not be on-trend with the prevailing public opinion, but it does not mean that it should be ignored on principle outright. Published in response to the latest consultation paper released by the Environment and Climate Change Canada Environment (ECCC) on August 1, 2023, as a starting point for a concerted reduction in the use or plastics for primary food packaging, VCMI’s long list of objections to the government’s appetite for heavy-handed regulation suggests that the journey to the Circular Economy for plastics in Canada will be anything but a stroll in the park. In fact, the subtitle of VCMI’s Benefiting the Environment and Ecologies by Reducing Plastics Pollution position paper sternly proclaims that, “Plastic packaging hammer policies are not the answer.” As the VCMI report argues from the outset, “One of the greatest risks facing industry today is well-intended though poorly conceived policies. “Poorly conceived policies and the mechanisms required for their execution have the potential to worsen the issue(s) that they seek to address,” VCMI states. While VCMI agrees with the overall aims outlined in the ECCC document, the devil is always in the details. “In our opinion, detailed objectives published by ECCC in April and August 2023, particularly the latter, are unachievable and will lead to widespread unintended consequences,”VCMI proclaims,

CANADIANPACKAGING · October 2023

warning about the dangers of exploiting the public’s newfound environmental awareness as a political ploy to boost the federal Liberal government’s sagging popularity. “The challenge facing industry and consumers is that activists find hammer policies and regulations appealing because they create a false sense of effective action, for which they claim credit,” VCMI states. “Due to the true cost of implementation and enforcement, and the expected benefits of implementing hammer policies and legislation rarely materializing, hammer policies and their regulatory mechanisms become a dead-weight loss on the national economy.” To tone down the expected wrangling and strong-arming,VCMI calls for a more compromising discussion that takes into account some key principles: • Policies must recognize the scale of the conflated relationships that exist between plastic pollution and GHG (greenhouse gas) emissions. • ECCC urgently needs to establish constructive dialogue with industry on addressing plastic pollution, or else risk losing its credibility as an authoritative government body. •The topic of plastic pollution cannot be viewed in isolation. Doing so will lead to widespread unintended consequences. • The need for negotiated agreements is particularly critical in Canada’s federated system, where provinces and municipal governments can impede change initiatives by having implemented conflicting regulations and misaligned systems. • Industry must be the driving force for change, with visionary leaders committing to achieve and be accountable for bold targets, and investing in the creation of harmonious pre-competitive solutions to address plastic pollution. • Government-implemented policies, regulations and programs need to incentivize and assist industry to address barriers that have historically inhibited formation of circular packaging economies. Your move, Ottawa, let’s hear it.

OCTOBER 2023 | VOLUME 76, NO. 8 Reader Service Print and digital subscription inquires or changes, please contact Angelita Potal, Customer Service Tel: 416-510-5113 apotal@annexbusinessmedia.com Mail: 111 Gordon Baker Rd., Suite 400, Toronto, ON M2H 3R1 Senior Publisher Stephen Dean | (416) 510-5198 SDean@canadianpackaging.com Editor George Guidoni | (416) 510-5227 GGuidoni@canadianpackaging.com Account Coordinator Barb Comer | (888) 599-2228 ext 210 bcomer@annexbusinessmedia.com Audience Development Manager Barbara Adelt | (416) 510-5184 Fax: (416) 510-6875 badelt@annexbusinessmedia.com Media Designer Brooke Shaw | (519) 428-3471 bshaw@annexbusinessmedia.com President/COO Scott Jamieson SJamieson@annexbusinessmedia.com Annex Business Media 111 Gordon Baker Rd., Suite 400, Toronto, ON M2H 3R1; Tel: 416-442-5600.

Canadian Packaging, established 1947, is published 10 times per year except for occasional combined, expanded or premium issues, which count as two subscription issues. PRINTED IN CANADA ISSN 008-4654 (PRINT), ISSN 1929-6592 (ONLINE) PUBLICATIONS MAIL AGREEMENT NO. 40065710 SUBSCRIPTION PRICE PER YEAR (INCLUDING ANNUAL BUYERS’ GUIDE: Canada $78.50 per year,USA $179.50 (CDN) per year, Outside Canada $203.50 (CDN) per year, Single Copy Canada $10.00, Outside Canada $27.10. From time to time Canadian Packaging will mail information on behalf of industry-related groups whose products and services we believe may be of interest to you. If you prefer not to receive this information, please contact our circulation department in any of the four ways listed above. Annex Privacy Officer Privacy@annexbusinessmedia.com Phone: 800-668-2374 DISCLAIMER: No part of the editorial content of this publication may be reprinted without the publisher’s written permission. ©2023 Annex Publishing & Printing Inc. All rights reserved. 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. We acknowledge the [financial] support of the Government of Canada

GEORGE GUIDONI, editor GGuidoni@canadianpackaging.com

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combining including light and Bottling Limited, the new Y3000 optimistic, a Coca-Cola Creations Zero Sugar is the sixth limited-edition Coca-Cola flavor developed as logo composed of effervescent bubbles, and the Coca-Cola part of company’s ongoing Spencerian Script font-face, with Coca-Cola Creations product fluid dot clusters that merge to development campaign, with the represent the human connections full-sugar version of the drink of our future planet. expected to be launched into the As The Coca-Cola Company’s market later this year. integrated marketing manager “Our ambition for Coca-Cola Solange Grimard relates, “After the Creations is to create unexpected label design was created by our and magical moments for our global team and their partners, our fans,” says Oana Vlad, senior design team in Canada worked on director of global strategy at The localizing it to reflect all local rules Coca-Cola Company. and regulations that we need to “Inspired by the timelessness of beverage is said to be the first futurNew Coca-Cola creation follow while keeping it light and istic flavor co-created with human Coca-Cola, we want to celebrate offers a positive spin on fresh to stand out on shelf. and artificial intelligence in what the everyone’s idea of what the future the AI-powered future “To capture the futuristic feel While most of North American Atlanta-headquartered beverage might look like,” Vlad says. and taste of Coca-Cola Y3000 Zero According to Vlad, Coca-Cola public is still processing how the producer calls a “celebration of an Sugar, the packaging showcases rapid growth and deployment of AI optimistic future through the con- created the Y3000 experience by liquid in a morphing, evolving tapping into human and artificial (artificial intelligence) technology nections we make.” state, communicated through the intelligence to understand how Available in individual 500-ml will affect their everyday lives, consilver base with light and optimistic fans envision the future through sumer brand-owners like soft-drink and eight-packs of 300-ml bottles, tones including violet, magenta emotions, aspirations, colors and giant Coca-Cola are already using the new beverage features embedand cyan,” Grimard explains. flavors, combining the fans’ this highly disruptive high-tech to ded AI-powered experience that “Also, the Coca-Cola wordmark perspectives from around the world make their packaging and labeling will give fans an exciting perspecfeatures a connected dot matrix with insights from AI to create the tive on what the year 3000 could more futuristic on every level. with fluid dot clusters that merge distinct taste of Y3000 beverage. Launched across Canada last look like by scanning the label. to represent the human connecThe new Creation features a Produced and packaged in month, the new limited-edition tions of our future planet.” futuristic packaging design Coca-Cola Y3000 Zero Sugar Canada by Coca-Cola Canada 23_006941_CN_PCKG_OCT_CN Mod: September 6, 2023 9:16 AM Print: 09/13/23 page 1 v2.5

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Leading packaging supplier unveils brand new facility for hands-on packaging automation

North America, the unique state-of-the-art building was designed to provide customers with a hands-on opportunity to explore and interact with advanced packaging equipment ranging from wrapping machines and tray-sealing equipment to autonomous forklifts, shrinkwrapping systems automatic case erectors, tape machines and other automatic packaging systems from elite global OEM (original equipment manufacturer) brands. “At Crawford Packaging, we understand that automation plays a vital role in streamlining

As birthday’s celebrations go, the grand opening of Crawford Packaging’s new state-of-the-art Automation Experience Centre in last month in Mississauga, Ont., was a joyfully fitting icing on the cake for a leading Canadian distributor of packaging equipment and materials proudly celebrating its 60th anniversary this year. Adding to the company’s tightly integrated network of nine distribution facilities across

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Taking direct aim at plastic packaging pollution, the federal government made a strategic $3.7-million investment earlier this year to enable Guelph, Ont.-based Omnia Packaging to purchase new equipment to make 100-percent compostable and recyclable paper trays, as well as 100-percent recyclable plastic trays, for the Canadian food industry. This substantial investment was fittingly showcased last month with the grand opening of Omnia Packaging’s brand new production facility, marking a significant milestone for Omnia’s Italian-based parent company Sunino Group. Says Omnia Packaging’s chief executive officer Paolo Sunino: “We are committed to RþąŊƄĪƹąþɷĜŒŵąĪĞŊɷöŒþƧɏ leading the way in innovative, sustainable ¡ƄąąŁɷ¡ĦÚƠĪŊĞ foodĜŵŒňɷ ƊĞąŵɷDÚĪŁƊŵą packaging with a commitment to producing exclusively recyclable plastic and paper food packaging, helping to increase recycling rates across Canada by 2025.” According to the Federal Economic Development Agency for Southern Ontario, which provided the funding, the new facility will create 50 new jobs in the Guelph region.

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reathing new life into an old case packer has never been easier, from both a dollar and good sense perspective. Almost every process in an older design from formatting through loading and palletizing can be upgraded using the latest electric automation (EA) technology. It can be done incrementally and cost-effectively, adding productivity-enhancing functionality or simplifying a task for greater reliability with less wear and tear, even potential labor and energy savings. For OEMs, giving a dated model a makeover can launch a new variant or options with a relatively small engineering investment. Upgrades can be offered as retrofit packages for machines in the field. Case packers are meant to last for decades. The role of boxboard and corrugated packaging isn’t about to change. For many end users, targeted retrofitting is a better economic move than buying a new machine to keep fulfilling the same orders. Over the last decade, EA technology has continued to improve while its inflation adjusted cost has declined, making incremental upgrading a better proposition than it might have been in the past. Upgrading can automate manual functions or substitute more capable EA tech for old pneumatic or electromechanical systems. Instant format changes are possible, often just a one-touch recipe on the HMI. A retrofit also can deliver greater throughput or eliminate low-value uses of staff overseeing the streaming of boxes and product for loading. Auto-

CANADIANPACKAGING · October 2023

mation is an elegant workaround for labor shortages and can make small-batch production or just-in-time order turnaround truly feasible. Manual reformatting a case packer for container or product changes is time-consuming and error prone. And much of the tribal knowledge of experienced hands is going with them into retirement. Employing the latest compact, low-energy servo technology like Festo’s CMMT drives with incremental encoder and EMMT motors to replace hand cranks and manual adjustment wheels assures exponentially faster changeovers with consistently accurate positioning. Festo’s inexpensive, easy-to-commission Simplified Motion Series actuators are ideal for single lanes requiring constant width changes or for marshalling box and product streams. For other processes, substituting the latest EA for pneumatics can increase throughput and reliability, with fewer positional or time-based errors. Compared to pneumatics, Festo EA solutions can boost cycle times, and improve reliability. They require less maintenance, run more smoothly and provide higher dynamic performance. For case/carton/tray erecting, an all-EA process is faster than pneumatics or the difficult-to-synchronize combinations or electrical, pneumatic and mechanical system often employed in older designs. EA increases reliability and is easier to maintain. For the loading function, 2D or 3D gantries like Festo’s EXCT perform as well as Delta or articulated robots and are clearly cheaper for small and medium-sized loads in particular. For the closing, sealing and

compression functions, EA solutions can cost a bit more than pneumatics, but offer a faster payback, measured in greater uptime and flexibility – like faster format changes – and potentially faster line speeds with lower air consumption. For loading and palletizing, an articulated or Delta robot often proves to be an over-investment. The right Cartesian gantry – correlating with payload and safety requirements – is easier to size correctly and commission. A single, compact Festo CPX-E controller can control the interpolating motion performed by multiple gantries, as opposed to the larger controllers needed to manage multiple articulated robots. All functions in an old case packer can be improved using EA technology. Festo’s e-book “Power Up with Electric Automation Solutions; Upgrading case packer designs through incremental change”, will help you identify and evaluate these and other upgrade opportunities, stage by stage, with the optimal solutions from Festo’s extensive EA portfolio.

Upgrade your case packer designs (festo.com) scan here to download the free eBook

CANADIANPACKAGING.COM

COVER STORY

From left: Atlantic Packaging’s Adam Pauwels, Vice-President of Sales, Corrugated Division, Ontario; Anthony Memme, Digital Print Manager; Andrew Tucker, Vice-President, Specialty Group, in the reception area of the company’s Tiffield Road plant.

ACROSS THE BOARD Venerable corrugated packaging manufacturer setting a high bar for digital printing excellence with new cutting-edge press technology By George Guidoni, Editor Photos by Naomi Hiltz

CANADIANPACKAGING.COM

ith digital printing press technology improving in leaps and bounds at a relentless pace, making a massive capital investment in current state-of-the-art digital printing technology is always fraught with the risk that it can become obsolete long before its anticipated best-before date—making a meaningful ROI (return-on-investment) a highly elusive target. And as more and more paper packaging producers and converters are swayed to invest in digital printing by

customers’ demands for more customized, personalized and higher-quality packaging graphics and more sustainable products, it is a challenge faced by a growing number of packaging suppliers, with corrugated boxboard producers no exception. Happily for the Toronto-based Atlantic Packaging Products Ltd., astute capital investment and keen understanding of the customers’ needs and market trends are very much near the top of the many core competencies that the privately-owned corrugated packaging producer has skillfully mastered over the last 78 years to become a major player in the North American market for corrugated boxes, trays, reOctober 2023 · CANADIANPACKAGING

COVER STORY

Clockwise A look inisde the hybrid drying section of the Delta SPC 130 digital press commissioned by Atlantic Packaging; a close-up of the freshly printed corrugated sheets passing through the drying station; manufactured at a Durst factory in Austria, the six-color Delta SPC 130 digital press measures about 50 meters in length.

tail-ready packaging, merchandising displays and many other paper packaging solutions demanded by a growing base of brands and CPG (consumer packaged goods) producers looking to improve their sustainability profiles and credentials. Nowadays operating 22 manufacturing and converting facilities in Canada and the U.S., the company has recently reaffirmed its long-standing credentials as the corrugated industry’s technology leader with the arrival of a gigantic 18

CANADIANPACKAGING · October 2023

press has been quickly fulfilling its promise as the proverbial industry “game-changer” since being commissioned at the company’s Tiffield Road retail packaging facility in Toronto’s east end in June of this year. Measuring about 50 meters in length, the new Delta SPC 130 is the first six-color digital corrugated printing press installed anywhere in Canada, according to Adam Pauwels, vice-president of sales at Atlantic’s Ontario Corrugated Division, and only one of four such presses currently operating in North America. “We expect this new press to become a real workhorse for us going forward,” six-color Delta SPC 130 digital printing Pauwels told Canadian Packaging on press manufactured in Austria by a recent visit to the Tiffield Road plant. “We did this for our customers so that Koenig & Bauer Durst GmbH—a joint-venture company formed in 2019 they had a cost-effective way to get new by Koenig & Bauer, the world’s products to market without costly printsecond-largest printing press manufac- ing plates and the need to commit to turer, and Durst Group, a leading labels or pre-print rolls which leads to global supplier of digital printing tech- obsolescence,” Pauwels states. “Our customers needed a quicker way nologies. Skillfully combining the advanced, to market, and digital was the solution.” As Pauwels reveals, “Right now we are best-of-breed technological capabilities and attributes of both joint-venture still focused on educating many of our partners, the new Delta SPC 130 digital customers to understand the full beneCANADIANPACKAGING.COM

fits of this press. “Being a truly disruptive technology, it will take time for the market to fully embrace it,” he acknowledges, “but based on the jobs we have run on it so far, we know our customers will be open to moving more and more of their jobs onto this press once they realize all the possibilities it opens up that were not available before with the traditional printing processes.” As Pauwels remarks, “Digital printing has become more and more commonplace in Europe, where they tend to be early adopters of digital technologies of all kinds, but we are convinced that once the Canadian market fully understands it, it will grow in a big way in Canada as well.” While earlier generations of digital press technologies have provided an adequate alternative for creating packaging prototypes and handling smallrun production by offering unprecedented levels of graphic design flexibility—notably in label and folding-carton production—the new Delta SPC 130 press represents a profound technological leap by combining superior print quality of up to 800-dpi (dotsper-inch) resolution with commercial-scale running speeds of up to 120 meters per minute, making it a perfect fit for the vast multitude of medium-volume production runs (up to 20,000 sheets) accounting for a large part of the company’s orders. Considering the significant capital investment involved in acquiring and installing such a sophisticated piece of machinery, Atlantic Packaging spent CANADIANPACKAGING.COM

Clockwise from top right The SPC 130 digital press employs high-precision Durst Quadro Array printheads equipped with hundreds of tiny spray nozzles to print in up to 800-dpi resolution. Overhead views of the Delta SPC 130 six-color press that can run up to 150 meters per

about four years carefully evaluating the available technologies in the marketplace before settling on the Durst six-color press, according to the company’s digital print manager Anthony Memme. “We really put the suppliers through the wringer with all the graphics trials, production trials and visits to their customers,” Memme recalls, “but we found that most of the existing technologies at the time were better-suited for making displays rather than retail or food packaging. “The print quality wasn’t quite up there, the speeds were too slow, and getting the thicker corrugated boards from one end of the press to the other in

one smooth pass seemed to be a real challenge. “So we waited a little for the technology to catch up,” Memme says, “and luckily for us there have been some significant gains made in both quality and speed in the last couple of years to justify our large investment in digital corrugated printing. “The mechanics have improved greatly, along with big advancements in software, the feeding section, inspection, defect rejection and so on,’ he says, “but the big thing for us is the modular design of this Durst press. “It’s not just one long, hulking piece of metal,” Memme states. “Being modular allows us to upgrade the press in step

Right The Delta Control Station for the Delta SPC 130 digital press features a large worktable to help facilitate optimal quality control and proofing for the press operators for any size of sheet. October 2023 · CANADIANPACKAGING

COVER STORY

with whatever future technological advancements come down the line by replacing the print section, for example, or updating the primer section, or enhancing the feed section.” For Atlantic Packaging, which prides itself on its sustainability track record, being able to user water-based inks on the SPC 130 press was also a major factor and selling point in its final equipment selection. “Water-based inks is one of the biggest things to happen in the market for digital printing,” says Memme, “because the absorption and the drying of waterbased inks on corrugated boards is a fairly complex process at high speeds.” Adds Pauwels: “Using water-based inks enables us to live up to our environmental goals and standards, as well as to ensure safe food contact and no odor. “Moreover, the digital printing press does not use any printing plates, so there is no need for any cleaning chemicals or wastewater from cleaning the plates, which is all bad for the environment.” In addition to widening the traditional CMYK color gamut with the addition of orange and violet, the SPC 130 press also includes an additional inline primer section to create ultra-vibrant colors directly onto uncoated corrugated in smooth single-pass process. According to Durst, the SPC 130 press combines a well-engineered mechanical 20

CANADIANPACKAGING · October 2023

Top Left A stack of finshed produce trays featuring fullboard, high-definition graphics created on the Delta SPC 130 digital press. Top right Memme, Tucker and Pauwels assessing the finishing quality of a freshly printed corrugated sheet.

design with easily accessible sub-assemblies and selected components to guarantee durable quality, high performance and reliability, along with Durst’s dropon-demand printhead technology, a non-hazardous ink system, and an efficient IR/UV drying process designed for high productivity. Configurable with up to six colors, the press can print any length of corrugated cardboard up to 110-inches (2,794-mm) wide or paper media of up to 12-mm in thickness, while offering optimal versatility, low maintenance requirements and 24/7 dependability. The Delta SPC 130 is equipped with recirculating Durst Quadro Array printheads and water-based, odor-free WT inks for production of high-quality,

indelible, glossy and non-fading end products in a single-pass process. The production process on SPC 130 begins at the feeder section, which is a fully-automatic, non-stop feeder with integrated cleaning station, built-in detection of damaged sheets, and automatic sheet ejection. Once inside, the sheets move through the priming section for optional digital pre-treatment of coated or uncoated material and on to the hybrid dryer, which combines thermal drying with IR (infrared) and hot air to ensure durable high adhesion on coated fiber-based materials without pre- treatment, whereby the thin coating layer and high adhesive friction of the ink surface prevent the stack from shifting.

“Using water-based inks enables us to live up to our environmental goals and standards, as well as ensure safe food contact and no odor.” CANADIANPACKAGING.COM

NEW NAME. SAME GREAT VALUE & SERVICE.

Adam Pauwels cheerfully shows off the vibrant colorful graphics created by the Delta SPC 130 digital printing press on corrugated board fresh produce trays using food-safe water-based inks. measuring devices for profilAfter passing through the sining and color checking; gle-pass printer section, where thousands of tiny inkjet dispens- • Six lockable compartments ing nozzles deposit tiny droplets for machine operators, inof water-based inks onto the cluding the cellphone charsurface, the boards move on ging option; through the quality inspection • A signal lamp to display the station to inspect any errors in printer status. the printing process, and on to All in all, the SPC 130 press the cooling station, before arriv- offers all the main advantages of ing at the fully automatic stacker the digital print press process in at the end of the line, featuring terms of design flexibility and integrated ejection of waste variability, exceptionally fast sheets from the final stack. changeovers, color stability, onThe entire process is centrally the-fly adjustments and design controlled and monitored from changes, and a virtually zean elevated, ergonomically-de- ro-waste, zero-scrap process that signed Delta Control Station is totally in line with Atlantic platform equipped with all the Packaging’s sustainability mindstate-of-the-art features and ac- set, according to Memme. cessories required for simple, “Our customers not only love clear, comfortable and central the print quality we get with this operation of the digital Durst machine,” he states, “but also the single-pass printing line, includ- consistency of it, whereby we can ing: digitally trap that color con• Worktable for a 280X130 sistency from sheet to sheet. “The big advantage for our centimeters sheet size for quality assessment, profiling customers with digital is that if they want to do a run of seasonal and color checking; • Camera server for clear mon- or promotional packaging, we can just add a pop of color of itoring of the printing line; • Two 55-inch monitors for some different graphics on the quality control, workflow selected sheets and insert it the monitoring, camera view, middle for a regular production and ERP (Enterprise Resource run, without interrupting the Planning) system networking; process. “It allows for the level of cus• One 32-inch touchscreen tomization and individualization control terminal; • Matrix screen control for that was just too cost-prohibitive customer-specific, freely before,” Memme says. “Hence it selectable assignment of the opens up a whole host of opportunities that were not available monitors; • Pull-out leather seat arm for with earlier digital print technologies. machine operators; “For someone who has been • Additional interface for color CANADIANPACKAGING.COM

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CANADIANPACKAGING.COM

COVER STORY

A freshly printed stack of corrugated sheets coming off the Delta SPC 130 digital press is ready for pick-up and delivery to customer.

living in print for most of my working life, I never thought that digital printing for corrugated would arrive as quickly as it has,” Memme acknowledges. “So the fact that the quality that we can get off this press, at the speed that we can get it off this press on a corrugated sheet, is really mind-blowing, really unbelievable,” he remarks. “For me, the biggest ‘Wow factor’ about digital printing is how quickly the technology has caught up with our requirements in the relatively short time since we started out on our digital journey,” Memme remarks. To maximize its digital investment, Atlantic Packaging has invested significant time and money to train its operators and maintenance staff on the machine, with Durst supplying much of that training right on-site at the facility. “The technology itself is fairly user-friendly,” says Memme, “with a pretty intuitive workflow and user-interface. “Of course, it is different from regular printing with a flexo press, let’s say, where you need to set up the tooling and the pressure levels, while constantly monitoring and adjusting all your ink levels with mechanical knobs. “Everything on this press is done through a computer interface,” he points out, “so it requires a somewhat different mentality for our operators. “They need to be really computer-efficient to run and troubleshoot this press properly.” For Andrew Tucker, vice-president of the company’s Specialty Group business, the successful commissioning of the SPC 130 digital press is a very gratifying outcome of a lengthy equipment evaluation process in which he played an instrumental part during the earlier stages. “When digital became the big new buzzword several years ago, everyone wanted to get in on it right away, with customers demanding the flexibility, the

CANADIANPACKAGING.COM

The reception area of Atlantic Packaging’s Tiffield Road plant features a graphic historical retrospective of the multiple memorable milestones and accomplishments achieved by the family-owned company over its 75-year history.

A Siemens Simatic HMI (human-machine interface) terminal displays all the critical feeder station information to the press operator in real time. quick response time, the quick turnaround time, and all the other cool features promised by digital printing,” he recalls. However, the technology available at the time was not suited for cost-effective continuous processing of corrugated board, according to Tucker, and thus it was mostly limited to the production of merchandising displays. “But some time about two years ago we started seeing new offerings from the like of Durst, and other press manufacturers,

that had really closed the quality gap to provide superb print quality with high productivity,” Tucker says. “So we expect this press to become a real workhorse for us, ultimately capable of processing up to 100 million square feet a year over a three-shift schedule. As Tucker concludes, “It really hits the sweet spot by combining high productivity and really good graphic while using water-based inks—enabling us to provide our customers with truly sustainable corrugated packaging solutions.”

Watch a video of the Delta SPC 130 digital press in action at Atlantic Packaging’s Tiffield Road plant in east-end Toronto on Canadian Packaging TV.

October 2023 · CANADIANPACKAGING

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CANADIANPACKAGING · October 2023

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AUTOMATE NOW

Bosch Rexroth Canada account development manager Christopher McGregor (left) joins IPAK engineering manager Davis Huang (center) and IPAK product manager Christopher Parkinson to display the high-quality, sturdy corrugated produce trays coming off the TF385 model tray former at the Wexxar Packaging manufacturing facility in Richmond, B.C.

FORM AND FUNCTION West Coast end-of-line packaging OEM hits its stride with servo control technology to raise machine performance to the next level of operational excellence and reliability By George Guidoni, Editor Photos by Dave Buzzard

CANADIANPACKAGING.COM

ounded in 1977 in Richmond, B.C., Wexxar Packaging Inc. is a proud and renowned Canadian packaging equipment manufacture specializing in building automatic, sturdy, high-speed end-of-line packaging machines such as case erectors, case sealers and tray formers used to make the corrugated shipping containers for transporting fresh produce, agricultural products, meat, beverages, packaged foods, household goods and many other types of everyday CPG (consumer packaged goods) to grocers, retailers and food wholesalers across North America. With a Wexxar machine available for forming or sealing anything from a basic “brown box” to complex specialty trays in the company’s comprehensive product

portfolio, Wexxar equipment has been installed in over 40 countries to date, according to the company, which has been operating as part of the ProMach group of companies, headquartered in Cincinnati, Ohio, since 2005. Prior to that, the company operated under the updated Wexxar Bel moniker following its 2000 acquisition of competing case forming and sealing machinery manufacturer Belcor to significantly boost its product offering, which was further expanded in 2009 with ProMach’s acquisition of the Richmond-based tray forming equipment builder IPAK, subsequently integrated into the renamed Wexxar Bel business. Despite the changing names and owners, the Wexxar brand name continues to be synonymous with productivity and reliability in packaging industry October 2023 · CANADIANPACKAGING

AUTOMATE NOW

Top Stacks of corrugated lined up behind the TF series tray forming machine, awaiting their turn to be shaped into final shipping trays. Bottom A close-up of the Rexroth IndraDrive servo motor installed at the blank advance station of the IPAK TF385 tray forming machine. circles, with some of the Wexxar Bel machinery reported to have been operating for over 30 years at some locations. Priding itself on its “solution-based engineering” philosophy, Wexxar had centralized all its manufacturing operations under the roof of a newly-built 100,000-square-foot factory in Richmond in 2014, thereby providing opportunities for greater synergies between the company’s major brands. One of the brands that has greatly benefited from these opportunities is the IPAK range of tray formers, which have been continuously enhanced in the last couple of years with improved design features and incorporation of advanced servomotor technology to enable the machines to form a variety of tray styles suitable for virtually any industry. Officially launched in the spring of 2022, the updated IPAK line of tray formers—comprising models TF385, TF485 and TF486—features multiple design upgrades that allow users greater accessibility for faster, easier, and safer changeovers than ever before, according to IPAK product manager Mike “Parky” Parkinson. “The big story with our new IPAK tray formers is that we made it much easier to do adjustments in the machine, which allows the operator to safely get it back up and running quicker—thereby really increasing the overall efficiency of the entire packing line, says Parky. “At Wexxar Bel, we constantly listen to our customers and continuously strive to improve our machinery to best meet their needs.” As Parky relates, updates to the new IPAK tray formers include redesigning the guard doors and other new guarding components to provide better access into the machine for faster adjustments and changeovers. Additionally, the number of adjustments needed for changeovers has also been reduced—making it easier for employees with varying skill levels to operate, while reducing the amount of required training and shortening the learning curve. As Parky notes, “Simplifying the design and improving machine access also aids maintenance crews by troubleshooting and servicing the machine more effi26

CANADIANPACKAGING · October 2023

“We constantly listen to our customers and continuously strive to improve our machinery to best meet their needs.” CANADIANPACKAGING.COM

Clockwise from top A close-up of the Rexroth IndraDerive servo drive and motor instlled at the mandrel of the IPAK TF 385 tray former; close-up of the corrugated blanks being moved through their paces at high speeds inside the TF385 tray former; finished corrugated trays coming out of the TF385 tray froming machine.

CANADIANPACKAGING.COM

ciently—minimizing downtime.” As part of this machine streamlining, the coalescing filter/ regulator unit on the redesigned IPAK tray former was relocated outside the machine—enhancing ease of accessibility when pneumatic adjustments are required. The relocation has also made pneumatic connections more direct and efficient, reducing the chance of air leakage and making for a more energy-efficient operation with an overall lower cost of ownership. Other changes include reinforcing materials on the overall machine and, notably, reinforced guarding and door hinges to increase overall operator safety and product life. “With these design improvements all centered around simplifying operation, IPAK really allows employees to take ownership of the machine,” Parkinson said. “Our goal was to build an even safer, more reliable tray former that expedites the changeover process, and we’ve done that with our new tray former.” The new IPAK automatic tray formers can create a broad variety of tray styles—including four-corner, six-corner, rollover, self-lock triangular corner, etc.—at robust throughput speeds of 15 to over 40 trays per minute, depending on tray type. According to Wexxar, the TF series tray formers utilize reliable and precise technology to form a perfectly square tray— ensuring the perfect aesthetic look and, more importantly, superior product protection. Featuring an active compression section, servo-driven blank advance and self-cleaning vacuums, IPAK trays incorporate a user-centric, intuitive design to reduce the amount of time required to learn, operate and maintain the machine. October 2023 · CANADIANPACKAGING

AUTOMATE NOW

Equipped with a large 10-inch touchscreen HMI (human machine interface) for user-friendly control and large doors to allow easy access to changeover and maintenance points, the tray formers allow for quick and tool-free size changeovers in under 20 minutes. Moreover, relocating the FRC to a centralized position on the machine has streamlined the entire pneumatic system and, according to Wexxar, reduced the overall energy costs while increasing machine reliability. One of the most impactful new machine performance features, according to Parky, was the installation of two IndraDrive HCS01 servo drives along with the IndraDyn MSK motor at the machine’s blank advance station and at the mandrel—to ensure superior speed, reliability and repeatability. Supplied by Wexxar’s long-time automation partner Bosch Rexroth Canada, the high-performance combination servomotors enable the TF series tray formers to handle a broader variety of tray styles, according to Parky, while also speeding up the process. “Once the tray enters into the compression station from the loaded hopper, the mandrel is going to come down and form that tray from the blank sheet of corrugated,” Parky explains. “With the two servos on this machine, giving us the ability to run up to 40 trays plus per minute, with the Bosch Rexroth servo advancing the blank through the machine with consistent performance, reliability and repeatability,” Parky states. “At the end of the day, that’s really what the customers are looking for.” Adds IPAK engineering manager Davis Huang: “For the last 15 years, we 28

CANADIANPACKAGING · October 2023

The IPAK TF385 model tray forming machine from Wexxar Packaging incorporates the signature-blue Nordson ProBlue Flex adhesive applicator for highly precise and repeatable application of hot-melt adhesive onto the corrugated surface to ensure reliable construction, performance and durability of each shipping tray coming out of the high-speed machine.

“Simplifying the design and improving machine access also aids maintenance crews by troubleshooting and servicing the machine more efficiently—minimizing downtime.” CANADIANPACKAGING.COM

have been very proud building the most compact machines that fit into most applications, thereby providing and forming the best possible trays for our customers. “With this project, the goal was to make flexible machines that our customers can adapt to make multiple styles of trays, and the Bosch Rexroth servo system is providing us that capability to do that. “The Ethernet-connected HMI on the machine allows us full control of the servo drive and the motor, while enabling customers to have less machines doing more work. “We chose to work with Bosch Rexroth servomotors because they make the machine more efficient and provide better control, with greater reliability, while improving efficiency,” Huang states, describing Bosch Rexroth as “a great partner for us to work with, especially at the product development stage.” Says Huang: “When we started trying to find solutions to move from our traditional control system to the more modern system, they (Bosch Rexroth) came in, introduced the available technology, and did a comparison of all options. “They then came in with their technical team to help us develop the product we wanted in a very short period of time. “We are very happy with the support we get from Bosch Rexroth,” Huang states. “We are happy with the products they supply,” he says, “and the level of collaborative interaction between us is always beyond expectation. “So when it comes to control autoCANADIANPACKAGING.COM

From left Close-up view of the touchscreen HMI (human-machine interface) terminal used for operator-friendly operation and recipe management of the IPAK tray forming machines. An IPAK TF series tray former being prepped for shipment to customer inside state-of-the-art, 100,000-squarefoot Wexxar Packaging manufacturing facility located just outside of Vancouver in Richmond, B.C.

mation,” he sums up, “they are always the first ones up for consideration as a partner.” Such feedback is a priceless compliment for Bosch Rexroth’s account manager Christopher McGregor, who was directly involved in the project from the start. “Our scalable servo drive and control range is flexible enough to handle any of Wexxar’s needs,” says McGregor, noting that Bosch Rexroth has been supplying Wexxar with automation components for over 10 years. “We act as a single source supplier for Wexxar—not only offering linear mechanical components but also all the drives and controls,” McGregor adds. “The partnership allows for increased efficiencies between both parties, as well as application-specific knowledge sharing within each other’s technology group.” As McGregor points out, “Bosch Rexroth leads the market in research and development of motion control—allowing our customers to equip their machines with the latest in drive and motor technology, while still maintaining support of their legacy products. “As an example, we are currently supporting Wexxar as they transition to

Bosch Rexroth’s newest servo motors that are smaller, lighter, and have impressive torque accuracy,” he says. “The global network of Rexroth engineering and our desire to be a market leader in automation requires us to work closely with our customers and develop new technologies to meet their application demands,” states McGregor. “Rexroth leads the market in R&D with new products like ctrlx (automation software), linear smart function kits and flex effectors, which are all disrupting our market and leading the way in industry advancements.” As Wexxar’s Parky sums up, “We’re best in class than what we do, and we look forward to showcasing our new improved equipment to our customers in coming years. “We are always working to meet the customers’ needs,” he concludes, “so we can grow with our customers as a trusted partner. “And as we look ahead, we look forward to Bosch Rexroth being therefor us to take care of all our drives and other automation needs.”

SUPPLIERS Wexxar Packaging Inc. Bosch Rexroth Canada

Watch a video of Wexxar’s model TF385 tray former, equipped with Bosch Rexroth servo motors and controls, in action at the company’s manufacturing facility in Richmond, B.C., on Canadian Packaging TV. October 2023 · CANADIANPACKAGING

CANADIANPACKAGING · October 2023

CANADIANPACKAGING.COM

SUSTAINABILITY

THE FUTURE OF FIBER Why fiber-based packaging is poised for long-term growth in global shift to the Circular Economy business model By Nate Pajka n a world with steady population growth and urbanization, the need for packaging is constantly growing. At the same time, packaging requirements are becoming more numerous, with environmental sustainability emerging as a common denominator. To succeed in the packaging industry, nearly every idea a company invests in must consider how it will reduce a product’s environmental impact. Sustainability can no longer be considered “just a trend,” as it was when the concept was first popularized. Consumers demand it on a global scale and our planet relies on its comprehensive implementation so it can operate naturally. Understanding the appropriate path forward for fiber-based packaging—in our quest to minimize the industry’s impact on the planet—must start on a macro level before homing in on specific actions that can be undertaken thoughtfully, but with due urgency. As with nearly any industry, the paperboard packaging market is impacted by both global and local trends. Globalization, and the ease and speed at which consumers digest information, has forced companies to think about more than what is directly related to paperboard. According to Mintel’s PESTEL analysis in their Global Packaging Trends 2023 report, there are several categories of global trends that we can monitor, including political/legal, economic, social, and technological. The most notable recent political event that affects this industry is Russia’s attack on Ukraine and the ensuing war. The war has soured international relationships, negatively affecting trade, as sanctions were placed on Russia and its

CANADIANPACKAGING.COM

allies by countries in neighboring Europe and around the globe. Before the war, Russia, Ukraine and Belarus were supplying close to 25 per cent of Europe’s timber and forest product needs, with that percentage since dropping to essentially zero. Not only has this created a shortage of fiber in general, but it has also forced suppliers to change their fiber mix without access to certain tree species. Russia was also a major supplier of energy to the EU (European Union) and the rest of the world, and without their contributions energy costs skyrocketed—resulting in increased production costs that get shuffled down the value chain to the consumer. Political polarization has been rampant since the height of the COVID-19 pandemic, creating divisions amongst consumers and a volatile purchasing environment. Today, every company seems to be one public relations nightmare away from a full-scale boycott of their products.

Produced by the Finnish-based paperboard packaging manufacturer Metsä Board Oyj, MetsäBoard Prime FBB EB is a dispersion-coated, lightweight barrier paperboard incorporating a medium barrier for protection against grease and moisture.

The upcoming U.S. election should exacerbate divisiveness, as campaign promises and subsequent conversations echo through living rooms across America. Because legislators believe they can make change through enacting new laws, we should expect to see a strict and dynamic regulatory environment moving forward. A principal issue in the packaging industry is centered on dealing with plastic waste, so we can expect investments in recycling infrastructure, deposit return schemes, more widespread extended producer responsibility legislation, and closer attention to the PFAS ‘forever’ chemicals. From an economic perspective, the report discusses the following trends directly affect the packaging industry: economic uncertainty, the rising cost of goods, supply chain challenges, labor shortages, the threat of a global recession, and inflation. As a result, a premium has been placed on value-based options. Industry October 2023 · CANADIANPACKAGING

SUSTAINABILITY

members need to consider how their packaging can help consumers stretch a budget without compromising quality, safety, sustainability, convenience, or freshness. Considering social factors is incredibly important in an era where information travels expeditiously across the globe via different media channels. Consumers today trust companies, governments and institutions less than ever, and as such they believe they bear the obligation to act responsibly. Now that consumers are a few clicks away from company and product information, transparency is key. 32

CANADIANPACKAGING · October 2023

Pristine and well-managed Scandinavian forestlands provide ample raw materials for the Metsä Board mill in Husum, Sweden, where high-quality paperboard is produced mostly with mostly fossil-free energy, and much of the volume is sent to the Americas.

vast impressionable audiences. For all the misery it caused, COVID -19 did accelerate many technological advances. One of them is the adaptation of the so-called ‘smart labeling,’ whereby a QR code can be used to communicate product details left off-pack. Narrowing our focus to corrugated packaging, we see some notable trends. The market is continuing to grow, but the proportion of fiber-based packaging is actually decreasing. This is due to higher growth rates in production and usage of other fiber-based products, coupled with lightweighting of the board itself. In 2023, factors such as inflation, destocking, near-recession conditions, and poor agricultural conditions are shrinking current demand, but it is expected to bounce back in 2024. In the long-term, corrugated packaging will remain a valuable product in high demand—primarily because consumer purchasing has been transitioning to online ordering and home delivery. From a sustainability perspective, corrugated board is becoming more lighter-weight as producers are using different combinations of liners to reduce board-specific carbon footprints and material use. Moreover, corrugated board is widely recycled, while often being made from 100-percent renewable raw materials. Consumer attitudes about sustainable packaging are constantly changing. Leading global management consultancy McKinsey & Company has published results from studies in two new reports —titled Sustainability in Packaging: U.S. Survey Insights and Sustainability in Packaging 2023: Inside the Minds of Global Consumers—which help us understand these attitudes. The studies found that the top buying criteria for packaging are price, quality, and convenience. Over two-thirds of consumers cite inflation as their top concern, as the price criteria has increased in importance by 11-per cent since the onset of COVID. The studies also show that environThis can be done through clear, thirdparty verified on-pack labeling that mental considerations depend heavily on communicates the company’s purpose. demographics, whereby Millennials, Gen This will also require being honest about Z and folks living in urban areas tend to challenges the company faces and how care more about environmental considerations than do those in older generations, they will be addressed. Consumers will also buy from brands or people living in rural areas. In terms of packaging characteristics, that hold similar values, so they pay attention to how a brand responds to the studies found that hygiene and food safety are highest-rated attributes, but controversial topics. With consumers spend more time on they have also become less important to line than ever before, there has been a consumers since the height of COVID. Nearly 40 per cent of the survey restrong push towards enhancing digital experiences. Influencers have influence, spondents said that environmental imso companies must be ready to respond pacts were either very or extremely imwhen emerging trends are broadcast to portant, which is down four per cent CANADIANPACKAGING.COM

Left Massive piles of logs and wood chips and outside the Humus mill indicate the resource- and energy-inensive nature of the global paperboard business. Right Metsä Board’s Elastic Carboard was created as an alternative to BubbleWrap. since 2020. This is likely due to the price increases causing consumers to prioritize other characteristics, but as the global economy normalizes, we should expect to see environmental impact regain significance to the consumer. Identifying a sustainable packaging type is difficult for most consumers, but compostable and plant-based packaging types tend to indicate to consumers that the package is sustainable, according to the study. Conversely, aluminum foil and multi-material packaging are seen as the least sustainable options. These studies also showed that consumers are willing to pay more for sustainable packaging. According to survey results, four to seven per cent of consumers are willing to pay over a 10-percent premium for sustainable packaging, while only five to eight per cent said they would not pay any premium. But about 50 per cent of consumers said that they would pay a

one- to three-percent premium for sustainable packaging. So, what will the future look like? We will continue to see product protection being paramount, because the least sustainable packaging is in fact the packaging that does not protect the product from being damaged or spoiled. Environmental impacts will be defined at the design phase, with material efficiency, designing for convenient recycling, and minimizing the environmental impact of the package across the entire value should be the principal considerations. We will also continue to see strong demand for fiber-based packaging because it is recyclable, lightweight, and made from renewable raw materials. While plastic is becoming a substrate of the past in many applications, it will be still difficult to replace outright for a number of characteristics, including high barrier properties, transparency

(seeing the product inside), and affordability. That said, the right messaging can help fiber-based packaging close the gap. The future for fiber-based packaging is bright, and as we continue to innovate, this industry has the opportunity to make significant contributions to mitigating climate change and realizing a truly circular economy. Understanding where the industry has been, where it is, and where it could be can be used to forge a more sustainable future.

NATE PAJKA is the sustainability manager at Metsä Board Americas Corp., a U.S.-based subsidiary of global paperboard manufacturing group Metsä Board Oyj, headquartered in Norwalk, Conn.

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October 2023 · CANADIANPACKAGING

2023-10-05 9:06 AM

CANADIANPACKAGING · October 2023

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SHOW REPORT

WHAT HAPPENED IN VEGAS Biennial PACK EXPO Las Vegas exhibition smashes all prior attendance records to stage a memorable masterclass of trade show excellence By George Guidoni, Editor

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xceeding expectations has really become the New Normal way of doing things for PMMI, The Association for Packaging and Processing Technologies, whose biennial PACK EXPO Las Vegas exhibition last month again smashed all existing show attendance and participation records to set yet another memorable benchmark for trade show excellence. Drawing over 32,000 visitors and more than 2,300 booth exhibitors to fill out more than one million square feet of buoyant and lively displays of the latest packaging machinery, materials and other packaging solutions and innovations in the market, the three-day event was a fitting testament to the growth-focused packaging and processing technol-

ogy suppliers still reaping rewards of pent-up post-COVID market demand— buoyed further by the gradual easing of global supply chain problems that created a big backlog of major capital projects waiting in line. Now that this backlog is finally being addressed, North American packaging suppliers should enjoy another couple of years of solid, if less spectacular, growth in shipments and revenues. According to the PMMI’s latest State of the Industry report, the North American packaging industry is currently enjoying a healthy 3.4-percent growth rate, with the U.S. market currently estimated at $10.2 billion. “PACK EXPO Las Vegas was a huge win for the packaging and processing industry,” said PMMI’s chief executive officer Jim Pittas. October 2023 · CANADIANPACKAGING

SHOW REPORT

“From attendance to exhibition space to educational sessions, the show surpassed expectations to provide our largest, most comprehensive show to date,” Pittas proclaimed. “This is proof that the industry continues to thrive and show up to provide the most innovative, sustainable, effective solutions the world has to offer.” Always a massive presence at all PACK EXPO series trade shows, automated packaging systems powerhouse Syntegon was once again one of main star show attractions with an expansive show-floor display featuring several leading-edge packaging solutions, including its newest fully integrated line for packaging delicate baked goods and other food that require particularly gentle handling. With the Syntegon DCG (Distribution Continuous Gentle) distribution center positioned at the front of the system—gently discharging 400 products onto the downstream packaging leg at 18 cycles per minute—the line incorporates an FIT inline module to continuously feed the products to the hygienic and reliable horizontal form-fill-seal (HFFS) Doboy Pack 403 machine, deploying linear motors to ensure gentle handling , while preventing products from sticking together or accumulating along the way. The single-wrapped products then

CANADIANPACKAGING · October 2023

Above A digital representation of Syntegon’s exhibit at the PACK EXPO Las Vegas show last month, featuring an innovative new DCG distribution center (above right) designed to ensure gentle handling of delicate food products. Below Flow Beverage Corp. founder and chief executive officer Nicholas Reichenbach hailing his company’s new Custom Printing partnership with the global aseptic packaging leader Tetra Pak.

continue at a rapid and steady pace on their way to the next leg of their journey— the robotic pick-and- system using delta robots that softly groups and deposits them in batches of four into the infeed of the Klikok MEC (Midrange Endload Cartoner) at the end of the line, Equipped with a patented rotary carton feeder, Klikok MEC then packs batches of four products in their own cartons at up to 170 cartons per minute. Making its North American debut at the Las Vegas show, Syntegon’s new DCG distribution center provides valid reflections of Syntegon innovation-based approach to new product development. Capable of discharging up to 32 rows of product per minute, the DCG is a compact pull-nose distribution system that is ideally suited for a variety of hardto-handle goods—such as sticky bars or baked products—with a variety of flexible features such as row aligners, quick belt changes, easy system integration, and fast commissioning, according to Syntegon. “When we were developing the Syntegon DCG, we placed particular emphasis on flexibility and hygiene,” explains Syntegon product manager Kimberly Kocer. “Depending on production requirements and layout options, different modules can be easily combined with

each other,” Kocer points out. “In addition, the distribution station’s open design makes it easily accessible,” she adds. “Sloped surfaces help catch product residue and keep the production environment clean.” With packaging sustainability fittingly being the overriding theme for all three days of the show, PACK EXPO Las Vegas provided a perfect platform for fast-growing Canadian water bottler Flow Beverage Corp. to announce its first-ever Customized Printing partnership with the global aseptic packaging products group Tetra Pak, whereby Tetra Pak will supply Flow with custom-printed beverage cartons printed on a new, production-scale digital printing press from Koenig & Bauer at Tetra Pak’s central U.S. manufacturing facility in Denton, Tex. “We are thrilled to be the first brand to market the unique Tetra Pak Custom Printing solution, which has allowed us to not only elevate the design of Flow’s cartons, but also to open up new horizons in advertising possibilities,” said Flow Beverage founder and chief executive officer Nicholas Reichenbach. “The packaging provides an artful medium that speaks volumes about our commitment to quality, sustainability, and memorable experiences,” Reichenbach said, noting the new cus-

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Measuring about a half of a football field, the new digital printing press manufactured by Koenig & Bauer at Tetra Pak’s manufacturing facility in Denton, Tex., is opening up unprecedented possibilities for brand-owners to customize and personalize their packaging within the same print run at high processing speeds with exceptionally high print quality.

tom-printed packaging has already enabled his company to strike up a distribution partnership with Live Nations, North America’s largest live concerts promoter. “And this is just the beginning,” Reichenbach stated. “We can’t wait to see more of our strategic food service and retail partners express their brand and sustainability values on-pack together with us,” said Reichenbach, “as we continue to flow with creative ideas and shape the future of beverage carton packaging together.” According to Tetra Pak, the company’s Custom Printing capabilities provide the first and only premium ink jet-based carton package printing solution to offer brands an innovative, cost-effective and customizable system, while providing all the environmental benefits of paperbased beverage cartons and a plate-free printing process. With this offering, companies can utilize promotional activations such as varied designs within a single case or limited-edition packaging collaborations to take their marketing and media mix to the next level, Tetra Pak explains. “Digital printing opens a world of opportunities for brands looking for powerful promotional campaigns, and it is an ideal solution for start-up businesses launching a new product,” said Tetra Pak’s executive vice-president of pack-

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aging solutions Ola Elmqvist. “By enabling crisp high-quality images and lifelike designs, it can also give products a premium look,” Elmqvist stated. “We look forward to innovating alongside more brands to unlock untapped potential with one-of-a-kind marketing collaborations through Tetra Pak Custom Printing.” Added Tetra Pak’s vice-president of marketing for the U.S. and Canada Pedro Gonçalves: “In today’s world, brands need the ability to quickly activate marketing efforts and capitalize on consumer trends, and Tetra Pak Custom Printing allows brands greater agility than ever before to create impactful, unique campaigns that diversify their advertising strategies in a cost-effective way. “We are proud to collaborate with Flow to bring to life five bespoke designs that will soon be available at select Live Nation Canada venues as concert attendees leave their favorite shows this fall.” This spirit of goodwill and collaboration was evident throughout the show floor, where many visitors commended the event for its vibrancy, energy and the sheer quality of the exhibits. “We didn’t quite know what to expect our first time at PACK EXPO Las Vegas, but we found the experience to be effective,” said says Jon Timbers, chief sustainability officer at insulation products manufacturer Epsilyte LLC of Woodlands, Tex. “We connected with value chain members that we normally don’t have a chance to connect with and discovered innovations, especially in sustainability, that we didn’t know existed,” he said. “We were pleasantly surprised.” Added Plastipak Packaging’s manager of marketing and business development Mary Mayled: “After years of being an attendee at PACK EXPO, making the decision to exhibit at PACK EXPO Las Vegas has brought us great value. “The Containers and Materials Pavilion was the perfect venue to showcase our capabilities,” she said, “and the show traffic exceeded our expectations. “We are planning to be back,” said

Mayled, echoing the general consensus among the show’s visitors. “I came to PACK EXPO Las Vegas to find new packaging and filling equipment and am excited by what I’m seeing on the show floor,” said Suzanne Dawis, vice-president of R&D at Bright Innovation Labs in Santa Clarita, Ca. “This might be the largest PACK EXPO I have ever attended. “It’s a well put-together event with a good representation of industry suppliers, which allows me to see so many solutions live and under one roof,” Dawis said. Notably, PACK EXPO Las Vegas was more than just a packaging and processing equipment and materials show—offering more than 130 educational sessions and plenty of networking opportunities. “I consult for a wide range of companies—from manufacturers of electronics to sealants to food and beverage CPGs,” said Kurt Ulmer, captain of a packaging design consultancy Crazy Contraption. “PACK EXPO Las Vegas is huge, all-encompassing, and a good place to network,” Ulmer stated. “I’m also here to see materials advances and find innovative solutions for sustainability—particularly lightweighting—and cost-savings in package design, and I a m very happy with what I have seen.” Another key highlight of the show came early on the second day of the event, when 750 industry professionals gathered for the Packaging and Processing Women’s Leadership Network (PPWLN) breakfast to hear the Canadian-born speaker Manjit Minhas, a renowned entrepreneur and founder of the Minhas Craft Brewery in Monroe, Wis., deliver an inspiring keynote address. “It takes coordination and participation from all parts of our industry to pull together an event of this size and caliber,” says PMMI’s vice-president of trade shows Laura Thompson. “We’re extremely grateful to all involved in making this show a record-breaking success. “The feedback from exhibitors and attendees is very encouraging, especially hearing success stories from both firsttime and long-time participants.” October 2023 · CANADIANPACKAGING

PRE-SHOW REPORT

SHOW AND TELL Upcoming national packaging exhibition to take center stage at the multi-disciplinary celebration of manufacturing excellence hile the wet and gray November may not be everyone’s idea of a perfect month, in recent years it has certainly become a permanent fixture in the calendars of Canadian packaging professionals anticipating of the next edition of PACK EX and other related industrial exhibitions grouped under the Advanced Design and Manufacturing (ADM) Expo show banner. Alternating each year between Montreal and Toronto, the show’s return to the Toronto Congress Centre next month, Nov. 7-9, 2023, promises to make ADM Toronto the Canadian packaging industry’s highlight of the year, as it has done so often in the past. Comprised of five co-located advanced manufacturing shows—PACK EX, Design & Manufacturing, Automation Technology Expo, PLAST-EX and Powder & Bulk Solids—the three-day event will definitely have something for everyone. According to the show’s organizers Informa Markets, “PACK EX is Canada’s only dedicated packaging event for suppliers and buyers to discover and engineer new technology. “ADM Toronto is the sourcing home for the widest array of packaging solutions in Canada across all verticals such as food and beverage, personal care, household, industrial and medical industries, among many others.” The expo floor will feature over 300 exhibitors, with top PACK EX companies including CAM Packaging Systems, Harpak-ULMA Packaging LLC, VC999 Canada, DIGI Canada Inc., Elmes Packaging Inc., Markem-Imaje, PLEXPACK Corporation, Whitebird and Tempo Flexible Packaging. In addition, the Canadian Food Innovation Network and PAC Global will be among Center Stage conference speakers, discussing topics that include plastics

CANADIANPACKAGING · October 2023

The Toronto Congress Centre building (above) will again be the host venue of the upcoming ADM Toronto exhibition next month, featuring PACK EX Toronto and four other related advanced manufacturing shows that have already attracted over 300 confirmed exhibitors between them.

use in the food sector and innovations in packaging. As always, the industry’s leading trade association PAC Global will host an expansive pavilion showcasing the winning packaging designs from the group’s recent global and Canadian award competitions, while also providing invaluable information on PAC Global’s authoritative packaging sustainability and education programs running throughout the year. This all-in-one, industry-wide event will let visitors explore the latest trends and technologies shaping the future in advanced design and manufacturing across automation, robotics, energy efficiency, packaging, plastics, processing and more to accelerate their business and career goals. From packaging design and materials to automation and turnkey packaging lines, PACK EX is Canada’s only dedicated packaging event for suppliers and buyers to discover innovation, engineer new technology, and build a better tomorrow. As the prime sourcing home for a full array of packaging solutions for the food and beverage, personal care, household, industrial, medical industries and more, the show will feature elite industry experts

displaying leading-edge solutions in: • Packaging Design; • Labeling; • Robotics & Automation; • Manufacturing Equipment; • 3D Printing; • Flexible Packaging; • Smart Manufacturing Systems; • Sustainable Packaging Solutions. This year, PACK EX Toronto will feature a series of focused product showcases displaying cutting-edge technology in automation, turnkey packaging lines and packaging design and materials—offering attendees a close look into the latest solutions and innovations advancing the manufacturing of packaging services and products. These will include:

TUESDAY, NOV. 7, 2027 12:00 - 12:15 pm Industrial Magnetics, Inc. Booth #323. Unlike anything the company has ever designed before, its new MTH (Mid-Tube Housing) incorporates two-inch-diameter rare earth tubes on four-inch centers into the innovative Drawer-In-Housing configuration for optimal ferrous metal CANADIANPACKAGING.COM