Canadian Packaging by Annex Business Media

MAY 2012 | $10

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Lee Tappenden, Chief Merchandising Officer, Walmart Canada Corp.

WHAT WALMART WANTS Retail giant staying the course with ambitious packaging sustainability agenda

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Story on page 23

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10.25”

15”

#GlassIsLife

MOMS KNOW GLASS CAN BE TRUSTED. Linus knows what tastes good. For his mom, Susanna Ko, foods packaged in glass are her first choice. “I’m very careful about what I feed my family,” she says. “When you’re eating food right out of the container, you want to know it’s safe. With glass, there’s just no question.” GlassIsLife.com

makers of food-loving, flavor-preserving glass packaging FOR MORE INFORMATION CIRCLE 101

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Sustainable Packaging for a Sustainable Future®

Atlantic Packaging Products Ltd. has been an industry leader in producing and supplying corrugated packaging using 100% recycled fibre. We were one of the first in North America to produce environmentally friendly 100% recycled containerboard and continue the tradition today with the recent addition of our technically advanced New Forest paper mill.

We have never cut down a tree.

Using our products not only provides you with quality packaging that meets the needs of your customers, but also demonstrates your company’s dedication to a sustainable future. Couple our Service Driven Commitment with our ability to provide products made from 100% recycled fibre and we give you the best of both worlds. Make purchasing decisions that not only have a positive impact for your company’s sales and bottom line, but decisions that truly make a difference!

Service Driven!TM

“Responsive to your needs” Atlantic Packaging Products Ltd.

Corrugated Division Scarborough-Progress Ave., Scarborough-Midwest Ave., Brampton, Mississauga and Ingersoll 416-298-8101 • 1-800-268-5620 • www.atlantic.ca Add Ink (Atlantic Decorated & Display) Toronto 416-421-3636 • www.addink.ca Color Pak (Pre-printed Linerboard) Toronto 416-298-5518 • 1-800-584-5817 • www.colorpak.ca Mitchel-Lincoln Packaging Ltd. Montreal and Drummondville 514-332-3480 • 1-800-361-5727 • www.ml-group.com FOR MORE INFORMATION CIRCLE 103

NEVER CUT DOWN A TREE.indd 1

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UPFRONT

MAD MEN AT WORK

VOLUME 65, NO. 5 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 Stewart Thomas • (416) 442-5600 x3212 SThomas@bizinfogroup.ca ADVERTISING SALES Munira Khan • (416) 510-5199 MKhan@canadianpackaging.com PRODUCTION MANAGER Kim Collins • (416) 510-6779 KCollins@bizinfogroup.ca CIRCULATION MANAGER Diane Rakoff • (416) 510-5216 DRakoff@bizinfogroup.ca EDITORIAL DIRECTOR Lisa Wichmann • (416) 442-5600 x5101 LWichmann@canadianmanufacturing.com EXECUTIVE PUBLISHER Tim Dimopoulos • (416) 510-5100 TDimopoulos@bizinfogroup.ca

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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, re-publish, 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 0008-4654 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) 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

COVER STORY 22

The Walmart Way By George Guidoni

WHAT WALMART

Walmart Canada’s new chief merchandising officer opens up about the retail giant’s ongoing pursuit of packaging sustainability as a key part of fine-tuning its vast global supply chain.

Cover photography by Cole Garside.

Retail giant staying

the course with ambitious Story on page 23

DEPARTMENTS & COLUMNS 5 6-7 8 10 12 35 36 37 38

UPFRONT By George Guidoni NEWSPACK Packaging news round-up. FIRST GLANCE New technologies for packaging applications. ECO-PACK NOW All about environmental sustainability. imPACt A monthly insight from PAC-The Packaging Association. NOTES & QUOTES Noteworthy industry briefs and updates. EVENTS Upcoming industry functions. PEOPLE Packaging career moves CHECKOUT By Rhea Gordon Joe Public speaks out on packaging hits and misses.

Lee Tappenden, Chief Merchandising Officer, Walmart Canada Corp.

WANTS

packaging sustainab ility agenda

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ferred option to a pound of cure, to borrow another time-tested adage, the ill-advised cuts could have devastating consequences not just for the Canadian consumers, but also for the Canadian food producers eager to expand their export markets, which just about everyone agrees is a fine and noble idea. Alas, that’s not going to happen unless potential new global customers can be completely assured of the safety and quality of food imports from Canada, and you just can’t provide that level of assurance when you’re planning to do things like: • Close down a CFIA-managed food lab in St. John’s, Nfld., which is responsible for sampling seafood and testing it for bacteria. Instead, the seafood is to be shipped directly to Dartmouth, N.S. for testing— disregarding the fact that with seafood’s shelf-life being 48 hours, a lot of that catch may simply not make it in time for testing or sale. • Cut the number of physical on-site inspections of many meat-processing facilities, which unfairly shift even more burden of responsibility onto the shoulders of meat producers themselves—raising their costs of production and, ultimately, consumer prices. • Remove CFIA from the process of verifying and validating nutrition claims on food labels—virtually leaving consumers with no recourse against wrong or misleading product claims. Whereas CFIA inspectors are specifically trained to evaluate the cholesterol and sodium levels across many food groups, few consumers have the sort of specialized knowledge or skillsets to make such accurate assessments on their own—leaving many Canadians with food allergies relying on little more than blind faith. For all the criticism that CFIA has taken over the years, right or otherwise, there is no denying that it performs a paramountly important function in safeguarding Canadians from nasty foodbourne disease outbreaks with potentially incalculable costs of human suffering and loss of public trust. Eroding that trust under the guise of fiscal responsibility would be a monumental step backwards for all the wrong reasons.

agreement #40069240.

MAY 2012

f the definition of insanity is indeed doing the same thing over and over again while expecting a different result, then the looming layoffs at the Canadian Food Inspection Agency (CFIA)—part of the federal government’s deficitcutting budget bulldozed through the House of Commons last month—is madness par excellence. One would think that after all the criticism leveled at CFIA for not being on top of things from the outset during the fatal listeriosis outbreak in 2008—resulting in 28 deaths and 35 serious illnesses by the time it was finally contained—the feds would know better than to knowingly undermine the country’s relatively efficient, but hardly infallible, food safety infrastructure. But with up to 100 inspector jobs rumored to be on the chopping block, and more than 200 other positions slated for elimination across the agency, the government’s credibility as a guarantor of public health and safety is fast-becoming stretched to the limit. While it could be argued that the 300-plus job cuts at CFIA and Agriculture Canada are a proverbial drop in a bucket in the context of an estimated 19,200 jobs that Ottawa aims to eliminate across the country’s entire civil service, that will do little to reassure the Canadian consumer public that it is not vulnerable to similar tragedies down the road, or that food safety in general is afforded the genuine commitment and scrutiny that it so clearly deserves. “It’s impossible to cut that many people and not affect food safety,” says Bob Kingston, president of the Agriculture Union of the Public Service Alliance of Canada (PSAC). Granted, there are no easy fixes when it comes to achieving serious federal deficit reduction, but compromising something as fundamentally important to Canadians as being able to trust the food they consume on everyday basis is ultimately asking for trouble, if not downright inviting it with open arms. With an ounce of prevention always being a pre-

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PACKAGING • PACKAGING

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FEATURES 14

COFFEE SHOP CONFIDENTIAL By George Guidoni Venerable Quebec coffee producer perks up its production and packaging competencies with cutting-edge industrial automation technologies. 18

JUST MILLING ABOUT By Andrew Joseph Iconic Quebec tissue products manufacturer steps into higher gear on its quest for meaningful carbon footprint reduction.

SAFE AND SECURE By Andrew Joseph Montreal-based flexible packaging converter leverages packaging innovation and strict quality control to maintain customer loyalty.

PROUD FOR RIGHT REASONS By Andrew Joseph Fresh-cut produce processor serves up a healthy mix of cutting-edge technologies and progressive management to grow its market share.

WWW.CANADIANPACKAGING.COM • 5

NEWSPACK

UNISOURCE BOOSTS CANADIAN PRESENCE

Leading packaging supplies and services provider Unisource Worldwide, Inc., has significantly expanded its Canadian operations with the opening of a new, 118,000-square-foot full-service facility in Edmonton last month to support growing demand for the company’s diverse product range—also including commercial printing and business imaging papers, wide-format equipment and media, and facility supplies and equipment—in northern Alberta. “This new warehouse and office facility positions Unisource Canada to better service our customers’ needs in the Alberta market with access to the best products from leading manufacturers,” says Unisource Canada president Dan Barbagallo. “At a time when others in2:23 ourPMindustry ReiserPkg_Food_v2012_CP_J_Reiser 3/28/12 Page 1 seem to be reconsidering their commitment to the demanding Alberta market, we remain bullish on

the future of all our core business units, which include paper, packaging, facility supplies and logistics,” says Barbagallo, adding Unisource plans to gradually increase product offerings and inventory levels at the new warehouse more than five-fold. According to Unisource, the new Edmonton distribution center (DC)—equipped with a state-ofthe-art warehouse management system (WMS), 22 receiving/shipping doors, and an environmentally-friendly motion-sensitive lighting system—is expected to be a fully-operational warehouse by June, with sales offices to be completed by mid-summer. The new facility—replacing a smaller 25,000square-foot local warehouse that received most of its inventory from Unisource’s 250,000-square-foot

DC in Calgary—will offer customers direct service capabilities out of the Edmonton, with its own Big Red fleet of tractortrailers (see picture) providing regular service to the fast-growing Fort McMurray oil sands development region, located about 450 kilometers northeast of Edmonton. “Having our own f leet of trucks in this region provides Unisource with an even greater ability to provide dedicated and reliable transportation, increase service levels, and control costs,” says Unisource Worldwide supply chain president Jeff Rudy. “This is also an opportunity for our customers to take advantage of our world-class logistics network,” says Rudy, adding the multi-truck fleet will deploy advanced logistics technologies such as GPS monitoring, RoadNET routing and real-time delivery data.

SIX-PACK WRAPS TO BEAT THE HEAT

Innovative packaging solutions in every shape and size. At Reiser, we offer a variety of packaging solutions designed for all types of food products and applications. From Repak form/fill/seal machines to to Supervac vacuum chamber equipment to Ross modified atmosphere tray sealers, Reiser is the one source for all your packaging needs. Join other satisfied customers that trust Reiser to deliver the perfect solution. For more information, call Reiser at (905) 631-6611.

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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 2012

Leading the food industry in processing and packaging solutions.

With hot summer months finally upon us, Toronto-based Steam Whistle Brewing is again using its renowned packaging savoir faire to help Canadian beer-lovers beat the heat with a cold one by shielding the 355-ml cans of its f lagship Steam Whistle Pilsner beer from the sun with a new paperboard carton that makes a perfect fit for outdoor activities like camping, golfing or hanging around the barbecue grill. Designed by the brewer’s inhouse art director Elton Clemente, the new Steam Whistle six-pack replaces traditional can carriers with a wraparound carton— converted by the Concord, Ont.based Printing Technologies Inc. (PTI) and pre-glued at a Cascades Inc. plant in Vaughan, Ont.—featuring a built-in carrying handle and sturdy end-panels to ensure pack stability, while offering a side peep-show of the signature green aluminum cans inside, manufactured at a Crown Metal Packaging’s Toronto plant. “This handy six-pack carrier makes for warm weather convenience for premium beer drinkers while providing added protection for beer,” says Steam Whistle’s co-founder Greg Taylor. As Taylor explains, beer and other beverages quickly lose their fresh taste when exposed to sunlight due to a chemical reaction that produces a substance called Mercaptan—giving off a “skunky” aroma regardless of the glass bottle’s color. But with paperboard wrap protecting most of the cans’ surface area, “Beer drinkers can enjoy a safer and troublefree beer drinking solution after summer activities without having to worry about glass breakage,” Taylor states.

CANADIAN PACKAGING • MAY 2012

NEWSPACK

CASCADES RESTRUCTURING ITS CANADIAN CORRUGATED ASSETS Leading Canadian paperboard and tissue products group Cascades Inc. says it will spend $30 million to modernize four Ontario-based corrugated plants operated by its Norampac division—while also shutting down three older facilities—as part of the company’s ongoing consolidation of its manufacturing assets. The Kingsey Falls, Que.-headquartered Cascades says it will carry out a series of capital upgrades at the Norampac operations in Vaughan, St. Mary’s, Etobicoke and Belleville, which will also absorb extra production capacity to be transferred there from the mothballed Norampac facilities in North York (Toronto), Peterborough and Mississauga. “The purpose of this restructuring is to optimize the productivity in our corrugated product plants in Ontario and enhance customer service,” explains Norampac president and chief executive officer Marc-André Dépin. “These steps are in line with our regional development strategy, which includes the recent acquisi-

tion of three Bird Packaging plants,” says Dépin, adding the restructuring is part of its parent company’s ongoing drive to improve the group’s profitability in a fiercely competitive market through consolidation and equipment modernization. “We are investing for the future by taking the necessary measures to strengthen our leadership in the market and demonstrate our commitment to our clients,” Dépin states. “The Vaughan, St. Mary’s, Etobicoke and Belleville plants have the ideal infrastructure in which to incorporate new equipment with cutting-edge technology, ranking them among the most competitive in Canada. “These investments will enable us to provide clients with a wider variety of packaging products, increase the speed of execution and improve the quality of our products and services,” adds Dépin, citing the high Canadian dollar as one of key factors behind the decision to discontinue operations at three locations. According to Norampac, many of the 200 employ-

ees to be affected by the three closures will be offered positions with other Norampac operations in the province. “The decision to close the OCD, Marc-André Dépin, North York and President & CEO, Peterborough plants Norampac. can be explained by a decrease in demand in the Canadian and North American corrugated products industry dating back to the beginning of the recession, as well as the large number of Norampac converting plants in Ontario,” says Dépin. “These factors, combined with adverse economic conditions, have forced us to restructure our assets in order to be more competitive,” says Dépin, adding the three plants will cease operations before the end of 2012.

INTERACTIVE JUICE-BOX CARTONS RUNNING UP THE SCORE FOR RECYCLING With soccer’s popularity continuing to skyrocket among Canada’s youth, paperboard packaging supplier Tetra Pak Canada Inc. has teamed up with leading Quebec juicemaker A. Lassonde Inc. to transform the 200-ml Oasis brand juice boxes into video game controllers letting users take part in an interactive online Oasis All-Stars soccer match. Launched as part of a national marketing campaign aimed at prolonging consumer engagement and enhancing brand loyalty, the redesigned juice boxes feature proprietary technology developed by Montreal-based animation software designers Augmented CPG, which enables the Oasis All-Stars juice-box game controllers to connect directly to the game with a webcam to play and interact with the game’s soccer star Nico. The participating player can select one of three game modes and act as a goalkeeper by using the fully-recyclable Oasis paperboard juice box—a 200ml Tetra Brik aseptic beverage carton decorated with promotional graphics designed by DraftFCB—to control the goalkeeper’s hands and to save shots from Nico. Throughout the game, Nico interacts with the players—encouraging them to stay active and to recycle the Oasis Classic, Oasis FruitZoo and Oasis Fruits juice boxes after use. “Over the past year-and-a-half, we have worked closely with A. Lassonde Inc. and Augmented CPG to develop an innovative technology that allows us to create a unique and engaging brand association for Oasis fruit juice and Tetra Pak juice boxes that is fun for the whole family,” says Tevfik Djamgouz, marketing manager at the

Richmond Hill, Ont.-based Tetra Pak Canada. to work with customers like A. Lassonde to help “We take pride in our customer relaCanadians understand the sustainable benefits of tionships and we collaborate with carton packages. them to develop innovative solutions “Through Oasis All-Stars, players are continulike the juice-box joystick … that are ously reminded to recycle their juice-box cartons Canadian catPackaging, 133 x 203 CC-en24-AZ033_04_12 meaningful toFlexiFruit, their marketing after they aremm, finished playing with it,” Djamgouz egory and consumer needs.” concludes. The on-pack marketing campaign is also being supported by instore promo trays and displays, on-shelf media, web media and a new dedicated microsite at www.oasissoccer. com “Given that soccer is the Number One sport for children aged five to 14 years in Canada, we designed an interactive soccer-focused game that is fun for the whole family,” says Luc Prevost, vice-president of marketing at the Rougemont, Que.-headquartered A. Lassonde. “By incorporating augmented reality onto our Oasis 200-ml juice boxes, Canadian families can have a unique experience while enjoying an Oasis 100-percent juice.” Adds Djamgouz: “It is important for us

krones FlexiFruit – doses fruit

chunks as if they’re hand-picked. www.krones.com

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FIRST GLANCE UNCOMMON TOUCH The new EZx 465 Touchless X-ray system from Thermo Fisher Scientific Inc. is engineered to enable users to eliminate the need for the heavy-lead or no-lead shielding curtains typically used to block radiation, while still complying with all the global safety standards, by conveying the product through the inspection chamber via a series of small slopes, while deploying an aperture with reduced height to ensure that X-ray scatter does not escape from the inlet or outlet areas of the system. Especially well-suited for lightweight and open-container food product contaminant detection— such as metallized snack-bags or unwrapped frozen meals in foil trays—the EZx 465 Touchless X-ray system is available with a commonly-used 400-mm-wide belt featuring a slightly tacky design that ensures products stay in place during the slight upward and downward slopes, according to the company, offering maximum speeds of up to 100 meters per minute for inspecting products measuring up to 65 mm in height. Thermo Fisher Scientific Inc.

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FEATHER IN THE CAP Claimed to be the first linerless plug closure for extended shelflife (ESL) and aseptic beverage packages, the new Steri-Shield 38-mm closure from Portola Packaging, Inc. is engineered to create an effective cap-to-bottle seal without using a liner for a wide-range of aseptically-filled beverages such as juices, isotonics, dairy, energy drinks, milk, vitamin waters, drinkable yogurt, teas, etc., while allowing brand-owners to achieve effective product differentiation with the cap’s tall profile. According to Portola, eliminating the need for using TPE (thermoplastic elastomer) or foil liners to achieve full seal integrity for both low- and high-acid beverages will enable end-users to minimize packaging costs and to achieve significant material source reduction. The lightweight closure is engineered to withstand an aseptic sterilization environment of up to 140ºF, as well as all the rigors of product transport and distribution. Portola Packaging, Inc.

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SHARP LOOKS The new Hawk Evolution vertical form-fillseal (VFFS) machine from Sharp Packaging Systems features a remarkably small footprint for a machine capable of filling bags as large as 12-incheslong and 18-inches-wide, while incorporating a double-stack, maintenancefree Kollmorgen stepper motor designed to run for hundreds of millions of cycles with little to no maintenance, according to the company. Designed to accommodate three commonly-used bag styles— gusseted bags; pillow bags typically used for potato chips and other snack products; and f latbottom bags used for one-pound coffee packages—the Hawk Evolution machine can run and

8 • WWW.CANADIANPACKAGING.COM

seal just about any polyethylene, laminated or metallized film, or foil structure used in candy, nuts, frozen-food, pet-food, fresh produce, soup and gravy mixes, coffee and pharmaceutical packaging applications. Sharp Packaging Systems

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PLANETARY QUEST The newly-developed planetary screw assemblies from Bosch Rexroth were engineered specifically to provide a cost-effective electromechanical solutions for a growing range of intermediate and heavy engineering applications such as pressing, machine tools and plastic injection-molding machines, according to the company, to facilitate high-speed movement of heavy loads with much quieter and more compact design than comparable ball screw assemblies. Contrary to ball screw assemblies, where the balls are continuously fed back through the return passage into the load-bearing area, the planetary bolts rotate inside the nut to ensure smooth running and low noise emissions, while Rexroth’s patented sealing technology also enables much longer lubrication intervals to achieve notable reduction in lubricant consumption and overall maintenance requirements. Initially offered in screw diameters of 20-, 30and 48-mm, and leads of five- and 10-mm, the ready-to-install planetary assemblies optimize their numerous contact areas to achieve high axial rigidity and load bearing capacity, along with a high level positioning and reproduction precision. Bosch Rexroth Canada

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ON THE DOUBLE The new combination filler from Spee-Dee Packaging Machinery, Inc. features threefiller configuration incorporating a Spee-Dee Servo 3600 auger filler with two volumetric cup fillers to address a broad range of tricky applications involving the filling of two particulates and a powder within a single pouch—soup and baking mixes, pasta and other side dishes, cereal products and convenience foods, etc.—at rates of up to 120 units per minute. According to the company, the use of a continuous-motion VFFS (vertical form-fill-seal) in place of a horizontals FFS machine enables the combination filler to improve cycle times and minimize the amount of production space required for the manufacturing process, while enhancing product quality through more efficient blending of the ingredients. Spee-Dee Packaging Machinery, Inc.

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FEEDING TIME The new servo-operated OMNI-Feeder system from Omega Design Corporation is a variable-speed feeder for desiccant and oxygen absorbers that accommodates both canisters and pouches, according to the company, at throughput speeds up to 300 units per minute. In addition to inserting canisters or pouches into rigid bottles, the equipment can be easily adapted to dispense

desiccants and oxygen absorbers into various packaging solutions, including medical diagnostic kits and medical devices, while also being able to execute multiple desiccant drops per bottle and to run different-sized canisters and pouches. Requiring less than five minutes for changeover, the fully-automatic feeder incorporates an AllenBradley programmable logic controller (PLC), a touchscreen operator interface terminal and a light-tower status display, along with anodized aluminum frame construction and a small-footprint design featuring a fixed inner belt with an adjustable outer rail assembly. Optional features include variable-speed drives, a remote canister bulk-feeding system, analog speed controls and timing screws. Omega Design Corporation

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FILL TO MEASURE The new Monobloc filling-and-capping systems from Filamatic are designed to perform a wide range of tasks such as sorting, feeding, filling, plugging, stoppering, crimping, capping, induction sealing, labeling, accumulating, etc., across a broad range of pharmaceutical and cosmetics industry applications. Offered with a variety of liquid metering systems to provide a are available to provide a fill volume range from 0.5-ml 500ml—while handling a wide range of viscosities from free-f lowing to viscous products—all Filamatic Monoblocs are digitally-controlled with menu-driven programs that electronically adjust operating parameters for quick-and-easy, toolless changeovers to accommodate a wide assortment of liquid products to be filled into microtubes, cryovials, glass vials, and various plastic containers. Filamatic (Div. of National Instrument, LLC)

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TAKING SIDES The new VDR-1AXIS labeling system from Labelling Technologies is capable of printing and applying labels to two adjacent sides, just one side (front or side), or around the corner of shipping cases, wrapped trays, pails and pallets, according to the company, to ensure bull GS1 standard product traceability compliance. Fully compatible with Zebra, Datamax and SATO print engines and thermal printers, the systems is designed for reliable, consistent and high-accuracy application of product labels onto the GS1recommended locations on all sorts of packages, and is supplied as a turnkey solution that includes the equipment mounting, installations, startup and all the pertinent training of operators and maintenance personnel. Labelling Technologies

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CANADIAN PACKAGING • MAY 2012

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ECO-PACK NOW

ACCESS TO PLASTIC RECYCLING GROWING ACROSS CANADA The vast majority of Canadians can easily recycle most of their used rigid plastic packaging through existing municipal recycling programs, says a new study commissioned by the Mississauga, Ont.-headquartered Canadian Plastics Industry Association (CPIA). According to the Residential Recycling Access for Consumer Plastic Packaging report prepared by CM Consulting, “An increasing number of Canadians have access to recycling many different forms of plastic packaging, including nearly country-wide access to plastic bottle recycling (over 95 per cent) and 91-percent access to recycling of household tubs and lids used for yogurt containers and other dairy products—up from 88 per cent in 2009.” The report also cites a three-percent rise in access

to recycling of PET (polyethylene terephthalate) non-bottle rigid packaging such as trays or bakery clamshells since 2009— with 76 per cent of Canadians now being able to recycle these materials at home—as well as a seven-percent rise in access to the recycling of foamed polystyrene used in food packaging. Moreover, the access to recycling of expanded polystyrene protective packaging has more than doubled across Canada since 2009 from 12 to 31 per cent, CPIA reports. “We believe that recycling access for foam polystyrene has risen significantly due to advances in affordable technology which can compact the foam material, thereby reducing its volume and improving cost-to-ship to recyclers,” says CPIA vice-president Cathy Cirko. While access to recycling of plastic shopping bags

MOLDED-FIBER BOTTLES FUEL GENERATION GAP Sustainable packaging solutions may not at first provide a perfect match for every product’ needs, but with little faith and innovation they can often turn an entire product category on its head. Which is how it’s been for Seventh Generation,

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Burlington, Vt.-headquartered manufacturer of all-natural liquid laundry detergents, dishwash liquids and household cleaners that has successfully employed innovative, breakthrough molded-fiber bottles to sell its products to green-minded consumers in the U.S. and Canada. Produced by the Oakland, Ca.based Ecological Brands, headed by Canadian-born president Julie Corbett, the 1.47liter bottles of the company’s 4X concentrated laundry soap are quickly becoming a bestseller at a growing number of leading Canadian retailers— including Loblaws, Fortino’s, Zehrs, Canadian Tire, Zellers, Metro and London Drugs. “It really seemed like an absurd idea to put laundry detergent in a paper bottle, but absurd ideas often bring innovation to the forefront, and we really do consider ourselves to be innovators at Seventh Generation,” says the company’s director of packaging Peter Swaine. “We

and other films is currently estimated at 56 per cent, these statistics do not account for the increasing number of retailers providing their own instore bag recycling programs, CPIA notes. “Plastic bags are accepted at many retail locations across the county, so the opportunity to recycle these is likely significantly higher than 56 per cent,” states the report, which was based on ‘virtual’ online visits to nearly every municipal recycling program in Canada to track which plastic materials were accepted in the existing municipal curbside, depot dropoff, beverage container redemption or curbside subscription programs. Says CPIA president Carol Hochu: “We are very pleased that so many Canadians have access to plastics recycling in their communities. “We will continue to work with stewardship agencies and municipalities across Canada to help increase awareness so that more people will recycle—diverting valuable plastic resources and supporting our recycling industry.”

have experienced record sales for this new product and packaging in Canada.” Available in 32-, 50- and 64-ounce sizes, the so-call eco.bottle line of containers introduced by Ecologic Brand in 2008 can also be used to package a wide array of other consumer liquid and dry food-grade products, according to Corbett. “Our goal is to give consumers and brands a choice when it comes to packaging,” she says. “There are hundreds of brands of liquid laundry detergent, but only one viable packaging option, plastic, until now,” Corbett says. “The demand for our bottles from brands around the world has been humbling, and it and confirms the need for differentiated and more sustainable packaging options. “We aim to replace rigid plastic and glass bottles in laundry detergent, home cleaning, dairy and juice, cosmetics, nutraceuticals and many other product categories. “The possibilities are endless and we are approached almost daily with new requests,” says Corbett, adding that switching to the eco.bottle packaging last year helped Seventh Generation 4X laundry detergent to become one of 10 bestselling detergents in the natural grocery channel in the U.S. “The Ecologic Brands bottles accommodate a range of film substrates and fitments suitable for various categories, including food and beverages, household cleaning products, healthand-beauty, nutraceuticals, chemicals, and even milk and powders,” Corbett adds, citing a recent in-store test at a Whole Foods outlet in Oakland that saw the sales of Straus Family Creamery’s organic nonfat milk soar by 72 per cent within a year of switching to eco.bottle containers.

CANADIAN PACKAGING • MAY 2012

Great Products Deserve the Best Labels. Primera has everything you need to produce gorgeous, full-color labels for your products. LX900 Color Label Printer

CX1200 Color Label Press and FX1200 Digital Finishing System The CX1200 Color Label Press delivers short to medium-run, full-color digital label printing at a breakthrough price. Utilizing one of the fastest and highest-resolution color laser engines available, CX1200 delivers the quality, speed and flexibility of digital presses costing many times more. Add Primera’s new FX1200 Digital Finishing System to laminate, die-cut, remove waste matrix, slit and rewind. Call Primera at 1-800-797-2772 www.primeralabel.com

The LX900 Color Label Printer is Primera’s newest, fastest and most economical to operate color inkjet label printer. Features include print speeds of up to 4.5" per second, individual ink cartridges and up to 8.25" media width. You’ll save time and money on every label you print! Call Primera at 1-800-797-2772 www.primeralabel.com

LX400 Color Label Printer

Introducing Primera’s CX1000 Color Label Printer. Save Time and Money by Printing Your Own Product Labels.

LX400 is Primera’s most affordable desktop label printer. It has a convenient single-cartridge ink system and up to 4.25" maximum print width. With LX400 you’ll be able to print highly professional full-color labels for all of your short-run products, helping you to sell more! Call Primera at 1-800-797-2772 www.primeralabel.com

Label Applicators

Primera’s AP-Series Label Applicators are the perfect semi-automatic labeling solution for cylindrical containers as well as many tapered containers, including bottles, cans, jars and tubes. See how fast and easy it is at www.primeralabel.com/videos. Call Primera at 1-800-797-2772 www.primeralabel.com

Label Supplies

Primera offers ink cartridges and a large selection of stock label sizes in various shapes. Need a quote on a custom label size? Just complete our custom label form on www.primerastore.com. Call Primera at 1-800-797-2772 www.primeralabel.com

Now you can print your own high-quality product labels in-house. CX1000 is 100% digital, saving you significant time and money. It prints at 2400 dpi with waterproof, highly UV-resistant toner, making your products look their best.

Call 1-800-797-2772 (USA and Canada) or +763-475-6676 for details and sample printed labels. Email to sales@primera.com or visit us at www.primeralabel.com.

©2012 Primera Technology, Inc. Primera is a registered trademark of Primera Technology, Inc. All other trademarks are the property of their respective companies. Content used in sample outputs is fictitious.

FOR MORE INFORMATION CIRCLE 108

ACCESS THE GLOBAL PACKAGING NETWORK ACCESS THE GLOBAL PACKAGING NETWORK

Watch for PACed Online Courses - Coming Summer 2012

PAC PACKAGING CERTIFICATE PROGRAM

2012 FALL

Packaging Certiﬁcate Program If you are a supply chain executive who has taken on a new responsibility or a relative newcomer to the industry, then this course is targeted for you. Up to 25 classmates – buyers, sellers, marketers, technicians, engineers and designers will network and work diligently learning the essentials of packaging. So sign up today and get yourself, Refreshed and Re-Energized for a successful year ahead. The Packaging Certificate Program is offered throughout the fall of each year with each three day course equating to three credits. To graduate from the Packaging Certificate Program twelve credits are required, earned by taking courses 1, 2, 3 & 4 of the education program.

A flexible program The four-course, twelve day certificate program can be taken either: • sequentially in one term over four months, or • in a random order over an extended period

Focus by topic Any of the certificate program courses can be taken individually according to your area of interest.

Course times: 8 AM – 4 PM daily. Continental breakfast and lunch included.

Full four course certificate program

Sustainable Packaging Conference VI

Member: $3,295 + HST per person Non-member: $4,295 + HST per person

Next steps Access the Global Packaging Network

Or take course(s) individually

Member: $995 + HST per course Non-member: $1,235 + HST per course

Accéder au réseau mondial de l’emballage

By professionals for professionals Courses are led and developed by renowned packaging industry experts: Derek Whitney, PAC Course administrator and lecturer, Packaging Program. Coordinator at Mohawk College with extensive industry experience. Paul Waller, Major contributor to and lecturer for Course 2, plastics. Packaging expert consultant, published in several trade journals.

Conference Agenda Walmart Canada Sustainability update – Shelley Broader, President and CEO, Walmart Canada Sustainability Index update – Fred Bedore, Senior Director Sustainability, Walmart Corporation Update on 2013/2025 Goal – Buy, Move, Sell – Guy McGuffin, VP of Sustainable Packaging, Walmart Canada Buy, Green Procurement – Moderated by Leon Hall, Manager of Sustainable Packaging , Walmart Canada Corp. ● Kimberley Clark –

Skip (Ed) Krasny

● Coca-Cola – Scott Vitters ● Johnson & Johnson – Mike Maggio, VP, Global Engineering

The only comprehensive course in North America that includes at least one plant tour with each course.

Walmart Sustainable Packaging Award – presented by

Guy McGuffin, VP of Sustainable Packaging, Walmart Canada PAC/Walmart/P & G Student Design Award – presented by Keith Fanta and Susan Nieuwhof, P & G

Certiﬁcate program courses - Each course is three days in duration, including plant tour.

Move, Supply Chain Innovation – Moderated by Guy McGuffin ● Walmart Supply Chain SVP – Andy Ellis

Course 1 - Sept. 18, 19 & 20

Course 2 - Oct. 16, 17 & 18

Course 3 - Nov. 13, 14 & 15

Course 4 - Dec. 4, 5 & 6

Graphic Design, Printing,

Packaging Polymers, Sheet

Paperboard & Folding

Corrugated, Distribution, and

Digital Printing, Printing

& Film Extrusion, Flexible

Cartons, Specialty Packaging, Machinery, Packaging Law,

Prepress, Bar Codes, Food

Packaging, Injection Molding,

Closures, Specialized

Quality Management Systems

● Sustainable Packaging Coalition – Adam Gendell

Safety, Food Preservation,

Blow Molding, Bottle Design

Packaging, Adhesive and

and Planning a Production

HACCP, Labels and

and Bio Plastics. Three days

● City of Toronto – Vince Sferraza

Introduction to Sustainable

Line. Three days including a

Perspectives on Packaging.

including a plant tour.

Packaging. Three days

plant tour.

● Progressive Waste Solutions – Geoff Rathbone

Three days including a plant

including a plant tour.

● Sealed Air – Ron Cotterman

Sell, End-of-Life Strategy – Moderated by Christian Shelepuk

Lee Tappenden, Chief Merchandising Officer, Walmart Canada

tour.

For more information contact Lindsey Ogle at 416.646.4641, logle@pac.ca or register at www.pac.ca.

12 • WWW.CANADIANPACKAGING.COM

CANADIAN PACKAGING • MAY 2012

ADVERTORIAL

SUPPLIER ALIGNMENT:

Making the best choices for your business In today’s business world, vertical integration and industry consolidation have made it tough to tell friend from foe.

By Mark Lichtblau

In the worst-case scenario, that new owner is a direct competitor.

The risks in such a situation are considerable: Complex ownership structures can easily in addition to potentially compromised disguise a supplier’s true ownership. And product recipes, confidential customer whether that disguise is intentional “Whereas previously information is now in the or not, it leaves the door open for hands of a rival. a supplier worked to a company to develop a business If your film supplier has relationship that may not be in its enhance a customer’s been acquired, or could best interests. be acquired, be sure to This is a particular concern in the packaging and plastics industries, which over the last decade have seen substantial consolidation. As noted in a 2011 Plastics Today article, “more than half of the top 50 packaging companies have been eliminated or changed ownership over the past decade.”

business by aligning with its goals and objectives, its new owner may have a different approach.”

The volume of consolidation has been particularly large in the last two years. In this drastically different landscape, companies that were previously only printers, converters or extruders are merging into multi-divisional packaging companies. This can create a sudden, and potentially detrimental, change in dynamic for a supplier/customer relationship. Whereas previously a supplier worked to enhance a customer’s business by aligning with its goals and objectives, its new owner may have a different approach.

take a close look at the implications this may have for your business.

One surefire strategy to avoid a conflict of interest is to deal with an independently owned supplier. Haremar Plastic has been working to grow and enhance its customers’ businesses since 1965. If you’re looking for a film supplier who wants to partner with you in growing your business — without competing for your marketshare — give us a call. As an independently owned company, we have built our business around supplying a product that makes your operations more productive and more competitive. We want to see you succeed. We promise. Mark Lichtblau is corporate vice president of Haremar Plastic Manufacturing Ltd.

Grow with Haremar At Haremar, building your business is a family affair Born out of the El-En Packaging Company, co-founded by Saul Lichtblau in 1965, Haremar Plastic Manufacturing started out as a 5,000-foot facility with just two extruders. Today, the Haremar manufacturing facility in Vaughan, Ontario, is a state-of-the-art affair, spanning almost 140,000 square feet and housing 10 production lines. Almost 50 years have passed, but the beating heart of Haremar remains the same. The company has had the same president, Fela Lichtblau, for 45 years and the same VP of operations for 25 years. Mark Lichtblau has been at the helm as corporate VP since 1995. The company’s rise from local operation to world-class facility has been fueled by a simple mantra handed down from Saul Lichtblau: “We succeed through our customers’ success.” Every major change Haremar has undergone has been sparked by customer need: a better building to house customer product, better machinery to enable innovation, and a bigger, better team to enhance customer service. What does that mean for you? A proudly independent, fiercely innovative and exceptionally loyal company dedicated to your success.

HAREMAR PLASTIC MANUFACTURING

FOR MORE INFORMATION CIRCLE 109

Haremar Plastics Manufacturing Limited 200 Great Gulf Drive | Vaughan, ON Canada L4K 5W1 Tel: 905.761.7552 | www.haremar.com

HAREMAR PLASTIC MANUFACTURING

PRODUCT ID NOW

Jean-Francois Vallée, Engineering & Maintenance Director, GMCR Canada Group L.P.

COFFEE SHOP CONFIDENTIAL Famed Quebec coffeemaker perks up its manufacturing prowess with world-class automation technologies and packaging know-how

BY GEORGE GUIDONI, EDITOR PHOTOS BY PIERRE LONGTIN

igh-speed robotics and highly-automated production and packaging may not be everyone’s cup of tea, but it’s proving to be just the perfect blend of shopf loor brains and brawn for a venerable Quebec coffee producer nowadays finding itself caught up in a fiercely competitive, high-stakes global marketplace. Founded in Montreal in 1919 by a French-born emigrant Albert-Louis Van Houtte as a specialty

14 • WWW.CANADIANPACKAGING.COM

grocery store, the company quickly sprang to local business prominence as a highly reputed supplier of gourmet, European-style roasted coffee—setting a solid foundation for decades of continuous business growth that made the Van Houtte coffee brand a household name for millions of Canadian coffee aficionados and connoisseurs right across the province of Quebec and throughout much of western Canada. After a rapid expansion of the company’s bistro business during the 1980s and a well-executed series of strategic acquisitions in 1990s made it one of

the country’s elite coffee processors and distributors, Van Houtte entered the 21st Century as a highly prolific, fully-integrated coffee company with a big presence in Quebec’s OCS (office coffee service) segment, a thriving chain of bistro-style cafes throughout Quebec, and a Canadian customer base estimated at over 60,000 offices, cafeterias, grocery and convenience stores, restaurants, hotels and other places of employment. With growing market share and exceptional brand loyalty making it an increasingly attractive investment proposition, the company was ultimately acquired by the Vermont-based Green Mountain Coffee Roasters, Inc. (GMCR) for a staggering $915 million at the end of 2010—setting stage for a healthy inf lux of capital investment from the new owners into Van Houtte’s two production facilities in Montreal, as well as a Torontobased Timothy’s plant also acquired by GMCR in 2009. “It is a highly competitive global business where you really need to have both product innovation and good process automation to succeed,” says Jean-Francois Vallée, engineering and maintenance director at the central Montreal production facility now operating under the GMCR Canada Group L.P. as GMCR’s CBU (Canadian business unit) manufacturing enterprise. Having joined the Montreal facility in January of 2006, Vallée is mandated with carrying out prime responsibilities for the specification, selection, installation, and integration of all of the plant’s

CANADIAN PACKAGING • MAY 2012

PRODUCT ID NOW processing, packaging, facility management, HVAC (heating, ventilation and air-conditioning) and other key systems and equipment deployed at the Montreal operations. Naturally, it’s a job that keeps Vallée and his highly-skilled teams of engineering and maintenance technicians busy throughout the year. “There’s always something that needs to be done,” says Vallée, who is also mandated to look after the equipment and systems employed at the smaller GMCR’s CBU plant in a nearby St-Laurent suburb, two distribution centers occupying over 140,000 square feet of warehousing space between them, and the administrative offices. Built in 1992, “this Montreal plant is a fairly big facility that has been already expanded a couple of time since then,” says Vallée, relating how Van Houtte took over the once-shared industrial park complex in four stages to become its sole, but extremely active, tenant. The 115,000-square-foot Montreal facility—currently employing about 350 people (with another 15 at the St-Laurent plant)—has been a grateful beneficiary of an extensive inf lux of cutting-edge, automated packaging and material handling systems to achieve the highest performance and productivity levels possible, according to Vallée. “You simply cannot afford to do jobs like casepacking, palletizing, packaging and just generally moving the stuff around manually any longer,” Vallée told Canadian Packaging in a recent interview.

Speed is King “Now that we are competing on an international stage, optimizing our production line speeds and capacity on ongoing business is essential for us to remain competitive, and GMCR is very proactive in investing in the latest automated processing and packaging technologies to ensure our plant remains competitive well into the future,” says Vallée, citing the plant’s strictly-observed Lean Manufacturing manufacturing regimen and ambitious SQF (Safe Quality Foods) targets and guidelines. “The Van Houtte name has long been a very popular product brand in both Canada and some areas in the U.S. northeast,” says Vallée, “and joining a company like GMCR, which also owns some of the best-known coffee products and coffee brewer appliance brand names in the U.S. (including Green Mountain, Keurig, Tully’s and Diedrich, as well as Timothy’s in Canada) will certainly help us grow that name recognition right across North America,” Vallée states. “We are playing in the big leagues now, so it is very important for us to stay focused on working to achieve superior product innovation from our research-and-development and marketing people, along with optimal manufacturing performance and top customer service from our logistics operations. “It is a tough task and a never-ending challenge, but with the world-class manufacturing capabilities we are acquiring under new ownership, it is a challenge we can definitely rise to,” says Vallée. “We take a lot of pride in what we do and make here in Montreal, and I think that pride really shows in the quality of our final product and the way it is packaged,” he states. The staggering number of broadly diverse coffee products produced at the plant—approximately 800 stock-keeping units (SKUs), including about 600 ground products—is as a defining testament to

MAY 2012 • CANADIAN PACKAGING

A food-grade FlexLink conveyor whisking a row of single-serve K-Cup packs past a Domino D-Series laser coder below.

the Montreal operation’s product innovation savoir faire as is the comprehensive range of packaging formats used to deliver the products into customers’ hands: including all sorts of bags, pouches, cans and, most notably of late, the single-serve K-Cup packs, which Vallée says are now the fastest-growing segment of the coffee industry. Originally invented in 1990 by Reading, Mass.based Keurig, now also a wholly-owned GMCR subsidiary, the so-called K-Cup packs—designed for quick brewing of a single cup of coffee, tea, hot chocolate of other hot beverage in singleuse lidded containers—is all the rage in the North America, Vallée explains, because of the unfolding trend towards quick, on-the-go beverage consumption with convenient, consumerfriendly packaging and a broad choice of coffee varieties, f lavors, and roast and blend options. While some companies have since introduced their own single-cup products, Vallée says that having Keurig operated within GMCR provides the

Montreal CBU with a massive competitive advantage in terms of brand recognition and authenticity, as well as numerous business synergies. “Our K-Cup pack volumes have been growing in the double-digits for years,” he points out.

Lining Up Offered in about 200 different SKUs, the K-Cup packs produced at the Montreal plant now have about half of all of the plant’s packaging lines dedicated exclusively to their production—all periodically with all these lines continuously upgraded to achieve higher processing speeds, according to Vallée, without compromising the plant’s stringent quality standards. Having the plant’s many packaging lines and all the end-of-line packaging operations equipment work in perfect tandem requires a lot of sophisticated software and IT (information technology) engineering, which the Montreal facility has exeContinues on page 16

A Domino model A220 small-character CIJ printer applies highly legible, multiple text and product code lines onto the round sides of the round plastic K-Cup packs making their way to the case-packing stations.

WWW.CANADIANPACKAGING.COM • 15

PRODUCT ID NOW COFFEE SHOP CONFIDENTIAL Continued from page 15 Jean-Francois Vallée shows off the flawlessly-etched permanent product code generated onto a product label by one three Domino scribing lasers employed at the Montreal facility.

cuted brilliantly by standardizing all the equipment on Rockwell Automation’s Allen-Bradley manufacturing systems platform. All the gathered manufacturing data is linked directly into the company-wide ERP (enterprise resource planning) PrM system to manage material, production and schedules planning, production monitoring and control, production and machine downtime analysis, demand planning, data entry and control, generating BOMs (bills-of-material), inventory control and shrink evaluation, and all other key shopf loor-related functions in real time.

Domino Effect With data integrity being a paramount must-have requirement for the whole operation to run like clockwork, the high-performance product coding/marking and identification systems supplied to the plant over the last few years by Domino Canada, Oakville, Ont.-based subsidiary of the U.K.-based auto ID and digital printing systems manufacturer Domino Printing Sciences plc, play a key role in fulfilling the plant’s vast product identification and traceability requirements.

software systems, and superior customer service enabled by Domino’s near presence at a fullystaffed branch office in St-Laurent. Says Vallée: “We use Domino for all our product coding needs, from date-coding and barcoding the K-Cup packs with small-character inkjet and laser units to printing and applying barcoded labels onto finished shipping cases with a Domino

“We just can’t afford to have a multimilliondollar equipment line sitting idle because of a technical glitch in a coding machine” Boasting system installations on all K-Cup pack lines as well as in the plant’s secondary and endof-line packaging operations downstream, the Domino product coding systems—featuring both inkjet and laser-based technologies—have rightfully earned their stripes as the plant’s product ID systems of choice the old-fashioned way by ensuring excellent print quality, ease-of-operation, seamless integration with the plant’s operating

label printer-applicator, and we never had a major downtime problem with any Domino equipment that either we could not remedy ourselves or that could be quickly fixed by Domino technicians. “Line downtime is the biggest enemy for an operation like ours: We just can’t afford to have a multimillion-dollar equipment line sitting idle because of a technical glitch in a coding machine,” Vallée points out.

A fully-automated SmartSeries turntable stretchwrapping systems from Wulftec/M.J. Maillis spring into action to wrap up a towering stack of two palletized product loads made up of seven layers of corrugated shipping carriers, manufactured by Norampac, boasting impeccablypositioned product identification labels attached by a Domino M200 series printer-applicator.

“Domino staff understands this perfectly and they are available to us at all times to make sure this does not happen.” “Their systems are also easy for us to operate for our staff, who really like working with them,” says Vallée, adding that the plant is in the process of purchasing six additional new Domino small-character coders to be installed onto the new incoming Keurig K-Cup pack lines. A close-up view of the inner workings of an OPEM filling machine used for K-Cup pack production, featuring Cognex machine vision cameras installed by the plant’s engineers to verify the exact placement and precise positioning of the foil lids, manufactured by Winpak, by displaying and storing an image of every passing lidded container on the user-friendly HMI (humanmachine interface) terminal (inset) in real time.

16 • WWW.CANADIANPACKAGING.COM

CANADIAN PACKAGING • MAY 2012

PRODUCT ID NOW

One of six fully-automated palletizing and case-packing workcells supplied by Schneider Packaging houses two model M-170 palletizing robotic arms and two model LP Mate packaging robots from FANUC Robotics to ensure safe high-speed end-of-line packaging at operations at the Montreal plant.

Since delivering six M200 model print-and-apply labeling systems to the Montreal plant back in 2007— outfitted with tamp-blow applicators and engineered for reliable application of multiple text lines and even the most complex barcode symbologies in any orientation, on virtually any surface, in pallet-labeling application—Domino Canada has since supplied the plant with eight more systems over the years, including: • Two model A220 and two enhanced model A200+ small-character CIJ (continuous inkjet) printers for high-speed product coding on primary packaging of virtually any surface material; • Two D-Series lasers for permanent product coding across a broad range of surfaces, including the K-Cup packs, to complement the older-version S200+ and two S100 laser-based coders installed between 2007 and 2009. Vallée says the highly reliable Domino systems offer a high level of connectivity and interoperability with a wide range of other best-of-breed, highly automated packaging systems employed at

the Montreal plant, including: • Six robotic palletizing and case-packing workcells—outfitted with Fanuc palletizing robots and interfaced with a Domino print-and-apply labeler equipped with a rugged SATO printhead—supplied by Schneider A Nordson ProBlue hot-melt adhesive applicator is used to secure the filled cases of product Packaging Equipment Co. shut just before a Domino tamp-blow applicator (below) attaches a pressure-sensitive product label onto the side of each passing carton headed to the palletizing workcell. Inc.; • Five state-of-theart, high-speed plastic cup filling-and-capping • A made-in-Italy pod pouchmaking machine; machines manufactured in Italy; • A SmartSeries stretchwrapping machine manu• Custom-made FlexLink conveyor systems, powfactured by Wulftec/M.J. Maillis to secure finered by heavy-duty SEW-Eurodrive motors; ished palletized loads for storage and/or transport to customer, outfitted with a Domino print-andOne of the plant’s three high-capacity coffee roasters apply system incorporating a ruggedly-designed (below) is powered by a series of heavy-duty motors SATO printhead; supplied by SEW-Eurodrive. All in all, Vallée says he is very pleased with the way all the new packaging equipment has boosted the plant’s productivity levels closer to “worldclass” manufacturing standards, adding that the addition of two new K-Cup pack lines later this year will put the operation even nearer to that coveted performance threshold. “I am already quite proud of what we have achieved at this facility in terms making the Montreal facility a highly-automated manufacturing enterprise,” he sums up, “and I am looking forward to building on those accomplishments both in the near future and down the road.”

For More Information: Domino Canada Schneider Packaging Equipment Co. Inc. Fanuc Robotics Canada, Ltd. SEW-Eurodrive Co. of Canada Ltd. Nordson Canada, Limited Norampac (div. of Cascades Inc.) Winpak Ltd. Crown Cork & Seal Canada Inc. SATO Labeling Solutions America, Inc. FlexLink Systems Canada, Inc.

MAY 2012 • CANADIAN PACKAGING

415 416 417 418 419 420 421 422 423 424

WWW.CANADIANPACKAGING.COM • 17

AUTOMATE NOW Looking for production line efficiency and energy savings, Kruger Products installed 40 Movifit and Movigear mechatronic drive systems manufactured by SEW-Eurodrive at its Gatineau paper mill.

JUST MILLING ABOUT Quebec tissue mill keeps the motors running in tune with its sustainability agenda

ANDREW JOSEPH, FEATURES EDITOR PHOTOS BY PIERRE LONGTIN

nightmare for elm trees? Not for Kruger Inc., an environmentally responsible producer of paper-based products. Founded in 1904, the Montreal, Que.headquartered Kruger is an iconic corporate institution in Canada’s venerable pulp-and-paper industry, with a major presence in the North American markets for publication papers, tissue, lumber and other wood products, corrugated cartons made from recycled fibers, and recycled paper and paperboard products. Based in Mississauga, Ont., the company’s Kruger Products L.P. division operates four mills across Canada and one in the U.S. to make a broad array of paper-based consumer products, with its sprawling papermaking complex in Gatineau, Que., playing a key part in Kruger’s long-enduring success in the North American marketplace for tissue products. According to Kruger Products vice-president of sustainability and innovation Steven Sage, “We are Canada’s market leader in consumer tissue products, as well as in the away-from-home segments.” Comprising 93,600 square feet of converting space and an additional 191,000 square feet devoted to papermaking, the Gatineau mill boasts papermaking capacity of 87,500 metric tonnes a year, notes Sage. Receiving third-party sourced virgin and/or recycled pulp de-inked at its Crabtree mill, the Gatineau mill produces a variety of paper grades, including bathroom tissue, facial tissue, paper towels and napkins for the away-from-home market segments such as hospitality, education, foodservice, healthcare, manufacturing, property management and public facilities—marketing its products in each of those segments under the company’s Embassy, Esteem and White Swan brands.

18 • WWW.CANADIANPACKAGING.COM

Also home to Canada’s bestselling facial tissue consumer brand Scotties, the mill was originally opened up under the E.B. Eddy banner in 1926 and bought out decades later by Scott Paper in 1988, ultimately becoming part of the Kruger family in 1997. Nowadays the mill employs approximately 470 people to produce a diverse range of tissue products shipped all over Canada and the U.S., according to Sage. Like all companies in the energy-intensive papermaking business, Kruger Products has considerable challenges on its hands in terms of reducing the environmental footprint of their manufacturing operations, Sage readily acknowledges, but it’s a challenge that Kruger has so far embraced with open arms.

Big Role “As Canada’s market leader, Kruger Products recognizes its responsibility to be a leader in sustainability as well,” Sage told Canadian Packaging in a recent interview. “Big companies can make big differences in environmental stewardship,” says Sage, citing a successful recent installation of a biomass gasification system at the company’s production site in New Westminster, B.C., which helped reduce the mill’s annual GHG (greenhouse gas emissions) by 36 per cent each of the past two years. “The project was the first deployment of this type of technology within the pulp and paper industry, as well as the first for any manufacturing industry, in Canada,” Sage declares. Not to be outdone, the Gatineau mill installed a new heat recovery system in 2010, relates Sage, “which has helped reduce energy consumption by 11 per cent at the mill, while reducing green house gas emissions by 15 per cent.” According to Sage, all the heat from the air that

used to escape outdoors is now being captured at the source and used to heat the facility during the winter, as well as to heat the process water. Such improvements are all part of a five-year sustainable development plan launched by Kruger in 2010 to reduce its environmental impact through reductions in nine measurable ares, explains Sage, citing energy use, GHG emissions, water consumption, waste and packaging as prime focus areas. According to Sage, Kruger has had some great successes, including: • reduction in overall energy consumption by 3.7 per cent, representing 370,000 GJ (gigajoules); • reduction of GHG emissions by 15 per cent; • a four-percent improvement in logistics efficiencies. “Kruger became the first tissue manufacturer to achieve Forest Stewardship Council Chain of Custody certification from the Rainforest Alliance, and now we are able to offer customers one of the largest tissue portfolios of FSC-certified products in North America,” says Sage, pointing out that Kruger Products has one of largest product portfolios of EcoLogo-certified tissue products in Canada. Adds Sage: “Right now, 93 per cent of our fiber is third-party-certified, and we will achieve 100 per cent by the end of 2012.” “Increasingly, there is an emphasis on using packaging materials manufactured from recycled materials, third-party certified materials, as well as eco-friendly materials,” mentions Sage, citing such examples as the Forest Stewardship Councilcertified KD shipping cases and cores for paper towels and bathroom tissue, along with biodegradable poly openings on facial tissue cartons and biodegradable shrinkwrap used on multipacks of facial tissue. “Gatineau is a key mill in the Kruger Products system, and it continues to contribute to the division’s success with an emphasis on quality, safety, continuous improvement and commitment to its talented employees,” says Sage, relating that the ISO-9000-certified mill makes extensive use of demanding Six Sigma quality control practices and procedures through its inhouse-designed Kruger Way system of continuous improvement. The mill also deploys a proprietary Environmental Management System, whereby a designated quality management team is deployed at the facility to coordinate across the Kruger system, includ-

Kruger Packaging vice-president of sustainability and innovation Steven Sage plays a key role in the company’s environmental stewardship development.

CANADIAN PACKAGING • MAY 2012

AUTOMATE NOW

A pair of SEW-Eurodrive Movigear drive motors power a conveyor system.

ing close interaction with the brand management teams to ensure consistency in achieving targets. During the summer of 2011, Kruger purchased a new, high-efficiency converting and packaging line for its Gatineau facility, which has been upand-running since December. “Making this capital investment was an easy decision for Kruger,” explains Sage. “In order to meet the growing demand for our products, we needed to upgrade our technology, which helped us improve our processes and increase our output at the facility.” Gatineau electrical projects engineer Martin Levesque says that Kruger Products has around 40 conveyors to handle the movement of products such as facial carton, carton multipacks, and bathroom roll bags throughout the operation, with all conveyor systems programmed and integrated by the Quebec City-based AIA Automation.

Saving Green According to Levesque, one of the key factors in the selection of the new conveying and packaging line—including a new conveyor system from Milton, Ont.-based Span Tech Canada—was the purchase of 40 Movifit and Movigear Mechatronic drive systems manufactured by SEW-Eurodrive Co. of Canada. Says Levesque: “Span Tech’s solution provided us with not only a great price, but f lexibility on how we could create a conveyor system that worked best for us. “After they suggested we go with SEW’s Movifit system, I did some research on the products and met with SEW-Eurodrive’s Montreal office here at

our facility to discuss it further before deciding to go with the Movifit.” The SEW-Eurodrive Movigear is a drive motor unit controlled by the Movifit, which is used to modulate the speed on the Kruger conveyor system. Levesque says that Kruger employs one Movigear for each conveyor, attached to the conveyor shaft. One of the biggest selling factors for Kruger was that the SEW-Eurodrive Mechatronic drive system provides them with energy savings as part of its integrated process solution. “In this system 25 motors can be running at the same time,” explains Levesque. “As Kruger has them running 24 hours-a-day, seven-days-a-week, we have determined that compared to a standard motor system, our SEW-Eurodrive system will help save us around $4,000 a year. “It’s not a huge amount of money,” he says, “but any way we can save money by running our production line leaner is good for the company.” Sage concurs: “It is consistent with our desire to reduce our energy consumption through our Sustainability 2015 initiative.”

Back Pay While SEW-Eurodrive drive components may be more expensive than conventional drive solutions, within one or two years, depending on range of usage, those costs are offset by the savings in energy expenses. Along with the energy savings from the Movigear, there is also a reduction of CO2 (carbon dioxide) emissions, says Sage. “Retailers and away-from-home companies— particularly government, accommodation, foodservice and property management segments—are looking for greener products from manufacturers who are focused on implementing sustainable initiatives to improve their position,” he sums up. “That’s why reductions in energy, water, emissions, waste and packaging are primary areas of focus for us, along with fiber-sourcing.”

Manufactured by Fanuc Robotics, the high-speed M-410iB/140H palletizing robot is capable of speeds up to 1,900 cycles per hour.

For More Information: Kruger Products L.P. SEW-Eurodrive Co. of Canada Span Tech Canada AIA Automation Forest Stewardship Council FANUC Robotics Canada, Ltd. Domino Printing Solutions

Thanks to its i-Tech ink system, the A320i inkjet coder from Domino Printing Solutions provides Kruger with maintenance savings optimizing operational running costs.

MAY 2012 • CANADIAN PACKAGING FOR MORE INFORMATION CIRCLE

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04.04.12 13:15

ONE-ON-ONE

Lee Tappenden, Chief Merchandising Officer, Walmart Canada Corp.

WHAT WALMART WANTS Retailing giant remains on track to deliver on its packaging sustainability pledge

BY GEORGE GUIDONI, EDITOR PHOTOS BY COLE GARSIDE

t is safe to say that no other annual event in the Canadian packaging community packs them in like the Walmart Sustainable Packaging Conference in Toronto. Organized and managed by PAC-The Packaging Association, the annual forum offers compelling proof of Walmart Canada Corp.’s unwavering commitment to packaging sustainability and meaningful carbon footprint reduction— right across its vast global supply chain. Always featuring top-ranking Walmart Canada executives and their leading CPG (consumer packaged goods) vendor partner counterparts, the highlyanticipated event routinely draws hundreds of senior representatives from the packaging and CPG industry, as well as environmental regulators and watchdog groups, to hear candid progress updates on the retailer’s much-lauded and closely-monitored implementation of its self-styled Packaging Scorecard vendor evaluation system—designed to enable the world’s largest retailer to achieve a fivepercent reduction in the amount of packaging sent to its stores by the end of 2013. With that firm deadline now just a year-and-ahalf-year away, next month’s Walmart Sustainable Packaging Conference VI—to be held June 19 at the Toronto Congress Centre—promises to be more even more relevant and educational for Canada’s packaging professionals than any of its

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earlier editions, with a top-level line-up of speakers offering priceless insights into how and why packaging sustainability must be a top corporate priority for all progressively-minded businesses serving Canada’s increasingly environmentallyastute consumer public. One of the senior Walmart Canada executives who will be addressing the Toronto conference audience for the first time is Lee Tappenden, who was appointed as the company’s chief merchandising officer last year.

conscious team of buyers whose purchasing decisions ultimately drive the company’s general merchandise, food, health-and-wellness and apparel businesses. The Canadian Packaging magazine recently caught up with Tappenden at his Mississauga office to get an update on how Walmart Canada’s packaging sustainability efforts, along with a little preview of what’s in store for the retailer’s Canadian vendors and their packaging suppliers as the company steps into high gear to meet is ambitious environmental pledges next year.

Global Approach

Please explain what environmental sustainability means to Walmart Canada, and what the company is doing to achieve it at its Canadian operations.

While still a relative newcomer to Walmart Canada’s headquarter operations in Mississauga, Ont., having joined Walmart Canada as senior vice-president of merchandising operations in 2010, he is anything but a newcomer to the parent company Walmart Stores Inc.’s far-f lung global business, with the University of Westminster business graduate embarking on his Walmart career with the retailer’s U.K. subsidiary ASDA in 1996. After transferring to the U.S. operations to accept a position with the Walmart global sourcing team, Tappenden continued to rise through a series of progressively senior roles within the U.S. operations before moving on to Walmart Japan, where he served as chief merchandising officer before moving to Canada for his next professional challenge. It is a challenge that naturally carries a considerable burden of responsibility for Tappenden, who is leading a highly-dedicated and environmentally-

At Walmart, we know that being an efficient and profitable business and being a good steward of the environment are mutually complementary goals that can work well together. Our broad environmental goals are simple and straightforward: • To be supplied by 100-percent renewable energy; • To create zero waste at all our operations; • To sell products that sustain both people and the environment. We are deeply committed to being a corporate leader in sustainability. Our commitment to sustainability helps us make good on our promise to help Canadians save money and to live better, while also doing our part to help out the planet in the process.

CANADIAN PACKAGING • MAY 2012

ONE-ON-ONE

What is Walmart Canada doing on a day-to-day basis to educate and encourage Canadian consumers to make the right purchasing decisions in terms of packaging and manufacturing sustainability?

cesses that the company has achieved with its Packaging Scorecard vendor evaluation metrics in Canada? The liquid laundry compaction was a major initiative where we have significantly reduced the amount of packaging used for that specific product category.

We have enjoyed good cooperation and support from our Canadian CPG (consumer packaged goods) vendors and partners since the launch of the Packaging Scorecard in Canada in 2009. There is much ‘behind-the-scenes’ work going on to improve the sustainability of the merchandise that we sell, so that we can provide better products to our Canadian customers and their families. This in itself helps them to ‘do the right thing’ at the store level without feeling overwhelmed by the inherent complexity of sustainability. To that end, we are currently working with the Sustainable Fisheries Partnership in our seafood category unique redesigned to advance sustainable and responsible plastic bottle marine stewardship, and we have a global effort underway to switch to sustainably-sourced palm oil in all our private-brand products. Similarly, we are also working closely with the Better Cotton Initiative in our apparel and home categories. up to 30% made With regards to packaging, we will from plants continue to work with our suppliers and the industry as a whole, whereby Walmart Canada encourages our vendor partners to provide our customers with reliable and accurate information with regards to packaging, as well still 100 as maintaining our long-standing assorecyclable ciations with leading industry groups such as the Sustainable Packaging Coalition (SPC) and PAC-The Packaging Association.

In addition, since we relaunched our Great Value private-label program, we reduced our paperboard packaging by 10 per cent. We have also made notable strides in the toys category by reducing the amount of packaging on our private-label Kids Connection program, and we are

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WALMART PACKAGING SCORECARD METRICS 15% 15% 15% 15% 10% 10% 10% 5% 5%

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MAY 2012 • CANADIAN PACKAGING

PlantBottle packaging is made in part from renewable materials sourced from sugarcane production to bring you the pure, crisp taste of DASANI remineralized water in a bottle designed with the planet in mind. ®

ONE-ON-ONE SUPPLIER SUSTAINABILITY ASSESSMENT: 15 QUESTIONS 1. Have you measured and taken steps to reduce your corporate greenhouse gas emissions? 2. Have you opted to report your greenhouse gas emissions and climate change strategy to the Carbon Disclosure Project (CDP)? 3. What are your total annual greenhouse gas emissions in the most recent year measured? 4. Have you set publicly available greenhouse gas reduction targets? If yes, what are those targets? 5. If measured, please report total amount of solid waste generated from the facilities that produce your product(s) for Walmart for the most recent year measured. 6. Have you set publicly available solid waste reduction targets? If yes, what are those targets? 7. If measured, please report total water use from the facilities that produce your product(s) for Walmart for the most recent year measured. 8. Have you set publicly available water use reduction targets? If yes, what are those targets?

also working with our industry partners to remove coated and non-coated wire ties—replacing them with paper strings. Since launching the Packaging Scorecard system, we have seen significant efforts and progress being made in the lightweighting of packaging materials across all of the CPG categories. One notable example of this progress can be found with the water bottles, where the weight of the containers has gone from 16 grams for a 500ml bottle to 10 grams or less. To note just one interesting example, our privatelabel Great Value water bottle is today made right

9. Have you established publicly available sustainability purchasing guidelines for your direct suppliers that address issues such as environmental compliance, employment practices, and product/ingredient safety? 10. Have you obtained third-party certifications for any of the products that you sell to Walmart? If so, from the list of certifications provided, please select those for which any of your products are, or utilize materials, that are currently certified. • Scores will be automatically calculated based on participation in the Packaging Scorecard in addition to the following: 11. Do you know the location of 100% of the facilities that produce your product(s)? 12. Before beginning a business relationship with a manufacturing facility, do you evaluate its quality of production and capacity for production? 13. Do you have a process for managing social compliance at the manufacturing level? 14. Do you work with your supply base to resolve issues found during social compliance evaluations and also document specific corrections and improvements? 15. Do you invest in community development activities in the markets where you source from and/or operate within?

here in Ontario from 100-percent recycled PET (polyethylene terephthalate), and that’s just one of a multitude of successful sustainable packaging stories that can be traced back to the Packaging Scorecard initiative launched by Walmart to encourage our vendors to reduce their packaging footprint. This year we are also accelerating the process of removing PVC (polyvinyl chloride) plastic from all of our private-label non-bottle rigid plastic packaging such as clamshells and blister-packs. Our goal is to transition these containers to PET, so that we can recycle this material in the same recycling stream as our PET bottles. We are also asking our brand-name vendor partners to voluntarily commit to removing PVC from their rigid packaging as well, because PVC is a lookalike material that contaminates the recycling stream for materials, such as PET, which are more easily recycled and therefore have a much higher value. What has been the consumer response and feedback to the environmentally-friendly product offerings carried at Walmart stores in Canada, such as For the Greener Good private-label products?

We currently stock hundreds of third party-certified, environmentally-friendly products. In addition, we are working with our suppliers to improve the sustainability of many conventional products— for both national brands and the private-label goods. You can see this with Our Finest product range, which is our premium grocery brand which offers Canadian consumers exceptional taste, quality, selection and variety with a broad variety of appetizers, sparkling beverages, chips, chocolates, candies, ice-cream and other food products at unbeatable prices. (See Pictures) As we do with all our private-label brands, our goal is to continuously improve the sustainability of Our Finest products. As the 2013 deadline for the Packaging Scorecard’s targeted five-percent packaging reduction approaches, where does Walmart’s packaging sustainability agenda go from there? We have two key aspirational goals that will continue to drive our packaging sustainability efforts well beyond 2013, which are to ‘create zero waste’ and to be ‘packaging-neutral.’ We will spend considerable time talking about our plans to work towards these long-term goals next month at this year’s Walmart Sustainable Packaging Conference in Toronto on June 19. Internally, we will continue to promote our associate-driven sustainability program called My Sustainability Plan, or MSP as it is widely known. It is a global voluntary, associate-driven movement that encourages our associates to choose and execute small, individual actions that make a difference, which can range from using a reusable coffee mug to switching over to energy-efficient

Last year’s edition of Walmart Sustainable Packaging Conference at the Toronto Congress Centre drew over 850 professionals from the retail, packaging and suppy chain industries to take in exceptionally informative presentations and lively panel discussions of Walmart’s ongoing pursuit of significant packaging waste reduction wordwide.

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CANADIAN PACKAGING • MAY 2012

ONE-ON-ONE

CFL (compact f luorescent light) bulbs at home. My personal MSP is to ride a bike or carpool to work at least once a week.

including 167 Supercentre stores, which are our key growth vehicle, and 166 discount stores—employing almost 90,000 Canadian associates. These stores serve more than one million What can you do in your position as chief merCanadian customers each day, and our regular 21376 E Can Packaging_7.875x10.75_21376 11-04-18 4:28 PM Page 1 chandising officer to help drive further sustainprice comparisons show that we save Canadian ability progress at Walmart Canada operations and throughout its supply chain?

families an estimated $17 million a month. Walmart Canada also has very strong philanthropy and sustainability programs. In fact, we are ranked ‘Number One’ in Canada for environmental leadership, according to the Ipsos-Reid polling firm, and last year we donated and raised more than $25 million to various Canadian charities. In coming years we will continue to maintain our keen focus on packaging optimization and on using more packaging materials that are easily recycled. In addition, we plan to increase recycled content of our product packaging, along with increasing the content derived from sustainably-sourced renewable resources across our full product range. To register for the Walmart Sustainable Packaging Conference VI, please contact Lindsey Ogle of PACThe Packaging Association at (416) 646-4641, or via email logle@pac.ca

Out of the three key global sustainability objectives mentioned earlier, it is ‘to sell the products that sustain people and the environment’ where

Arnold Drung, President, Conestoga Meat Packers, Breslau, Ont.

the merchandising team can have the biggest impact of all. For us, selling sustainable merchandise means examining the entire lifespan of a product: from conception to materials and on to its use as an endproduct and, finally, to its disposal. Naturally, we can only improve the sustainability of a product by working in close partnership with our suppliers and their packaging partners, and by sharing all our information and our best practices with them. Please reflect on Walmart Canada’s accomplishments to date, and also on what Canadian consumers can expect from you in coming years? Walmart Canada is a mature business within Walmart’s global operations. We started up in Canada with 122 Woolco stores and 16,000 associates, whereas today we have 333 stores—

MAY 2012 • CANADIAN PACKAGING

“Our financing with FCC is just right for our business.” When you talk financing with Farm Credit Canada, we’ll listen Ready to expand your business? We’re ready to help. We get to know you and your business. Once we learn how you want to grow, we’ll create a financing package that helps you do it. Work with the leading lender to agriculture, agribusiness and agri-food in Canada. Let’s talk business. www.fccfinancing.ca

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FLEXIBLE PACKAGING

SAFE AND SECURE

Product innovation and relentless focus on safety enable Quebec flexible packaging converter to make waves in a competitive marketplace

Karl Boustany, Vice-President, Sales and Development

Charles Boustany, President and CEO, Flexipak Industries Inc.

ANDREW JOSEPH, FEATURES EDITOR PHOTOS BY PIERRE LONGTIN

t’s not often that a 15-year-old company in the packaging products sector would dare to call itself a leader, but that is exactly the type of bravado that one thriving Quebec-based f lexible packaging manufacturer credits for helping it get where it is today, along with its strict adherence to the most stringent and demanding food safety protocols out there. Residing in the Saint-Laurent district of Montreal, the privately-owned Flexipak Industries Inc. may not be one of the country’s largest producers of flexible packaging products, according to the company’s vice-president of sales and development Karl Boustany, but what it lacks in size and scale is more than offset by the cutting-edge innovation and exceptional customer service that has enabled the company to build a loyal client base stretching coastto-coast in Canada and the U.S. “We have customers right across from Nova Scotia to Hawaii,” says Boustany, whose father Charles founded Flexipak in 1997 and still serves as its very much hands-on president and chief executive officer.

According to Boustany, Flexipak currently prints and converts about three million pounds of plastic annually to create a broad range of high-quality, monolayer and multilayer f lexible packs for a growing list of faithful customers in the confectionary, baked goods, frozen fruits and vegetables, pet food, fertilizer, landscaping materials and other sectors who are often attracted to the company’s f lair for innovative value-added features that differentiate its products from run-of-the-mill competition.

New Ideas “We are constantly looking for something new that could set us apart,” Boustany told Canadian Packaging in a recent interview. “For example, since 2008 we have been looking for a bag closure that could be more effective than the standard zipper,” he relates, “and I do believe we have finally found it.” Employing about 45 people at its 40,000-squarefoot Saint-Laurent facility, the family-owned business has its fair share of small- to medium-size customers, according to Boustany, but the bulk of its business is accounted for by national corporate heavyweight such as Weston Bakeries, MetroRichelieu and PepsiCo, including both national

A winder on the Hudson-Sharp wicketer is powered by an SEW-Eurodrive motor.

26 • WWW.CANADIANPACKAGING.COM

brands and private-label work. Boustany says that the company’s recentlydeveloped alternative to zippers came about after he had heard about a new plastic Velcro product and wondered if it would be possible to incorporate into its f lexible bag structure. After a two-year joint development project with Velcro USA, Flexipak was able to commercialize the use of the new resealable Press-Lok closure that uses an attached Velcro strip for opening and closing the plastic film bags. “We conducted numerous tests on new Velcro bags to ensure that even after repeated opening and closings, the Press-Lok bag would continue to work with the same efficiency,” states Boustany, recalling that the extensive tests took place over a period of several months in order to leave nothing to chance. “We all had our doubts initially,” he relates, “but the long-term testing between Velcro’s technical support and our R&D (research-and-development) team proved that the Press-Lok was the freshest and most practical alternative to the press closures.” According to Boustany, one of the main technical drawbacks of the regular press-to-close zipper is that it can fail to close if granules or small particles become lodged in either the male or female side.

A Flexipak employee uses a Bobst Black Box video control system to monitor a print run.

CANADIAN PACKAGING • MAY 2012

FLEXIBLE PACKAGING

An eight-color Bobst Schiavi EF 4040 gearless press is used extensively by Flexipak to produce high-quality flexible bags for customers across Canada and the U.S.

“We needed to determine if the same thing could happen with the Press-Lok bag we were developing, so we tested it with a variety of granular products like sugar, coffee powder, and cocoa, to name just a few,” Boustany recalls. “We tested it every which way we could think of,” he recounts, “and it passed each time with f lying colors.” While the seal was able to hold, Flexipak also wanted to ensure that the structural integrity of adding a Velcro zipper to a f lexible plastic bag could pass the muster. Boustany adds it was also important that the new closure would be able to be properly heat-sealed onto the various types of laminated films produced by Flexipak, while ensuring that the closure would remain resistant and closed even if Velcro’s closure wasn’t aligned perfectly to ensure a fully-sealed bag.

Big Step “It worked out great,” Boustany extols. “In my opinion, it even outperforms the ziplock-style reclosable pouches. “It really is a huge step forward in the evolution of the reclosable f lexible bag,” he asserts, pointing out another value-added feature that allows the Velcro zipper a partial three-quarter seal to leave just enough space for a slight opening to form a spout—thereby facilitating a more controlled pouring and dispensing of the product. “This can be very useful, for example, to avoid damaging large-sized bags for pet food, sugar or f lour,” Boustany notes, adding that the overall cost of the Press-Lok bag is comparable to that of other standard reclosable bags. “As an added bonus, for companies looking to use the Press-Lok, there are no modifications or adjustments required to their existing horizontal bagging machines,” he points out. “Our Press-Lok can be grasped, opened, filled and sealed at the same speed as any other ordinary bag.” When Boustany joined his father’s business after completing business school and working in

MAY 2012 • CANADIAN PACKAGING

related fields as well as a financial institution, he pany first looked at the Asian competitors and came armed with ideas on how to take Flexipak their contamination disasters eating into the North to the next level of packaging security by having it American market, he wondered how they would become certified as a PACsecure company. be able to keep f lexible packaging local, profitable, The brainchild of PAC-The Packaging and still be able to gain larger customers with longAssociation, PACsecure is a HACCP (Hazard and short-run requirements. Analysis Critical Control Points)-certification specif“We started with HACCP in about 2008, and ically designed for packaging companies involved when PACsecure came about in 2009, the whole with the food industry, a criteria that is now reccompany, from top to bottom, came onboard,” ognized by the United Nations and most of the explains Boustany. food industry worldwide, including the U.S.-based “Two years later, we earned the certification and Food Safety Alliance for Packaging (FSAP). a lot of doors began opening up for us.” It also recently received recognition of its standards Full Contact with the Global Food Safety Initiative and the Boustany explains that customers such as Kraft, Canadian Food Inspection Agency. Nestlé, Con Agra and PepsiCo., and privateDeveloped by the PAC for f lexible plastics, rigid label brands for Loblaws, Metro and Sobeys plastics, glass, paper and metal packaging, PACsecure want to work with a packaging supplier that can covers 24 general manufacturing practices for the provide such a level of protective packaging for manufacture of the specific packaging materials. food contact. “For Flexipak, PACsecure was a key way to Says Boustany: “Because of our PACsecure certificaensure our customers that our products are certition, we were able to respect these strict requirements. fied as being food-safe,” explains Boustany. “We would never state that we are the best, howFlexipak is the first f lexible packaging company ever we do say we work with the best suppliers,” in Quebec to achieve this prestigious certification, declares Boustany, “which helps bring out the best joining five other companies throughout all of in us.” Canada to obtain PACsecure certification in 2011. “We’re certainly the smallest company to become PACsecure,” says Boustany. “Although becoming certified requires a lot of investment, achieving the PACsecure designation for packaging has actually made the way we perform our duties a lot easier.” It was not a quick process to become PACsecure. Back in 2008, when the com- Flexipak uses Sun Chemical inks for some of its printing needs at the Montreal facility.

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FLEXIBLE PACKAGING

11875_Flexipak_Pub_CanPack_8_125x10_875_P1_O_HR.pdf

7 May 2012

10:16 AM

A Karlville pouch machine is used by Flexipak to convert printed film to bags.

The Flexipak plant employs an eight-color Bobst Schiavi EF 4040 CI gearless press that was installed in 2005, and the hard-working machine has, according to Boustany, more than paid for itself over the years. “It’s provided us with excellent quality, but what has been even more impressive is the service we have received from Bobst,” Boustany relates. “Great people; great support.” Boustany says that the 24/7 active data connection with someone always on the other end of the line has endeared Bobst to Flexipak. “We once had an issue with part wear-and-tear occurring on U.S. Independence Day,” says Boustany. “We had someone on the phone troubleshooting with us within five minutes of the call. To me, that is unheard of in the industry.” Thanks to the service and the print quality, Boustany says Flexipak is now considering investing in a 10-color high tech press. Flexipak also heavily utilizes a 60-inch-wide Sabaflex six-color geared press and a Modern slitter/rewinder, both manufactured by Bielloni in Italy. “The Sabaf lex has been a workhorse for us,” notes Boustany. “It was what allowed us to start up our business of printing quality f lexo.” Flexipak also uses six bagmaking machines from the Hudson-Sharp Machine Company, and LEMO with AMI zipper attachments. Other suppliers and equipment used by Flexipak include: • Sun Chemical and Pemla Inks, who provide all of the inks used to print on its f lexographic films; • Schawk, SGS and CML to provide all of the in-house prepress work; • Bobst Eco Junior 450 solventless laminator. Flexipak considers itself a onestop shop for a customer’s f lexible packaging needs, providing 100-percent full traceability by using great extrusion partners such as PolyExpert, and providing its own prepress team, printing its own film, and then manufacturing bags from it. “We’re a different company from the competition, for sure,” sums up Boustany. “Not only are we an innovative company backed with a top packaging security certification, but we also have a different way of working with the client. “We’re not just content to take a customer’s request and just do it. We look at it and see what they really need and how we can save them some money, because we know that when a customer is happy with our value-added efforts, then trust and loyalty become a recipe for a longterm relationship.”

For More Information: Flexipak Industries Inc. Velcro USA Inc. PAC-The Packaging Association Bobst Canada Inc. Bielloni Converting s.p.a. Hudson-Sharp Machine Company LEMO Maschinenbau GmbH AMI (Div. of Zip-Pak) Pemla Ink Technologies Sun Chemical Limited Schwak Inc. PolyExpert Inc. Karlville Development Group CML Printing Plates Inc. SGS International, Inc.

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Flexipak

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PACKAGING FOR FRESHNESS

PROUD FOR RIGHT REASONS Canada’s largest fresh fruit and vegetable processor takes pride in its quality assurance efforts to bring only nature’s best to the table ANDREW JOSEPH, FEATURES EDITOR PHOTOS BY COLE GARSIDE

t’s not really considered bragging when a company is already widely acknowledged as an industry leader in its chosen field. And it’s really been a field of dreams in recent years for Pride Pak Canada Ltd., Canada’s largest fresh fruit and vegetable processor with a stellar reputation for quality and food safety that more than justifies the company’s self-assured choice of a name. In fact, there is plenty to be proud of for a company that its chief executive officer Steven Karr founded in 1984 after identifying untapped vast demand in Canada’s fast-growing market for highquality, healthy, easy-to-serve fresh food sold at a reasonable price. But unlike many other one-time competitors that have tried to cash in on new market opportunities but ultimately failed, Karr not only talked the talk, but also walked the walk to become the Canadian market leader in fresh-cut processing—leveraging remarkable business savvy and unyielding genuine desire to provide Canadian consumers and foodservice customers with a truly value-added product. Today operating out of a state-of-the-art, 135,000-square-foot facility located a half-hour drive west of Toronto in Mississauga, Ont., Pride Pak still considers itself to be a regional producer, as Karr explains. “Even with the size and output of our company, we are a regional processor, which allows us to receive fresh product daily,” he says. “And by ‘fresh’ I mean that we are always processing that product today for delivery tomorrow.” Pride Pak’s extensive product covers the full gamut of popular fresh-cut produce blends and mixes— including carrot and celery sticks; broccoli and cauliflower florets; shredded lettuce, carrots and cabbage; diced or slivered onions, peppers and celery; chopped iceberg and romaine lettuce; stir fry and other vegetable mixes—along with a broad variety of salad recipes and soup mixes, including Minestrone, Potato and Leek, and Kale and Potato recipes. Despite enjoying a well-earned, well-respected reputation within the industry, most Canadian consumers are probably not intimately familiar with Pride Pak because up to now the company has resisted the urge to create its own flagship brand—instead consciously choosing to concentrate on private-label products shipped directly to grocery retailers, foodservice distributors and other food processors. Nevertheless, the odds are pretty good that most average Canadian consumers have eaten Pride Pak products far more often than they realize, according to Karr, because they are featured quite prominently in salads and sandwiches served at many global fastfood restaurant chains operating across Canada. “We have over 100 SKUs (stock-keeping units) we produce on a regular basis, but we can and will design any value-added fresh product to meet a customer’s needs and specifications,” says Karr, citing Pride Pak’s impressive product shelf-life ranging from eight to 21 days.

MAY 2012 • CANADIAN PACKAGING

Gary Turner, Vice-President & General Manager

Angelo Karr, Vice-President, Administration Greg Karr, Vice-President, Logistics Gary Brar, Director, Finance & Administration

Along with its smaller satellite facility that Pride Pak opened up in 2006 in Paradise, Nf ld., the company has the capacity to process over three million pounds of product weekly—without the use of any artificial preservatives—to serve a loyal base of customers across Canada and in parts of northeastern U.S., according to Karr. “Being a Canadian company, I obviously feel it is important for us to support Canadian-grown products whenever possible,” Karr told Canadian Packaging during a recent visit to the Mississauga facility running two shifts per day, with a third shift for cleaning, seven days a week. “I love what I do,” Karr states. “I’ve been involved in all aspects of fresh vegetable processing in my career, and I am also a part-time farmer in my spare time.” The company’s success is naturally an enormous source of personal pride and fulfillment for Karr, with three of his children playing key roles in its day-to-day operations. “But I treat all of my employees as though they are family,” Karr quickly points out. “In fact, not only do we have many employees with over 10, 15 and 20 years of employment here, we feel that once

After being filled with product and sealed by a Matrix ProStar machine, finished bags of produce pass through Fortress Technology’s Phantom metal detection system.

Paul Slipper, Plant Engineer

Steven Karr, CEO, Pride Pak Canada Ltd. Jennifer Karr, SQF Practitioner

you are here past six months, you will want to stay as long as you can.” According to Karr, the value-added produce segment has enjoyed exceptional growth in Canada over the past 15 years, with fresh-cut fruits and vegetables and packaged salad mixes now accounting for approximately 20 per cent of the total produce department sales at grocery stores across the country. “Foodservice operators have also increased their use of value-added produce, which comes as a direct result of the maturation and refinement of this industry,” notes Karr. “Foodservice operators like our customers recognize the value of purchasing washed, ready-to-eat fruits and vegetables which translates to less labor, less waste, higher quality, improved food safety and controllable costs,” he explains. “The thing is, Pride Pak was already active in the value-added produce industry long before fresh-cut fruits and vegetables became popular in Canada.” Prior to launching Pride Pak, Karr worked as a wholesale distributor of fresh fruits and vegetables to restaurants, hotels and private clubs in the city of Toronto. During that time, Karr says he often heard a lit-

A Domino V100 model thermal-transfer printer is mounted onto one of two Hayssen vertical form/fill/seal machines employed at Pride Pak’s production facility in Mississauga.

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PACKAGING FOR FRESHNESS

After passing through a metal detection unit, bags of fresh-cut produce are swiftly hand-packed into cartons for shipment to customers.

any of complaints from his demanding chef customers: not so much about his product, but rather concerns over food costs, space constraints, excessive waste, availability and cost of labor, and other things that affected their bottom line. Hearing those complaints naturally gave him an idea of creating pre-bagged salads for his customers, he recalls. “I told them that my salad bags could save them time and labor ... that all one had to do was open the bag and pour the salad into a bowl. “Of course, everyone thought I was crazy,” he chuckles. Crazy or not, Karr went about doing what he said he was going to do—cutting ingredients to size, washing them multiple times, bagging them, etc. Before long, what originally started as a once-

per-week product offer, the bagged salads produced at Pride Pak became increasingly more and more popular with newer and larger customers joining the fold. The fast-growing demand soon made it imperative for the Pride Pak plant to automate many aspects of its operations over the years to remain a competitive and successful business, Karr relates. “Back when we started, it took 12 people a total of 16 hours each to pack 20-pound cases containing 25 bags apiece,” recalls Karr. “Nowadays we do about 10,000 pounds of produce an hour on a single automated line,” says Karr, explaining that the Pride Pak facility has been designed and set up to be operated as a high-output processing plant that can offer its customers safe, quality food at a reasonable price, with impeccable on-time delivery. “Thanks to our investment in automation and our dedicated employees, as long as we get a minimum of 24 hours’ notice, we can get it into the customer’s hands,” he asserts. “Our customer service is second to none,” Karr stresses. “We set the standard, and we are fortunate to have the support of our suppliers, customers, employees and the government to ensure that these goals are continually met. “Our f lawless record is one we are very proud of, but it takes a lot of work,” relates Karr. “It’s not only about the integration and cooperation of all the departments and employees: it’s also about integrating all the automation we use on our production lines,” he says noting that both Pride Pak plants have been recognized for achieving the coveted Gold standard during independent, thirdparty HACCP (Hazard Analysis and Critical Control Points) audits administered by the highly authoritative Guelph Food &

One of five multibucket Ishida weighscales from Heat and Control used to dispense about 95 per cent of all product processed at the Pride Pak plant into plastic bags, with the remainder packed inside trays.

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Leading corrugated producer Norampac supplies the Pride Pak plant with all its corrugated shipping cartons.

One of several high-perfomance conveying systems installed at the Pride Pak plant by Hager Industries.

MAY 2012 • CANADIAN PACKAGING

800 227 5980 / 510 259 0500 info@heatandcontrol.com www.heatandcontrol.com

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PACKAGING FOR FRESHNESS

Palleted boxes filled with bags of Pride Pak products waiting to be stretchwrapped for transport to Canadian and U.S. customers.

Technology Centre (GFTC). Karr says Pride Pak’s uncompromising food safety and quality assurance programs were developed following strict guidelines of the CFIA (Canadian Food Inspection Agency) and FDA (U.S. Food & Drug Administration), along with its own in-house GMP (good manufacturing practice) procedures and HACCP programs—all periodically reinforced with continuous staff training. “Food safety and product quality is the responsibility of each and every employee at Pride Pak and its suppliers,” states Karr. The company has even gone a step further, he relates, by formed a buyers group with other Canadian and some U.S.-based processors, which contracts key growers up to three years in advance to secure the most advantageous land elevations—thereby minimizing risks of adverse weather conditions such as too much or too little rain. Moreover, Pride Pak employs its food safety auditor to inspect each ranch prior to seeding, during growing, and prior to harvest, Karr reveals, with the thorough inspections including the review of all documents and analytical work on the raw product by an independent lab. Any noncompliance with Pride Pak’s specifications leads to immediate rejection of the field for future harvesting, he explains. “It’s one of the reasons why when we develop a raw product supplier, they remain our raw product supplier, as each must follow structured food safety protocol with excellent results from reputable third-party auditors,” he states. The Pride Pak plant’s designated quality assurance team tracks and documents the critical control points on a continuous basis to make sure all product—from raw to finished goods—are inspected to meet the company’s high quality standards. Currently running a total of eight production lines, the Mississauga plant is looking at adding another line or two before the end of the year, says Karr. “Six of our lines are bagging lines and the other two are tray-sealing lines,” says Karr, citing two Hayssen lines runs between 40- and 60-bpm (bags per minute); three Matrix Packaging Machinery lines running at 40- to 50-bpm; a generic spring mix line of fresh-cut veggies; a tomato tray line; and a dual apple packaging lines running at speeds of 60- to 80-bpm. All of the pre-printed bags used on the bagging lines are supplied by the Toronto-based Lynnpak Packaging Ltd., according to Karr. “Four of our bagging lines utilize a nitrogen gas-f lush when required, with the balance of the lines using MAP (modified-atmosphere packaging) lidding and plastic film to help extend the shelf-life of the products,” he notes. While each of the lines is different to some extent, Karr is quite proud of the equipment installed on the plant’s Line No. 1, which he calls “one of the most technologically advanced lines in our business.” Along with the plant’s Line No. 2, this high-performance line is dedicated to processing all of the lettuce products handled at the facility. Continues on page 34

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CANADIAN PACKAGING • MAY 2012

DECENTRALIZED DRIVE SYSTEMS DECENTRALIZED DRIVE SYSTEMS

MOVIGEAR® Movigear® is distinguished by its high level of system efficiency, a significant factor in reducing energy costs. The integration and coordination of all the drive components lead to a long service life and system availability. Movigear® is an intelligent system with its own control concept. Its high-quality networking helps reduce startup time and supports monitoring and maintenance tasks. When combined with a functional user software, drive tasks can be solved as quickly and easily as possible.

In many industries and applications, implementing economical automation concepts means utilizing decentralized systems throughout. Long rows of control cabinets with complex wiring, expansive space requirements and long distances between control cabinet and motors are too rigid and not very economical. Only the combination of flexible, versatile, economic and target-oriented modules will provide an efficient solution. This is the reason why system operators opting for decentralized drive systems from SEW-Eurodrive are always ahead of the game.

Our Drive Solution Pyramid.

MOVITRAC® LTE B The range of functions provided by MOVITRAC® LTE B is particularly well adapted to less complicated applications. Its user-friendly design makes integration quick and easy, it also meets the high quality requirements of everyday requirements. The Movitrac® LTE B is also available in IP66/NEMA 4k making it suitable for special ambient conditions. These frequency inverters operate reliably and flexibly even when exposed to dust or water.

VFDs: RELIABLE, COMPACT & VERSATILE

SERVO PACKAGE: SIMPLE, FAST & DIVERSE

PSC

Planetary servo gear units The low backlash PSC planetary servo gear units are designed for torque classes from 30 to 305 Nm. They are designed to offer the greatest possible flexibility and ROI, as not every application demands machines designed for maximum performance. These planetary servo gear units are the basis for versatile, dynamic, and above all cost optimized drive solutions.

MOVITRAC® LTX Simple, fast and diverse: as part of the Smart Servo Package, SEW-Eurodrive offers the new Movitrac® LTX servo inverter for universal use. It stands out with advantages such as ease of operation, short startup times as well as optimized costs. Available in two sizes and covers a power range from 750W to 5.5 kW. The Movitrac® LTX is particularly suitable for use in applications such as secondary packaging, handling, and logistics.

DECENTRALIZED CONTROL: MODULAR, FLEXIBLE & ECONOMICAL

The demands on material handling systems today have never been more wide ranging or more challenging. That’s why SEW-Eurodrive offers drive solutions for every kind of industry application. From the simple to the sophisticated, our pyramid of solutions allow you to control costs and limit complexity by giving you the ability to tailor our products to the exact intelligence and performance specs you require. Reducing energy consumption is also an important imperative today for the modern production line. Just ask Coca-Cola, who achieved a sensational 75% reduction in energy consumption by incorporating 40 of SEW-Eurodrives’s revolutionary decentralized MOVIGEAR® units in a recent overhaul of a European bottling plant transport line. Driving the world

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PACKAGING FOR FRESHNESS

Pride Pak is an active user of CHEP returnable pallets. PROUD FOR RIGHT REASONS Continued from page 32

Before it enters the production line, raw product is inspected for quality and then loaded into a crate dumping system that tips the product onto a trimming conveyor system manufactured by the Hamilton, Ont.-based Hager Industries Inc. “Once the product has been trimmed and cored, it is inspected again before being sent along a conveying system to be cut to the customer’s specifications,” states Karr. After passing through an Urschel Translicer, the pre-cut product enters the Model 450 automated inspection system manufactured by Raytec Vision S.p.A., which thoroughly checks the product for foreign materials and any defects in

color and density. The product then passes into a Turatti three-stage wash system, becoming progressively cleaner with each station. After the product is fed into automated spin dryers to remove excessive moisture, it is conveyed to the actual packaging line, where it passes through state-of-theart chilling tunnels to maintain optimal temperature before moving up and into one of five Ishida weighscales (Pride Pak also has a Yamato weigh scale)—before being packed by a Hayssen Ultima horizontal form-fill-seal (F/F/S) bagger. After bagging, all product is inspected by a Fortress Technology Phantom metal detection unit, checked for seal quality and weight accuracy, and then packed in corrugated cartons for storage in the company’s refrigerated storage area to await same-day shipment. Other key systems and materials employed at Pride Pak include: • eight Domino thermal-transfer printers to apply the time and date of production, as well as the best-before dates; • various 3M and custom-built automated carton tape-sealing machines;

• high-performance rollstock bag film supplied by Haremar Plastics and JG Packaging; • corrugated cartons manufactured and supplied by the Norampac division of Cascades Inc. “You could ask anyone involved in the produce industry, and they would all tell you that it can be a very stressful business,” ref lects Karr, “but it is also a very, very fulfilling business. “I can tell you without a shred of doubt that I love providing people with high-quality produce and that I have a lot of fun doing it,” he sums up. “We take pride in our work, and we are proud of the quality and safety of the products we produce. “Pride Pak is not just our name: it’s also our philosophy.”

For More Information: HayssenSandiacre (Div. of Pro Mach Inc.) Lynnpak Packaging Ltd. Urschel Laboratories Hager Industries Inc. Raytec Vision S.p.A. Turatti Srl Ishida Canada Inc. Yamato Scale GmbH Fortress Technology Domino Printing Solutions 3M Canada Co. Haremar Plastics Manufacturing Ltd. JG Packaging CHEP Norampac (Div. of Cascades Inc.)

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Mississauga, ON

NOTES & QUOTES  Newly-formed package printer Cutting Edge Paper Ltd. has completed the acquisition of the business assets of Mississauga, Ont.-based paperboard converter Baldwin Paper Company Ltd. last month—shortly following Baldwin’s filing from creditor protection earlier this year—with former Baldwin Paper operations manager Ivo Marinella revealed as one of the new company’s co-owners. “I believe in playing old games by new rules, with out top priority to always provide a superior product and service to our customers,” Marinella states. “We achieve this by incorporating quality control measures and inspections at numerous stages of the process [and] supporting our customers with the most innovative materials and solutions on the market today to ensure they get increased performance on the line, and improved brand presence on the shelf.” Contact: 820 Gana Court, Mississauga, Ont., L5S 1N9. Tel. (905) 670-0850.  Processing Technologies International (PTi), manufacturer of high-performance plastic sheet extrusion machinery, has announced plans for a US$$3-million plant expansion at its headquarters in Aurora, Ill. (see picture) in response to growing demand for its sheet extrusion equipment, according to the company. “Our business has hit record levels the last three years and our products are being well-received throughout the packaging markets in North America,” says PTi president Dana Hanson, citing growing demand for the company’s “dryer-less” PET (polyethylene terephthalate) systems for the expansion and increasing market share. According to Hanson, the expansion will also help create up to 40 new jobs at the Aurora plant, including mechanics, engineering and general production personnel.  St. Louis, Mo.-headquartered rigid packaging products group TricorBraun was selected as the inaugural recipient of the new Award for Excellence in Structural and Graphic Design from the Institute of Packaging Professionals (IoPP) in beverage category for outstanding work on the new

eye-catching container for the ROXOR premium brand of “designer” gin. Boasting a square bottle shape with a f lat windowpane relief inspired by world-famous skylines, and made with cosmetic-grade super f lint glass that sparkles in bright light, the bottle’s stylized appearance gives ROXOR a strong marketing appeal with the unique shape and ref lective quality to differentiate it from the traditional round smooth spirit bottles in both retail and back bar settings, according to the judges. The IoPP award continues a strong recent run of industry acclaim for TrciorBraun products, which also recently picked up two Ameristar Awards in two highly competitive categories: • Pet and Vet category: Lickety Stik brand of lowcalorie dog treats packaged in a traditional roller-ball deodorant bottle the dispenses a liquid reward— offered in savory chicken, braised liver or smoky bacon f lavors—as the dog licks the roller ball; • Automotive Products category: 3M Automotive Car Care products in newly-designed packaging manufactured with 25-percent post-consumer recycled content PET (polyethylene terephthalate), rather than traditional PVC (polyvinyl chloride).  The newly-formed Active and Intelligent Packaging Industry Association (AIPIA) reports to have already signed over 40 ‘blue-chip” member-companies from the food, pharmaceutical, cosmetics and logistics industries to help the organization, based in The Netherlands, drive emerging “smart packaging” technologies out of R&D (research-and-development) stages into actual commercial use. “We have been delighted by the reaction to the formation of AIPIA: it seems all sectors of the industry agree the time to look at the commercial

applications for active and intelligent packaging is right,” says AIPA director Eef de Ferrante, citing Dow Performance Packaging, Bayer, Motorola, Avery Dennison RFID, UPS and Marks & Spencer as some of its diverse, highprofile members. “Companies have spent many years developing radio-frequency identification (RFID), track-trace technologies, gas scavengers, sensors and antimicrobial products and materials, and we now have the ability to bring these to a huge market, along with developments such as nanotechnology, NFC (near-field communication) and mobile commerce,” explains de Ferrante. “In addition to knowing the condition of the product by using sensors, scavengers and antimicrobial or contaminant, sensors will become the accepted means of monitoring product shelf-life—eliminating the need for sell-by/use-by dates, and also using this technology to enable the reuse of unused pharmaceuticals, with potential for huge cost-savings.” Scheduled for October in Japan, the group’s first AIPA Showcase will be used to set its future agenda and action plan, according to de Ferrante. “Japan is further ahead in implementing and using active and intelligent packaging, so it will be an excellent venue for a first meeting.”  Minneapolis, Minn.-based Accraply, Inc., a Barry-Wehmiller Companies, Inc. subsidiary specializing in automatic labeling and label converting and finishing systems, has completed the acquisition of the U.K.-based Turpins Packaging Group Ltd., which specializes in high-performance shrinksleeve application solutions marketed under its Sleevit brand of standard and customconfigured sleeving systems used across a broad range of industries. “This acquisition strengthens Accraply’s commitment to the shrinksleeve labeling industry and expands our footprint in Europe,” says Accraply president Rob Leonard. “The addition of Turpins and the Sleevit brand within the family of Accraply, Graham, Trine and Stanford brands complements our position as a global provider of a complete range of labeling and converting equipment, backed by an extensive service and parts support network.”

Unisource Canada, Inc. and Plan Automation Announce Newly Launched Strategic Alliance Unisource Canada, is a subsidiary of Unisource Worldwide, Inc., and is Canada’s national supplier of printing and imaging, packaging and maintenance supply products – operating from 18 locations across Canada. Unisource Canada is committed to being the choice for integrated business solutions that drive customers to improved performance. Unisource offers many packaging solutions to customers, including packaging consumables and equipment, package design as well as kitting and fulfillment programs. The new strategic alliance with Plan Automation now puts Unisource in the position to provide complete line automation solutions that can help increase operating efficiencies and reduce manufacturing costs.

Plan Automation, a specialist in providing quality automation, is dedicated to the concept of best practices in all areas of packaging automation. With specialists in the food, pharmaceutical and consumer packaged goods industries, Plan Automation provides a wide range of services, including facility design, line integration, custom engineering and, of course, equipment solutions from many of North America’s and Europe’s most respected manufacturers of automation equipment. Understanding that providing quality automation equipment is only the first link in the chain, Plan Automation also provides comprehensive after-sales support. This collaboration brings together Unisource Canada’s material consumable expertise and Plan’s expertise in line automation, promising to deliver new advantages to customers in manufacturing and food processing industries looking for strategic automation solutions.

EVENTS May 22-24

May 22-25

Philadelphia, Pa.: EastPack, packaging technologies exhibition by UBM Canon. Concurrently with MD&M (Medical Design & Manufacturing) East, ATX (Automation Technology Expo) East, Atlantic Design & Manufacturing and Green Manufacturing Expo. All at Pennsylvania Convention Center. Contact Lonnie Gonzales at (310) 996-9418; or via email Lonnie.Gonzales@ubm.com

Munich, Germany: AUTOMATICA 2012, international showcase of automation technologies for medical, pharmaceutical and cosmetics industries by Messe Munchen International. At the New Munich Trade Fair Centre. To register, go to: www.messe-muenchen.de

June 4-5 Washington, D.C.: 2012 Corrugated Industry Fly-in,

joint conference by the Association of Independent Corrugated Converters (AICC) and the Fibre Box Association. At Hotel George. To register, go to: www.aiccbox.org or www.fibrebox.org

June 6-7 Chicago: Sensors Expo & Conference, industrial sensors and sensor-integrated technologies exhibition and forum by Questex Media Group LLC. At Donald E. Stephens Convention Center. To register, go to: www.sensorsexpo.com

June 17-20

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Exclusive One-Day Forum: June 6, 2012 Metro Toronto Convention Centre Join business, government and industry leaders to discover top strategies for cost and carbon control!

HEAR FROM INDUSTRY EXPERTS: Dr. Blair Feltmate, Chair of the Climate Change Adaptation Project, will share meaningful, practical and cost-effective approaches to climate adaptation strategies for business. A Award-winning columnist with the Globe & Mail, Margaret Wente, will discuss energy policy friction, and ideas for building consensus between government, industry and environmental groups. Debbie Baxter, Vice-President of CSR and Chief Sustainability Officer with LoyaltyOne will moderate a session on using social media to include your employees, shareholders and customers in your corporate responsibility programs. Counsel with Bennett Jones LLP, Gray Taylor is on deck to share insights on carbon regulation, policy and market pressures in Canada. George Stedeford, Chief Executive Officer, Carbon Offset Aggregation Cooperative, will provide an overview of an expanding BC program cutting carbon and costs in transportation. Global Strategy Advisor and Director of Business Development, Etienne Boaknin of Quantis, will present on product inputs and supply chain improvements. To view more speakers, visit www.carboneconomysummit.ca

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To register contact: mpaquin@bizinfogroup.ca 416-510-6833 toll-free in Canada: 1-800-268-7742 x6833 For sponsorship opportunities contact: jmeli@bizinfogroup.ca 647-823-2300

New Orleans, La.: EskoWorld 2012, digital packaging, labeling, printing, flexo and finishing technologies end-user conference by the Esko User Group International (EUGI). At Hilton New Orleans Riverside. Contact Irvin Press at (508) 304-0608; or go to: www.esko.com

June 19 Toronto: Walmart Canada Sustainable Packaging Conference VI, annual event by PAC-The Packaging Association. At Toronto Congress Centre. Contact Lisa Abraham at (416) 646-4640, or via email labraham@pac.ca

Sept. 11-13 Chicago: Labelexpo Americas 2012, labeling technologies conference and exhibition by Tarsus Group plc. At Hotel Transamerica. Contact Camilla Colborne at +44 (0) 20 8846 2731; or go to: www.labelexpo-americas.com

Sept. 28-30 Ottawa: World without Packaging Waste, national conference by PACThe Packaging Association. At Fairmont Chateau Laurier. Contact Lisa Abraham at (416) 646-4640, or via email labraham@pac.ca

Oct. 1-4 Atlanta, Ga.: 2012 SuperCorr, corrugated industry exhibition and conference by TAPPI (Technical Association of Pulp and Paper Industries) and AICC (Association of Independent Corrugated Converters). Contact Kristi Ledbetter of TAPPI at (770) 209-7319; or go to: www.supercorrexpo.org

Oct. 28-31 Chicago: PACK EXPO International 2012, global packaging technologies exhibition and conference by Packaging Machinery Manufacturers Institute. At McCormick Place. Contact PMMI at (703) 243-8555; or go to: www.packexpo.com

Nov. 14-15 Montreal: PACKEX Montreal, packaging technologies exhibition by UBM Canon. Concurrently with Expoplast 12, ATX Automation Technology Expo Montreal, Design & Manufacturing Montreal, Contract Manufacturing Expo, Powders & Bulk Solids and AerCon. All at Palais des congrès de Montréal. To register, go to: www.canontradeshows.com

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CANADIAN PACKAGING • MAY 2012

PEOPLE  Pawcatuck, Conn.-based plastics extrusion and processing equipment manufacturing group DavisStandard, LLC has appointed David Hochhauser as vice-president and transformational controller, with primary responsibility of managing the financial aspects of the transitional period resulting from the recent acquisition of DavisStandard by ONCAP, a midmarket private equity platform of Toronto-headquartered venture Hochhauser capital group Onex.  Anilox roll supplier Harper Corporation of America of Charlotte, N.C., is saddened to announce the passing of the company’s co-founder Ronald “Ron” Lee Harper last month, following an illustrious career in the global f lexographic printing industry. Launching the company in 1971 with his wife Katherine, Harper is widely credited with helping revolutionize Harper f lexographic printing quality over

the years by utilizing advanced printing technology, while expanding the Harper brand of anilox products worldwide to make the company one of the global leaders in the f lexographic printing and package converting fields.  Jonathan Ellaby, vice-president of international operations for Schaumburg, Ill.-headquartered INX International Ink Co.—third-largest printing inks manufacturer in North America operting over 20 manufacturing and distribution facilities in the U.S. and Canada—was elected as recipient of the highly-prestigious Printing Ink Pioneer Award of the National Association of Printing Ink Manufacturers (NAPIM) at the group’s recent 96th annual convention in Palm Springs, Ca., in recognition of the U.K. native’s distinguished professional career spanning over 40 years in the global printing industries. Jonathan Ellaby displaying his NAPIM award alongside his wife Sandie.

FREE PRODUCT INFORMATION For further information on either advertisements or editorial in this issue, please circle the appropriate numbers below. Once you’ve filled out your contact information, fax this form back to us at: 416.510.5140

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IMPORTANT: Please complete the following questions What is the primary business at your location? Which of the following do you plan on purchasing within the next 12 months?  Advesives  Checkweigher  Machine Vision  Adhesive Applicator  Colour Label Printer  Metal Detector  Bar Code Equipment  Conveyors  Modified Atmosphere  Capper  Filler Packaging Machinery  Cartoners  Ink Jet Equipment  Palletizer  Case Packer  Intermediate Bulk Containers  Pallets  Case Sealer  Labeler  PLC’s, Sensors, Controls Approximate number of employees? Is this company a:  Package User  Custom Packager  Package Maker  Supplier

 Print & Apply Label Applicator  RFID Equipment  Robotics  Scales & Weighing Equipment  Shipping Containers  Shrink Film  Shrink Wrapper

 Strapping Equipment  Stretch Wrapper  Stretchwrap Film  Shipping Containers  Tape  Vacuum Packaging MAY 2012

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WORKING OUT THE PACKAGING NAME GAME

t takes a lot of effort, pain and sweat to get really fit and healthy. I know this first-hand—having been making smarter food choices since January, while also resurrecting my Bowflex home mini-gym that has been idled since 2007—putting it right next to the newly-purchased treadmill. For all that, I still find myself struggling with my conscience whenever attending a house party or social gathering where waiters f loat trays of picturesque hors d’oeuvres around the room. Call it weakness, but sometimes an extra 20 minutes on a treadmill is a fair trade-off for actually enjoying yourself at a party with a little overindulgence. The trick is to keep your self-discipline intact when making such choices on everyday basis, which is why I really appreciate loud “in your face” product labels that steer me to making healthier choices.

The California-based Fresh Gourmet Company does this trick convincingly with the zippered stand-up pouches of Fresh Gourmet Organic Seasoned Premium Croutons—using large-sized, allcaps lettering to full effect to trumpet the product’s “ORGANIC/BIOLOGIQUES” credentials before the shopper’s eyes move elsewhere on the package. The green lettering outlined in black against the white background, with the brand logo outlined in a subtler shade of green, makes for one very compelling organic declaration, with the appetizing ‘good-enough-to-eat’ salad graphics with large, perfectlytoasted croutons proving once again that a good picture really is “worth a thousand words.”

Sometimes the nature of the product is so inherently repugnant in terms of subject matter that the only way to market it effectively is to come up with a really playful name to override the “ick factor.” In this respect, Royce’s Toe Juice ointment from the Idaho-based G Cubed LLC fits the bill to a tee, or to a toe rather—in large part thanks to a bight-yellow, foot-shaped tag attached to the 135ml plastic bottle filled with light, aqua-colored liquid. Featuring a hilarious picture of a baby with monster-sized feet virtually leaping off the surface of the label, the attention-grabbing tag explains the rationale behind the product— formulated by a real-life chemistry teacher—and lists all the skin ailment and body parts for which this product can provide “natural refreshment” and effective medicinal relief.

It’s a similar story with the wildly-named Anti Monkey Butt sweat-absorber/friction relief powder from the Texas-based Anti Monkey Butt Corp. Distributed in Canada by Associated National Brokerage Inc., this is another product name that could get one’s knickers in a bunch without adequate explanation by clear, to-the-point product label proclaiming it to be “ideal for butt busting activities” that may cause uncomfortable friction from skin-againstequipment or skin-against-skin tenderness that often occurs while biking or playing hockey, football and other sports. But it is really the outrageous cartoonish graphics of a monkey sprinkling Anti Monkey Butt where it counts on the back of the shaker-bottle container that steals the show with its ingenious “Monkey see, Monkey do” directness.

ADVERTISERS’ INDEX R.S. No.

• WS Packaging Model 1600 Front-Back Labeler • AllFill Auto Powder Auger Filler SHAA-600 • Abal Top & Bottom Case Taper Model 10 • Pillar 2 Kw Heat Induction Sealer Unifoiler • Damark Heat Tunnel Model STB-16APC • Imaje Ink Jet 2 Line Date Coder Model 9020 • Qty 2. 48in Thomas Accela Coaters 48-M-111 • Highland 65G Full Sweep SS Jacketed Kettle • Emplex MPS 600 Table Top Bag Sealer MPS6140 • 16” Stainless Steel Round Coating Pans • Brunner Horizontal Cartoner Model CMI-11 • Nordson Durablue 4-L Hot Melt Systems

38 • WWW.CANADIANPACKAGING.COM

ADVERTISERS’ INDEX

Page

122

ABB Robotics

103

Atlantic Packaging Product Ltd.

112

Coca-Cola Refreshments Canada

113

Ellis Packaging

114

Farm Credit Canada

115

Flexipak

110

Harlund Industries Ltd.

109

Haremar Plastic Manufacturing 13, 36

117

Heat and Control, Inc.

105

Krones Machinery Co. Ltd.

123

Muller Martini Canada Inc.

118

Multivac Canada

116

Norampac Inc.

101

Owen-Illinois

4 23

2 9

Name Title Company Name

Paper Packaging Canada

108

Primera Technology Inc.

Address

121

R E Morrison

104

Robert Reiser & Co. Inc.

City

111

Schubert Packaging Machines

119

SEW Eurodrive Co. of Canada

124

Unisource Canada Inc.

120

VC999 Packaging

102

VideoJet Technologies Canada

MAY 2012

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

Premier Tech Systems

19, 38

Rhea Gordon is a Toronto-based freelance writer.

PRODUCT INFORMATION

107

20,21

Kudos also to tissue giant Kimberly-Clark Inc. for the new, elegantly upscale paper towel boxes used to package its f lagship Kleenex brand of paper hand towels designed to dispense “a clean, fresh towel every time,” as the mailbox-shaped countertop box proudly proclaims. Boasting a faux industrial look achieved with subtle metallic colors and a patterned sprinkling of embossed dots throughout the surface, the box carries a large, removable side-panel label illustrating the product’s alternate dispensing method when placed upside-down on a towel rack—displaying the versatility and convenience that already made the Kleenex brand synonymous with tissue packaging value-added and innovation.

FREE

106

In terms of Beavis and Butthead school of humor, the so-called Original Sneaker Balls Shoe Fresheners, imported by Implus Footwear, LLC of Durham, N.C., are definitely a giggle-worthy creation requireing an informative product label to avoid misunderstanding. The blister-card packaging for these toy-like balls—offered in a broad variety of colors and patterns—does a fine job of communicating the message that these spherical air-fresheners mean serious business when it comes to keeping smelly gym odors and scents under control, touting the use of a patented TX-3 odorblocking counteractant as the main weapon in subduing the undesirable odors in sneakers, gym-bags, lockers et al caused by heavy perspiration.

Prov.

P/Code

Telephone Fax Email Address

CANADIAN PACKAGING • MAY 2012

Photos by Rhea Gordon

CHECKOUT RHEA GORDON

Fit for difference

Muller Martini Alprinta V Web Offset Press For every demand the right application The Alprinta V size-variable web offset press is exceptionally well suited to the production of flexible packaging and labels. Virtually any print length can be produced. To change printing size, there is no need to change the complete printing insert, it suffices to change the carbon fiber cylinders. The Alprinta V handles a wide range of printable substrates and is therefore very flexible: paper, film, composite materials, work as well as self-adhesive label stock. Alprinta V stands out thanks to short changeover, reduced waste and minimal printing plate costs. Alprinta V offers hybrid applications including flexo, screen, gravure and digital printing and it is available with electron beam, UV and hot air drying technologies. The Alprinta V is available in two widths (520 mm and 740 mm) and it permits rapid size changes with printing lengths of 20”-28 1/3” (508 mm- 720 mm) by exchanging carbon fiber cylinders. The printing size range can be extended to print lengths up to 40” or 1016 mm, using insert cassettes.

Müller Martini Canada Inc. 20 Caldari Rd. Concord, ON L4K 4N8 Telephone 905-660-9595 Fax 905-660-9555 www.mullermartinicanada.com FOR MORE INFORMATION CIRCLE 123

Great packaging doesn’t just contain. It sells. Unisource Engineered Solutions’ team of structural engineers and creative designers offers expertise in sustainable packaging. We bring material-neutral design, advanced engineering, in-house testing and the latest graphics and printing technology to enhance our customers’ brands. The result: leading-edge, environmentally friendly solutions that not only protect and secure your product, but help you stand out from your competitors. Contact Unisource Canada’s Packaging Solutions Experts to learn how we can deliver the right packaging for your products.

www.unisource.ca

CUSTOMER SOLUTIONS IN A GLOBAL MARKET FOR MORE INFORMATION CIRCLE 124

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