Modern Packaging & Design - January-February 2012 by Infomedia18

Modern Packaging & Design

January-February 2012

EDITORIAL

Leap for the Next t the outset, here’s wishing a Great New ‘Leap’ Year to all of you! With expanding ecosystem of enterprises and rising demand from the emerging sectors, as India’s manufacturing and technology prowess comes of age, one can look forward to the country becoming the fastest-growing economy on the globe, sooner than later. This promises unparallelled opportunities to take the present product and service portfolio to the next level, and in the process, transform a multitude of cities and states as well as the lives of millions.

In retrospect, the year 2011 was eventful for the Indian packaging sector and the country, in general. Amid sweeping mega global trends – from the Jasmine Revolution to the unprecedented stress on the Euro Zone and their rising ricochets across the globe – India stood tall as one of the few key growth markets, albeit with tapered rate of economic ascent. Since product innovation and diversity form the core of crucial success quotient for packaging enterprises, and given the existence of both large and small scale manufacturers, there is fairly fragmented competition in this market. Going forward, the rising competitiveness in the global marketplace and the availability of additional capacities in some geographies will determine the next phase of market development as well as the sustainability of market positions of the leading players in this space. In the near future, it will be interesting to see if the sector can adopt the approach to leapfrog rather than merely catch up in the race to offer greater productivity, energy efficiency and flexibility by virtue of next-gen products and processes. That said, it is imperative to put into action adequate safeguards and regulatory practices to ensure that the Indian growth momentum is carried forward in an increasingly uncertain global market.

Editorial Advisory Board P V Narayanan Member of Board APEDA (Ministry of Commerce)

This edition of ‘Modern Packaging & Design’ reflects the above and more, with a focussed mix of the past, present and future. All these should lead to smarter technology, precise pricing, superior customer service and proficient performance for the packaging sector. Of course, we will review the emerging trends regularly and present the analysis for you in the times ahead.

M K Banerjee Director-Creativity & Innovations (Global) Essel Propack Ltd

R Krishnamurthy Director-Marketing & Operations Orient Press Ltd

Manas R Bastia manas@infomedia18.in

S Das Managing Director Nordson India Pvt Ltd

Modern Packaging & Design January-February 2012

CONTENT S

45 FSS machines ...........................46 Innovation index ....................48

Cosmetics Packaging............ 36

Roundtable ........................... 50 Activity integration

Challenges in cosmetics packaging.............................. 38

Special Focus

Interface - Anuj Prasad ........ 36

in packaging ......................... 52 UV curing technology .......... 54

Insight & Outlook

Practical tips ......................... 56 Colour management ............. 58

Newsmakers of 2011

FSS machines in pharma: Gaining profitability through accuracy

Life cycle analysis: ‘Flexible’ opportunities in packaging

Plastics in food packaging: Monitoring food contact stipulations

Automation Trends

Energy Management

Policies & Regulations

In Conversation With

Yatindra R Sharma, MD, KHS Machinery Pvt Ltd

Shilp Gravures Ltd: Im’print’ing standards of excellene

Strategy

Packaging techniques: Approach for enhanced shelf life

Tips & Tricks

Labeling solutions: Creating a lasting impression

Event Report

India Converting Show 2011 Industry meet on packaging for liquor business

Facility Visit

Details on pg no. 34, 51, 71 Cover photo courtesy : ABB Ltd

Highlights of Next Edition Special Focus: New Packaging Materials Insight & Outlook: Sustainable Packaging Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise

REGU L AR SEC T ION S Editorial ................................. 7 News, Views & Analysis ...... 18 Technology & Innovation .... 24 Design Innovation................ 26 Technology Transfer ............. 30 Projects ................................. 70

Event List............................. 71 Book Review ........................ 76 Products................................ 77 List of Products.................... 87 List of Advertisers ................ 88

Modern Packaging & Design January-February 2012

Business Insights •Technologies•Opportunities

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Modern Packaging & Design January-February 2012

NEWSMAKERS OF 201 1

Acquisition Nordson to buy Belgian manufacturer Verbruggen

Pro Mach acquires Matrix Packaging Machinery

( July-Aug) Nordson Corp is buying Belgium’s Constructiewerkhuizen G Verbruggen NV, which manufactures equipment for the flexible packaging industry. Nordson manufactures equipment for applying adhesives and other materials to consumer & industrial products. Verbruggen makes flat dies and co-extrusion equipment used in the manufacture of bags, wraps, pouches, etc.

(Nov-Dec) Pro Mach Inc has acquired Matrix Packaging Machinery, which will join its Primary Packaging Business Unit, thereby expanding Pro Mach’s primary packaging solutions. The Matrix management team will remain with Pro Mach. Matrix’s strength in vertical form-fill-seal packaging allows Pro Mach to reach new markets worldwide with its diverse brands of high-performance equipment and integrated solutions.

Appointment Robert Willett becomes CEO at Cognex Corporation

Nick Talbot is new Global Design Head at Tata Elxsi

(May-Jun) Robert Willett, President and COO, Cognex Corporation, was promoted to CEO. Willett will continue reporting to Dr Robert J Shillman, Chairman of Board, who will take on the newly created role of Cognex’s Chief Culture Officer. Dr Shillman said, “Willett has well managed our business during the 2009 downturn and laid the groundwork for our company’s excellent financial performance in 2010.”

(Sep-Oct) Design veteran Nick Talbot was appointed as the global design head for the Industrial Design (ID) division at Tata Elxsi. He will be based in the Bangalore headquarters of the company. He will be responsible for all design initiatives at ID across the globe, as well as for IP portfolio creation. An alumnus of Royal College of Art, London, Talbot comes with over 20 years of design experience.

Collaboration & Partnership Schneider Electric becomes an OYSTAR Global Automation Partner ( Jan-Feb) OYSTAR IWK has introduced TFS E tube filler, featuring innovative solutions that significantly reduce product changeover times. The product served as a pilot project for international collaboration between IWK and Schneider Electric, where Schneider Electric served as an international technology partner and a supplier of automation and electrical equipment.

Nichrome, TOTPACK collaborate for innovative packaging solutions (May-Jun) Nichrome India Ltd will offer special Horizontal Form-Fill-Seal (HFFS) machinery with re-closability and pourability features for packaged products. It has collaborated with TOTPACK from Spain. The company will use advanced Spanish technology to manufacture and sell these machines domestically and internationally at Indian prices.

Cardia Bioplastics collaborates with Nestlé ( Jan-Feb) Cardia Bioplastics has announced its collaboration with Nestlé SA to reduce the environmental impact of packaging. This collaboration is in line with Cardia’s strategy of working with global brand owners who are looking for alternatives to conventional packaging. Cardia’s technology enables them to reduce their carbon footprint by using less oil in their packaging while maintaining product performance.

Minnesota firm to develop packaging in India ( July-Aug) Northern Technologies International has announced that it will sell corn-based resins for plastic coatings and packaging to ITC Ltd. The two companies will develop new biodegradable and compostable bioplastic packaging for food, personal care products, etc. This deal follows India’s focus on the use of highvolume packaging, thus triggering demand for alternatives that do not face environmental and waste disposal challenges.

Exhibition & Conference OPA encourages achievers and innovations ( Jan-Feb) A three-day exhibition ‘PrintArt 2010’ was recently organised by Offset Printers’ Association (OPA), Ludhiana, with support from printers associations of North India. OPA organised the 6th edition of ‘Best of North’ competition to mark excellence in offset, digital and screen printing. It was sponsored by XEROX India and judged by printing experts from Kurukshetra University and GJ University, Hisar.

Modern Packaging & Design January-February 2012

Second Indo-German Conference on developments in packaging printing ( Jan-Feb) Experts and industry authorities in packaging printing recently convened to discuss and share the latest developments & advancements in packaging printing. The theme of the conference was ‘Technology Trends and Developments in Packaging Printing’. The conference brought together professionals from the German and Indian printing industry.

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Exhibition & Conference Innovations abound at PACK EXPO International 2010

QuadTech presents innovations at PackPlus South 2011

( Jan-Feb) Brand owners and packaging & processing professionals participated in PACK EXPO International 2010, Chicago – a comprehensive packaging and processing trade show in the world. Charles D Yuska, President & CEO, PACK EXPO, said that true measure of success in a trade show is the degree to which attendees and exhibitors believe that participation has been a good use of time & resources.

( July-Aug) Among world’s leading press control solution providers, QuadTech showed various automated inspection, verification and colour measurement solutions for flexo & gravure printing at PackPlus South 2011. At the event was displayed QuadTech’s Autotron™ 2600 with ClearLogic™ register guidance system – an integrated, flexible & costefficient tool for minimising waste & improving print quality.

Dates set for Interpack 2014

Packaging companies get a glimpse of latest technological developments in Gujarat

( July-Aug) The next edition of Interpack will be held during May 8-14, 2014, at Düsseldorf trade fair centre. Companies wishing to participate as exhibitors can register from autumn 2012 onwards. The exact dates will be announced in due course by Messe Düsseldorf. Till the next staging of the fair, the show website will feature the latest industry news and articles.

(Nov-Dec) India Package Meet 2011, organised by PrintPackaging.Com on September 10 in Gujarat, focussed on technological developments in packaging & printing industries. It highlighted technological developments with products from providers of machines, materials & services to end users, package converters and corrugated box makers.

Innovation BERICAP offers valve-function for squeezable products

TATA ELXSI designs packaging for Freedom Oil

( Jan-Feb) BERICAP, a leading company producing plastic closures for food & beverage and the chemical industry globally has introduced a hinge closure with a valve function for ketchup & mayonnaise. The valve opens on pressing the bottle and a well-dosed squeezable product exits. On releasing the pressure, the valve closes and the area of the opening remains clean.

( Jan-Feb) TATA ELXSI has designed the packaging for Freedom Sunflower Oil – product of a relatively new company Gemini Edible Oils & Fats. The oil available in 5-litre jars must look dynamic and convey the brand value of ‘Your right to happiness’. Bright colours are used to give the product a greater shelf appeal. A series of waves culminates to the jar neck to reflect energy, dynamism and the theme ‘Happiness’.

Investment HNGIL to invest to hike production capacity

Rexam PLC, HTWL to invest in India’s beverage can market

(May-Jun) Hindusthan National Glass Industries Ltd (HNGIL) plans to invest ` 5,000 crore in the next five years to set up new facilities and expand existing capacity. The firm, with total production capacity of 9.40 lakh tonne in the last fiscal, expects it to reach 12 lakh tonne in 201112. HNGIL currently has plants at Bahadurgarh (Haryana), Nashik (Maharashtra) and Neemrana (Rajasthan).

(Sep-Oct) Rexam PLC and Hindustan Tin Works Ltd (HTWL) announced setting up of a new high-speed beverage can manufacturing line at HTWL’s site in Taloja, near Mumbai. The capital investment of the new line is ` 220 crore over two years. It will initially produce 33 cubic litre and 50 cubic litre cans and later move on to slim cans. Production will start in the final quarter of 2012.

Market Review Big leap in flexo print industry with Zircon

Asda, Bezier’s 25-year long relationship ends

( Jan-Feb) Zircon had chosen EskoArtwork’s CDI Spark 4835 high-definition imager for flexo, with unique inline Ultraviolet (UV – main exposure) to boost quality, consistency and enhance productivity. Zircon is a pioneer in high-quality flexo label printing in South Asia. High growth in the packaging industry has also encouraged Zircon to expand its existing set-up.

(Mar-Apr) Asda has ended a 25-year, multimillion-pound supply relationship with point-of-sale group Bezier after the Londonbased Delta Group won a competitive tender for the job. Bezier’s staff working on the Asda contract in Leeds are to move to Delta to continue work at the supermarket. David Mitchell, Chairman, Bezier, informed that Bezier had recently refinanced, thus proving its financial backers’ confidence in the business.

Modern Packaging & Design January-February 2012

NEWSMAKERS OF 201 1

Market Review Profit hike for Mondi corrugated after UK pull-out

Saint-Gobain says no to pack division

(Mar-Apr) Profits increased more than fivefold in Mondi’s international corrugated business in 2010, when it pulled out of UK corrugated manufacture. The Anglo-South African paper & packaging group said that restructuring and improving prices and establishment of a new mill in Poland had led to a 417 per cent increase in the division’s underlying operating profits.

(Mar-Apr) Saint-Gobain has turned down a series of private equity offers for its € 3.4 billion glass packaging business Verallia. The second-biggest glass manufacturer in the world had rebuffed an offer from a group of private equity firms, including TPG Capital, Blackstone Group and AXA Private Equity. Saint-Gobain is planning to retain a stake in the business. The IPO is estimated to value Verallia at over € 4 billion.

A&R Carton buys stake in SP Containers

China becomes export destination for Hindustan Tin Works

(May-Jun) Swedish cartons group A&R Carton had bought another 34 per cent of food and retail packaging supplier SP Containers, becoming the majority shareholder of the company. With this, A&R, which has 14 factories across 8 countries in Europe, now owns 67 per cent of SP Containers. The deal came two and a half years after A&R first invested in the company.

(May-Jun) Hindustan Tin Works Ltd (HTWL), with a fresh order from China, potentially made India another export hub for metal can industry in Asia. Exports from HTWL grew by 341 per cent in the last five years. It now exports to 22 countries across the world including the US, Australia, Europe, Africa, the Middle East and South East Asia, with its latest customer, China.

Crown, Clemson join for packaging education programme

Redington India to be Objet’s Master Distributor in India

(May-Jun) Crown Holdings Inc is the first corporate ‘Partner in Packaging’, a new initiative of the packaging science programme at Clemson University. Crown will donate a gift of cash for use as unrestricted programme funds, and gifts-inkind of metal packaging fabrication equipment, faculty travel & regular participation of company personnel in this programme.

(Sep-Oct) Objet Asia Pacific Ltd, a subsidiary of Objet Ltd, had appointed Redington India Ltd its master distributor for India. Redington India will distribute Objet’s 3D printing systems & products across the country. Ashan Dhunna, Sales Director & ME, Objet Asia Pacific, said, “We are confident that with Redington, we can successfully make 3D printing and Objet a familiar technology in India.”

New Machinery Kabra Gloucester showcases first five-layer film plant

Printing & labelling solutions from Markem-Imaje

(Nov-Dec) KAGE is the brand name for film plants manufactured by Kolsite Group, using engineering designs and technology of Gloucester Engineering Co. The first five-layer fully loaded 2,200-mm film line has an installed capacity of 4,000 tonne/year and output up to 600 kg/hr. This plant is all set to be delivered to Prropyl Packs Ltd, Kerala. It is used to pack oil and also for producing high-quality lamination films.

(Nov-Dec) Markem-Imaje has launched its 2200 Series, an ultra-efficient range covering a broad choice of interchangeable applications, optimised operational intervention and unparalleled label application rates. The new 2200 Series has demonstrated its reliability, efficiency and ease of use. The new machine can print and apply labels at rates in excess of 125 boxes per minute.

Regulation & Certification HTWL gets HACCP and ISO certification (Mar-Apr) Hindustan Tin Works Ltd has been certified by Transpacific Certifications Ltd for ISO 9001:2008 and Hazard Analysis and Critical Control Points (HACCP). The certifications are applicable to quality assurance, systems, procurement, storage, printing, manufacturing, packing, dispatch of tin containers. HACCP is used in food industry to identify potential food safety hazards, and take actions to reduce these.

Modern Packaging & Design January-February 2012

DCGI makes barcoding mandatory for pharma packaging (May-Jun) Drug Controller General of India (DCGI) has proposed to make it mandatory for medicines intended for domestic supply to bear barcodes. This was announced by Dr Surinder Singh, DCGI, Ministry of Health & Family Welfare, Government of India. The Commerce Ministry unveiled a scheme to add serial numbers to exported medicines.

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Sustainability Danone Canada adopts green packaging technology (May-Jun) Danone Canada has announced two major innovations in packaging: a new ecological manufacturing process for its individual serving products, called ‘expansion’, and an ecological high-density polyethylene for its drinkable yoghurt packaging. The expansion process involves adding an inert agent to polystyrene plastics. This agent forms a thin layer of foam in polystyrene, reducing the overall density of the plastics.

Compostable packaging films effective against mineral oil residues (Sep-Oct) NatureFlex™ by Innovia Films has been scientifically tested and proven to provide effective barrier against mineral oil residues. A recent study at the Zurich Food Safety Authority in Switzerland proved the efficacy of compostable NatureFlex™ films, as it detected alarming levels of mineral oil residues that transferred from recycled cardboard packaging into food.

Miscellaneous HNG unveils robust expansion plans

Bobst India opens Competence Centre in Pune

( Jan-Feb) Hindusthan National Glass & Industries Ltd, with over 55 per cent marketshare in the organised sector, has embarked on a significant deal in the Indian glass industry. The deals worth close to ` 2.5 billion have been undertaken with international companies like Emhart Glass (Switzerland), Heye Glass (Germany), Pennekemp (Germany), Horn Glass (Germany) and Zippe (Germany).

(Mar-Apr) As part of Bobst’s strategy to use local resources to better serve its packaging customers in India & Indian Subcontinent, Bobst India has started a Competence Centre, at its headquarters at Pirangut, Pune, to offer consultancy and support services. The Competence Centre is equipped with a NovaCut and an ExpertFold with more machinery for high-end performance to prospective users of the centre.

HNG Float signs MoU at Vibrant Gujarat

Rajasthan Ventures invests in PR packaging

(Mar-Apr) At Vibrant Gujarat Global Investors’ Summit (VGGIS) 2011, HNG Float signed an MoU for investment ` 750 crore to set up a new float line at its existing float glass manufacturing plant at Halol, Gujarat. The new production line will have a capacity of 1,000 million tonne per day. This is the second line being set up at Halol with the existing one producing 600 million tonne per day.

(May-Jun) Rajasthan Venture Capital Fund has invested `15 crore in the second round of funding of PR Packaging Ltd (PRP) located in Faridabad. The funds will be used to widen its customer base by enhancing its capacity, exploring new opportunities and widening its product portfolio. PRP produces high-quality folding cartons like printed mono cartons, fluted boxes, pouches, brochures, leaflets, etc.

Greiner Packaging expands printing technology with K1 plus

HTWL bags 5th IPA Innovation Award for Canvironment Week

( July-Aug) Greiner Packaging announced completion of its classical dry offset printing method using print-relevant optimisation. K1 is Greiner Packaging’s cups made of plastics decorated with dry offset printing. This technology has been enlarged by new printing variants, which is called ‘K1 plus’. A modern eight-colour offset printing unit combined with individually manufactured laser clichés provides a brilliant printing image quality.

(Sep-Oct) At International Packaging Association’s (IPA) latest General Assembly in San Marino, Italy, in June 2011, the fifth IPA Innovation Award was presented to Hindustan Tin Works Ltd for creation of Canvironment Week, a global eco-friendly initiative to promote sustainability of metal cans. IPA promotes the inherent material and environmental value of steel packaging. Members of IPA stimulate the innovation process within the group by annually presenting the Innovation Award.

New film laminate from Avery Dennison

Alternative energy from non-recycled plastics

(Nov-Dec) Avery Dennison has introduced Global MDO in its innovative Machine Direction Oriented (MDO) film product line. The new film laminate bridges the gap between the high-performing MDO film range and PE85 film and features major productivity and sustainability improvements, eg, significant reduction in web breaks, up to 50 per cent less ooze, double amount of labels per roll and on-shelf label clarity for home and personal care applications.

(Nov-Dec) A new study conducted by the Earth Engineering Center of Columbia University and sponsored by American Chemistry Council found that if all non-recycled plastics currently dumped into landfills each year in the US are converted to energy by using currently available technologies, they could provide at least enough energy to fuel 6 million cars annually. Also, if all non-recycled plastics discarded in the US annually are diverted to modern waste-to-energy facilities, they could produce 52 million MWh of electricity.

Modern Packaging & Design January-February 2012

NEWS, VIEWS & ANALYSIS

Sanjay Bhatia re-elected as Chairman of Indian Institute of Packaging

Sanjay Bhatia

At the 45th Annual General Body Meeting and 198th Governing body meeting of Indian Institute of Packaging (IIP), Sanjay Bhatia, Managing Director, Hindustan Tin Works Ltd, was unanimously re-elected as Chairman of IIP. After the announcement, Bhatia said, “It is an honour for me to carry on the responsibility of this premier Institute and would like to thank the governing

Linpac Packaging to increase film capacity in France On an expansion drive, Linpac Packaging will invest € 10 million to increase film capacity at its plant in Noyal-Pontivy, France. The production capacity of stretch film, used to wrap fresh food such as meat and butter, will rise by about 1,500 Tonne Per Annum (tpa) or 30 per cent by 2014 when it is due to come on stream. Roland Castellanos, Vice President, Linpac Packaging (Spain, France and China), said, “Much of the spending at the Brittany facility will be dedicated to boosting output of multilayer barrier film.”

Shirplass, STM Polythene join hands

body for reposing confidence in me for the third consecutive year as Chairman of the Institute. I will put in my sincere efforts and work towards promoting the packaging industry and overall development of the institute.” He further observed that he would lead the team with N C Saha, Director, IIP, to build the image of the institute both at the national and international level. However, he has appealed to all the governing body members for their kind support and cooperation for the growth of the Institute. The governing body has elected R V S Ramakrishna, Chairman, ITW Signode India Ltd, and S K Ray, Sr Executive Vice President, Reliance Industries Ltd, as Vice Chairmen of the Institute for 2011-12. The Institute has reported a fairly steady growth since it was established and has attained self-sustainability over the period.

H B Fuller, Graco enter strategic partnership

Other recent investments at the Noyal-Pontivy plant include installation of a seven-layer film extrusion line to make high-barrier lidding film for meat packaging. This has led to an expansion of exports across Europe and beyond, according to Linpac in France. The Brittany facility is one of two operated in France by UK-based Linpac Packaging, the second being Linpac Packaging Dalidet in Ballée, east of the city of Rennes. The two film businesses have annual sales worth € 200 million and export the greater part of their production.

H B Fuller has partnered with Graco Inc in an attempt to provide specialised fluid handling equipment that will pump, process and dispense innovative Liquamelt adhesive. The adhesive and equipment system has been tested extensively with customers. The Liquamelt system is an alternative for both conventional hot and cold adhesive systems and brings several advantages to the packaging market. It provides environmental benefits with its formulation that consists of 40 per cent sustainable raw materials. Jim Owens, President and Chief Executive Officer, H B Fuller, said, “I am pleased to announce this partnership with Graco. The new delivery equipment, designed specifically for H B Fuller’s Liquamelt adhesive solution, will enable us to help our customers drive out cost and complexity from their processes. We look forward to many years of collaboration as we continue to commercialise this unique new adhesive technology.” This partnership is an important first step in developing a new adhesive platform, which will impact packaging as well as other markets in future. Together, H B Fuller and Graco will deliver indepth, technical knowledge of adhesives chemistry, proven equipment engineering expertise and practical application experience to help customers in many industries meet their specific needs.

Avani Jain

Annabel Dsouza

Polythene envelope and packaging specialist STM Polythene has expanded after merging with rival Shirlplass and buying online specialist KT Supplies. Norwich-based STM, which trades as Sefton TransMail, completed the merger with the Northampton-based Shirlplass. Esther Evans will be Managing Director of the combined group, while Mark Dodge, General Manager, Shirlplass, will continue to run the Northampton site. Evans said, “This is an excellent merger of two strong SMEs. Shirlplass is well

Modern Packaging & Design January-February 2012

developed in markets that STM is not represented in and vice versa.” Evans added that for both customers and suppliers, it would be business as usual from both production facilities in Norwich and Higham Ferrers. The integration of the KT operation will allow us to enhance STM e-commerce function to offer existing and new customers a onestop shop for all their packaging and mailing requirements. We plan to extend the product ranges that are available. Anwesh Koley

NEWS, VIEWS & ANALYSIS

Grafica exhibits printing excellence at SGIA Expo 2011

Coke invests heavily in development of plant-based plastics Coca-Cola Co has invested in three bio-based companies in an effort to accelerate the development of a PlantBottle made entirely from plants. The three companies include Virent Inc, which makes a bio-based feedstock, ie, BioForm X for paraxylene; Gevo Inc, which has developed a 100 per cent renewable isobutanol – a building block for paraxylene; and Avantium Research and Technology whose YXY chemical catalytic technology has led to the development of a new bio-based plastics, ie, PEF to make 100 per cent bio-based bottles that could be a replacement for today’s PET bottles. With this investment, the company aims to advance the technology to make purified terephthalic acid from nonpetroleum sources. Since December 2009, Coke has been marketing a

PlantBottle made from non-petroleumbased renewable resources. Rick Frazier, Vice President-Commercial Product Supply, Coca-Cola Co, said, “Moving to a PlantBottle made entirely of plants is imperative, as the company’s goal is to double the daily serving from Coca-Cola beverages to 3 billion by 2020. Further, to double our business in a sustainable way, we must find a new way to do more with less,” he said.

At the recently concluded SGIA 2011 expo at New Orleans, USA, Grafica had showcased its Nano series screen printing machines and allied equipment packaged as Nano Premier League (NPL) and NPL plus. Grafica had also displayed a large collection of creative print finishing samples of thick film deposit, abrasive, wrinkle, glitter, deep high gloss, textures, micro-embossing and many other UV special effects. Bhargav Mistry, Managing Director, Grafica Flextronica, said, “These samples were screen printed during regular workshops at DMI. Although my initial excitement was focussed on introducing Grafica’s Nano range of machines, the expo was an exciting teaching experience. Most visitors to our stall spent more time to understand the techniques of incorporating various special effects.” Participation in SGIA 2011 was a new beginning for Grafica as far as the US market is concerned.

Avani Jain

Annabel Dsouza

Cardia Bioplastics and Polyden Folien cooperate on sustainable packaging films Taking forward the sustainable packaging drive, Polyden Folien has joined forces to develop a new range of packaging films for the European market. The new range is made with Cardia Biohybrid™ technology that meets the highest packaging performance standards. The Cardia Biohybrid™ proprietary technology combines renewable thermoplastics with polyethylene material to reduce dependence on finite oil resources and also carbon footprint. The companies aim to launch the range of sustainable packaging films in late 2012. Peter Moser, Managing Director, Polyden Folien, said, “The combination of packaging performance, environmental profile and cost-effectiveness have made Cardia Biohybrid™ technology the solution for Polyden Folien’s sustainable packaging needs. Our packaging products made from their Biohybrid™ resins will form an integral part of our responsible packaging offering. We are looking forward to presenting our customers the Biohybrid™ packaging films, particularly for shrink film applications.” Avani Jain

Diageo unveils sustainable and premium pack targets Drinks giant Diageo has published its first ever sustainable packaging guidelines with a pledge to take on the challenge that lighter packaging is perceived as being less valuable. The guidelines outline numerous sustainability targets on areas such as reusability and recycled content for the business, which owns brands like Guinness, Smirnoff, Johnnie Walker’s and Gordon’s. However, the company acknowledges that in Diageo’s market of drinks and spirits, there are specific challenges around making packaging that is optimised from a sustainability point of view and has a premium feel as well. A document from the company states: ‘Our vision is to have packaging that is both premium and sustainable, but this is a challenge for our sector in general – especially with the perception among consumers that lighter means less valuable.’ David Gosnell, the group’s president of global supply and procurement, said, “This is an important milestone that will ensure a consistent approach to developing new packaging and reviewing existing packs. “The guidelines will not only help us meet our stretching sustainable packaging targets for 2015, but also support our engagement with customers and consumers – and further strengthen our position as corporate leaders in environmental sustainability.” Anwesh Koley

Modern Packaging & Design January-February 2012

NEWS, VIEWS & ANALYSIS

Rexam set for a major overhaul Manjushree Technopack wins WorldStar Awards 2011

Bengaluru-based plastic packaging major, Manjushree Technopack Ltd has won the prestigious ‘WorldStar Award’ 2011 for two of its packaging designs. Manjushree has won this recognition for the design for Unilever’s Kissan Squeezo ketchup bottle and CadburyKraft’s Bubbaloo jar. Instituted by the World Packaging Organization (WPO), the awards are considered as the highest recognition of packaging excellence in the world. These awards are given by the WPO, in its effort to recognise excellence in packaging solutions and encourage advancement in packaging. Vimal Kedia, Managing Director, Manjushree Technopack, said, “The WorldStar Awards are a recognition of our ability to go beyond the norm for our clients and develop packaging solutions which are truly innovative and amongst the best in the world. Today, the end customer is paying a lot of attention to packaging, as it directly affects product quality and usability. It is therefore important for packaging companies to respond to consumers’ needs by coming up with solutions that are practical, attractive and adhere to the highest quality standards. ” Annabel Dsouza

Global consumer packaging company, Rexam has plans to expand the current operations at its US production facility, Excelsior Springs in Missouri. The company will expand the capacity by more than 50 per cent to support growing customer demand for its products. As part of the expansion, the facility will add moulding and assembly equipment to help further boost the triple-digit revenue increase attained over the last 10 years. The facility serves the healthcare, food and personal care markets. Julie Vergnion, Category Manager, Rexam Personal Care Division, informed that the expansion further demonstrates the company’s desire to

New twist on perfume bottle with DuPont overmoulding material DuPont’s Surlyn thermoplastics alloy has been overmoulded on a glass perfume bottle for a novel aesthetic effect and also improved protection against damage. The bottle concept from Italian glassmaker Bormioli Luigi, marketed under Linkx, was devised by French luxury design specialist QSLD. The twisted shape of the glass inner bottle is accentuated in perfect transparency by the thick walls

support customer growth. Marlon Pass, Rexam Plant Manager, has said that the facility supports its major customers who ship to the Midwestern US and the company’s culture of continuous improvement would continue to create growth opportunities for the personal care division. The company had also recently announced plans to invest £ 68 million over the next three years to build a new beverage can plant in Mantsala, Finland. The two lines of the plant are expected to be operational by 2013 and 2014, respectively, with an output capacity of 1.35 billion for 330 ml and 500 ml aluminium cans. Anwesh Koley

of the Surlyn cube that encases it. This is a collaboration between Bormioli Luigi, DuPont and Italian injection moulding specialist Pibiplast. Bormioli Luigi’s patented Sparkx glass formulation is cited as stronger and durable than ordinary glass, with high transparency. Corrado Lusetti, Marketing Manager, Bormioli Luigi, said, “Linkx gives free rein to one’s imagination in terms of shapes, colours and optical effects for bottles. The glass provides high resistance to alcohol and other chemicals and a luxurious sense of weight. The Surlyn shell can be used to magnify and enhance the visual effect of the bottle and render it less susceptible to damage. Also, the material’s favourable tactile properties make the bottle both smooth and pleasant to the touch.” Avani Jain

Sealed Air launches PakNatural™ loose fill Sealed Air has introduced PakNatural™ loose fill, a protective packaging product made from 95 per cent non–food-based renewable materials. Besides its sustainable properties, PakNatural™ loose fill provides superior protection and produces less dust, offers greater anti-static performance and has increased inherent strength as compared to similar products & starch-based loose fill products in the market. Operations already designed for loose fill packaging can easily switch to PakNatural™ loose fill without changing their current packaging process.

Modern Packaging & Design January-February 2012

Mirella Andrianno, Product Manager, Sealed Air, said, “Loose fill packaging has interesting applications in the protective packaging market and has potential for growth as companies demand more sustainable packaging materials. PakNatural™ will provide companies with outstanding environmental and product protection performance. Further, with PakNatural™ loose fill, we have developed a solution that offers sustainability and performance benefits at a competitive price, giving our customers another option to meet their protective packaging needs.” Avani Jain

NEWS, VIEWS & ANALYSIS

Britton Taco invests in nine-layer extruder

O-I asserts its position as market leader

Theegarten-Pactec continues strong growth

Britton Taco plans to install a nine-layer blown film extrusion line in its latest multi-million pound investment. The Winsford, Cheshirebased flexible packaging business plans to install the Hosakawa-Alpine line. This will be the fourth new Alpine line to be installed at the site since 2006. Britton was recently bought by private equity house Sun European Partners, and since then has been put at the heart of a pan-European flexible business to be led by former CEO Edwin Goffard. It will offer film widths of up to 2,000 mm from nine individual extruders and produce film suitable for applications such as lidding films, retortable barrier films and cheese packaging pouches. In comparison with the typical seven-layer structure for EVOH or nylon barrier films, the nine-layer structure will allow Britton to add outer layers of Polyethylene Terephthalate (PET), nylon or Polypropylene (PP) directly to the film rather than having to buy them separately and laminate them to the barrier films. The company believes that cutting out the laminating stage will give a cost advantage and remove potential problems with solvents.

Glass containers manufacturer O-I is to buy French bottle maker VDL Company after agreeing to a new strategic relationship that will make it the biggest supplier of Perrier water bottles. Under the $ 15 million (€ 10 million) acquisition, O-I will become the largest supplier of glass bottles for the iconic Nestlé Waters sparkling water brand. VDL employs 132 staff and runs a single bottle production plant at Vergèze, near the Perrier bottling facility. O-I had already supplied bottles for Nestlé Waters’ S Pellegrino range. Jose Lorente, President, OI Europe, commented, “As a result of this deeper strategic relationship with Nestlé Waters, O-I has the opportunity to support some of the pre-eminent brands in the water segment and reinforce the position of glass in this important category.” VDL has undergone some restructuring to make its cost base comparable with that of other O-I Europe plants. The Ohio-headquartered O-I said that it expected the acquisition to add to its profits in the coming financial year.

The demand for TheegartenPactec’s packaging machinery and turnkey solutions for packaging of small confectionery items is higher than ever. The order volume for Markus Rustler 2011 is expected to be above that of the last year, which equates to continued growth for the fifth consecutive year. The company also anticipates moderate growth in turnover. The number of employees has also increased to about 320. India and the Asia-Pacific region are important markets for TheegartenPactec. The demand for packaging solutions for hard boiled candies, toffees and chewing gum is still predominant, although the packaging machinery manufacturer is experiencing a trend towards chocolate products. Total order volume for the first half of 2011 has increased. The markets are important not only due to their economical dynamics, but also because creative product innovations are developing here, which require sophisticated packaging challenges as a reuslt of rising quality expectations of domestic consumers. Markus Rustler, CEO, Theegarten-Pactec, said, “Due to our global presence, we could compensate for the slow economic situation across continents.” This year’s Interpack fair was used to refresh existing business relations and to bring about new customers, although other national exhibitions in various countries also contributed to stimulation of business contacts.

Anwesh Koley

Annabel Dsouza

APPE automates PET preform quality control Considering that manufacture of Polyethylene Terephthalate (PET) preforms is becoming a challenge with increasing demand and more recycled PET (rPET) resin blends as well as use of performance additives, APPE has invested € 1.5 million to develop and install Sample-PreWatcher technology from inspection system supplier Intravis.

The new system automatically checks the key quality parameters in preforms. The company engaged Intravis on the basis of good performance by previous inspection systems: ColourWatcher ensures preform colour consistency; PreWatcher is for high-speed preform selection; and BottleWatcher is for container inspection. Sample-PreWatcher replaces manual inspection to provide an automated, rapid and more in-depth analysis of preforms.

Modern Packaging & Design January-February 2012

Tasks carried out include a complete visual inspection, colour analysis, cavity number recognition and neck dimension examination. Billy Jansen, Quality & Sustainability Manager, APPE Group, said, “This offline tool provides a rapid analysis of key preform quality parameters. The extended feature-set has resulted in more consistent quality, early identification of quality issues and scrap reduction.” Avani Jain

TECHNOLOGY & INNOVATION

New tray sealer delivers increased flexibility

Ishida Europe has launched a new generation of its market-leading QX-1100 tray sealer, combined with a brand new concept for the market. The new twolane QX-1100-SDL (Split Dual Lane) can operate each lane independently at different speeds, enabling companies to run two separate tray sizes, pack weights or products at the same time in one machine footprint. The machine is specifically designed for the fresh food industry, delivering high speeds, maximum hygiene and highquality pack and product presentation. The QX-1100-SDL features an open design to allow easy access for cleaning and maintenance. In particular, self-draining curved surfaces, absence of exposed cables or motors and easy-to-remove belts & conveyors allow fast and comprehensive wash-down. Quick-release belts and conveyors minimise downtime for product changeovers. The intelligent control includes auto-set features along with complete servo-driven motion for accurate and consistent tray handling at high speeds to maximise product throughput.

Renewable lightweight coffee pouches Innovia Films has produced a range of cellulose-based films – NatureFlex™ – which, when laminated with other biomaterials, can provide a fully renewable filmic structure suitable for coffee pouches. NatureFlex™ films offer a viable alternative to coffee producers who want a complete packaging structure that is lightweight and able to not

Jetrion 4900 offers end-to-end digital label production EFI™ has launched Jetrion 4900, a revolutionary Ultraviolet (UV ) inkjet digital printing system that combines high-quality digital printing with in-line laser finishing for label converters. It makes shortrun digital label jobs more efficient and profitable by eliminating set-up time, substrate waste and inventory requirements associated with the label finishing process. It produces eyecatching, durable labels on an array of substrates.

Jetrion 4900 is an industrial press ideal for label converters looking to transfer high-cost, short- and mediumrun jobs to digital systems, f rom print file through to finished roll. It is a versatile system that combines the proven performance of EFI’s marketleading Jetrion UV digital presses with an industrial web finishing and transport system. The system prints four-colour and highly opaque white UV inks in a single pass, delivering flexo-quality labels that are resistant to heat, cold and chemicals and is UL-certified on select substrates.

Deepgrip® bottles further widen PET’s potential APPE, the packaging division of LSB, has introduced a new technology to allow manufacture of large-sized Polyethylene Terephthalate (PET) containers with a deep recess for easy handling. This will provide a radical alternative to conventional extrusion blow moulded High-Density Polyethylene (HDPE) bottles with integrated handles. Developed in an exclusive partnership with Sidel, the new bottles can be produced in sizes up to 7 litre with a deep recess on each side, creating an effective integral handle. End markets for these include food, dairy, juice, edible oils, motor oils and home & personal care. The new bottles offer significant sustainability benefits. These enable significant lightweight savings over equivalent HDPE bottles and offer a

lighter weight alternative to clip-on handles or boxed grips. PET containers are fully recyclable and the DeepGrip® solution ensures a single-material bottle for the recycling stream. Various blowmoulded neck finishes are available, providing a re-sealable, leak-free closing mechanism.

only protect their product but is also compostable & made f rom renewable resources. This is the real point of differentiation for NatureFlex™, as existing laminate structures for lightweight coffee packaging can be difficult to dispose of, except through landfill, whereas NatureFlex™ can be composted. These films can be combined with other biopolymers by a converter, to produce a renewable alternative to the

above structure. NatureFlex™ films comply with standards for compostable packaging, including EN13432, AS4736 and ASTM D6400. Depending on individual films selected, the finished laminate structure could be certified compostable to the same standards subject to the choice of appropriate ink, print design and adhesive. If required, the pouches can be vented or a fully compostable zip closure could be added.

Modern Packaging & Design January-February 2012

TECHNOLOGY & INNOVATION

A next-generation film Manulock

Borealis introduces highperformance PP for thin-walled packaging Borealis has introduced the BorPure™ RJ766MO, which is an addition to its range of BorPure™ random Polypropylene (PP) copolymers with improved organoleptics. BorPure™ RJ766MO is intended primarily for transparent injection moulded, thinwalled food packaging. Its excellent organoleptic properties mean that it will not impart taste or odour to the packaged product. BorPure RJ766MO is the product of a combination of Borealis’ Borstar® PP polymerisation technology and Borealis Nucleation Technology (BNT). Together these technologies produce a material with a tailor-made Molecular Weight Distribution (MWD) and crystalline structure resulting in fast crystallisation and a good balance of stiffness and impact properties.

New label material enables latestage decoration of vacuum shrink bags Avery Dennison Label and Packaging Materials (LPM) has introduced a new brand enhancing pressure-sensitive labeling solution for meat and dairy packaging applications. Termed as Avery Dennison Shrink PS, the material is engineered to survive the vacuum-shrink process without wrinkling, enhancing shelf appeal and providing productionrelated benefits. Avery Dennison Shrink PS labels are applied to shrinkable bags off-line or inline prior to filling and vacuum sealing. Compared with pre-printed shrink-bag labeling, the Shrink PS solution offers enhanced labeling flexibility and the opportunity to differentiate products at a later stage in the packaging process. As a result, food processors can reduce or eliminate multiple sets of pre-printed shrink bags in inventory, cutting overall costs and increase flexibility. Avery Dennison Shrink PS labels exhibit excellent aesthetic appeal due to their exceptional shrinking behaviour.

Energy savings are achieved thanks to the material’s excellent flow characteristics, which enable processing equipment to run at lower temperatures than possible with many competing materials with sufficient organoleptic properties. With its high melt flow rate of 70, BorPure RJ766MO brings energy-saving advantages to containers with even the thinnest walls. When immersed in hot water following vacuum sealing, the Shrink PS labels conform and shrink with the bags and packaged products to deliver a smooth finish, without the wrinkling sometimes associated with labels applied by hand to packaging after it has been vacuumpacked and shrunk. The Shrink PS labels’ water-resistant construction and strong permanent adhesive ensure that the labels stay firmly attached. The labels can be affixed to the bags using automatic label applicators, minimising manual labour.

Manuli Stretch has launched Manulock – a three-layer co-extruded film - which ensures palletised goods with the highest protection and reliability during transport and storage. This new development is highly puncture and impact-resistant, and provides secure packaging without tearing. Manulock is extremely versatile, as its technologically advanced mix of raw materials and the special structure give it excellent elasticity and stretch, making it easy to use with various packaging machine systems. One size adapts to different pallet formats to give a containing force to suit any personalised solution. The film offers high clarity for easy reading of bar codes and excellent visibility of the goods. Lack of heat during use ensures that it does not cling to the packaged goods and provides protection against humidity and dust. High machinability and low energy consumption during application contribute to the optimisation of operating costs so that Manulock can be used and appreciated in different sectors.

Classic bottle washer for mid-tier companies Krones AG, Neutraubling, Germany, has come up with an ultra-compact singleend bottle washer designed specifically for the small and medium output ranges. The Lavatec E2 can be conveniently installed even in small areas, and provides perfect cleaning results, as it carries the bottles through the machine in a horizontal loop for maximum caustic dwell time. The rotary jetting tubes are used to clean the inside of the bottle from different angles of incidence. The outside of the bottles is cleaned from above by largevolume jetting units. In the post-caustic tank, the newly developed double nozzles additionally clean the bottles from below, accurately targeting the shoulder area of the bottles for an enhanced cleaning effect. Before they leave the machine, they are cooled down in the post-treatment zones with a small quantity of fresh water, and the final residues of dirt and caustic are thus removed.

Modern Packaging & Design January-February 2012

DESIGN INNOVATION

In a sea of look-alikes, the challenge is to bring to the market new and improved product concepts where the packaging does more than simply contain and protect the contents. Packaging innovation is crucial to the future of packaged goods, with user convenience being a key driver. As smart packaging concepts are predicted to be commonplace features in the future, this column is a tribute to the latest innovations in packaging designs.

EASYergonomic for trouble-free writing Stabilo International has launched its latest product range, EASYergonomics experts (ergonomic pens), on the European market in an appealing, youth-orientated packaging designed by Burgopak Germany. Targeted towards children and adolescents, the package design takes the theme of ‘human engineering’, reflected through unification of structure & image for an eye-catching retail solution. The packs feature the hand as a clear window on the front of the pack, visually displaying the contents – a beginner’s pencil, filler-pen plus cartridge, mechanical pencil plus 3 refill-pencil-leads, ergonomic pencil for advanced beginners, eraser and a comprehensive booklet. It uses a two-colour variation in blue and pink. The packaging features added benefits of a retail-ready hanging hook and user-friendly carton board structure. Manufacturer: Stabilo International

Hike up your spirit Polaris has kicked off the second phase of rebranding for hike – the premium beer brand of Ukrainian Beer Manufacturer Obolon. The company strengthened the brand positioning to improve upon hike’s core values. The logo’s font has been made new & dynamic. The spirit of new slogan ‘Freedom is your way’ makes the renewed hike a clear choice for youngsters. Polaris has changed the heraldic sign with ears of wheat by dynamic shield. The active orange colour of the label has given way to golden-orange, which the company believes will work better for the beer category. The outline of logotype is now more noticeable and confident and the direction of eagle flight has become progressive. The attribute of hike – the wings – is a sign of freedom and an urge towards the new. Manufacturer: Polaris

Modern Packaging & Design January-February 2012

DESIGN INNOVATION

Designs for outstanding performance P Z Cussons’ longstanding design partner Blue Marlin has created standout packaging for Carex Protect Plus, an innovative hand wash product that protects against germs for up to two hours after use. The integrated design and branding agency crafted a look that differentiates Protect Plus from the rest of the market-leading Carex range. Blue Marlin has overhauled the main Carex packaging structure and graphics, with a distinctive, contemporary design to better highlight the brand’s core benefits.

Juice packs now FSC-certified

Manufacturer: Carex Protect Plus

In the US, Johanna Foods has launched ‘Earth Wise’ brand juices and juice drinks in combibloc Mini 125-ml and 150-ml carton packs from SIG Combibloc with Forest Stewardship Council (FSC) label. The FSC label verifies that the raw paperboard used to make the carton packs was manufactured using only wood fibre that can be proven to originate from responsibly managed forests certified according to FSC guidelines, or from other controlled sources managed in accordance with FSC standards. These packages are renewable. Manufacturer: Johanna Foods

New MEMS quality inspector Schott and Moritex present an innovative inspection system for silicon wafers in Microelectromechanical Systems (MEMS) manufacturing. ‘IR-MEMS Inspector’ uses visible and infrared light to examine the outer surface of the substrates and the internal quality of the wafer. Scanner and detection software provide a flexible and economical solution for MEMS and semiconductor fabrication. MEMS are key devices for various innovative applications and, due to their low material and energy consumption, these are highly costefficient. However, their assembly is quite a challenge due to the fine structures of the components. Manufacturer: Schott and Moritex

Modern Packaging & Design January-February 2012

TECHNOLOGY TRANSFER

Technology Offered As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration. Vacuum sealer and gas injection machine

Areas of application

A Thailand-based company is providing technology for preserving and extending shelf-life of food products. Proper packaging is critical for avoiding food spoilage. The vacuum sealing and gas injection technique prevents contaminating microbes from entering the container, thus increasing the shelf-life of the product.

Forms of transfer

A Chinese organisation offers an addtype flame-retardant plasticiser ‘IPP’. Raw materials and equipment required are POCL3, phenol, propane, reaction cauldron, boiler and vacuum pump, adsorption tower and store jar.

Areas of application

A Czech Republican company is offering the technology for recycling of PET wastes (plastic PET bottles, X-ray films, etc) to produce polyester polyols. The process consists of the following steps: Collection of PET wastes, sorting out & shredding of collected PET wastes, simple chemical process of glycolysis & esterification and production of polyester polyols.

Food processing industry, agro-based industry

Chemical industry, plastics industry

Areas of application

Forms of transfer

Know-how, joint venture

Polyestersare base materials for the chemistry of polyurethanes, especially the production of polyurethane foams, which are primarily transferred into material saving and sealing applications

Plastics industry, construction industry Technology transfer

Flame-retardant plasticiser

Technology licensing

Adhesives with anisotropic conductivity

Plastic composite panel for partitions, claddings An Indian organisation offers plastic composite panels. These are combinations of plastics with conventional materials, which often provide properties that are not attainable by the individual constituent materials. Core materials broadly in use are polyurethane and polystyrene foams, paper honeycomb, aluminium beam grid and woven fabrics. These panels possess excellent sound insulation, built-in decoration, easy installation and low maintenance. These are lightweight materials having good thermal insulation, and are suitable for partitions, claddings and flush doors.

A Russian organisation offers a newly developed conductive adhesive with high conductance anisotropy. The adhesive is homogeneous on the molecular level and contains no metallic components. It provides reliable electric contact between metals, including aluminium, semiconductors and their combinations. The adhesive is transparent so that it can be used for conglutination of transparent conductive materials such as ITO.

Recycling of PET wastes into polyester polyols

Forms of transfer Technology licensing, others

Food packaging machinery An Indian firm offers all machinery for packaging f ruits, vegetables, poultry, meat and fish. Manufactured in Europe, the machinery is easy to use and makes high-quality food products. It also offers ice making machines.

Areas of application

Chemical industry, polymer industry, electrical/electronics industry

Food processing, agro-based industries

Forms of transfer

Consultancy, Turnkey

Manufacturing licence, joint venture

Forms of transfer Equipment

Supply,

Share Your Technology Propositions The mission of Modern Packaging & Design is to spread the technology culture. We offer you an opportunity to participate in this endeavour by publishing the best technology ideas. Technology developers/sellers are invited to furnish the techno-commercial details (with environmental beneﬁts, if any) for publication in the Technology Transfer column of Modern Packaging & Design. R&D organisations, technical consultancy organisations and individuals assisting small and medium enterprises send the relevant literature, indicating the scope & services and the areas of speciﬁcation. Contact: Modern Packaging & Design Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022-3024 5000 • Fax: 022-3003 4499 • Email: spedit@infomedia18.in

Modern Packaging & Design January-February 2012

TECHNOLOGY TRANSFER

Technology Requested Recycled PET bottle machinery

Forms of transfer

A Poland-based company specialising in recycled PET polyester polyols manufacturing is looking for an alternative proposal of design and engineering of bigger (approximately 25 ktpa) production plant. It plans to start with proper quality recycled PET flakes being delivered in big bags. Hence, the company needs a complete package offer for this service.

Commercial agreement with technical assistance

Areas of application Plastics and polymers industry

Forms of transfer Others

Roll of PP/EVOH film to seal food trays A Spanish company works in high-technolog y packaging for regional pre-cooked and fresh food. For the highest possible safety and quality, equipment and materials with the latest technology are needed. During the process and handling, the lowest possible loss of food quality, guarantee and safety is sought, as well as the lowest possible quantity of (or null) by-products and emissions generation. For its process of food packaging by thermo-sealing, the company needs a roll of plastic polypropylene (PP)/ Ethyl Vinyl Alcohol (EVOH) film that should be able to bear a temperature of 120ÂşC and microwave-resistant.

Areas of application Materials, plastics, polymers, food packaging/handling

Adhesives, specialty additives and their intermediates A leading UK-based company is searching for innovative investment opportunities in organic chemistry, chemical formulations or processes including manufacturing, technology licensing, acquisition, joint venture and distribution. The company has a reputation for technical innovation, and high-quality performance products. The company seeks to acquire rights to novel chemistry products, innovative technologies, formulations, compounds and applications that are synergistic to its current range of activities, and that will increase the diversity of its manufacturing base. Patents or knowhow would be desirable.

Areas of application Additives, biocides, water treatment and filtration chemicals, etc

Forms of transfer Manufacturing, technology licensing, acquisition, joint venture, and distribution

Stearic acid for PVC chemicals An Indian company is engaged in the manufacture of Polyvinyl Chloride (PVC) chemicals that are used in manufacturing all the PVC products like pipes, profiles, etc, and also cable compounds. The major raw materials used are lead and stearic acid. The

consumption of stearic acid is 120 MT150 MT per month. The company is, therefore, planning to set up a stearic acid plant in order to cater to its own requirement and as well market to others. It would like to acquire the technology for production of stearic acid, which is palm-based or rice branbased, with iodine value less than two and acid value in the range of 205-210.

Areas of application Chemical industry, plastics industry, polymer industry

Forms of transfer Know-how, technical equipment, turnkey plant

assistance,

Disposal and recycling of plastics waste A Polish firm seeks the technology for dry processing of all kinds of plastics waste or a magnetic processing method in the electrostatic field. The technology should allow sorting of all kinds of plastic materials, hay-silage foils, PET, HDPE, PVC, etc, by excluding dangerous waste. Specific technical requirements include initial cleaning without the use of water, sorting of all kinds of plastic materials after cleaning in a closed system, and a maximum processing capacity of 10,000 tonne of waste per annum.

Areas of application Plastics industry, waste recycling, waste management

Forms of transfer Others

Information courtesy: Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, United Nations - Asian and PaciďŹ c Centre for Transfer of Technology (APCTT), APCTT Building, C-2, Qutab Institutional Area, New Delhi 110 016, Tel: 011 - 2696 6509, Fax: 011 - 2685 6274, Email: krishnan@apctt.org, Website: www.apctt.org For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer / seeker through this website, before contacting APCTT for further assistance.

Modern Packaging & Design January-February 2012

IN CONVERSATION WITH: Yatindra R Sharma

â&#x20AC;&#x153;Rigid packaging will definitely lead the beverage packaging segmentâ&#x20AC;? â&#x20AC;Śopines Yatindra R Sharma, Managing Director, KHS Machinery Pvt Ltd. In a conversation with Avani Jain, he talks about the growth and opportunities for the beverage packaging industry in India. He also underlines the need for highly innovative packaging solutions in the beverages segment in the present scenario. What is your outlook for the beverages segment? The beverages sector has been consistently growing at doubledigit rates, and this has resulted in a high growth in demand for beverage packaging machines. All big players in the beverages segment require packaging machines and equipment with high speeds, high degree of automation, innovative technology features and total solutions for their projects. Therefore, essentially, the demand for machines is high and growing fast every year.

Elaborate on the demand for rigid packaging versus flexible packaging. Rigid packaging for beverages is defined in terms of Polyethylene Terephthalate (PET), High-Density Polyethylene (HDPE) and Poly(Phenylene Ethynylene) (PPE) bottles, glass bottles and aluminium cans apart from carton packaging. Compared

Modern Packaging & Design January-February 2012

Yatindra R Sharma

to flexible packaging, these forms of containers are used extensively in beer, soft drinks, water, milk, etc. Except purified water and packing of milk in Low-Density Polyethylene (LDPE) pouches, flexible packaging has not been able to significantly penetrate the beverages segment. Thus, rigid packaging will definitely lead the beverage packaging segment and will hold the major marketshare against flexible packaging.

What are the emerging trends in this segment? In case of rigid packaging, the new trend is aluminium bottles with high decorative element and screw caps. Similarly, in plastic PET bottles segment, there is an increasing demand for light weighting of bottles, which can reduce raw material and energy consumption. This is achieved by developing high-performance stretch blow-moulding machines. Even the glass containers industry is looking for development of elegant shapes and lightweight solutions.

What challenges and opportunities are being faced by this segment? The demand for high-tech solutions, cost-competitiveness in relation to international players and efficient project management capabilities are some of the major challenges faced by this segment. Companies that will be able to meet the above challenges have excellent opportunities to grow steadily in local as well as global markets. Further, each beverage segment, such as beer, soft drink, milk, juices and water, is looking at packaging solutions that can provide much higher production speeds, less energy consumption and a higher level of automation.

What are KHS Machinery’s future plans? We are looking forward to enter into the milk and aseptic juices market with the help of our German partners; here, we will design low-capacity and highly efficient aseptic plants, which can handle milk-based products as well as juices. The second area of innovation will be

the flexible packaging space, which is increasing due to the growth in the retail market and small volume requirement of the rural market.

What are the five things that you check before signing a deal/ partnership? Product leadership in terms of technology and performance assumes high importance, as this will help it sustain in the long run. Business dynamism and vision of the other company or individual. This will make the partnership worthwhile. Thus, it is important to understand the thought process of others. Thought process alone is not sufficient, it is extremely important to analyse the ability of the others in delivering what they are claiming. It is important to gauge whether the two companies are on the same wavelength and will be able to strike a profitable partnership. Everyone may be good in their respective fields, but whether they will be able to create a progressive alliance in future is a big question that needs to be answered. The spirit of sharing on part of companies assumes major importance.

Tell us about a situation where you got lucky. In my entire career, I have never pursued a specific sector for very long. I began my career by working in a chemical industry followed by oil, pharmaceutical and plastics machinery industry. After this, I decided to become an entrepreneur. My first project was in the field of specialised rubber moulding machinery, and after that I entered the present business. I am pleased to say that whatever I did in each space, I have fared well or I could say I have been lucky throughout. The major reason behind this success is that I have always tried to live up to the expectations of the people. I have often asked myself one question about what best and more I can do for the people around me and worked accordingly.

What is the business etiquette you value the most? One should have trust on oneself and also on others. Without this mutual trust, nothing can be achieved in life. Be it business or personal life, trust is the major criteria for success.

How do you deal with a tough situation? I take up the challenge as it comes and work towards it incessantly till I find an appropriate solution.

What motivates you the most in your life? A sense of adventure in creating a new business motivates me the most. People face numerous hurdles in the beginning but when things start falling into place gradually, it gives you immense pleasure.

What has been the toughest business decision taken by you? Ours was a 60-40 joint venture company till 2006. Our partners wanted further higher share of capital, so we decided to part with our equity shareholders. That was a tough business decision for me. Another turning point in my career was the day I decided to become an entrepreneur.

What would be your message to aspiring and upcoming entrepreneurs? ‘Believe in yourself and give your best.’ This is the mantra of success for any businessman. Here, ‘best’ means giving your 110 per cent, and not just 100 per cent. It is observed that people often create a success story and fall in its trap and are unable to see things beyond that. This results in a situation where people do not appreciate anything else and are unwilling to innovate. This is where you start losing. We become used to our comfort zone and celebrate the success forever, but if you do not know how to handle your success, then you may not succeed in the long run. Email: avani.jain@infomedia18.in

Modern Packaging & Design January-February 2012

SPECIAL FOCUS

Cosmetics Packaging Cosmetics packaging Augmenting aesthetic appeal ................................................................................................36

Challenges in cosmetics packaging Discovering the power of design ..........................................................................................38

Interface Anuj Prasad, Founder & CEO, Desmania Design ..............................................................41

Modern Packaging & Design January-February 2012

SPECIAL FOCUS: Cosmetics packaging

Augmenting

aesthetic appeal

Courtesy: Lacura

When it comes to ease of application, quality assurance and consumer demand, cosmetics packaging in India has ticked all the right boxes and is receiving global attention. With the rising demand for cosmetics, it is only natural that the sector is witnessing continuous improvement in technology and design elements. Anwesh Koley analyses how manufacturers are striving to enhance the aesthetic value of products.

ndia has tremendous growth potential for the cosmetics packaging sector, which has shown steady progress over the years. Earlier, the quality of Indian packaging was not up to the standards desired by the international clientele, but looking at developments in recent years, the quality of Indian packaging is at par with and, in many cases, better than international standards. G S Kochhar, Managing Director, Precision Moulds and Dies, says, “The reason why we find it difficult to emerge as the absolute leader in packaging across the globe is the price factor. Cosmetics around the world are priced high. However, this cannot be the case with

India, where a substantial chunk of the cosmetics market belongs to the middle class.” Cost of packaging accounts for 60 per cent of the cost of cosmetics. With regard to benchmarking the international best, India is inching towards international quality. “Investments are flowing into the sector, but we still need to attain expertise in two-colour packaging, use of polycarbonates as well as shiny materials,” adds Kochhar.

the higher the number of cavitation in the mould, the cheaper is the final price. If the volume runs into millions of pieces, the general production cost of the cap is considerably lower. For highend cosmetics, the volumes are not there, but the mould cost has to be borne by the manufacturer. Thus, the price of each unit of the final product goes up. It does not justify the investment that it demands, considering the low volumes involved.

Cost-volume considerations Plastics is the key material used today in packaging. Here, volume is the key. The higher the volume, the cheaper is the final price of the product. In making a mould for a cosmetic cap or bottle,

Modern Packaging & Design January-February 2012

Innovative efforts While Indian design houses do undertake regular Research & Development (R&D), a number of designs, shapes and mechanisms are being imitated from

Cosmetics packaging

the West. Developing new designs and mechanisms requires R&D efforts and this is expensive. “We have the R&D available, but are not spending much on these. As time passes, design concepts change. Since companies abroad have already designed numerous concepts, Indian companies find it easier to replicate the design that works well everywhere; however, that cannot be considered as innovation in the true sense,” says Kochhar. A lot of indigenous efforts can be seen today in the field of packaging. Various double-injection caps are currently in use, which come in two colours; different types of dispensers are also available. These fields are witnessing indigenous efforts. Indian companies are proficient in making designs that are partly their own and partly imitated from overseas, and this mix-n-match results in an exceptional final product.

Technological advancements In terms of mould making equipment, Indian manufacturers are right among the best ones across the world. Even in terms of production capacity and the latest injection moulding technology, Indian manufacturers are at the top. The technology remains the same for cosmetics packaging. However, injection moulding machines have changed over the years. Currently, the cosmetics packaging industry employs relay-based moulding machines, fully microprocessed machines and the best of injection moulding machinery available in India, which give higher throughput. The cosmetics market in India is restricted for high-end products, and this is due to low volumes. “Today, most plastic products are in demand for their eye-catching and innovative packaging & attractive printing on the pack. We have to create a unique identification of a product to make it desirable from other competitive products on shelves,” says Kochhar. Packaging companies have to ensure a harmonious sync between the design of the product and quality of paint & print applied, which help make the final product visually attractive.

Bottlenecks to conquer Doing business in India is difficult. Corruption in every step and government procedures waste a lot of productive time. Electricity is a huge problem and frequent power cuts are a normal occurrence here. Power problem destabilises operations and wastes operating time. “We use the same materials that are used worldwide. It depends on customers as to what kind of product they need. For bottles and containers, we initially used High-Density Polyethylene (HDPE) and then graduated to polypropylene. However, it has some limitations in terms of finish and quality. Enter PET, but this material has a high lead content and is gradually being looked down upon by the global packaging fraternity,” expresses Kochhar. Another material called polycarbonate has been used extensively for high-end products. The latest polymer used in cosmetics packaging is Triton, which is more expensive than polycarbonate, but is the safest material till date.

As time passes, design concepts change. Since companies abroad have already designed numerous concepts, Indian companies find it easier to replicate the design that works well everywhere; however, that cannot be considered as innovation in the true sense. G S Kochhar Managing Director, Precision Moulds and Dies

Designing it right Cosmetics packaging involves a lot of outof-the-box aesthetical design elements, which not only help in securing the content inside, but also provide innovative dispensing options to the customer. While the middle class in India has started spending on cosmetics, it is still not up to global standards. With continuously improving technology and steady advent of global designs into the country, the Indian cosmetics industry can be expected to set standards worldwide. Email: anwesh.koley@infomedia18.in

Modern Packaging & Design January-February 2012

SPECIAL FOCUS: Challenges in cosmetics packaging

Discovering design

the power of

Increasing spending power and fashion consciousness among people have given an impetus to the Indian cosmetics industry. Industry players are also spending heavily on promotional activities to increase consumer awareness. Anwesh Koley traces how the cosmetics packaging industry has shown resilience against challenges in implementing some innovative concepts.

he market size of cosmetics industry, which is currently estimated at ` 10,000 crore, will double to ` 20,000 crore by 2014; this growth is expected owing to emergence of a young urban elite population with increasing disposable incomes and increase in working women looking for lifestyle-oriented and luxury products.

Business of beauty Improvement and strengthening of the Indian economy in the coming years will also pave the way for the Indian cosmetics market over the forecast period and develop the cosmetics industry. The plastic packaging industry has been continuously evolving. Cosmetic products have conventionally been packed in glass bottles and jars, but the same or better decoration is now possible using plastic pacagking for

cosmetics by using heat transfer technology. There are many brands opting for plastic packaging, as it lends design versatility to the product. Today, women in the age group of 30 years and above are becoming selective about the type of products they use. They have more cash to spend and are more conscious of their appearance, especially skin, and hence are willing to spend more on separate sets of creams and lotions that target problem areas. They are also more open to buying higher priced products. Karl Vandenbussche, Director, Reynders Label Printing India Pvt Ltd, says, â&#x20AC;&#x153;The latest printing offices are equipped with stateof-the-art presses capable of combining several printing techniques (eg, flexography, screen print, hot & cold foil stamping, etc) to obtain the highest result. Through our suppliers, we can obtain the largest range

Courtesy: 21st Century Skincare

Modern Packaging & Design January-February 2012

of printable materials and adhesives to tackle the most difficult applications in the most unfavourable conditions.â&#x20AC;?

Classifying the industry Products falling under the price range of ` 50-200 are in the mass market category. The middle market price can be in the range of ` 200-1,000. In the high-end market, pricing can range anywhere from ` 1,000 to ` 10,000. There is also a premium range of products where the pricing can touch up to ` 50,000. The Associated Chambers of Commerce and Industry of India (ASSOCHAM) conducted a countrywide survey, seeking views of over 6,000 odd consumers on cosmetics. Over 65 per cent of the teenagers in the country are of the opinion that their branded cosmetic consumption has gone up by 75 per cent in last 10 years; 62 per cent of male youth said that their expenses on cosmetics application have risen by 45 per cent as against 57 per cent of the upper middle age group, claiming that they spend nearly 42 per cent in buying cosmetics products to maintain their external appearance. The survey revealed that on an average in this segment, a majority of respondents felt that they would spend less than ` 1,000 on cosmetic use in the year 2000, but exceeded ` 5,000 per month now. The major reason for this is that massive advertisements both in electronics and print

Challenges in cosmetics packaging

Cosmetics consumption patterns

The latest printing ofﬁces are equipped with state-of-the-art presses capable of combining several printing techniques (eg, ﬂexography, screen print, hot & cold foil stamping, etc) to obtain high quality results. Karl Vandenbussche Director, Reynders Label Printing India Pvt Ltd

media have influenced the customers in this segment such that they were inspired to increase the allocation of their monthly expenses towards these items. In the current scenario, it is observed that males have developed a particular enthusiasm for cosmetics application as compared to their female counterparts, with their monthly expenses rising by 60-80 per cent during the period.

The consumption pattern of cosmetics among teenagers went up substantially between 2000 and 2011 because of increasing awareness for up-keep of their external appearance. About 75 per cent of male teenagers have increased spending on cosmetics to ` 3,000-4,000 per month as against their average expenditure of less than ` 1,000 in the year 2000; thus, the increase was more than 300 per cent due to growing awareness. Cosmetics packaging generates interest among teenagers who often go by the first glance on the attractiveness of the product. Quality is given utmost preference by female consumers. This is also due to attractive and informative labeling by companies. “Last year, the cosmetics sector was given preferential treatment with the introduction of many new constructions such as the flexible duolabels for use on squeezable tubes, shrink-duolabel, a special construction with both informational and security features as well as duolabels with a static closure,” adds Karl. The quality of packaging for cosmetics is the primary cost of the product. While cosmetic products in the developed markets of the US and UK come in larger quantities, Indian products are available in much

Courtesy: Lotus Herbals

Modern Packaging & Design January-February 2012

smaller packages, making them accessible to customers with lower budgets.

Adding to the growth story The flourishing Indian fashion industry is fueling growth of the cosmetics industry in India by making Indians realise the importance of good looks. The Indian cosmetics industry is divided into skin care, hair care, colour cosmetics, fragrances and oral care segments, which is estimated at ` 15,000 crore, and expected to grow at over 10 per cent annually. Today, the herbal cosmetics industry is driving growth in the beauty business in India and is expected to grow at a rate of 12 per cent as more people shun chemical products in favour of organic ones. India’s per capita cosmetics and toiletries consumption is 40 times less than that of Hong Kong, 18 times less than Japan and half of China, despite high penetration levels of cosmetic products because of its population and size. The areas of concern for the cosmetics packaging industry are meagre infrastructure and lack of power. Also, various shapes and sizes of cosmetic products require different surface finishes, which require a customised approach by manufacturers.

Reasons to flourish The expanding market size for cosmetic products is the direct result of the changing socio-economic status of Indian consumers, especially women. Higher paying jobs and increasing awareness of the western world and beauty trends have served to change the tastes and customs of the middle class and higher strata of the society. The women from such social strata have become more conscious of their appearance, and thus willing to spend extra for further enhancements. The Indian market for cosmetics is witnessing a high growth rate and European companies are fast making headway in this market, as they find a vast potential for a successful business in the country. This, coupled with the increasing potential of the consumer to buy high-end products makes India a ready market for the style conscious. Email: anwesh.koley@infomedia18.in

SPECIAL FOCUS: Inter face - Anuj Prasad

“Innovative designs will help create a distinct product identity” …believes Anuj Prasad, Founder & Chief Executive Officer, Desmania Design. The cosmetics packaging industry in India has numerous possibilities to innovate and break the conventional design trends. In an interaction with Anwesh Koley, he explains various advancements in the packaging sector, which have led to the emergence of design as an essential element for success.

What are the latest technologies used in the cosmetics designing industry? The latest technology in the cosmetics design industry should enable designers to transfer any type of texture to plastics. Earlier, the external painting for plastics packaging meant applying flat colours or metallic paint, but today, new possibilities have emerged because manufacturers undertake a lot of research and development on these paints. Design specifications can be created on computer and have numerous possibilities as well. Fluidic printing uses a similar technique for plastics technology. This process helps create any texture, eg, tone texture, marble texture, etc. To give a rubber finish to a plastic packaging material, a rubberised spray paint can be used, which when sprayed, feels like a rubber surface.

technology, wherein a roller moves in the plastic moulding process. The film is fused with a plastic sheet, yielding high gloss or matt finish as required. Another technique called in-mould decoration creates different types of graphics, which can be printed on any plastic component. Another concept is vacuum metalising, which yields toned and gold finishes. The colour and texture can be changed besides other possibilities on the metalising side of printing. It helps achieve a shiny toned finish on plastic bodies. It provides the vital external finish, which is most important for the first visual attraction towards the product. Masterbatches can be used for a sparkling finish in a product. Sparkles can be of different shapes & sizes and various textures can be achieved through masterbatches.

Highlight some specific techniques involved in designing.

How has the cosmetics design industry evolved?

The most common technology used for cosmetic designing is in mould roller

Five years back, the only methods available for decorating plastics included

painting, metalising or blazing. But today, with various products available in the market and new models being launched, clients want to differentiate their products from one another. This requires use of different textures and finishes. Colour, finish and material are crucial for the success of any product designed. The key here is to offer value-added features to customers, eg, innovative dispensing techniques to packaging to make it user-friendly or designing a shape that differentiates the product from its competitors.

What is the future of cosmetics packaging industry in India? With sales going up, people’s requirements are changing, and thus, the sense of design and aesthetic appeal is going up. Most industries consider design as a source of business revenue. The market is evolving and requirements are growing in a more thought-oriented, innovation-based and qualitative manner. Email: anwesh.koley@infomedia18.in

Modern Packaging & Design January-February 2012

FACILIT Y VISIT: Shilp Gravures Ltd

Photo: Vijaykumar Soneji

Im‘print’ing standards of excellence The flexo and especially gravure printing are the leading processes in the dynamically developing packaging markets. Leading the segment is Shilp Gravures Ltd – the country’s pioneer company with substantial marketshare in the flexible packaging industry. Avani Jain explores how the company works to achieve its motto of fast and quality delivery to customers.

glance at the share of the different printing processes in the production of flexible packaging material used in huge quantities by large brand owners to pack food products and confectionery shows gravure to be excellently positioned. The USP of gravure – excellent quality and high consistency even with long print runs – favours its position in the Indian markets. Leading the electromechanical engraving segment, Shilp Gravures Ltd is committed to provide cutting-edge technology to its customers. Ambar Patel, Managing Director, Shilp Gravures Ltd, opines, “The gravure printing technology is majorly used by companies in the food packaging industry, and this industry is growing at a rate of 10-15 per cent per year.” The company started its commercial production in 1995 when the gravure industry was in its nascent stage and, over the years, has grown to lead in the segment.

Manufacturing facility Today, the company boasts of state-of-theart manufacturing facility, with in-house cold extrusion unit, digital proofing unit, copper plating unit, electro-mechanical engraving unit, screen engraving unit, flexo plate processing unit and graphics department. It is known for manufacturing gravure cylinders/rollers, including electromechanically engraved rollers, mechanically engraved rollers, chemically etched rollers & laser technology for gravure cylinders, flexo plates and engraved screens for rotary screen printing.

Production process The production process for gravure cylinders starts with roller pre-fabrication followed by preparing the design to be engraved, galvanising & polishing the roller, engraving and proofing stage. In the pre-fabricating stage, from the quality of cold-extruded carbon steel seamless pipes to the hardness required, from the accuracy of dimensions to use of adequate thickness in the roller wall and from dynamic balancing

Modern Packaging & Design January-February 2012

to cylindrical grinding, the company has technical experts who produce flawless rollers in-house. Further, the company has developed expertise in copper plating of gravure cylinders to achieve even and fine crystalline hard copper deposit. Shilp Gravures is well equipped with a hi-tech pre-press shop having various software to translate the design into engravable data with high precision to maintain the design quality. In the engraving stage, the company’s forte is in electro-mechanical engraving, but it also does chemical etching, mechanical and laser engraving of cylinders. Finally, in the proofing stage, five rotogravure proofing presses with state-of-the-art technology produce sample proofs of the engraved designs in just a few hours. Atul Vinchhi, Chief Operating Officer, Ship Gravures Ltd, explains, “The process involves buying the steel pipe, cutting it to get the required size, cleaning it, nickel plating and soft copper plating followed by hard copper plating of the roller. Later, the final cutting and finishing of the roller

Shilp Gravures Ltd

is done. The next stage is the engraving stage where the design is engraved on the roller. Subsequently, chrome plating is done followed by the final proofing stage. In case of used rollers, the old design is removed and the polishing and engraving processes are repeated.”

Quality consciousness Comprehensive, round-the-clock quality checks are performed at every step of the manufacturing process. Vinchhi details, “The company checks the quality of steel roller before getting it to the factory. It also has high-precision measuring instruments for final quality check.” After the graphics department processes the design, it is sent for customer’s approval before it is engraved on the roller. As deposition of copper coating and hardness of copper are integral to quality, the company’s experts verify this as well. Vinchhi says, “The in-built, processbased and documented QA&C system ensures that the customers are delivered the quality that has been promised. There are many equipment and machines in our laboratory to ensure the quality of products.” At the proofing stage, the accuracy of design, correctness of the colour composition, printing marks and the printability of the engraved cylinder are checked. This gives the reference proof on the substrate, permitting faster & finer adjustments in correct colour and ink standards without costly rework and press downtime and minimum time lapses.

Research & development Shilp Gravures Ltd is committed to provide the best technology to its customers. Vinchhi says, “R&D is a continuous

The proofing department

process. There is a need to understand the customer, his capability and, accordingly, modify the parameters. There is a need to be aware of the happenings in the related technology field.” He adds, “When we started this business, printing machines ran at a slow speed, but new-generation machines run at high speeds. Further, thickness of films has reduced. Earlier, customers used 12micron films, but now they use 8- to 10-micron films. Gravure making methods are impacted by these new developments, which calls for R&D. Thus, considering the above points, we have made necessary changes in the techniques.”

Ensuring sustainability The company is continuously making efforts towards attaining sustainability. Vinchhi notes, “We regularly conduct energy audits to ensure energy savings. There were 30-40 steps recommended, of which we have implemented 15-16 steps and are in the process of implementing the remaining steps. When we purchase the machine, we always look for the efficiency of the machine; this is because an efficient machine consumes lesser energy. We have also installed a windmill and an effluent treatment plant at our facility where the water is treated and reused.”

With rising demand for food packaging, and fast moving consumer goods products packaging, the demand for gravure printing technology is set to increase. Ambar Patel Managing Director

With rising demand for food packaging, and fast moving consumer goods products packaging, the demand for gravure printing technology is set to increase.”

Future expansion plans

The gravure printing industry is growing qualitatively in India. Patel opines, “Earlier, low output machines were available, but now people are opting for highly efficient machine with high speeds. The engraving speed in today’s machines is 8,100 cells per second. Thus, the demand for highspeed engraving machines has increased.

The company wants to expand its operations in future as well. Currently, the company has the capacity of manufacturing 150 cylinders. “Expansion might not be only in terms of capacity, but also in terms of technology employed. We want to be the technological leader in our field and serve our customers in the best possible manner. We also provide customers with appropriate solutions at their doorstep. Our motto is fast and quality delivery to the customers. We believe in 360-degree excellence,” concludes Vinchhi. Email: avani.jain@infomedia18.in

Chemical etching process

The packaging unit

Future growth

Photo: Vijaykumar Soneji

Modern Packaging & Design January-February 2012

Business Insights •Technologies•Opportunities

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Dear Reader, ‘Modern Packaging & Design’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the packaging industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Modern Packaging & Design’. Authors whose articles are published will receive a complimentary copy of that particular issue and an honorarium cheque. Published by Infomedia 18 Ltd, ‘Modern Packaging & Design’ is the leading bi-monthly magazine exclusively for manufacturer and user fraternities of the packaging industry. Well supported by a pan-India readership of over 80,000 and our strong network of 26 branch offices across the subcontinent, this magazine reaches out to key decision makers among the manufacturers of products, machinery and allied segments. Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost. So get going and rush your articles, write-ups, etc… Look forward to hearing from you, soon! Yours sincerely,

Business Insights Technologies Opportunities

Manas R Bastia Senior Editor Infomedia 18 Limited ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India

D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E manas@infomedia18.in W www.infomedia18.in

INSIGHT & OUTLOOK

Filling, Strapping & Sealing Machines FSS machines Maximising accuracy, minimising waste ............................................................... 46

Innovation index Enabling versatile performance .............................................................................. 48

Roundtable How is the industry working towards maintaining the cost-quality ratio of FSS machines? .................................................................50

Activity integration in packaging Unifying operations for better margins...................................................................52

UV curing technology Discover the right light ...........................................................................................54

Practical tips Effective solutions for brand security ......................................................................56

Colour management Harmonising art and aesthethics ............................................................................58

Modern Packaging & Design January-February 2012

INSIGHT & OUTLOOK: FSS machines

Courtesy: Krones

Maximising accuracy, minimising waste Focussing on advanced technologies as per customer demand, the packaging industry is bringing in more innovations to filling, sealing and strapping machines, which offer great flexibility to customers. Avani Jain explores the latest trends, technologies and innovations making headway in the segment.

he pharmaceutical, food & beverage and many other industries have shown rapid growth in the last decade. These industries are looking for hi-tech machines to meet the ever-increasing demands of the world market. This growth has also led to sparkling innovations in the packaging segment. The highly fragmented packaging industry in India is estimated at ` 8,000 crore and growing at a rate of 22-25 per cent per annum. With regard to packaging, especially in the machinery segment, the Filling, Sealing and Strapping (FSS) machines are considered as the fastest growing products due to their role in increasing the flexibility in production.

Umesh Sharma, Managing Director, Julison Packaging India Pvt Ltd, notes, “These machines reduce manpower requirement for packing goods in bulk. Also, these make the packaging attractive and draw in customers who generally believe that if the appearance is good, then the product inside would also be of good standard. Further, good packaging increases the shelf life of the product, makes it easy to handle products and ensures that the contents do not get spoiled or spilled during transportation.” Until recently, the quality of filling and sealing machines was not at par with the global industry standards. There were several issues regarding size and facilities, and it was a challenge to cater to different requirements in the industry. But, the scenario has changed with the advent

Modern Packaging & Design January-February 2012

of new technologies, and the flexibility issues have also been dealt with.

Filling and sealing machines The recent trend in the market for filling and sealing machines in India is towards ensuring more efficient machines and advanced technologies. Sharma avers, “ We are moving towards electronic automation, ie, AC/DC drives, electronic temperature controllers, various types of sensors to control movements, etc. Thus, the need for gears, chains and belts would be reduced.” Another new technology making headway in the filling and sealing machine is the servo technology. “The servo technology is the answer to future needs of manufacturing and

FSS machines

packaging process. The existing normal electric/fuel-driven motors transmit power to various points of movements through gears, chains, belts and pulleys, which are heavier and bigger. On the other hand, in servo motors, all movements in the machine are powered by appropriate size of motors controlled by drives and sensors, which are smaller, lighter & convenient,” says Sharma. The growth of sensor technology has also made the filling and sealing machine flexible. The latest sensor enables filling machines to count, test the quality, quantity and accuracy. Similar developments are taking place in ultrasonic sealing as well. This technology generates heat within the banding material seal area only, so there is no external heat on the product. For offering online control of sealing parameters, ultrasonic sealing technology suits applications that involve horizontal packaging or products in pillow packs. Today, new machines are equipped to fill nitrogen during the filling process. This is mainly used for packing snack foods, tea, rice pulses, etc. It prevents spoilage from fungal and bacterial growth, and hence the packaged product retains its freshness for prolonged periods. Industries are making constant efforts to improve the efficiency of machines. Sharma notes, “The use of a pneumatic system to make the machine smarter and faster is one of the important steps taken by the industry. Apart from that, electronics, solid state components, use of plastics, Teflon and other advanced materials have changed the appearance & efficiency of new-age machines.” Further, new-generation filling and sealing machines offer standardised interfaces for easy integration and retrofitting of the equipment. Such a system offers integrated packaging line solutions to customers.

Strapping machines Strapping enables the boxes, packages and bundles to be held tight and closer.

These are loaded with a roll of material. This is then dispensed, which seals a box or package. These machines are convenient and useful, particularly in manufacturing, merchandising and shipping. One of the key tasks of modern packaging technology is to make a product safe for transportation, but it should also be economical because it offers no added value for the producer. This is the major reason why companies from various industries prefer the material and energy-saving strapping technology. Strapping machines are available in different speeds and versions, eg, semiautomatic low-volume models, semiautomatic moderate volume models and fully automatic high-volume models. New-generation strapping machines have evolved to meet high-end user demands. The machines exhibit improved performances in areas such as handling, quality of sealing and consistency in operation. An important trend spotted in the strapping machines industry is the use of sensors. “These are used for switching on/off, detecting tension and various other functions. In a way, they have made the machine easier to handle. The change f rom mechanical system to electronic system is quite evident. This trend will increase in future.” Although these machines have changed a lot over the years, the basic design has remained the same. Sharma notes, “There is not much change in the design of strapping machine except that sensors are being used for detecting tension in place of some micro switches. Belts and pulleys are still used in semiautomatic strapping machines. However, in advanced automatic strapping machines, servomotors are used for replacing belts, pulleys and gears, which do not appear economically viable at present, considering the nature of application of a strapping machine.” Thus, the modern strapping technology has proven to be the most efficient and environment-f riendly packaging solution for many industries.

New-generation ﬁlling and sealing machines offer standardised interfaces for easy integration and retroﬁtting of the equipment. Such a system offers integrated packaging line solutions to customers. Umesh Sharma Managing Director, Julison Packaging India Pvt Ltd

These machines are evolving with their multi-purpose and all-rounder functionality for various applications. The new-generation, fully automatic strapping machine with high-speed ultrasonic technology gives a high degree of security and versatility.

Challenges and opportunities Even though the new-generation machines have evolved in functionality, meeting the increasing customer demand remains a big challenge in the area of filling and sealing machines. A task before the industry is to avail the best technology at an affordable cost. Like in any other sector, competition is tough in the filling and sealing machines sector as well, but the industry is working to serve customers in the best possible way by increasing flexibility. Therefore, FSS machines form an integral part of the end-of-the-line packaging for major sectors such as pharmaceutical and food & beverage. As these offer great flexibility to customers, their demand is set to increase in future. Email: avani.jain@infomedia18.in

Modern Packaging & Design January-February 2012

INSIGHT & OUTLOOK: Innovation index

Enabling versatile performance Smartest, fastest and smallest are the buzzwords defining innovations in the packaging machinery segment, especially filling, sealing and strapping machines. Avani Jain analyses some of the smart ways for reducing the size and enhancing speed & overall efficiency of the machines.

he $ 28.6 billion world packaging machiner y industry will increase 5-6 per cent yearly through 2014 and among the variety of packaging machines, the next-generation Filling, Sealing and Strapping machines (FSS) will be more in demand. Until recently, the quality of filling and sealing machines were not at par with global industry standards. In fact, there were several issues regarding size, speed and accuracy and it was quite a challenge to cater to different requirements in the industry. But, the scenario has changed today with the advent of new technologies. Niket Mankad, General Manager, Pace Packaging Machines Pvt Ltd, notes, “Form, fill & seal technology has changed considerably over the years. The most conventional rigid mechanical systems with shaft, gears and cams have been replaced by flexible, electronic synchronised drives, which have extended machine lifecycle and also produce less noise. Further, the industry has moved towards fully automatic form, fill and seal machines. One of the most advanced technologies in the segment is continuous motion platform in vertical foam, fill and seal machines.”

Innovative technologies Today with the major focus on reducing the size and enhancing the speed of the machine, companies have

made many changes in the machines. New-generation filling and sealing machines are getting smaller, with several facilities for adjustments. “To make a 50-gm or 100-gm pouch, you just have to change the parts. Today, the machines come with several adjustments,

resulted in increased speeds and space reduction. The present machines are 60 per cent smaller than their counterparts in the past.” On tracking the history of filling and sealing machines, it is observed that the earliest machines were mechanical machines. “These were followed by machines with stepper motor and the latest technology is machines with servo motors, which have helped reduce the size, wastage of film and increase the accuracy and speed of the filling & sealing machines to a large extent. While machines with stepper motor had the capacity of producing upto 200 pouches per minute, the servo machines can produce 350 pouches per minute,” avers Panchal. The servo technology offers more than one advantage to the customer and has highly improved the efficiency of filling and sealing machines. Mankad says, “Our three-axis servo solutions with SIMOTION Technology platform instead of normal Programmable Logic Controller (PLC) provide a cutting edge to the machines. Benefits offered by these machines include real sealing Vertical form-fill-seal machine time, synchronised filling, low Courtesy: Pace Packaging Machines Pvt Ltd wastage with synchronisation in and this has increased the flexibility of gag pulling, sealing & unwinder sections, the customer and reduced the cost of on-board status for troubleshooting putting two machines for producing through Human–Machine Interface different sizes,” notes Shailesh Panchal, (HMI)/touch panel. The product quality Managing Director, AD Industries. He is also improved by use of registration adds, “The new multi-track machines mark control, which enhances seal and that produce 5-7 pouches/minute have cut accuracy.”

Modern Packaging & Design January-February 2012

Innovation index

He adds, “Servo axis on the roll of film is used to maintain tension in the process, so that the exact amount of film material can be used with minimal waste. The servo axis feeds the correct length of film into the formed film tube, based on the instructions provided by the operator. If the film is pre-printed, a registration sensor adjusts the film position to maintain correct print position.” He further elaborates, “As the feed servo axis pulls the film down, the goods to be packaged are gravity-fed into the tube, often by a precision scale, which ensures that the proper amount of goods is placed in the pouch in a consistent manner. Before a product is put into the pouch, the cross jaw servo axis seals the bottom of the pouch. It is then filled and indexed.” Currently, when the customers demand machines with higher speed in terms of bags per minute coupled with filling solutions that match these speeds and offer high accuracy, servo motors are of immense help. This facilitates reduction of production cost per bag and maintains margins despite rising input costs in a competitive environment. Further, customers are seeking machines that can produce a wider variety of bag styles on their machines as well as option to pack different products on the same machine. To meet these trends, machines have been designed such that they ensure lowest operating cost. “The machines of today require zero maintenance; these do not need regular lubrication and are easy to clean. Thus, the machines of today are more user-friendly and have a long working life as compared to their counterparts in the past,” avers Mankad. An equally important trend in new-generation filling and sealing machines is low film wastage. The present-day machines come with the capability of operating with all types of films available in the Indian market at any speeds. Further, the machines demonstrate maximum efficiency with minimum breakage or rejection. “The use of Supervisory Control and Data

Acquisition System (SCADA) leads to central monitoring of all machines and helps minimise wastage and achieve greater accuracy,” notes Mankad.

Strapping machines Strapping machines have also undergone modifications. Today, there are machines that can be integrated into most production lines and strap at the rate of 30 bundles per minute. Strapping machines equipped with new ultrasonic sealing heads are not only faster, but also more economical and produce low emissions. Practically, these machines produce no fumes. Strapping can withstand gear stress during transportation. Besides, it is often possible to use low-cost, narrow or thin-strapped materials.

To make a 50-gm or 100-gm pouch, you just have to change the parts. Today, the machines come with several adjustments, and this has increased the ﬂexibility of the customer and reduced the cost of putting two machines for producing different sizes.

The future

Shailesh Panchal

Considerable reduction has been done in the size of FSS machines. “Further size reduction is not visible in the near future. This is because the filling process depends on the volume of the end product. If the form is large in size, the machine has to be large likewise. Strapping machines also are compressed sufficiently, leaving only a slight possibility of reduction in size in the near future,” avers Panchal.

Managing Director, AD Industries

In a nutshell Novel technology and design innovations in machinery will be the change enablers, as these have a huge and versatile potential. The new capabilities in the next-generation filling and sealing machines will benefit customers with better and long-term performance levels. Moreover, speed is paramount in today’s business climate. Innovative packaging machiner y and line configuration that are capable of handling a wide range of product variations are on the horizon. With all technological advancements currently happening in the industry, it is believed that the FSS machines market is all set to soon witness a mini revolution. Email: avani.jain@infomedia18.in

The use of Supervisory Control and Data Acquisition System (SCADA) leads to central monitoring of all machines and helps minimise wastage and achieve greater accuracy. Niket Mankad General Manager, Pace Packaging Machines Pvt Ltd

Modern Packaging & Design January-February 2012

INSIGHT & OUTLOOK: Roundtable

industry

How is the maintaining the

cost-quality ratio of

FSS machines?

Filling, Strapping & Sealing (FSS) machines are highly automated assembly-line product packaging systems, commonly used in the food and pharma packaging industry. With the arrival of new-generation FSS machines with enhanced flexibility and efficient output, Annabel Dsouza analyses the task before the industry to avail the best technology at affordable cost. Ashok Gourish Business Head, Bosch Packaging Technology Ltd

The Indian market is extremely price-conscious, and thus demands the best technology at low price. In order to get the best quality at an optimal price, manufacturers are working on their internal manufacturing processes, supply chain and supplier development. Customers seek machines that can produce a wider variety of bag styles on their machines and also have the option to pack different types of products on the same machine. To meet these trends, machines have been designed that ensure lower operating cost. The new Servo technology has made filling and sealing machines smarter, and is picking up pace in the market. New machines have been devised, which offer servo drivers and other advanced solutions. The market for these machines is growing at a over 10 per cent annually. The middle segment of the market will show the highest growth rate, while the low-end segment will see the lowest growth.

Shashikant Ghorpade Senior Manager, Motion Control Production Machines, Drive Technologies, Siemens Ltd

Filling & sealing machines form an integral part of the end-of-theline packaging for major developing sectors such as pharma and food & beverage. Even the growing fast moving consumer goods sector finds numerous applications for these machines. The pharma and food & beverage sectors have registered a robust growth of 15 per cent per annum in India, and hence there is an equally healthy demand for newgeneration filling & sealing machines. Quality should be the key criteria for the industry. Machinery manufacturers are working towards creating awareness about the technological competitiveness and competency of new-generation filling & sealing lines. Once the converting fraternity realises the return on investment for these cutting-edge solutions, price concerns will be settled. Todayâ&#x20AC;&#x2122;s cost-effective FSS lines are reliable, high-precision and ergonomically sound.

Editorial take:

Umesh Sharma Managing Director, Julison Packaging India Pvt Ltd

Profitability is built entirely on cost savings in the integrated packaging process. New-generation FSS machinery lines have improved performance in areas like handling, quality of sealing and consistency in operation. They use gears and electronic sensors instead of belts and pulleys, which offer better control & easier handling, translating into cost-savings on labour & enhanced brand equity. As Indian convertors strive to keep pace with the global packaging industry, it is imperative to establish machinery infrastructure for highquality and consistent performance. A lot of innovations are happening in the filling and sealing machines. Clients today demand higher amenities. A big challenge here is to maintain the filling speed, volume accuracy and also packaging bottle safety. Low wastage is another key advantage offered by FSS machinery available today. These machines can operate with all types of films at any speed.

Owing to enormous opportunities for cost savings that FSS machines offer, the machine manufacturers are working towards integrating the packaging process to leverage on technological competitiveness and competency.

Modern Packaging & Design January-February 2012

INSIGHT & OUTLOOK: Activity integration in packaging

Unifying operations for better margins

The increase in awareness among consumers about significance of packaging directly affects the supply chain. Various methods are used to spread awareness for assurance of quality and quantity, but these cannot function in isolation. Hence, this requires an integrated and coordinated effort by the industry.

P V Narayanan

he growth, expansion and diversification witnessed in the packaging sector over the last five decades have compelled the industry to review and revamp its strategies. The sector has become more domestic. The opportunities supported by the technological capabilities and infrastructural facilities set up have made the packaging industryâ&#x20AC;&#x2122;s outlook global, thus addressing customersâ&#x20AC;&#x2122; needs through large multinationals on the basis of global requirements. The reach is aimed at new markets, stateof-the-art packaging, accessibility and optimisation at manufacturing with logistics becoming a crucial component. The managerial acumen achieved has provided a leadership quality that enables economies of scale in production by adopting best practices

and growth under one roof & brand, with an aim to become the category winner. Specialisation drives innovation, encourages closer customer relationship and helps a company become a total & optimum packaging solution provider.

Opportunities to seize The packaging industry, with a Compounded Annual Growth Rate (CAGR) of 12 per cent, aims to produce over 20 million tonne of packaging by 2012. This may be even higher if the growth estimate of the retail sector is any indication. In simple mathematical terms, the industry sources of supply of converted packages are all set to double. Interestingly, what matters most is not numbers, but new concepts. New materials suit the changing taste of every dynamic market display and product-package recipients. The industrialisation set in can only grow and it is unlikely to witness any deceleration. The demand on the industry

Modern Packaging & Design January-February 2012

will be to specialise in niche areas. With the per capita consumption valued at only $ 10 as against the global average of $ 70, the demand augmentation is a clear indication of the road the packaging industry is heading towards. In crude terms, the market is watching the industry and consumers are eager, and together the two generate opportunity. Sustained growth in the economic environment, demographics and skill base show a positive trend aided by liberalisation and deregulation towards developing a conducive business environment. What matters is not how one grows but how much one will grow. India has a positive advantage of the cross section of the demographic population, with 50 per cent below the age of 20 years and 64 per cent below 3 years. In essence, the market movers and takers constitute a high percentage, and are on the way to set the trend of packaging. The per capita income is

Activity integration in packaging

set to quadruple by 2020, which would result in higher personal disposable income of consumers, and thereby a higher purchasing capacity.

Growth potential The packaging industry strategy today is global, with leadership and specialisation all aimed at increased value and better market with profit through performance. On average consumption, the growth potential in India is about 700 per cent, which indicates future demands and potential for the packaging industry. Demands will be dynamic, and concepts need to be alive and moving. The requirements will be technology, process and manpower. New products, brands, choices and convenience features will be the driving forces. Marketers and design & development personnel must be on constant move. Having become a revolution, packaging brings in fundamental changes and massive expansion, leading to exponential development. The context indeed is social, emotional and technology changes. The demand mover in this era is the retail sector. Indian retail is the eighth largest in the world, valued at about ` 35,000 crore. The current 4-5 per cent organised retail will soon reach more than 10 per cent. This shift will add to the challenges to the raw material suppliers, machinery and technology suppliers & manufacturers. The watchword will be ‘Industry converts opportunity into reality through technology adoption and implementation’. The growth of the industry is highly market oriented, and hence dynamic; it is thus poised to remain stable with an increasing flow of innovations. With recent trends and emphasis on eco-friendliness, a greater responsibility lies with packaging, which acts as a facilitator in product distribution and marketing.

Amalgamation of activities The subject of packaging today has assumed special significance, opening up opportunities in many areas. The awareness of the relevance of packaging,

having gradually and steadily increased among consumers, has a direct impact on the entire supply chain. What matters here is the assurance of quality and quantity. The association of packaging with all other activities and with growing awareness of consumerism & increasing competitiveness resulting in more product substitutes & alternatives, brands have raised the expectation from packaging to an enviable level. It has become the centralised integrating stem of an umbrella, which brings together many activities in an organisation. It would be more appropriate to sum up the responsibility of packaging as the exclusive source to integrate all disintegrated activities. The diagnosis would lead to: Industry recognition but ‘positioning of packaging’ Packaging as part of organisational structure at par with others Packaging personnel-career opportunity and growth The need is to remove the myth and make packaging the frontline subject in industry and academics over the years. Thus, the enhanced role of packaging in the economic growth of nations worldwide will receive greater appreciation. Packaging will also be recognised as an effective aid to reduce the overall waste rather than add to waste. Scientific packaging and breakthroughs & developments offer the best means to ensure safety and economy. In essence, packaging is one of the most indispensable elements of the nation’s growth. This requirement is, therefore, to direct the application and adaptability of packaging towards product processingproduction-fabrication, technological & infrastructural developments. These should be adequately percolated to the grassroots levels for adoption.

Practice for perfection Training and education in the field of packaging assume greater significance in spreading awareness of the need and contribution of packaging as a value added factor. Being industry oriented, it has wide employment potential, scope

for entrepreneurship – for expansion or diversification and, importantly, new entrepreneurship opportunities, which are available at different levels. A basic in-depth technological exposure with practical industry orientation is the best way to lay the right foundation to build personnel who would satisfy the core needs. The objective is to address the constraints of the past, changing needs of the present and expected requirements of the future. The peculiarity and exclusiveness of the subject of packaging is that it involves various sciences, technologies, arts, commerce and is a convergence of engineering, electronics, communications and marketing & management. The major connectivity is linked to materials, supply chain, marketing, production, systems, operations, etc. It provides ample scope for research both infield and off the field. The packaging personnel with such an in-depth association to science, engineering, arts, commerce and various technologies is a privileged source to yield a variety of outputs, and hence unlimited opportunities. In order to attract more people into the field of packaging, the wide gap felt the world over need to be bridged quickly and effectively. The task is interesting and challenging and requires a two-pronged approach. Upgrade the skill of existing personnel at all levels through human resource development programmes Create and develop fresh technocrats at all levels

Coordination concerns A number of parameters influence packaging and its growth. Thus, an integrated and coordinated effort is the need of the hour for the industry. P V Narayanan is a Member of Board in APEDA (Ministry of Commerce). He is also Secretary General - IPMMI and Chief Executive - PFFCA. He is a recognised UNIDO, ITC and CFTC (UK) expert consultant in the field of packaging. Email: pvniyer@hotmail.com

Modern Packaging & Design January-February 2012

INSIGHT & OUTLOOK: UV curing technology

Ultraviolet (UV) curable inks are 100 per cent solid and do not discharge solvents – a major reason why screen printers today prefer UV inks over solvent inks, which are an environmental hazard. Here, we tell you how to choose and use the right UV ink curing system to increase production speed and facilitate superior bonding to ensure a profitable business.

Bhargav Mistry

se of finer mesh screens with Ultraviolet (UV) curable inks results in printing with greater details. UV saves significant floor space as compared to wicket dryers or conventional hot air dryers. It consumes lesser energy than gas or electric conventional dryers. The nearly instant drying of UV yields higher output from existing presses and fast completion of a job.

Achieving appropriate UV curing UV curing or ‘drying’ is achieved

Modern Packaging & Design January-February 2012

through photo-polymerisation. Mercury vapour lamps generate UV energy, which has a strong spectral peak of 3,650 Angstrom. This energy is absorbed by the photo-initiator within the liquid formulation of the ink or coating. The process produces free radicals, which attack the double bonds of the resin (monomeric) molecules. The molecular weight increases as the particles join together to form cross-linked chains, resulting in a solid polymer film. The process of converting a mobile liquid into an immobile solid coating takes place in a fraction of a second. This is accomplished without solvent waste, and

UV curing technology

the method usually consumes less energy than conventional methods. The photo-initiator–resin ratio is determined by the material supplier and the ink comes premixed prior to shipment. Usually, UV inks and coatings are ready for use in their packaged form. The material supplier selects these pigments at an optimum concentration, which are capable of transmitting UV light. But, some pigments transmit UV energy more readily than others; for example, black & white inks are perhaps the most difficult to cure because black inhibits UV light penetration and white reflects UV light. Both can be cured with increased exposure. The spectral hues cure faster than black and white and exhibit lesser differences in cure rate among each other. The intensity of UV energy is, for the most part, determined by the type of lamp and reflector used. The current standard for the industry is 200-300 Watt/inch mercury vapour lamp housed in an aluminium reflector, of which the inside surface is plated and polished for maximum UV reflectance. Higher wattage leads to faster production. In this context, Grafica – manufacturer of screen printing machines – has successfully sold UV Curing Machine up to 600 Watt/inch. The thickness of the ink and coating is a concern for the screen printer because if excess of ink is deposited, the UV will be unable to penetrate, and thus result in an incomplete cure. Because UV curable inks are 100 per cent solid, mesh counts per inch in the range of 140-180 threads/ cm (355-457 threads/inch) can be used to maintain thickness in the curable range. The thickness of clear coatings is not as critical because these do not contain pigments that reduce cure rates. The substrates on which the ink and coating are cured often affect the cure rate. For instance, a surface that reflects UV energy would cure faster than a dark surface, as it would absorb UV energy.

Buying the right UV curing machine When purchasing a UV curing machine for screen printing, two important features to look for are:

Factors governing cure rate Photo-initiator–resin ratio in liquid or ink Ability and concentration of the pigment to transmit UV energy in case of a screening ink Intensity of UV energy in Watt-seconds/CM2 produced from mercury vapour lamps Thickness of ink to be cured Substrate on which the ink and coating are to be cured How well the manufacturer handles the heat generated by UV lamps How well the conveying system transports the light stock through the reactor UV lamps produce three types of energy – ultraviolet energy (which is absorbed by the coating or ink and produces cure), infrared and visible light. Visible light is contained by the sheetmetal enclosure of the curing tunnel, which protects the operating personnel. Infrared or heat produced by the lamps must be controlled to keep the stock dimensionally stable. This is done by either water-cooling the lamps and reflectors or air-cooling the curing tunnel, or both. A separate cooling module can also be added that allows the screen printer to process highly heat-sensitive substrates after curing, eg, vinyl and polyester films. For conveying light stock, a vacuum holdout conveyor must be provided to ensure smooth transport through the curing tunnel. The vacuum holdout should begin one foot before the stock enters the reactor to prevent the sheet from fluttering as it enters the curing chamber. The conveyor belt should consist of a material that rapidly dissipates heat, eg, Tefloncoated, open-mesh, fibreglass belt. Other considerations for purchasing UV curing machine are number of lamps required to achieve proper cure at a desired speed. This should be coordinated with the ink supplier who can recommend the number of lamps needed at a given production speed. Conveyor speed control should be precise and repeatable to prevent over- or

under-curing, and drives should vary from 30 to 150 Feet Per Minute (FPM).

Striking the right balance When converting a conventional line to UV, a few difficulties arise, which must be dealt with. Screen fabrics and mesh counts should be changed. As UV curable inks are 100 per cent solid and do not discharge solvents, the amount of ink initially printed is the amount of ink left after cure. Therefore, monofilament screens with 140-180 threads/cm (355457 threads/inch) should be used for screen printing UV curable materials. A difficulty with UV inks is opacity. If the pigment level in UV ink is extremely high, the ink will not cure; therefore, the screen printer who requires true opacity for a job cannot use UV inks in this case. Anything less than true opacity can be achieved by UV. Material suppliers have long been facing problems with adhesion of UV curable ink to certain substrates, but they have overcome this obstacle by altering the formulation of the coatings for a specific substrate. In some UV curable inks, the monomers in the formulation are a cause of concern with regard to toxicity. The user needs to handle these inks properly. The coating supplier is responsible for informing the user about the extent of toxicity of the material supplied and also for providing instructions on their proper handling. Incidentally, for example, UV energy is currently used in dentistry for curing photoreactive material in filling tooth cavities.

Creating a bright impression UV curing has a bright future in the screen printing industry. The process is widely accepted and will continue to grow, enabling the industry to provide new & better products. Bhargav Mistry is Director of DMI, and MD of Grafica Flextronica, manufacturer of fully automatic and semiautomatic screen printing machines. Email: bhargav@graficaindia.com

Modern Packaging & Design January-February 2012

INSIGHT & OUTLOOK: Practical tips

s n o i t u l o s e v i Effect

for

y t i r u c e s

A brand must be protected against attacks like counterfeit, copyright, patent infringement, etc. In today’s global market, companies are in a constant race to protect their brands from those who seek to take advantage of successfully created businesses. Here are some strategies and features for different target groups.

ntellectual property is a company’s most valuable asset. There are several forms of Intellectual Property Rights (IPR) violations, including counterfeiting, trademark infringement, grey market/diversion, country of origin, non-compliant parts, etc. Counterfeit products are at the forefront of these IPR issues. Any recognisable brand is at the risk of being counterfeited – clothing and handbags, watches and sunglasses, music and movies, films, pharmaceuticals, medical devices, agricultural chemicals, parts of automobiles, luxury goods, auto and industrial parts, food & beverages. Government agencies and industry sources estimate the cost of global

counterfeit problem at $ 600 billion per year. Thus, Federal Bureau of Investigation (FBI) has labelled counterfeiting as the ‘Most Vulnerable Crime of the 21st Century’.

spend an average of $ 2-4 million per year to combat counterfeiting. Some have even reported spending up to $ 10 million annually for this purpose.

Preventing counterfeit Counterfeiting: An urgent global issue Brand counterfeiting can threaten the very life of a major business. Counterfeit merchandise has led to numerous risks for consumers worldwide, from significant health and safety concerns over counterfeit life-saving drugs, to flammable electrical devices, destroying the brand reputation of legitimate companies so it poses product liability claims. Fortune 500 companies have reported that they

Modern Packaging & Design January-February 2012

From production to transport, counterfeiting is avoided using various pigment formulations. This can be done during primary and secondary packaging and coating. From transport to distribution to wholesaler, retailer and, finally, the end-consumer, there are many ways for protecting a brand. Threats change, technology moves on and criminals learn quickly. Thus, the only viable approach is to revisit the brand protection strategy, at

Practical tips

a fundamental level and regular intervals. A consistent concept of protection at all levels of a product is required, especially in case of pharmaceuticals.

Security market at a glance The market for brand protection has two distinct segments: High security market and product security market. The high security market includes currency and state issued Identification (ID) documents such as currency, banknotes, ID cards, passports, visas and documents of value, eg, credit cards, cheques, stamps, etc. The product security market includes products, eg, pharmaceuticals, perfumes, tobacco, textile, vouchers, tickets, sports equipment, CD, DVD and software. Security pigments are used exclusively in the product security market, ie, for protection of consumer goods, which includes protection of packaging material and labels for consumer goods.

Protection for different target groups Security markings are different for different target groups. Product protection specialists have differentiated security markings by designating them as overt, covert and forensic. Security markings with overt features can be easily identified with the naked eye and does not require any device for authentication, eg, holograms, thermochromic inks, optically variable pigments, micro-/nanoembossing, watermark, etc. This security feature is essential for end-consumers. The covert features include covert taggant, liquid crystals, grey market coding, security screening, dual-Ultraviolet (UV) fluorescence, etc. These are detected using devices such as UV-spectroscopy lamp, decoding lens, code reader, chilling-spray and magnifier. Traders, retailers, custom officials, authorities, etc, look for such security features. Forensic features can only be detected with special laboratory equipment such as laser projection device, special readers and microscope. These are used to mark higher risk value products.

Efficient brand protection Efficient brand protection is possible by combining all features, ie, a multi-level approach of security features across the overt, covert and forensic levels. These features can be combined with a design concept to provide additional security. In order to prevent imitation, product protection specialists also use methods having secure, well-documented logistics. The protection provided by security pigments can be improved by using intelligent tactics. For example, instead of printing or colouring products over a large area, the security features can be specifically placed at certain spots. This is done to inconspicuously integrate the markings into the existing design, so that they are not immediately recognisable as security features. Thus, one must remember these: Do not become a victim of counterfeiting, forgery or illegal imitation. Choose wisely the security product with the right pigments for your brand. Courtesy: Merck

Modern Packaging & Design January-February 2012

INSIGHT & OUTLOOK: Colour management

Harmonising art and aesthethics Colour and its reproduction involve the physics, chemistry and psychology as well as artistic & aesthetic considerations. Colour has moved on from being just a shade to an aspect that forms the basis of a product’s identity. Here is a peek into the world of colours that express brand quality.

Kiran P Prayagi

olour management not only deals with International Color Consortium (ICC) profiles or International Commission on Illumination (CIE for the French name Commission internationale de l’éclairage) systems of colour that are quite popular today, but also covers sufficient background information important to understand this subject. Everything that affects colours is part of colour management. Colour management is often considered to be a matter only for the pre-press or ink personnel and has nothing to offer to the press, post-press and others within the organisation, or even customers. Colour exerts a strong influence on our lives. It affects the

way we see, feel and act as well as our impression about ourselves. It forms a part of the structure of every society. In any arrangement that uses colour, whether it is a room setting, clothes, painting, packaging or design, the relationship between colours is as important as the choice of colours.

Tradition of colour The tradition of painting our houses goes back to the beginning of building construction and beyond – into the painted caves of our prehistoric ancestors. Historically, our towns and cities have been built using local materials and, until the beginning of the 19th century, were painted with pigments made from local deposits of earth. Our home is essentially a private domain with the hues of our choice.

Modern Packaging & Design January-February 2012

Recently, research has been conducted on the effect of colour on the visual size of rooms. If the quality of light represents an external influence on our colour vision, then our personality represents an internal and private influence on the choice of colour. Among the various colour personality tests, ‘The Lüscher Colour Test’ is the most popular one. Colour therapy or chromotherapy is the science that uses a variety of colours to change or maintain vibrations of the body to the frequency that signifies health, convenience and harmony.

Messenger of identity The world of advertising offers a deluge of multi-coloured images f rom the pages of magazines, television screens and hoardings in cities. In advertising,

Colour management

colour has a greater impact as compared to any other sense. Indeed, some advertisements rely solely on colour to instantly communicate their meaning. Departmental s t o re s and supermarkets generally stock hundreds and thousands of items. A single store can have thousands of items at any given time. Colour is used to single out individual brands or products to increase identification or make them more appealing. Furthermore, as more than half of all supermarket sales are unpremeditated, colour functions as a tool to attract the impulse-buying majority. A closer look at the products and their packaging finds the basic colour language. High-legibility hues such as red and yellow flash ‘new’ and ‘improved’ messages on packaging, while background colours are often used on products concealed in packets, tins and bottles to communicate the actual, desired or ideal hues of the unseen product. For instance, various permutations of blue, white and grey are often employed to depict the purity, freshness and unadulterated state of various brands of sugar, flour, salt and milk. Adding a touch of red to the

package increases a sense of power, as is seen in case of bleach or toothpaste. Green and yellow project the freshness of vegetables and fruit. Orange, either individually or in combination with other ‘power’ hues such as dark blue and yellow, signifies a healthy energy when associated with vitamins and breakfast cereals, but when combined with ultramarine, it conveys the power to clean the weekly wash. The colour of the product and, indeed, its packaging, can determine people’s judgement of its strength. For example, products such as baby lotion, moisturising cream, tissues, oil and soap that claim to be mild & gentle on the face and hands generally tend to be identified in pink. Statistics show that approximately 200,000 tonne of additives are consumed each year in the UK alone to make foodstuffs attractive at the supermarket. Almost 90 per cent of the 3,700 chemical compounds used are solely for cosmetic purposes. These figures reflect our demand for the ‘correct’ appearance of f ruits, vegetables and meat, and also respond to our strong associations of bright colour with f reshness and flavour.

Various industries such as clothing, beauty & cosmetics and soft furnishings, for their existence, depend heavily on the customers’ constantly changing preferences for colours. Indeed, their success in the market hinges upon accurate forecasting of the future trend-setting colours. The product designs represent a common language of colour for the international market. The combinations on each package are the result of market research. Most companies not only use colour psychology to advertise package and mass market their products or services, but have also directly linked their company with a particular hue, eg, WalMart blue, Spencer’s orange, Kodak red, Reliance green, Jet Airways blue, etc.

The science of colour Colour can never be ignored. Technology has penetrated the modern world like never before. In the production of commercial printing and packaging, all parameters can be specified, eg, size, quantity, type style & size, delivery date, etc, except for the precise definition of quality and colour. In order to reproduce colours as closely and best as possible to reflect what has been said so far, the artists, photographers, television industry and, especially, the printing industry, have the herculean task of using their limited number of colours. This is further compounded with the variable lighting and viewing conditions that people encounter in everyday life. All these happen because the language used to describe colour is often imprecise.

References 1. Robert Cumming & Tom Porter, The Colour Eye, BBC Books, London 1990 2. Max Luescher, The Luescher Colour Test, Pan, Germany 1987 Kiran P Prayagi is a Managing Partner at Graphic Arts Technology & Education (GATE), and heads pmIndia, a joint venture with Chemnitz University of Technology, Germany. Email: gate@bom5.vsnl.net.in

Modern Packaging & Design January-February 2012

AUTOMATION TRENDS: FSS machines in pharma

Gaining profitability

through accuracy

Increasing emphasis on quality, aesthetics and adherence to regulatory norms in packaging of pharma products have prompted companies to automate their production processes in order to pack products with accuracy and at faster speeds, thereby shortening the production cycle time and increasing efficiency. Rax Serrao

part f rom the basic requirement of protecting the drug, a pack must be appealing and distinct enough to promote itself. With the increase in modern packaging in the pharmaceutical industry, brands exploit the power of distinctive packaging design to stand out from the competition and increase profitability. The pharmaceutical industry not only demands aesthetics and appeal, but also requires strict adherence to the laws governing the packaging process since it is a matter of human life. Hence, it becomes more critical as compared to packaging in other sectors.

Automation in pharma Automation in packaging ensures peace of mind along with increased return on investment for pharma companies. Automation improves productivity and avoids human errors, which occur during manual feeding. At every stage, sensors sense the presence or absence of the components and reject the pack if one or more components are missing from the pack. This also assures that the right components go into the right pack.

New technology Technology can be a boon for pharmaceutical companies exporting their products to highly regulated

Flow wrapper with multifeeding capability

markets like the US and Europe. Since these are highly regulated markets and even if a single component, which affects the efficacy of the drug or explains the dosage, is missing in the pack, it can lead to rejection of the whole batch. Another technology where use of flexible laminates can result in costeffective and accurate packaging is Horizontal Form Fill Seal (HFFS) machines. Filling of powder with pellets or unit dosage in liquids or ointment gels in a flexible laminate can be done using an HFFS machine. By changing over from bottle to pouch, pharma packaging can be taken to the next higher level of sustainable packaging in a cost-effective, attractive and safer manner. If the composition of the drug is known, the barrier properties of the film can be decided on, and the cost optimised without compromising the quality. Ease of handling of the end pack is also a decisive factor here.

Modern Packaging & Design January-February 2012

Packing profits Here, an example can be considered of replacing the filling of liquid/powder/gel product from high-density polyethylene bottles/lamitube to a flexible pouch. This approach immediately reduces the cost of packaging material, transportation and the taxes on it. Since the packaging material of a flexible pouch is a film on a reel, it occupies lesser space, freeing up space in the factory for other functions. Packaging of pharma products using flexible laminates in a flow wrap or the form-fill-seal format provides an excellent alternative and automation opportunity. It increases productivity and accuracy, thereby raising the profit margins. Rax Serrao is Packaging Specialist at Clearpack India Pvt Ltd, Andheri, Mumbai. Email: info@clearpack.com

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ENERGY MANAGEMENT: Life cycle analysis

‘Flexible’ opportunities in packaging With increasing interest in sustainable solutions, the global packaging fraternity has turned its attention to flexible packaging, as it weighs less than many other types of rigid packaging. Annabel Dsouza looks at the finer details of flexible packaging as a weight-saving strategy to reduce energy consumption and greenhouse gas emission.

he global packaging sector is witnessing phenomenal growth, particularly in developing markets. The Euromonitor 2011 research estimates that the flexible packaging industry in BRIC nations (Brazil, Russia, India and China) is currently valued at $ 13 billion and expected to grow by 9.2 per cent per annum to reach $ 17.7 billion by 2013. With growing awareness and emphasis on convenience and recyclability, flexible packaging is outperforming conventional methods of packaging as it weighs less than many other types of rigid packaging, including metal, rigid Polyethylene Terephthalate (PET) and glass containers. By using lightweight packaging, such as flexible pouches, companies can reduce the amount of fuel used as well as greenhouse gases emitted during transportation. Flexible packaging encompasses materials such as paper, metallic foil, polypropylene and polyethylene. The latter plastic substrates make up almost 60 per cent of the packaging film demand in India. This trend is driven by the Indian retail industry’s emphasis on innovation, long shelf-life, ease of

production & distribution and overall profitability. Charles Brignac, Marketing Manager, Graphic Packaging, says, “Among all packaging materials, flexible

These advantages are possible because a large percentage of flexible packaging is produced by using sophisticated engineered materials. Adhesive laminates and co-extruded films are among the widely used flexible plastics in burgeoning industries such as processed foods, pharmaceuticals, chemicals, cosmetics and personal care products.

Energy concerns

plastics offers an excellent product-topackage ratio and cube utilisation as well as superior barriers required to protect & preserve many products. It also enables many consumer conveniences such as recloseability and microwavability.”

The lifecycle attributes of flexible packaging demonstrate many advantages across numerous packaging applications. Flexible packaging starts with less waste, reducing landfill discards. Also, innovation and technology have enabled flexible packaging manufacturers to use fewer natural resources in their packaging. Also, improvements in production processes reduce water and energy consumption, greenhouse gas emissions and volatile organic compounds. Also, lighter-weight flexible packaging results in less transportationrelated energy & fossil fuel consumption and environmental pollution. Brignac adds, “The concept of sustainability recognises the importance of a thriving economy. Flexible packaging

Modern Packaging & Design January-February 2012

Life cycle analysis

Flexible packaging proves its worth and value for business as well as consumers and the environment. With flexible packaging, converters, manufacturers, shippers and warehouse personnel gain more cost-efficient production & handling. Charles Brignac Marketing Manager, Graphic Packaging

proves its worth and value for business as well as consumers and the environment. With flexible packaging, converters, manufacturers, shippers and warehouse personnel gain more cost-efficient production & handling. Retailers benefit from tighter, more eye-catching shelves with products having longer shelf life. Transparent collation films reduce the need and cost of printing on secondary packaging and efficiently combine shipping & retail packaging, thus reducing back-end waste.” Flexible packaging can provide traceability and brand protection, thus reducing potential losses. In order to demonstrate tangible energy savings and monetary savings of flexible packaging, one can consider the example of canned foodstuffs that are shifting to flexible packages. Among the obvious design advantages, these innovative packages: Contain 88 per cent less packaging by weight as compared to metal cans Reduce weight of waste to landfill by 72 per cent versus metal cans (taking recycling rates of cans into account)

Use 20 per cent less space in shipping than cans Offer energy savings equivalent to 17,200,000+ gallon of gasoline per year in manufacturing and transportation. The potential for reducing actual petroleum use by reducing package weight in transport is impressive.

Basics of machinery Flexible film processing plays an important role in the overall performance of the material as a sustainable packaging solution. Following are some pointers for flexible film processors to reduce energy consumption and increase profitability: Use of flexible extrusion equipment (eg, screws & dies) with excellent self-cleaning effects that allow faster changeovers and less scrap Autoprofile systems to improve overall gauge tolerances that improve yields through resin utilisation as well as increased printing/converting speeds for more uniform film Operator-friendly, easy-tounderstand and operate computer controls [Human Machine Interface (HMI)], which allow the customer to changeover products with less scrap and downtime Availability of production data such as temperature, tension settings and process conditions for product quality and consistency Automation mechanisms for higher film quality, reduced scrap and less damage to the expensive finished product, due to the use of shaft and roll handling systems Silos used for easier monitoring of polymer usage, order reports, power consumption, line efficiency, etc help run an efficient operation While purchasing new film extruders, convertors should ensure an increase in output, better film quality, operatorfriendly system, service and back up from the supplier and reliability of equipment. On-time delivery and startup, reliability of the equipment and good service

Modern Packaging & Design January-February 2012

should also play an important role in any decision. Cost savings in energy efficiency and manpower usage will be the driving forces for enhanced profitability and brand equity for packaging convertors.

Route to recycling In keeping with the environmental concerns, the flexible packaging industry takes into account all aspects of the triple bottom line (financial, social & environmental) and each stage of a package’s life cycle, including raw materials, production processes, transportation, functionality, end-ofuse options as well as sustainability of the product being packed. Today, through technology and innovation, flexible packaging is at the forefront of important trends in product protection, package design and minimisation, customer convenience, waste reduction and resource conservation, positively impacting the environment, consumers and businesses. Brignac highlights, “Flexible packaging contributes less to landfills even when considering the recycling rates of other packaging formats. If the packaging consists of a single-layer flexible construction, it can also be easily recycled at the end of its useful life. However, most of these packages are difficult to recycle, which creates endof-life challenges for flexible packaging waste.”

Driving sustainability Throughout its lifecycle, flexible packaging proves its usefulness and its value for businesses, consumers, environment and future generations. Innovations in flexible packaging have increased product protection and consumer convenience, enhanced retail shelf impact and improved manufacturing efficiencies, while ensuring lesser use of packaging and natural resources as well as creating less waste. Using innovative flexible packaging is an excellent, sustainable choice that offers more value with less packaging. Email: annabel.dsouza@infomedia18.in

POLICIES & REGULATIONS: Plastics in food packaging

Monitoring food contact

stipulations

The foreign direct investment in retail bill has raised pertinent questions about India’s ability to manage, distribute and supply the nation’s enormous output of food crops. Annabel Dsouza highlights the regulatory norms that govern food packaging applications and their considerable advantages in domestic as well as export markets.

ackaging provides an important medium whereby manufacturers can provide information on product features, nutritional contents and ingredients. Packaging is a system for preserving the safety and quality of food products throughout the entire distribution chain to consumer by: Maximising shelf life Carrying important information on the label relating to preparation, safety and nutrition Providing evidence that the package is intact and the product has not been tampered with Identifying the date and location of manufacture for inventory control & identification of potential hazards

Purpose of packaging Packaging is an essential medium for preserving food quality, minimising food wastage and reducing use of preservatives in food. It serves the important function of containing the food, protecting against chemical and physical damage while providing information essential to consumers and marketers. The recent Central Government directive permitting up to 51 per cent Foreign Direct Investment (FDI) in the Single Brand Retail Trading (SBRT) sector has again brought under the spotlight one of India’s largest administrative mishaps concerning post-harvest loss in food grains. The Ministry of Food Processing assesses that post-harvest losses of farm produce, especially fruits, vegetables and other perishables, have

been estimated to be over ` 1 trillion per annum, 57 per cent of which is due to avoidable wastage and the remaining due to avoidable costs of storage and commissions. Apart from retail logistics and cold chain infrastructure, this issue highlights the state of packaging as well as packaging technologies in India against the backdrop of surging food demand from the nation’s teeming population.

What the law says? Pundits of packaging affirm that a package must protect what it sells and sell what it protects. Hence, it is imperative that the choice of a packaging material should not affect the nutritional quality of a product. The packaging materials chosen to protect and transport food must comply with existing

Modern Packaging & Design January-February 2012

Plastics in food packaging

To supply plastic packaging materials to the food industry, ISO: 22000 is mandatory and people are slowly realising the importance of this certiﬁcation. Vimal Kedia Managing Director, Manjushree Technopack Ltd regulation, such as Materials and Articles in Contact with Food Regulations (EU Regulation 1935/2004) and equivalent Food and Drug Administration (FDA) requirements in the US. Material-specific requirements must also be considered, especially for plastics: 2002/72/EU and its five amendments as well as FDA CFR 21 specify the exact amounts & types of additives that can be used to manufacture these plastics, each one having been tested and approved for food applications. Use of plastics for food packaging applications is increasing both in quantum and variety. Plastics packaging materials are available in various forms, eg, monofilms, coextruded films, laminates, sachets, jars, bottles, etc. Realising the versatility of plastics packaging, which has prompted its wide usage in food packaging in the country, it was considered expedient by the Bureau of Indian Standards (BIS) to formulate a standard on this subject – IS: 10171-1982, Guide on Suitability of Plastics for Food Packaging. This standard is expected to provide general guidance to the food packer in selecting the specific thermoplastic material or its combination to design an acceptable food packaging system. But, the standard does not provide guidance on the actual design of the food packaging system or cover the shelf-life requirements for various food products. The standard also

states that the plastics used shall be of food grade material and should be safe for food contact and conform to relevant Indian standards. It must also be used in conjunction with the series of standards on food contact plastics, of which it forms a part. These standards are being adopted worldwide by packaging manufacturers to help improve their manufacturing facilities and ensure the best quality and hygienically manufactured packaging. Plastics additives for food contact are placed onto positive lists in these regulations. In order to ensure that any migration from the necessary additives used in the manufacture of plastics is kept within tightly regulated limits, migration requirements for the finished plastics packaging must also be met. The supplier of packaging and packaging materials must deliver appropriate compliance documentation such as Safety Data Sheets and Food Contact Statements. Vimal Kedia, Managing Director, Manjushree Technopack Ltd, informs, “Any organisation into plastic packaging for the food industry must comply with food grade certifications and regulations. The raw materials used should also be of food grade quality. To supply plastics packaging materials to the food industry, ISO: 22000 is mandatory and people are slowly realising the importance of this certification. In case of raw materials, eg, for Polyethylene Terephthalate (PET) materials, the FDA code is 21CFR177.1630 and, similarly, in India, it is IS 12229/1512252. ”

Quality wise Pre-packaged foodstuffs must comply with the mandatory harmonised standards on labelling and advertising. The details that must appear on packaging include the name under which the product is sold, a list of ingredients and quantities, potential allergens, minimum durability date and conditions for storage. In many countries, nutritional information is also required. To ensure the safety of the domestic and global food supply, government regulations and brand protection demands from customers are on the rise. To address these growing requirements, food processors along

Modern Packaging & Design January-February 2012

the supply chain have introduced traceability systems. Kedia asserts, “Packaging convertors need to invest in upgradation and installation of latest equipment to comply with certifications and regulations besides process improvements. In most cases, these investments also help the convertor directly or indirectly with their good manufacturing practices. Hence, forward looking companies continue to invest and upgrade their standards.” Developing the packaging service subsector, specifically pre-packing of food products for export, and outsourcing the packaging of food products to specialised companies, will provide a boost to the packaging industry in developing economies like India. These will not only lend affordability to packages and packing, but also enhance handling and distribution efficiencies to exporters, specifically to small and medium enterprises.

Export agenda Among the challenges that beset the Indian packaging sector include limited packaging solutions to meet international market requirements, and the small size of the domestic demand for packaging materials that leads to low investment by the packaging industry. This, in turn, limits a convertor’s ability to enhance product quality to meet standards of increasingly discriminating consumers, both in domestic and international markets. Adhering to Indian and global food packaging standards greatly increases the convertor’s brand equity in the export market. Kedia concludes, “Most companies abroad insist on certifications like BMF for the pharma industry, British Retail Consortium/Institute of Packaging BRC/ IOP certification for the food industry, etc. The BRC global standards are a leading global safety quality certification programme widely used by customers and global retailers. They facilitate standardisation of quality, safety, operational criteria and manufacturers’ fulfillment of legal obligations. Most customers make their purchase decision based on whether a particular supplier is complying with this certification.” Email: annabel.dsouza@infomedia18.in

STRATEGY: Packaging techniques

Approach for enhanced shelf life With increasing consumer awareness, packaging has become challenging over the years. Today’s consumer not only wants packaging to be attractive, functional and safe, but also such that it increases the shelf life of the packaged goods. Avani Jain explores some novel ways of packaging that could increase the shelf life of packaged goods.

ackaging is a means of ensuring safe delivery of a product to the final user in a sound condition and at a minimum overall cost. All attributes of a package can be summed up as a coordinated system of preparing goods for transport, distribution, storage, retailing and end use. The package must contain and maintain product quality and have long shelf life to the satisfaction of the user – value for the price. Currently, with the trend shifting from loose products to packed products, customers are demanding increased shelf life of packaged goods so as to retain them for a longer period. This has prompted packaging companies to develop new methods and technologies to ensure this.

Strategising the concept Considering the emphasis on increasing the shelf life of packaged goods, companies have taken some positive steps in this regard. Rajesh K Pandya, Vice PresidentOperations, Parikh Packaging Pvt Ltd, notes, “We have developed high-barrier low-thickness packaging solution with improved shelf life by using the latest technologies available in the market. In some applications, metalised films instead of aluminium foil are used, as these help retain the desired shelf life of products. These metalised films are light weight and the cost of raw materials used to manufacture these films is also low.” Extrusion laminates are of considerable help in this regard. Some properties of extrusion laminates, which help in increasing the shelf life of packaged goods, include airtight (vacuum) seal, high

barrier to water vapour/moisture, good barrier for low oxygen transmission rate, nitrogen flushing, leak proof, etc. Pandya notes, “Extrusion laminates made from polyethylene layer instead of adhesive provide cushioning to the aluminium foil/metalised film, helps avoid foil/metal cracking, thus enhancing product shelf life. Besides, high-performance advanced polymer technology provides higher moisture barrier. For example, we use degassing valve pouches for enhancing the shelf life of coffee, although this concept is not yet popular in India.” As a result of sugar browning reactions while roasting, freshly roasted coffee exudes carbon dioxide for about a week in its whole bean form. For this reason, coffees of the highest quality are typically packaged immediately after

roasting in a moisture-proof laminated coffee bag containing a one-way degassing valve. The degassing coffee valve allows the carbon dioxide to escape without ballooning or rupturing the bag, and prevents oxygen from entering. Pandya notes, “This technology helps retain the taste, aroma and freshness of coffee for longer periods.”

Future trends Packaging will become more dominant as time progresses. The trends will be both technology- and market-driven. Package developments will witness more research and development, as only innovations will provide the answers to many concerns of the consumers, including their demand to further increase the shelf life of packaged goods.

Modern Packaging & Design January-February 2012

Packaging techniques

Aseptic packaging is a manner of packaging where maximum hygiene is ensured. Not only the products to be packaged are handled carefully, but the entire machine and all inert machine parts are also cleaned thoroughly, leaving no scope for contamination. Rajesh K Pandya Vice President-Operations, Parikh Packaging Pvt Ltd

“Some of the future trends for increasing the shelf life of packaged goods include Modified Atmosphere Packaging (MAP) and aseptic packaging. Aseptic packaging is a manner of packaging where maximum hygiene is maintained while packing. Not only the products to be packaged are handled carefully, but the entire machine and all inert machine parts are also cleaned thoroughly, leaving no scope for contamination. This helps in increasing the shelf life of products, as there is no scope of product spoilage as a result of poor packaging. At present, only few companies in India are involved in aseptic packaging, but this trend will grow in future,” notes Pandya. MAP is a relatively new concept as compared to aseptic packaging. It is also known as gas flushing, protective atmosphere packaging or reduced oxygen packaging. By using a modified atmosphere, the visual, textural and nutritional appeal of fresh and minimally processed packaged food products can be maintained. It is an optimal blend of pure oxygen, carbon dioxide and nitrogen in a

Modern Packaging & Design January-February 2012

high-barrier or permeable package. The controlled MAP environment enables food packaging to provide an extended shelf life without requiring the addition of chemical preservatives or stabilisers. Pandya avers, “This technology is new to India and costly as well. It will take a long time for processors to adopt this technology. But, there is an increasing trend of using nitrogen flushing while making the pouches so as to increase the shelf life of packaged goods, but that is only a part of MAP. The technology is not fully developed in the country.”

Packing a punch Packaging is a significant tool to curb waste and ensure product availability – seasonal or processed – at uniform quality and price throughout the year. An eye-catching design is as crucial as long shelf-life and safe storing of contents. This demand has led to development of packaging practices, which help in increasing the shelf life of packaged goods to a large extent. Email: avani.jain@infomedia18.in

TIPS & TRICKS: Labeling solutions

Creating a lasting impression Appropriate labeling on the packaging of a product not only increases customer awareness, but also ensures that the product information is effectively registered with the customer. Anwesh Koley provides some pointers on how labeling creates the first positive impression with the potential customer and increases the attractiveness of the package.

he heavy investments pouring in, the constant research and development taking place and the exchange of fruitful ideas among stakeholders of the packaging industry, all hint towards

one imperative target â&#x20AC;&#x201C; maximising customer awareness. The package labeling industry acrossthe globe has taken up the task to introduce some of the unique labeling solutions to the market, which will distinguish their

products f rom their competitors. There have emerged numerous means by which pac kaging companies can make the most of such informative labels. Email: anwesh.koley@infomedia18.in

There are different types of labels that can give a powerful market image by adding value to products, thereby triggering brand loyalty:

Booklet and leaflet labels: Booklet labels have a real â&#x20AC;&#x2DC;bookletâ&#x20AC;&#x2122;, glued at the back and leaflet labels contain a folded multi-page flyer. Different types of these labels can be produced, either with paper or synthetic films. Such labels are used to provide additional information on a packaging where the space available for text or images is rather limited.

Continuous printing: This includes flexography, offset or combined techniques up to 11 colours and up to 410 mm roll width. This type of labeling is used around small boxes with cheese or cheese spread or dust bin liners and other products sold on rolls. These can also be used for individually packed chocolates, cookies and ready-to-eat meals.

Dry peel coupons: These use up to 10 colours distributed over the three printable sides. It uses a nonadhesive top layer made of paper or synthetic film and a base label in non-adhesive synthetic film (transparent or white). This label is easy to use and fast detachable with a special grip zone. There is no adhesive residue and the initially covered information is visible again on removing the top layer.

Biodeg radable labels: These use specially developed biodegradable paper, which contain a highly developed biodegradable adhesive. These labels are intended for identification of individual biodegradable products, biodegradable packaging or packaging films, as well as for labeling of conceptual packaging that requires 100 per cent biodegradability.

Coupons: These are printed in letterpress or flexography with a maximum of 8 colours, with two stations reserved for printing on the verso sides. Only a small part of the label is adhesive, while the larger (central) part is not. This adhesive can be easily removed by perforations. Such labels are preferred for promotional actions in which an instant discount is awarded at the checkout desk.

Duolabels: These labels use up to 10 colours and are divided over three printable sides. Integrated numbering (continuous or random) and integration of a scratch layer are also possible. These provide additional information on packaging where space for text or images is limited. These are promotional labels with a gaming element, and are easy also to open and close if required.

Modern Packaging & Design January-February 2012

PROJECT S

New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, raw material suppliers, plant & equipment manufacturers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the packaging, printing and converting industries.

Bottling plant Coca-Cola

Project type New facility

Project news As part of Coca-Colaâ&#x20AC;&#x2122;s increased focus on emerging markets, the company has announced the construction of a new bottling plant at Bandar Enstek industrial park in Nilai in the southern state of Negeri Sembilan, Malaysia. Coca-Cola will invest $302m (1 billion Malaysian Ringgit) over the following five years in the new plant. The facility is expected to open towards the end of 2011. Nilai was chosen because of the lower logistics costs for transporting raw materials and finished goods. The city is also close to Kuala Lumpur and Port Kland, and has a good supply of water and electricity.

Project location Negeri Sembilan, Malaysia

Project cost $ 302 million

developed in phases and is expected to be completed by 2018. It is expected to be completed by the year end and commence production in the first quarter of 2012. The Naidupeta facility will be the largest glass manufacturing complex in South East Asia, with a production capacity of 3,500 million tonne of glass a day.

Project location Naidupeta, Andhra Pradesh

Project cost ` 400 million

Implementation stage Construction of first phase commenced in February 2011 with an initial investment of ` 70 million.

Industrial packaging Time Technoplast

Contact details: Jinny Chong F&N Point No. 3, Jalan Metro Pudu 1 Fraser Business Park 55100 Kuala Lumpur, Malaysia Tel : +603 - 9235 2288 Fax : +603 - 9222 3900 Email: jinnychong@fn.com.my

Glass manufacturing complex Hindustan National Glass (HNG)

Project type New facility

Project news Hindustan National Glass (HNG) is setting up a new manufacturing complex at Naidupeta, Andhra Pradesh. The complex will have five furnaces, three for glass containers and two for float glass. Estimated to cost ` 400 million ($8.8 million), the project is being

Not known

Implementation stage Planning Contact details: 102, Todi Complex 35 Saki Vihar Road Andheri (E) Mumbai - 400 072 Tel: +91 22 28039999/28039700 Fax: +91 22 2857 5672 E-mail: ttl@timetechnoplast.com

Packaging materials Tetra Pak

Project type Contact details: Hindusthan National Glass & Industries Ltd 2, Red Cross Place Kolkata - 700001 Tel: +91 33 2254 3100 Fax: +91 33 22543130 Email: hngkol@hngil.com

Implementation stage Construction

Project cost

Project type New facility

Project news Time Technoplast is setting up an industrial packaging project in Malaysia, about 140 kilometers south of Kuala Lumpur. The company will manufacture their well established plastic packaging products including Intermediate Bulk Containers (IBC), plastic drums & containers to service its international customers and local industry in Malaysia and Singapore. The project is likely to commence production in mid 2012. Time Technoplast shall also be setting up reconditioning / re-bottling plant in the same premises to provide full range of products and services to its customers in Asia. Project location Kuala Lumpur, Malaysia

Modern Packaging & Design January-February 2012

New facility

Project news Tetra Pak is setting up a new packaging material factory in India at Chakan, Pune in order to meet its target of five billion packages by 2013. The total capacity of the new plant will be 8.5 billion packages per year, with the potential of scaling up to 16 billion packages across carton packaging materials as the Tetra Brik Aseptic (TBA), Tetra Fino Aseptic (TFA) and Tetra Classic Aseptic, making it amongst the top five packaging material plants for Tetra Pak worldwide. The plant will also support the companyâ&#x20AC;&#x2122;s growth in South East Asia and the Middle East.

Project location Chakan, Pune

Project cost ` 600 crore

Implementation stage Planning Contact details: Tetra Pak India Pvt Ltd Global Business Park Tower C, 5th Floor Mehrauli-Gurgaon Road Gurgaon - 122 002 Tel: +91 124 412 4600 Fax: +91 124 406 4308 E-mail: aksingh@tetrapak.in

EVENT LIST

National

Aurangabad Maharashtra Feb 17-20, 2012 Garware Stadium, Chikkalthana

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details contact: Infomedia 18 Ltd, Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: engexpo@infomedia18.in • Website: www.engg-expo.com

Intelpack 2012 In its 12th edition, this exhibition will showcase the cutting-edge technology and converting applications. With concurrent events like Foodtek and Pharmapack, visitors will find innovations & solutions to make their business more efficient and profitable; February 23-25, 2012; at Bombay Exhibition Centre, Mumbai For details contact: 113, New Sonal Link Industrial Estate Building No 2, Link Road Malad (W), Mumbai - 400 064 Tel: 022-28803977/28803978 Fax: 022-28819008 Email: intelexpo@vsnl.net Website: www.intelexpo.com

Kandivali (E) Mumbai - 400 101 Tel: +91 22 66997437 Mob: +91 9820441799 Website: www.gate.co.in Email: kprayagi@gmail.com

July 6-9, 2012; at Hyderabad International Trade Exposition Centre (HITEX), Hyderabad

N PRINTECH TODAY 2012 This exhibition will highlight the next generation printing solutions encompassing all the innovations & latest technology for the packaging and converting industries. From small print shops to full-scale packaging-printing companies, there is no doubt that the digital revolution has transformed printing industry to a new dimension with emphasis on quality, speed and efficiency; April, 20-22, 2012; Chennai Trade Centre, Chennai

Indo-German Conferences on Printing This will be a special conference on the latest innovations in the world of printing technology. The experts and industry authorities will highlight the latest trends & developments in the field of packaging printing and the issues like brand protection and anti-counterfeiting; March 1-3, 2012; at Hotel Novotel, Juhu, Mumbai

For details contact: Buysell Interactions Pvt Ltd No 5, Shanmugam Street, Royapettah Chennai - 600014 Tel: 044 28353739 Fax: 044 28350839 Email: ravi@buysellint.com Website: www.nprintech.com

Packplus South 2012 For details contact: Kiran Prayagi Graphic Arts Technology & Education 2-B, 202, The Neighbourhood CHS Lokhandwala Township Akurli Road

This will be an opportunity to focus on the emerging opportunities in the fast industrializing markets of South India. The packaging sector of this region will be represented through its latest trends and technologies, especially by SMEs;

For details contact: Prateek Kaushik Print Packaging Pvt Ltd E-6, 1st Floor, Lajpat Nagar 2 New Delhi, India Tel: 011-2981 2833/2981 2934/2981 2834 Mob: 09313011029 Fax: 011-4172 2130 Email: webmaster@print-packaging.com Website: www.print-packaging.com

International Packtech India With India poised to be the third biggest packaging market in the world, this event will bring together manufacturers of machines and systems for packaging, process technology and the printing of packaging materials. This will be an ideal platform for entrepreneurs, engineers and buyers to explore the latest developments in packaging raw materials, equipment, services, etc; November 6-8, 2012; at Bombay Exhibition Center, Mumbai For details contact: Messe Düsseldorf India Centre Point Building, 7th floor Junction of S.V. Road & Juhu Tara Road Santacruz (W), Mumbai-400 054 Tel: 022 6678 9933, Fax: 022 6678 9911 Email: messeduesseldorf@md-india.com Website: www.md-india.com

Modern Packaging & Design January-February 2012

EVENT LIST

International VERPACKUNG 2012 The event is an ideal platform for packaging professionals to discover the latest developments in branded packaging. These include senior managers, proprietors, brand managers, marketers, from all major application industries of packaging and allied services like automation, testing & control operations and transport & logistics; January 25-26, 2012; at Hall A3, Hamburg Messe, Germany

For details contact: Converting Technical Institute Iwamotocho-Takahashi Bldg 3-4-6, Iwamoto-cho, Chiyoda-ku Tokyo 101-0032, Japan Tel: +81-3-3861-3858 Fax: +81-3-3861-3894 Email: event@ctiweb.co.jp Website: www.convertechjapan.com

PCD 2012 For details contact: Sarah Jakowczyk easyFairs Deutschland GmbH Hilblestrasse 54, 80636 München, Germany Tel: +49 (0)89 127 165 180 Fax: +49 (0)89 127 165 111 Email: sarah.jakowczyk@easyfairs.com Website: www.easyfairs.com/verpackung-2012

WestPack 2012 This exhibition will showcase packaging technology innovations like new equipment & materials, cost & waste reduction strategies, bags, containers, contract services, custom automation machinery, package design and printing, robotics, supplies, software, etc. It will offer an opportunity to stay updated with the latest developments in the global packaging industry; February 14-16, 2012; at Anaheim Convention Centre, California For details contact: Canon Communications LLC 11444 W. Olympic Boulevard Los Angeles, CA 90064 United States of America Tel: +1 (310) 445-4200, Fax: +1 (310) 445-4299 Email: info@cancom.com Website: www.canontradeshows.com/expo/wpack11

Convertech Japan 2012 The show will highlight the material and machinery making headway in packaging technology. It will be a platform to learn and showcase printing technologies for producing electric circuits on functional materials and flexible substrates; February 15-17, 2012; at Tokyo Big Sight - East Hall, Japan

This edition of PCD (Perfumes, Cosmetics & Design) will be dedicated to packaging innovation for the cosmetic packaging. This exhibition-cum-conference will highlight issues relating to preservativef ree products, new designs and functionalities from packaging experts in different special fields (materials, surface treatments, forming, processing, artwork, etc); February 8-9, 2012; at Porte de Champerret, Paris For details contact: Oriex 25, rue André Joineau Le Pré saint Gervais, Paris - 93310, France Tel: +33 1 48918989 Fax +33 1 48434994 Email: congress@oriex.fr Website: www.pcd-congress.com

IPACK-IMA 2012 This exhibition will show case the latest innovations and trends in the world of packaging, processing and material handling technology. It will be a common platform for technology suppliers and end-user companies to increase business, create value, share knowledge and expertise within the packaging professional community; February 28 – March 3, 2012; at Fieramilano, Milan, Italy For details contact: Ipack-Ima SpA Corso Sempione 4 20154 Milano, Italy Tel: +39 02-3191091

Modern Packaging & Design January-February 2012

Fax: +39 02-33619826 Email: ipackima@ipackima.it Website: www.ipackima.it

SINO-PACK 2011 This will be the ideal platform for the Asian packaging industry to showcase its upcoming technology and innovations in raw materials and machinery. It will serve as an interactive environment for international investors and suppliers of the packaging sector; March 7-9, 2012; at China Import & Export Fair Pazhou Complex Pazhou, Guangzhou, China For details contact: Adsale Exhibition Services Ltd 6/F, No. 321 Java Road, North Point Hong Kong Tel: (852) 2811 8897 Email: pfp@adsale.com.hk Website: www.chinasinopack.com

NPE 2012 A leading international plastics technology trade fair held in the US will showcase a broad range of polymer technologies for the packaging industry. It will present innovative polymer technologies to advance medical device industry as well as automotive manufacturers; April 1-5, 2012; at Orange County Convention Center (OCCC), Orlando, Florida USA For details contact: Hemah Saxena Comnet Exhibitions Pvt. Ltd # 217 B, 2nd Floor, Okhla Industrial Estate Phase III, New Delhi - 110 020, India 011 - 42795055/42795000 Email: hemasaxena@eigroup.in Website: http://www.npe.org

The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of Business Insights •Technologies•Opportunities

EVENT REPORT: India Conver ting Show 2011

Enabling platform to convert potential into reality India Converting Show recently closed on a high note at Bombay Exhibition Centre, Mumbai, registering a footfall of 5,200 visitors. The exhibition featured 125 exhibitors, more than 25 product launches and about 50 running machines. A report... Mahua Roy

he packaging industry is growing at an enviable rate in India, and dedicated events like India Converting Show aid this sector to seek newer heights. The show proved to be a launchpad for various new products and the exhibitors were satisfied with the relevant visitors, thus leading to many positive business leads.

An ideal launchpad Quadtech Inc, one of the leaders in design and manufacture of control systems, launched its all-new inspection system and colour measurement system Spectralcam at the exhibition. The system, providing film stabilisation and on-the-fly high-definition dot viewing, received several leads at the show. Intergraphic Sales & Services chose this platform to present its highfrequency polyethylene terephthalate box die-cutting machine. Amit Sheth, Director, Intergraphic Sales & Services, said, “There have been some serious customers who shoed interest in our machines. After the show, we will follow-up with them.” Enigma Ventures, one of the leading carton machinery manufacturers, launched its rotary die-cutting chain type with slotting attachment - OSRD-2 Om Swastik. “This machine can work as a die-cutting machine as well as a four-bar rotary slotter. There is no need for two machines, when a job can be done by a single one. The show has given us several leads, and we are expecting good business in the coming days,” said officials from Enigma Ventures.

Positive response Kody Equipments, offering its unique

slitter rewinder machine, has always generated good business at the PackPlus editions. And India Converting Show 2011 is no exception. BST Sayona Automation showcased its all-new range of tension control products such as pneumatic and magnetic particle brakes, load cells and controllers. The company, attracting a gamut of visitors at its stall during the exhibition, also presented its web guides and web inspection systems that are geared towards optimising performance, results and yielding a faster Return on Investment (RoI). Maxcess India Automation displayed Tidland Blade Sharpening System and Fife SE-46 Digital Line Guide, and Trident Packaging Solutions unveiled a range of new solutions including impact software for packaging and small die shop concepts. Suddha Converting Machines, one of the renowned names in the Indian converting industry, presented its aluminium foil converting, flexible packaging and special purpose machines like polyvinylidene chloride coating machine, paper moisturiser, aluminium

foil separator and ultra light-gauge aluminium foil slitter. The company sold two of its slitter rewinder machines on the second day of the exhibition, out of which one is to the packaging giant ACG Worldwide. “We have some more orders in pipeline, which would be reviewed after the exhibition,” said Ashis Banerjee, Managing Director, Suddha Converting Machines.

International pavilions The China and Taiwan pavilions showcased corrugated box making machinery at the show. “It has been a pleasure to participate in India Converting Show as it helped us know more about the prospects of the rising Indian market,” said Sandy Zhao, International Sales Director, Guangdong Dongfang Precision Science & Technology, China. “With Mumbai and the nearby cities being a hub of leading converters and corrugators, the show was destined to be a big hit,” asserted Neetu Arora, Director, Print-Packaging.Com, the organisers of the event. Email: mahua.roy@infomedia18.in

Modern Packaging & Design January-February 2012

EVENT REPORT: Industr y meet on packaging for liquor business

Unleashing opportunities In a bid to broaden the use of Polyethylene Terephthalate (PET) for packing liquor, Reliance Industries Ltd, with support from some industry members, recently organised a national seminar in Pune. The event, a first-of-itskind national seminar on liquor packaging in India, aimed to support manufacturers reposition their products by improving brand appeal and cost-competitiveness as well as inform end-users about PET packaging advantages, latest technical developments, lowering carbon footprint, etc. A reportâ&#x20AC;Ś

olyethylene Terephthalate (PET) has carved a niche in alcoholic beverage packaging, as it helps extend product shelf-life, provide greater consumer convenience and is cost-effective. Globally, PET bottles are established for packing liquor in diverse pack sizes, from 30 ml to 3 litre. In India, the use of PET is limited to sizes up to 750 ml, with larger-sized bottles (2 litre and above) being popular in the southern states. In 2009-10, total usage of PET in the alcoholic beverages sector was 55 Kilotonne Per Annum (KTA), and is 65 KTA in 2010-11. This is set to further grow at 20 per cent per annum in the next 3-4 years. The Indian PET industry has identified alcoholic beverages as a key focus area for development and promotion. PET usage in this industry for both the Indian Made Foreign Liquor (IMFL) and country liquor is growing with more states now approving this move.

In high spirits In order to appraise end-users on all aspects and address techno-commercial concerns, Reliance Industries Ltd (RIL) along with five other industry members had organised a national seminar â&#x20AC;&#x2DC;Unlocking the value of packaging for liquor businessâ&#x20AC;&#x2122; on November 18, 2011, in Pune. The seminar on liquor packaging and filling focussed on country liquor and IMFL manufacturers along with statutory bodies in the western region. It explored advantages of PET packaging systems, labeling, filling, shrink wrapping systems and emerging global trends in packaging. The idea was to increase PET usage in the liquor sector by engaging endusers on a long-term basis by providing

All speakers in the question and answer session

holistic and innovative solutions. It served as a platform for industry members to network, brainstorm and establish PET as a solution provider for emerging packaging opportunities and create novel applications. Brand owners in the liquor industry and affiliates attended the event. Besides, over 100 invitees from end-toend community including 60 plus brand owners of liquor majors from all over India attended the seminar.

RIL is the largest manufacturer of PET bottle grade resin in India and, by 2013, is all set to become the largest manufacturer in South Asia and the Middle East. The company has a fully established techno-commercial team backed by its technology center. It works closely with converters, end-users and brand owners to provide complete solutions in the PET packaging sector.

Welcoming new trends Partnering to lead The five industry members, besides RIL, at the event included Sunrise Containers (one of the leaders in PET preforms & bottles industry); S S Packaging (stalwarts in the filling industry); Gallus (pioneer in label printing machinery globally); MAKS Automation (supplier of shrink wrapping system); and Avery Dennison (global leader in label stock materials). These partners joined hands to enable total value-addition possible in packaging and filling operations for the liquor sector.

Modern Packaging & Design January-February 2012

The seminar commenced with a welcome address by B Arun, Senior Executive Vice President, RIL, which set the tone for the evening. It was followed by a keynote address by Dr Srinivas Ayodhya, Vice President, Reliance Technology Group, who stressed on trends, technology and developments, focussing on the liquor industry. It was a first-of-its-kind national seminar in India to help manufacturers reposition their products by improving brand appeal and become more costcompetitive. It focussed on PET

Industr y meet on packaging for liquor business

response from the industry, who, in turn, benefited as their queries were addressed by experts in this field.

Unlocking new avenues

RK Gera, AVP-Business development, RIL, making a presentation

advantages, filling line solutions, printing innovations and cost-reduction process by shrink wrapping and developments & trends in liquor labels. The forum highlighted new PET packaging variants, materials and processes for liquor to brand owners and opportunities for cost reduction at different stages.

As it addressed operations and packaging issues, personnel from the plants and packaging & marketing team, besides owners and senior management teams, were also present. The presence of decision-makers of the liquor majors reflected the appeal of this event with the industry. The event received good

The seminar was seventh in the series for sectoral promotion by RILâ&#x20AC;&#x2122;s PET Division. Liquor majors have welcomed this effort, as it has helped address the changing trends in the industry. It has brought all solution providers under one roof, which will guide endusers to develop strategies to meet the challenges of packaging, shelf-life requirements and changing consumer consumption patterns. The seminar concluded with an interactive question and answer session, where issues critical to usage of PET bottles were deliberated in detail. This helped solution providers to understand the finer requirements of industry. The forum thus proved to be an ideal platform to network and share manufacturing & packaging areas of interest. Email: spedit@infomedia18.in

Modern Packaging & Design January-February 2012

BOOK REVIEW

Packaging the Brand Authors : Gavin Ambrose & Paul Harris Price : ` 12,500

The book Packaging The Brand begins with a brief introduction on the role of packaging design in the branding exercise. It is divided into five specific sections, each of which begins with an extract of critical writing from a broader spectrum of design visualisation. This allows the reader to react and challenge the perceptions of design. It also features design elements that include diagrams. Section 1: ‘The Packaged Brand’ has been well presented with write-ups followed by excellent photographs of the designs. It includes case studies with reference to real life examples, and also key elements of a package design and its impact on marketing. Section 2: ‘Research and Concepts’ deals with the process of designing from devising a meaningful brief through to concept generation and design development. Section 3: ‘Design Approaches’ deals with colour combination. It covers design features for packaging materials like flexible, rigid, plastics, metal, glass, etc. Section 4: ‘Forms and Elements’ describes 10 principles of design. It includes design elements, ergonomics, surface graphics and their impact on the final design. Section 5: ‘The Future’ deals with virtual packaging and virtual distribution. The conclusion of the book inspires the reader to think about packaging in different ways and stimulate new ideas. The unique feature of this book is the list of contacts of the agencies whose packages have been referred, along with their websites and country of origin. This book can be recommended for packaging graphic designers as well as students of packaging technology, who need to understand the impact of graphics in branding. Reviewer: Prof C S Purushothaman – Chair Professor Director – SIES School of Packaging, Mumbai

Food and Beverage Packaging Technology Editors : Richard Coles & Mark Kirwan Price : ` 10,400

The second edition of the book Food and Beverage Packaging Technology provides a contemporary overview of food processing/packaging technologies. Since packages play a major role in drawing consumer attention and earning brand loyalty, it has become increasingly important to consider new & better options for packaging materials. This book acquaints the reader with food preservation processes, shelf-life and logistical considerations, as well as packaging materials, machines & processes necessary for a wide range of presentations. The added sections on environment sustainability concerns examine applications of emerging technologies such as Radio Frequency Identification (RFID) and nanotechnology. The new edition also addresses a chapter on bioplastics, which continues to establish niche markets in the packaging of food and beverage products. The contributors are an authoritative team close to the latest developments in food and beverage packaging technologies. This book will provide a resource for those in and associated with the food & beverage industry who need to know about the packaging needs of the products. It will help those in manufacturing of food and beverage products to understand how their product packaging needs are met in manufacturing, storage, distribution & retailing. It will be valuable for those who create and manufacture packaging materials & packaging products, for packaging engineers and students studying packaging technology, food science and all other packaging-related subjects. Reviewer: Rini Ravindran, Lecturer, Department of Biochemistry and Food Science & Quality Control, Ramnarain Ruia College, Matunga, Mumbai

Avaliable at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 Tel: 022-2207 4484/6631 8958 • Telefax: 022-2203 4058 • Email: thadam@vsnl.com

Modern Packaging & Design January-February 2012

PRODUCT S

M Manufacturer E Exporter D Dealer I Importer This section provides information about the national and international products available in the market

Cable trays

X-ray inspection systems

Sumip Composites oﬀers ﬁbreglass

Jay Instruments & Systems oﬀers

cable trays. These are better in

X-ray

loading as compared to conventional

detection of dense contaminants,

material trays with good corrosion

like metal, stone, bone, plastics,

resistivity and faster installation.

etc. These systems are designed for

Other important features include

safe operation (for the operator &

strength

the product).

and

durability,

ﬁre-

inspection

systems

for

retardancy, lightweight and UV stability. All ﬁttings are pre-fabricated and

Its features include simultaneous

have same speciﬁcation as of straight trays. Two standard composite resin

inspection of individual products

systems are also available.

on multiple lane conveyors; quick release conveyor belt for easy cleaning & re-assembly; masking function to eliminate constant dense area; on-screen

The ﬁbreglass cable trays ﬁnd applications in power plants, fertiliser plants,

simultaneous imaging & operating adjustment; variety of models for packed,

paper mills, reﬁneries, oﬀshore platforms, laboratories, etc.

unpacked, bulk & liquid products; rejecters to every application; and IP69K protection model available.

Sumip Composites Pvt Ltd Ahmedabad - Gujarat

The X-ray inspection systems ﬁnd applications in packed products, ready-to-

Tel: 079-26933456

eat products, packed yogurt, packed noodles, packed biscuits, etc.

Email: sales@sumip.com Website: www.sumip.com

Jay Instruments & Systems Pvt Ltd Mumbai - Maharashtra

Cleaning and washing systems

Tel: 022-23526207

Email: ctpsales@jayinst.com Website: www.jayinst.com

Scanvik Packaging oﬀers a wide range of FlexoWash cleaning and washing

Hot-melt coating and laminating machines

systems. These systems use a safe and

gentle cleaning method that does not harm even the most delicate rolls. With

Shanghai Huadi Machinery

these systems one can both deep-clean

Co oﬀers hot-melt coating

the rolls and wash them on a daily basis without harming even the ﬁnest rolls.

and

By simply placing the roll in the anilox roll/plates in the cleaning machine and

These machines are equipped

pressing start, the process begins. The whole cleaning process starting with

with horniness alloy steel spray

liquid spraying, rinsing with high-pressure water and, at the end, drying by

head, which ensures high-

means of air will run through automatically in one cycle.

quality coating, and it can run

There is no need for manual cleaning or drying, thus ensuring minimum

laminating

machines.

at a speed of 120 m/min.

manual handling of rolls/plates. The quick and gentle system is fully automatic

The advanced PID control in these machines is used for temperature

and leaves the anilox roll/cylinder/plates 100 per cent clean & dry ready for

control systems. These machines are used for producing conductive clothes,

use in a short time. Cleaning of anilox roll/cylinders/plates and parts is done

double-sided tapes, cloth tapes, craft paper tapes, etc.

by eco-friendly liquids, which can clean all types of inks. The machines are also suitable for producing cleaning tapes, foil tapes, medical These systems are used for anilox rolls, gravure cylinders, printing plates and

accessories tapes, ﬁbre tapes and masking tapes.

parts for narrow web & wide web presses. Shanghai Huadi Machinery Co Ltd Scanvik Packaging

Shanghai - China

Mumbai - Maharashtra

Tel: +86-21-57794228

Tel: 022-40106327

Email: huadi@huadi.us

Email: ashvin.nebbar@yahoo.com

Website:www.shhuadi.com

Modern Packaging & Design January-February 2012

PRODUCT S

M Manufacturer E Exporter D Dealer I Importer Vision sensors Laminating pouch ﬁlms

M Baumer India oﬀers series 1800

Bori Machinery oﬀers BR-

VeriSens vision sensors that allow

L series laminating pouch

barcodes, matrix codes and printed

ﬁlms and thermal lamination

characters to be read automatically.

ﬁlm production lines. These

By supporting all common 1D and

machines are equipped with

2D codes, including EAN, UPC, and

high-precision

ECC200, the series 1800 guarantees

full-seal

original imported die heads

ﬂexibility for identiﬁcation and inspection tasks. In addition, information on

that ensure high-quality lamination.

the quality of printed codes can be used to improve the labelling process.

The speed can be up to 260 m/min. High-precision PLC (Siemens &

The series 1800 comes with an integrated Optical Character Recognition

Mitsubishi) is used for controlling, with full automatic constant tension control

(OCR) function and permits the reading of any character or numeric sequence

for reeling, unreeling and every tension point. These are used for LDPE,

without time-consuming font training. Identiﬁcation functions of the series

LLDPE, HDPE, PP, EVA, EAA, EMA and other coating grade resins to

1800 together with the enhanced functionality for the control of position,

produce pouch ﬁlms and thermal lamination ﬁlms.

location, presence and completeness allow a wide range of applications,

These machines are suitable for base materials such as BOPP, BOPET, BOPA

These vision sensors are used in packaging industry or handling, where

and aluminium foils for resins.

parts must be properly identiﬁed/inspected in any conceivable location and position.

Bori Machinery Imp & Exp Corp Jinhua City - China

Baumer India Pvt Ltd

Tel: +86-579-82050435

Pune - Maharashtra

Email: bori@bori.cc

Tel: 020-25286833

Website:www.bori.cc

Email: sales.in@baumer.com Website: www.baumer.com

Plate-making machines

Barcode label printers

Innovative Flexotech oﬀers a wide range

photopolymer

plate-

Great Eastern Impex oﬀers TEC B-

making equipment in model A2SSF.

Ev4T series barcode printers for on-

Manufactured from stainless steel,

demand labelling applications. With

these are compact in design and sturdy

market-leading

in construction. Other features include

build quality and reliability, the new

all-stainless

exposing/drying/

Toshiba TEC B-Ev4 series sets new

4-in-1

benchmark in the industry.

steel,

washout/treatment,

design,

compact, simple operation, best plate result, etc. The equipment consists of four

features, exceptional

Using the latest 32-bit Toshiba processing technology, these give rapid on-demand printing at speeds of up to 5 inch per second. Alongside the high-

units for exposing, drying, washout and treatment that allow simple operations

speed 12 Mbps USB & 10/100 Mbps LAN interfaces, serial and parallel

and better plate results. These come in measurement of 90 x 90 x 112 mm and

connections allow the printers to simply slot into existing legacy systems

weigh 200 kg net and 300 kg gross. Power required is 1.2 kW.

without software or driver changes.

The plate-making machines are used for printing ﬂexography, label, PE/ PP

These are used for fast, on-demand labeling/ticketing direct from users

ﬁlms, paper, corrugated board, paper carton, knitting bag, etc.

desktop and for producing professional labels quickly & easily.

Innovative Flexotech Pvt Ltd

Great Eastern Impex Pvt Ltd

Ahmedabad - Gujarat

Gurgaon - Haryana

Tel: 079-26852439

Tel: 0124-2347431

Email: info@ﬂexo.co.in

Email: sales@geipl.com

Website: www.ﬂexo.co.in

Website: www.geipl.com

Modern Packaging & Design January-February 2012

` `

PRODUCT S

M Manufacturer E Exporter D Dealer I Importer Product inspection systems

M S+S

Separation

Sorting

Technology oﬀers Raycon product inspection systems for packaged and bulk materials. Features include high-performance longlife X-ray tube with integrated high-voltage power supply unit; high-resolution detection unit; compact system design & low centre of gravity requiring minimum footprint; excellent radiation protection in accordance with statutory X-ray regulations; easy-to-clean & maintain; and ﬂexible rejection & product handling options. These product inspection systems detect all contaminants that due to their density, chemical composition or mechanical dimensions absorb X-radiation to a lesser or greater degree than the surrounding product, eg, metal, glass, ceramics, stone contaminants in food, etc. The heart of the Raycon control is a high-performance industrial PC incorporating a real-time operating system and sophisticated image processing software featuring user administration, multi-product memory, etc. These are used for detecting plastics (eg, PVC, rubber) as well as other product defects (eg, cracks, trapped air), etc. S+S Separation & Sorting Technology GmbH Schonberg - Germany Tel: +49-8554-3080 Email: info@se-so-tec.com

Grain moisture meters

M Uniphos Envirotronic oﬀers grain moisture meters that are pre-programmed to measure the water content of diﬀerent types of grains. The grain moisture content is an important parameter, which is sought by both the producers and the buyers. It determines the shelf-life of grains, their taste, quality and the price. Knowledge about this parameter is also helpful to determine the extent of drying necessary before storing the product. The grain moisture meters are durable and yield accurate readings with superior quality. The grain moisture meters are highly versatile instruments used for measuring the moisture content in grains, oil seeds, etc. Uniphos Envirotronic Pvt Ltd Ahmedabad - Gujarat Tel: 079-40371646 Email: cel@uniphos.com Website: www.uniphos-she.com

Modern Packaging & Design January-February 2012

PRODUCT S

M Manufacturer E Exporter D Dealer I Importer Multi-lane packaging machines

Hydraulic pallet trucks

Clearpack India oﬀers multi-

W H Brady & Co oﬀers hydraulic pallet trucks

lane

machines

that have excellent manoeuvrability and roll

that are available with dosing

easily on sealed ball bearings. Hydraulic rams

systems.

packaging

are hard chrome plated to reduce wear and

machines are suitable to the

These

corrosion. The pallet trucks have lightweight

characteristics of the products.

control handles with spring-back action for

The dosing control system is in

pumping and steering. Unloading is done by

line with check weighing and

lifting the handle slowly so that hydraulic

automatic rejection of sachets outset a preset tolerance.

jack can lower. The pallet trucks come with easily replaceable suction-cum-

These packaging machines also have product feeding systems, coding

pressure cartridge insert with built-in ﬁlter.

system for variable data, system for orderly collation of sachets and system

Articulated axle, ﬁtted with hardened bushes, ensures permanent four-

for automatic linkage with cartoning, cardboard forming, bag ﬁlling and

point ground contact. This balances load on uneven and littered ﬂoors and

wrapping.

prevents frame twisting. Top and bottom steering bearings share the load to ensure easy steering wheel rotation. Wheels are designed in such a manner

The multi-lane packaging machines are used for feeding owder and cream

that they maintain their own level of uneven ground and can thus smoothly

products.

glide in and out of small potholes and slightly uneven surfaces.

Clearpack India Pvt Ltd

The hydraulic pallet trucks are provided with nylon wheels that ensure

Mumbai - Maharashtra

excellent manoeuvrability.

Tel: 022-28596422 Email: sales@clearpack.com

W H Brady & Co Ltd

Website: www.clearpack.com

Mumbai - Maharashtra Tel: 022-22048361

Semi-automatic weighfeeders

Email: bradymumbai@vsnl.com

HDPE/PP woven sacks and bags

Sensograph Packaging oﬀers semi-automatic weighfeeders that are provided with load cell-

based 32-bit advanced controller. The controller

Kanpur Plastipack oﬀers small

has user-friendly operator interface where

HDPE/PP woven sacks and bags.

one can set diﬀerent weights as per diﬀerent

Some of the salient features of

batches and even diﬀerent products. The feeder

these sacks & bags include circular

is available in single-head, twin-head and multi-

woven fabric and bags; laminated

head versions. Manual sealer can be used to seal

and/or unlaminated; printed and/

ready bags.

or unprinted; all types of small

The

semi-automatic

weighfeeders

are

equipped with smart controller, 200 mm x 100

bags, eg, valve, bale wraps, liner bags, gusseted bags, etc.

mm display, HMIs compatible with all Indian

These HDPE/PP woven sacks and bags have reel-to-reel printing with

regional languages, etc. Since the controller uses

corona treatment UV stabilised option. The comprehensive range of bags is

pneumatic control system and not magnetic, its

used in many industries.

operation is noise-free. Applications are in fertilisers, agri products, cement, sugar, ﬁbre, plastic These machines are ideally suited for products such as farsan, pulses, wafers,

polymers, chemicals, sand, seeds, salt, minerals, etc.

dry fruits, tea powder, grocery items, vermicelli and candies. Kanpur Plastipack Ltd Sensograph Packaging Technology Pvt Ltd

Kanpur - Uttar Pradesh

Mumbai - Maharashtra

Tel: 0512-2691113, Mob: 09838101789

Tel: 022-41420002, Mob: 09920232025

Email: info@kanplas.com

Email: mgt@sensograph.in

Website: www.kanplas.com

Modern Packaging & Design January-February 2012

PRODUCT S

M Manufacturer E Exporter D Dealer I Importer Cushioned packaging materials

M Tender-Care oﬀers

International

Airplast

air

bubble

cushioned packaging materials that

are

two-layer

LDPE

cushioning-packaging materials, manufactured with high-quality German technology. These eliminate damage to product in transit, minimise packing cost and handling time and add value to the product. The packaging materials can also be tailor-made into pouches, cut-pieces, ABF-lined mailing envelopes, etc, to suit each application. The packaging materials are available in all four international bubble diameters, eg, 6, 10, 20 and 30 mm. These are also available in anti-statics grade. These are used in industries such as electronics, computers, pharmaceutical bottles & vials, ceramic ﬁlters, glassware, automobile components, machine tools & spares, textile machines & spares, atomic energy, aerospace machines & components, copper & aluminium sheets, tubes, proﬁles and domestic packing. The packaging materials are also used in fruit & vegetable packaging, research laboratories, defence, space missions, airlines, railways, etc. Tender Care International Mumbai - Maharashtra Tel: 022-26854908 Email: airplast@mtnl.net.in Website: www.airbubbleindia.com

Packaging machines

M Indra Machines offers a wide range of packaging machines for different applications. The product lineup includes vertical form-fill-seal machines, volumetric cup fillers, weigh fillers, liquid fillers, etc. Model VEFC is used for packing various products such as sugar, tea and detergents. Packing material used are laminated films, eg, BOPP, polyester poly, paper poly, aluminium foil, glassine poly, etc. The machines also incorporate monolayer films LDPE, polypropylene, HM and HDPE. Model VEFL is provided for packaging liquids, like shampoo, syrups, lubricants, milk, edible oils, etc. These machines are available for packing right from 0.5 to 1,000 gm. Special models are also offered to pack up to 25 kg, eg, adhesives in drums and cans. These models are suitable for packing nut-bolts, washers, pins, confectioneries as well as pack both solid and liquid products. Indra Machines Mumbai - Maharashtra Tel: 022-28432281 Email: indrapackaging@rediffmail.com

Modern Packaging & Design January-February 2012

PRODUCT S

M Manufacturer E Exporter D Dealer I Importer Inkjet print modules

Oxygen permeability testers

Unigraphica oﬀers IPAS425i inkjet print modules

Elixir Technologies oﬀers oxygen

for personalisation, addressing and barcoding.

permeability testers for precise &

Important features are resolution from 150 to

fast testing of ﬁlms and foils for

1,200 dpi; print speed and production capacity 180

oxygen permeation. The OPT-5000

m/min at 300 x 600 dpi; print width from 4.25

tester is developed with a view to an

to 17”, 1 to 4 modules stitched; modular inline or

easy user-interface and with focus

oﬄine applications; black water-based ink for all

on reliable testing. Anybody can

print jobs; simple software enclosed, eﬃcient to

perform a quality test with minimum

issue a document; and licence-free full version.

training. The user-interface is based

The IPAS425i inkjet print modules combine the best of diﬀerent worlds: speed, high-resolution and low-cost solutions for

easy-to-use

touchscreen

operation display.

digital printing market. High-quality imprinting capabilities make this print

The display indicates the test

engine ideal for various types of printing. Their modular design provides users

cycle and the permeability rate is

with a ﬂexible, cost-eﬀective imprinting platform that is already Unigraphica

shown in real numbers. The measuring process can be with either closed loop

tested and validated. These can print at speeds up to 182 MPM and at print

or continuous ﬂow. Model OPT-5000 is independent of whether the testing

resolutions up to 1200 dpi with a 108-mm print width.

range is for low or high permeability. Together with the easy-to-use concept, this makes the tester extremely versatile in terms of application.

These are ideal for personalised addressing & direct-mail messaging, forms & catalogues, barcodes, statements & bills, lottery and gaming tickets.

The oxygen permeability testers are used within the organisation, such as in laboratory or in the production by trained operators.

Unigraphica AG Liechtenstein - Switzerland

Elixir Technologies

Tel: +41-423-3758189

Bengaluru - Karnataka

Email: andrea.lieberherr@unigraphica.com

Tel: 080-23190706

Website: www.unigraphica.com

Email: info@elixirtechnologies.in Website: www.lixirtechnologies.in

Agitation systems

Belt conveyors

Axomatic oﬀers Axomix turbo emulsiﬁers

that are three-coaxial agitation systems where

Accuweigh Automation &

the combined action of the counter-rotating

Solutions

blades, the fast homogenising turbine

belt conveyor systems with a

Top-Entry

high potential for saving time

and

the

product

discharge valve placed in the centre line, make the vessel free from any mechanical part. These are especially designed for

oﬀers

modular

and money. As a result of using standard extrusions

aluminium for

the

base

production of stable emulsions having extremely small particles for chemical,

construction, the conveyors

cosmetics, pharmaceutical and food industries. The Axomix turbo emulsiﬁer is

can be integrated into frames

available in the range of 5-3,000 litre.

or existing systems using standard parts and elements from the modular automation system.

The agitation systems are used for production of stable emulsions, eg, creams, milk, gels, balms, lotions, ointments, toothpastes, etc.

This ﬂexibility oﬀers the integrator time saving, as special connection parts no longer need to be procured or manufactured.

Axomatic Srl Milan - Italy

Accuweigh Automation & Solutions P Ltd

Tel: +39-2-3285370

Pune - Maharashtra

Email: sales@axomatic.com

Tel: 020-65261699

Website: www.axomatic.com

Email: sales@accuweigh.org

Modern Packaging & Design January-February 2012

PRODUCT S

M Manufacturer E Exporter D Dealer I Importer Continuous inkjet printers

M Codeinx offers continuous inkjet printers (model Linx 6900) from Linx Printing Technologies. These have a simple-to-use keyboard and screen, which allow for easy code creation and editing, a robust design for trouble-free operation and a powerful feature set to help one meet current and future traceability requirements. Full colour screen with simple menu structure provides quick and easy code set-up and minimises coding errors. Flexible code options, offering up to five lines of text, barcodes and graphics, meet traceability coding requirements. This has a compact design with plug-in connectors for easy setup and movement between production lines. Automatic print-head cleaning and printer shutdown minimises the need for manual print-head maintenance and provides error-free power down. Versatile connectivity options, including Ethernet and parallel input/output, provide centralised code management and easy integration with production control equipment. These inkjet printers provide a flexible coding solution, which is designed to be easy-to-use in any environment. Codeinx New Delhi Tel: 09873926230 Email: sales@codeinx.com Website: www.linxglobal.com

Vacuum sealers

M P J Electronics offers Airzero nozzle-type vacuum and gas flushing packaging machines from Intrise Co Ltd, Korea. These are new-concept packaging machines with many merits as compared to chamber-type packaging machine. In addition to the digital control box and vacuum sensor, these have more special merits, such as packing process control both by vacuum degree and time, digital indicator of vacuum degree, separate control first and second vacuum degree, LCD/ LED indicator showing the operation and condition of the machine, etc. These machines do vacuum-pack directly inside the packing envelope by using nozzle stroke, so that the work is completed quickly. P J Electronics Pune - Maharashtra Tel: 020-26058710 Email: info@pjelectronics.co.in Website: www.pjelectronics.co.in

Modern Packaging & Design January-February 2012

PRODUCT S

M Manufacturer E Exporter D Dealer I Importer Pallet stretch wrapping robots

Tube ﬁlling & closing machines

Robopac Perks Machinery oﬀers pallet

stretch wrapping robots that are capable

Wimco’s engineering division

of wrapping, protecting and stabilising

oﬀers double-head tube ﬁlling

loads by simply turning around. These

and

machines work very fast and wrap any

have an optimum speed of 120

load following its proﬁle with an idle

tubes/min. These machines have

guiding wheel.

a proven high-quality hot air

closing

machines

that

The machines are safe as they stop

sealing system for plastic and

immediately when the bumper touches

laminated tubes. They are highly

any obstacle. These are aﬀordable,

adaptable for various retro kits

stout, reliable, easy-to-use and highly

for diﬀerent applications. Filling

productive. They go where the load is and

range can be from 1 to 250 cc with change of pump inserts.

wraps it. No ﬁxed electric installation is needed. It wraps up to 80 loads with just one battery charge.

Tube diameter can be up to 45 mm and tube length up to 200 mm. Standard features include: automatic tube infeed, automatic tube orientation, tail-free ﬁlling system, smooth operation by using Ferguson drive, automatic

These machines can wrap any type of object, viz, light, heavy, regular,

coding on the tubes, machine cladded with SS 304, inbuilt centralised

odd-shaped, fragile, etc.

lubrication, no tube-no ﬁll device and variable frequency drive.

Robopac Perks Machinery (I) Pvt Ltd

These are combination sealers for both metal tube folding, laminated and

Mumbai - Maharashtra

plastic tube sealing.

Tel: 022-32511048 Email: robopackperks@vsnl.net

Wimco Ltd - Engineering Division

Website: www.perksengineering.com

Thane - Maharashtra Tel: 0251-2682281

Linear weigh ﬁllers

Email: engg@wimco.in

Website: www.wimcoengineering.com

Inpack Fabrications oﬀers high-speed linear

Band sealers

weigh ﬁllers to pack all types of granules in

pouches. These electro-pneumatic machines have load cell-based combination weighing

Sealers India oﬀers Maxi series

system. Filling range is 5 to 5,000 gm. Pouches

vertical and horizontal type band

like centre-seal pillow pouch and gusset pouch

sealers.

can be ﬁlled using this machine. Laminated

Machined parts are made from

or LDPE ﬁlms are used for packaging

graded steel and castings. Conveyor

the products.

load baring capacity can be 75 kg.

Required accessories are double-stage reciprocating type air compressor, three-phase 15-kVA servo stabiliser and Z-type bucket elevator. Optional

These sealers come with robust

systems can be batch coding device, nitrogen ﬂushing system, static charge

body construction with epoxy

eliminator and extra collars & trays. The machine can ﬁll and pack products

powder coated.

like rice, pulses, sugar, whole spices, seeds, grains, etc; and non-free ﬂowing & irregular shaped products.

Sealers India Mumbai - Maharashtra

The machines can feed products like ready-to-eat snack foods, confectionery,

Tel: 022-67969578

chips, candies, cookies, cashew nuts, vermicelli, oats, corn ﬂakes, etc.

Email: udayudani@vsnl.com

Inpack Fabrications Pvt Ltd Hyderabad - Andhra Pradesh Tel: 040-27243869 Email: ifpl2004@rediﬀmail.com

Modern Packaging & Design January-February 2012

The information published in this section is as per the details furnished by the respective manufacturer/ distributor. In any case, it does not represent the views of Business Insights •Technologies•Opportunities

LIST OF PRODUCT S

To know more about the products in this magazine, refer to our â&#x20AC;&#x2DC;List of Productsâ&#x20AC;&#x2122; or write to us at spedit@infomedia18.in or call us at +91-22-3003 4684 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better. Sl No Product

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Agitation systems ............................... 84 Auto sealers ............................................. 85 Axial flow fans ........................................ 85 Band sealers ....................................... 86 Barcode label printers ............................. 78 Batch counters ........................................ 75 Battery chargers ...................................... 39 Bearings .................................................... 8 Beer filling lines ...................................... 57 Belt conveyors ......................................... 84 Beverage filling lines ............................... 57 Blowers & fans ....................................... 85 Bottle testing equipment ........................ 17 Bottle unscramblers.............................. BIC Bottle/container filling machines .............. 4 Cable carriers ....................................... 8 Cable connectors ....................................... 8 Cable trays .............................................. 77 Cap sealers .............................................. 83 Capping machines ............................... BIC Cartoning machines ..................... 3, 4, BIC Case erectors ........................................ BIC Case packers......................................... BIC Case sealers .......................................... BIC Centrifugal air blowers ........................... 85 Chains ....................................................... 8 Cleaning & washing systems .................. 77 Compact pneumatic cylinders................. 29 Compressors ............................................ 85 Concrete blocks......................................... 3 Connectors ................................................ 8 Container filling lines ............................... 3 Continuous bag sealers ........................... 83 Continuous inkjet printers ...................... 85 Converters ............................................... 75 Conveyers belts ....................................... 81 Conveying blowers .................................. 85 Conveyors............................................. BIC Coolant pipes .......................................... 10 Counters & power supplies ..................FIC Counters.................................................. 75 C-slot pneumatic cylinders ..................... 27 Cushioned packaging materials .............. 83 Design concepts ................................. 23 Digital temperature controllers ............... 68 Dosing/sealing systems ............................. 4 Drives & automation .............................. 39 Drives ...................................................... 68 Dual channels with Modbus .................. 68 Dust collector systems ............................ 85 Dynamic controllers................................ 68 Electric actuator & grippers................ 29 Embedded systems.................................. 39 Encoders ...............................................FIC EngineeringExpo exhibitions.................. 34 Exhibitions .............................................. 34 Expanded polyethylene cap seals .............. 5 Expanded polyethylene seal liners ............ 5 Factory production displays ................ 75 Fibreoptic controllers .............................. 27

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61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119

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Filling machines ............................. 83, BIC Finished packages ................................... 23 Flow rate indicators & totalisers ............ 75 Flow wrapping machines ..................... BIC Foot sealers ............................................. 83 Form-fill-seal machines ............... 3, 4, BIC Fuel burners ............................................ 85 Gas flushing machines ........................ 83 Gaskets...................................................... 5 Grain moisture meters ............................ 81 Guided compact pneumatic cylinders..... 29 Hand sealers ....................................... 83 Hand-type impulse sealers ...................... 85 HDPE/PP woven sacks & bags ............. 82 Heater controllers ................................... 39 Horizontal form-fill-seal machines3, 4, BIC Horizontal form-fill-seal-packaging machines .......... 15 Hot-melt coating & laminating machines77 Hydraulic pallet trucks............................ 82 Induction sealers ................................ 83 Industrial control & sensing devices.....FIC Inkjet print modules ............................... 84 Inverter/variable frequency drives .........FIC Inverters .................................................. 39 Isolators ................................................... 75 Labelling machines ................... BIC, BC Laminating pouch films.......................... 78 Length counters ...................................... 75 Level controllers....................................FIC Linear weigh fillers ................................. 86 Liners ........................................................ 5 Liquid sealers .......................................... 83 Liquid-ring vacuum pumps .................... 85 Load cell indicators................................. 75 Long bar sealers ...................................... 85 Lonizer.................................................... 29 Material testing instruments ............... 17 Measuring & monitoring relays ...........FIC Motion controls ....................................FIC Motors .................................................... 21 Multi-lane packaging machines .............. 82 Multi-stage centrifugal air blowers ......... 85 Nitrogen extrusion sealers ................... 85 Non-nozzle type vacuum sealers............. 85 Nozzle-type vacuum sealers .................... 85 OEM controllers ................................ 75 Oil/gas firing equipment......................... 85 Over-wrapping machines..................... BIC Oxygen permeability testers.................... 84 Packaging development engines .......... 23 Packaging machines ................................ 83 Pallet stretch wrapping robots ................ 86 Palletisers .............................................. 3, 4 Paver machines.......................................... 3 PET bottle testing equipment ................ 17 Photoelectric sensors .............................FIC PID temperature controllers ................... 75 Plate making machines ........................... 78 PLCs ....................................................... 68

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Pneumatic conveying systems ................. 85 Portable loaders ....................................... 85 Pressure gauges ....................................... 10 Pressure sensors....................................... 27 Product inspection systems ..................... 81 Profile controllers .................................... 68 Programmable logic controllers ......FIC, 68 Programmable terminals .......................FIC Proximity sensors ..................................FIC PU tubes ................................................. 10 Pumping filtering units........................... 85 Pumps ..................................................... 85 Push fittings ............................................ 10 PVC flexible braided hoses ..................... 10 Railway products ................................ 39 Refrigerated compressed air dryers......... 29 RFIDs ...................................................FIC Robotic palletisers ................................ BIC Safety light curtains ......................... FIC Scanner ................................................... 75 Sealing machines..................................... 83 Self-adhesive tapes .................................. 81 Semi-automatic weighfeeders ................. 82 Shrink bundlers.................................... BIC Shrink films ..................................BC, BIC Shrink machines ..................................... 83 Shrink sleeve applicators ...................... BIC Shrink warp sealers ................................. 85 Shrink wrapping machines .................. BIC Side channel blowers .............................. 85 Skin wrapping machines ........................BC Sleeve wrapping machines ...................... 83 Solar powers ............................................ 39 Solenoid valves ........................................ 10 Strapping machines................................. 83 Stretch wrappers ..................................... 83 Switching relays ....................................FIC Temperature controllers.............. 68, FIC Testing instruments ................................ 17 Thermoforming machines ................... BIC Timers .............................................75, FIC Trade show organisers............................... 6 Transmitters ............................................ 75 Tray sealing machines .......................... BIC Trim handling systems............................ 85 T-slot pneumatic cylinders ..................... 27 Tube filling & closing machines ............. 86 Universal controllers ........................... 68 UPS systems ........................................... 39 Utility support equipment ...................... 39 Vacuum pumps ................................... 85 Vacuum sealers ........................................ 85 Vane dampers .......................................... 85 Ventilators ............................................... 81 Vertical form-fill-seal machines ... 3, 4, BIC Vision sensors .................................78, FIC Water-ring vacuum pumps .................. 85 X-ray inspection systems ..................... 77

FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

Modern Packaging & Design January-February 2012

LIST OF ADVERTISERS Advertiser’s Name & Contact Details Clearpack India Pvt Ltd

Pg No BIC

Advertiser’s Name & Contact Details

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Nichrome India Ltd

Advertiser’s Name & Contact Details Sreelakshmi Traders

T: +91-22-42532222

T: +91-20-66011001

T: +91-44-24343343

E: anthony@in.clearpack.com

E: marketing@nichrome.com

E: sreelakshmitraders@gmail.com

W: www.clearpack.com

W: www.nichrome.com

Engineering Expo

T: +91-80-40726400

E: engexpo@infomedia18.in

E: in_enquiry@ap.omron.com

W: www.engg-expo.com

W: www.omron-ap.com

Hi-Rel Electronics Pvt Ltd

T: +91-22-22826751

E: contact@hirel,net

E: bhushan@pakona.com

W: www.hirel.net

W: www.pakona.com 27

T: +91-09322215410

E: info@ifm-electronic.in

E: pvs.prasad@plastictechnologies.com

W: www.ifm-electronic.in

W: www.plastictechnologies.com 8

Taiwan External Trade Development Council (TAITRA)

E: taitra@taitra.org.tw W: www.taitra.com.tw The Indian Electric Co

E: iecmktg@indianelectric.com W: www.indianelectric.com Ultraplast Chainbelts Pvt Ltd

Presto Stantest Pvt Ltd

E: info@ultraplast.in

E: info@igus.in

E: gaurav@prestogroup.com

W: www.ultraplastindia.com

W: www.igus.in

W: www.prestogroup.com

Universal Corporation

Progressive Engineers

T: +91-79-26870825

T: +91-22-30944289

E: info@mifasystems.com

E: progressive-engg@vsnl.net

W: www.mifasystems.com

W: www.progressive-engg.com

Monarch Appliances

E: samson7@vsnl.com W: www.samson-grp.com

Reynders Label Printing India Pvt Ltd

Vacunair Engineering Co Pvt Ltd

E: monarchrajkot@gmail.com

E: india@reynders.com

E: info@vacunair.com

W: www.polysealindia.com

W: www.reynders.com

W: www.vacunair.com

Roechling Engineering Plastics (Ind)

T: +91-79-22770865

T: +91-22-42178706

E: marketing@multispanindia.com

E: yogesh.sawatkar@roechling_india.com

W: www.multispanindia.com

W: www.roechling.com

Nanjing Lehui Light Industry

Shanghai Dase-Sing Packaging

Equipment Co Ltd

Technology Co Ltd

Vora Packaging Pvt Ltd

T: +91-22-24012330 E: pankaj@vorapack.com W: www.vorapack.com BC

Wu Hsing Electronics Co Ltd

T: +886-4-2271-1498

T: +86-25-5273-3625

T: +86-21-3365-8333

E: njsales@lehui.com

E: leo@dasesing.com

E: wuhsing@ms17.hinet.net

W: www.lehui.com

W: www.dasesing.com

W: www.wuhsing.com

Our consistent advertisers

T: +91-79-22910771

T: +91-149-3305400

T: +91-22-23436320

T: +91-281- 2461826

Multispan Instruments Co

T: +91-129-4113187

T: +91-129-4085000

T: +91-20-24456062 23

T: +91-80-39127800

Mifa Systems

T: +886-2-2725-5200

Plastic Technologies

T: +91-231-2672770

Igus India Pvt Ltd

FIC

Pakona Engineers India Pvt Ltd

T: +91-79-23827180

IFM Electronics India Pvt Ltd

W: www.sreelakshmitraders.com

Omron Automation Pvt Ltd

T: +91-09819552270

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FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

COMPLETE ENGINEERING UNDER ONE ROOF @ www.eng-expo.com

Modern Packaging & Design January-February 2012