Modern Packaging & Design
July-August 2012
EDITORIAL
Seven pearls of packaging he developing economies of yesteryears are very much on the driver’s seat today and unequivocally defining the next growth phase of the world. At the same time, however, the global economic order seems to have shifted gears from the Brazil, Russia, India, China and South Africa (BRICS) buoyancy to the Portugal, Ireland, Italy, Greece and Spain (PIIGS) spin. As the cloud of political and economic uncertainty remains far from clear over Greece, and hence, the European Union, followed by its projected ripple effect on the entire world, perhaps, the moment of truth has arrived to make some tough strategic decisions that will hold the business in good stead in the future.
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Against this backdrop, here is a snapshot of the packaging sector as it has been shaping up recently at the global, regional and national level. Undoubtedly, the spotlight is on India, of late, in this category. According to a recent market report, the Indian packaging industry is on its way to becoming the fourth-largest packaging market in the world, with revenue to rise in excess of $ 43 billion by 2016. Given its consistent doubledigit growth rate over the last few years as well as low per capita packaging consumption, this figure appears within reach. While retail, pharmaceutical and processed food have been the major demand drivers for packaging over the recent years in both India and abroad, the domestic sector continues to be fairly fragmented. That said, the next phase of evolution in packaging is likely to witness greater demand for various sustainable products and practices, packaging as a more focussed tool for marketing and distribution, smart packaged products with state-of-the-art safety features, nanotechnology in food packaging and anti-counterfeiting devices, among others.
Editorial Advisory Board P V Narayanan Member of Board APEDA (Ministry of Commerce)
M K Banerjee
With such a dynamically evolving ecosystem, welcome to the 7th Anniversary Edition of Modern Packaging & Design! This edition extraordinaire delves deeper into the above and more such emerging avenues. Turn to the Anniversary Special section (with seven sub-sections, each representing a crucial cog in the packaging value chain) to discern what the experts have to opine, not just on the underlying trends and technologies, but also on the future prospects & pitfalls. We believe that you will benefit from exploring this special edition as much as we have enjoyed ‘packaging’ together these highly informative pieces of actionable knowledge. Have a good read and looking forward to your valuable feedback. Cheers!
Director-Creativity & Innovations (Global) Essel Propack Ltd
R Krishnamurthy Director-Marketing & Operations Orient Press Ltd
S Das
Manas R Bastia manas@infomedia18.in
Managing Director Nordson India Pvt Ltd
Modern Packaging & Design July-August 2012
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CONTENT S
Anniversary Special ‘Pack’ing a punch with innovation
28 36 44 52 60 68 74
Design Materials Machinery Logistics Safety Security Sustainability
Insight & Outlook
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In Conversation With
Consumer-friendly packaging: Enhancing customers’ experience
Event Preview 88 PackPlus South 2012: Emphasising on India’s packaging prowess
Highlights of Next Edition Special Focus: Plastic Packaging
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Ajit Singh, Chairman, ACG Worldwide
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Uflex Engineering Ltd: Pioneering innovations in flexible packaging
Facility Visit
Insight & Outlook: Caps & Closures
REGUL AR SEC T ION S Editorial ................................. 5 News, Views & Analysis ...... 12 Technology & Innovation .... 18 Design Innovation................ 20 Technology Transfer ............. 22 Projects ................................. 84
Tenders ................................. 85 Event List............................. 86 Book Review ........................ 90 Products................................ 93 List of Products.................... 99 List of Advertisers .............. 100
Details on page no.86 Cover illustration and design: Chaitanya Dinesh Surpur and Sharad Bharekar Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise
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Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Infomedia 18 Ltd. Senior Editor: Manas R Bastia Printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. Modern Packaging & Design is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 27106. Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition.
Modern Packaging & Design July-August 2012
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GUEST EDITORIAL: Ashok Goel
Indian packaging industry is at an inflection point
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he packaging industry plays a unique role by way of value creation through manufacturing activities and preservation of the integrity of packaged products. It reflects the society’s economic progress. We have come a long way in packaging innovation, from using leaves and terracotta pots to films with radio-frequency identification for packaging foods or bottles in different shapes and sizes made of different materials. In terms of innovation, the Indian packaging industry is at an inflection point today due to the quality consciousness of the consumers complemented by the increased awareness of hygiene & health and growth of modern retail. But, here, it is primarily driven towards cost innovation because of high commodity prices, reiterating our focus on value for money and buying power per unit. We in India are geared to innovation in process and products, keeping the functionality intact. The Indian packaging machinery sector is fast catching up on innovations and is being influenced by requirements within India rather than on a global level. Globally, the economic condition is in a challenging phase, with developing nations developing at lower growth rates and investments shrinking in new capacities. In this scenario, the Indian packaging industry should try to push the efficiency graph upwards through scrap reduction, increasing throughput, improving supply chain efficiencies and using new and cheaper materials. There is still much to do on the sustainability front, but the disjointed actions of the concerned authorities and their knee jerk reactions are defeating the purpose of growth. Plastics constitute the majority share in packaging, and it is looked upon as a threat to the environment. But, in reality, it has actually helped in conservation of natural resources such as paper, glass and metal for packaging. Another advantage of plastics is that it is easily reprocessed and recycled umpteen times. So, the real challenge lies in waste management, which must start with waste segregation at source, making easy and effective recycling, in order to address the sustainability issue successfully. With the demographic changes, packaging revolution in India has started and soon Indian packaging will make a mark on the world canvas. Ashok Goel, Vice Chairman and Managing Director, Essel Propack Ltd
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Modern Packaging & Design July-August 2012
GUEST EDITORIAL: Anil Sharma
Packaging is in the driver’s seat of India’s growth story
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hanging lifestyle, high disposable income and a more organised retail is driving consumerism and positioning packaging to the driver’s seat in India’s growth story. All these have enhanced the buying experience of the Indian consumer. Not only has this benefitted the Indian economy by preserving the quality and lengthening the shelf-life of innumerable products, but also influenced the shelf appeal, creating a new wave in the widespread adoption of product branding. Brand owners are looking at packaging as a differentiation tool, which helps their products to stand out in the competitive marketplace. The Indian packaging industry has evolved significantly over the last two decades. The market has witnessed the sachet revolution, unique to emerging markets. Companies have leveraged local industries in paper, films and plastic resins to create new solutions. Technology adoption has been fast and new ideas are being experimented with everyday. For example, decoration of product packaging has evolved from wet glue to self-adhesive pressure-sensitive technology on automatic lines, improving aesthetics, operating efficiencies and durability. The industry has made considerable progress in materials, adopting cutting-edge printing & dispensing solutions and localising packaging equipment at competitive price and performance points, thus providing excellent packaging solutions to enhance brand visibility. The future is bright for the Indian packaging industry. Fundamentals are in favour of India, with a buoyant youth populace, rising incomes, changing lifestyle and an emerging middle class. The outlook is optimistic and the industry is positive of emerging even stronger. The companies are now tougher and have learnt from the previous setbacks during the slowdown. They are more focussed and driving harder on innovations and efficiencies in times of caution. This augurs well for the industry and is helping companies compete in the domestic market and expand their forte beyond India & into other markets. Anil Sharma, Managing Director, Materials South Asia, Avery Dennison
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NEWS, VIEWS & ANALYSIS
Heidelberg and Landa enter global strategic partnership
presses based on Landa Nanographic Printing™ technology. Benny Landa, Founder, Chairman and Chief Executive Officer, Landa Corporation, said, “ The Heidelberg-Landa alliance is a major step towards achieving our strategic goal of industry-wide adoption of nanography for mainstream digital printing. As a market leader, Heidelberg’s adoption of Landa Nanographic Printing for its new-generation digital presses is a clear message to the entire market: In foreseeable future, offset and digital will not only co-exist, but will complement one another – offset for medium-to-longer jobs and digital for short-to-medium run lengths, not to mention variable data printing. Finally, there is a digital printing technology with speed and customer economics to fill that role – and Heidelberg is certainly well-positioned to take it to market.” Anwesh Koley
Benny Landa
Heidelberger Druckmaschinen AG (Heidelberg), Germany, and Landa Corporation of Rehovot, Israel, have entered a global strategic partnership for the development of Nanographic Printing™ presses in order to expand digital offerings for mainstream printing, eg, short-to-medium runs, variable data and quick turnaround printing. Heidelberg intends to develop, manufacture, sell and service new-generation digital printing
COMPACK 2012 explores sustainability efforts
international level, boosting the domestic packaging industry. The focus of the exhibition will be on plastic waste management by creating a better cognisance and urging the packaging industry to be more responsible towards the environment & consumer safety. COMPACK 2012 aims to bring a better regulatory framework for the management of plastic waste generated from packaging by attempting to bring forth a consensus within the industry and Government circles. Lionel Alva
The Comprehensive Packaging Expo (COMPACK) 2012, to be held in Chennai during July 13-15, 2012, will act as a platform for manufacturers of packaging & printing machines and raw materials providers to meet, while gaining insights into the trends in the packaging industry. The third edition of the comprehensive packaging expo is expected to garner an even greater response than the previous exhibitions. The event has great significance at the national and
Mamata Machinery on an expansion drive
Gujarat-based Mamata Machinery Pvt Ltd is on an expansion drive. In order to
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increase its production, the company is shifting its operations from the present facility in Vatva to a new facility in Changodar in Ahmedabad, Gujarat. The new facility has a total land area of 36,000 sq m and is much larger than the previous one. Abhijit Deshmukh, Senior Sales Manager, Mamata Machinery Pvt Ltd, informed, “The new facility will be completely operational in few weeks. The major reason behind this shifting of operations to a new facility was the small size of the previous facility
Modern Packaging & Design July-August 2012
BOBST launches advanced printing press for flexible packaging at Drupa 2012 BOBST unveiled a wide range of trailblazing innovations at Drupa 2012. Among these is the new Fischer & Krecke 20SIX CS flexo printing machine. This is an advanced Central Impression (CI) flexo printing press for flexible packaging. Avra Mitra, Senior Manager-Key Accounts, Business Unit-Web Fed, Bobst India Pvt Ltd, commented, “The machine has received a good response at the event. It took us almost two years to develop this machine, which is an evolution of the acclaimed Fischer & Krecke FP 16 S and upgraded to include improvements in printing quality, ease of use and versatility. This is the most compact press available in its category and has the lowest wavelength from the unwinder to rewinder.” He elaborated, “This machine enables highest printing speed even with the most demanding jobs. It is also user-friendly and requires less maintenance. Further, with the incorporation of latest patented technology Smart Graphic Positioning System 2, the startup material wastage is reduced. Another patented feature, ie, Smart COL, helps the convertor to carry out shade matching offline as well.” Avani Jain and its inability to handle large-scale productions.” Further, at Plastindia 2012, the company had launched Vega 1200 Split – a dual-draw roll plastic bag maker. With this technology, one can process two printed bags of two different sizes at a time, thereby doubling the production but at a reduced cost. At the event, the company had also showcased the shaped stand-up pouches, ie, Vega 610, for the first time in India. Avani Jain
NEWS, VIEWS & ANALYSIS
Borouge awarded for innovative sustainable solutions RG 4 6 8 M O , a Polypropylene (PP) random copolymer produced by Borouge, bagged the Green Material Award for Innovation Application in recognition of its contribution to the development of packaging industry. James Ong The recognition was made during the 2012 China Plastics Industry Awards ceremony. James Ong, Marketing Manager-Moulding, Borouge, informed, “RG468MO is the result of a product that was developed with the customer’s needs in mind to address the energy shortage in China. This high-flow PP resin grade has enabled our value chains to generate higher productivity yield while lowering their energy consumption. RG468MO represents a step-change in rigid packaging material, without compromising performance or aesthetics.” The benefits of such proprietary Borealis Nucleation Technology (BNT) comes with improved mechanical performance allowing faster and better crystallisation of PP, which boosts the productivity cycle time by 20 per cent, yet maintains a consistency in transparency and visual aesthetics required in the packaging value chain. Ong added, “The Award recognises and reinforces our continued effort in advancing sustainability development across value chains, ensuring that our products are used appropriately throughout their lifecycle.” Avani Jain
Automated Packaging Systems focusses on Asia Automated Packaging Systems, the world leader in high-reliability bag packaging systems, has established a new regional headquarters in Bangkok, Thailand. This headquarters for Automated Packaging Systems Southeast Asia will provide comprehensive sales and service support for customers in countries that are part of the Association of Southeast
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Modern Packaging & Design July-August 2012
Plastiblends adds appeal to colour masterbatches
Innovative packaging solutions from LINPAC
Plastiblends India Ltd (PBI) has recently made significant strides in colour masterbatches for the packaging industry. The new colour masterbatches have an iridescent effect, which is an important innovation for packaging manufacturers. “This will capture the attention of packaging manufacturers in the retail space since this market is driven by aesthetics. With the utilisation of colour masterbatches with the iridescent effect it will be possible to create more visually appealing products at almost no extra cost. It will also help brands to acquire a distinguished presence on the retail shelves and we foresee tremendous demand for this product,” averred Ashish Kothavade, Senior ManagerBusiness Developments, PBI. Plastiblends has developed antimicrobial masterbatches, Ultraviolet (UV) inhibitors for polyster films and UV stabilisers since light permeation is an important aspect of packaging today. UVA slows down the degradation process by preferentially absorbing harmful UV radiation and dissipating it as thermal energy.
LINPAC Packaging has developed a range of smart packaging solutions to combat food bacteria and help consumers & retailers reduce food wastage. The leading food packaging company, which caters to the bakery, fresh produce, fast food and meat, fish & poultry Alan Davey sectors, has partnered with several supplier companies to develop antimicrobial tray & film solutions in order to reduce spoilage and increase the shelf-life of food by inhibiting the growth of bacteria, moulds & yeast. The antimicrobial technology reduces the risk of contamination from pathogens such as Escherichia coli, Salmonella, Listeria and Campylobacter – the most common cause of food poisoning and the focus of much debate within the food industry. Alan Davey, Director–Innovation, LINPAC Packaging, said, “While correct handling and preparation of food prevents bacterial contamination, the antimicrobial technology is another safeguard to control and significantly reduce the risk of bacterial contamination.” Using food-safe, proven biocides, LINPAC has developed its new range of trays and films using additives that can be applied in many ways according to customer requirements and the food to be packed. Another option is to apply antimicrobial varnishes to films and trays post processing.
Lionel Alva
Asian Nations (ASEAN), including Thailand, Indonesia, Singapore, Malaysia, Philippines, Vietnam and Cambodia. The new office will have access to the company’s full line of bag packaging systems and materials to provide streamlined packaging solutions for customers in various industries, including food, automotive, electronics, hardware, plumbing, commercial
parts manufacturing and e-commerce fulfillment. “We are committed to delivering high-quality bag packaging products and services to this region, where manufacturing and distribution are growing. We have experienced professionals in the new office to provide our customers with worldclass assistance,” said Cliff Brehm, President and Chief Operating Officer, Automated Packaging Systems.
NEWS, VIEWS & ANALYSIS
Atlantic Zeiser showcases new AIDC software at ACHEMA The Atlantic Zeiser Group, a leading developer and provider of modules & integrated total solution systems for industrial and security printing has introduced its new software Personalization Management Platform (PMP) for track & trace and anticounterfeiting solutions at ACHEMA. PMP can control the entire production, identification and dispatch processes of packages for pharma products by using interfaces to access relevant data on all levels of a production system. It makes them available as required in real-time during the individual process stages. PMP can be embedded into adjacent and higher-level software systems such as Manufacturing Execution S y stem (MES) and Enterprise Resource Planning (ERP), or even used as an MES itself. In addition to the universal control of different production levels, PMP Track & Trace offers individual reports and audit functions as well as an integrated random number generator for unique product ID codes. At ACHEMA, the company also exhibited other applications for the software platform in the pharma industry. This is significant because product tracking and authentication and realtime checking are critical components of comprehensive anticounterfeiting solutions for the pharma industry.
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ACTEGA’s innovation breaks new ground at trade show
At the recently held ‘World of Private Label’ trade fair in Amsterdam, ACTEGA DS, a new entrant to the fair, was selected for the New Product Expo for its innovative twist-off cap that features the PROVALIN® compound without Polyvinyl Chloride (PVC) and plasticisers developed & patented by the company. Based on advanced Thermoplastic Elastomers (TPE)
technology, this compound is processed by the company’s development partner Pano in its PANO Blueseal powered by PROVALIN® metal seals. The compound is available for use in different methods such as pasteurisation, sterilisation and cold-filling processes. It is also available for a wide variety of lid sizes and closures such as Twist-Off, Bandguard and P/T, and hence for all kinds of glass jars used in the food industry. ‘World of Private Label’ is a renowned annual trade show that exhibits innovations by leading international retailers. Product innovations distinguished in terms of innovative value, ingredients, packaging or concept are presented at the event.
Manjushree’s exports to double with rising overseas demand for PET Manjushree Technopack Ltd, one of India’s leading rigid plastics packaging manufacturers, expects to double its exports for this fiscal 2012-13. The growth in the international earnings comes in the wake of increasing demand for Polyethylene Terephthalate (PET) preforms from the developed and developing countries. “We witnessed a 100 per cent increase in our exports last
year, and we expect it to double this year as well, with a growing interest for PET preforms from the US, South & West Africa and Thailand. Our strong focus on innovation has seen us introduce new designs such as short-neck preforms, and we expect significant demand for such designs, particularly from the beverage segment. We hope to close next year’s earnings at over ` 400 crore from the current ` 300-crore turnover,” said Vimal Kedia, Managing Director, Manjushree Vimal Kedia Technopack Ltd.
Asia’s middle class drives BOPP film markets According to a latest report on the global Biaxially Oriented Polypropylene (BOPP) film market from AMI Consulting, the BOPP film industry continued to show robust growth during 2011, with demand advancing by 5.5 per cent as compared with that in 2010 to top 6 million tonne for the first time. Global demand for this is increasingly driven by developments in Asia, particularly China, India and Indonesia. With over 60 per cent of BOPP usage happening in food packaging, the growth in demand in these countries for an everwidening variety of packaged foods sold
Modern Packaging & Design July-August 2012
through supermarket outlets is one of the principal drivers for this material. With large, youthful and expanding populations; increased urbanisation; and rising incomes, it is the developing markets of Asia that will continue to drive growth in BOPP film demand. AMI believes that the BOPP film market has the potential to continue growing at a strong rate of 6-7 per cent per year over the next five years. This would add another 2.3 million tonne of demand. As seen in 2011, the strongest growth is likely to continue in India, driven by development of the organised retail sector opening up to foreign investment.
TECHNOLOGY & INNOVATION
GCS launches new light-weight dispensing closure for tubes
Zeller Plastik France has launched Touareg, a new light-weight 35 mm diameter snap-hinged dispensing closure for tubes to complete the Zeller standard range from 30-mm to 50-mm tubes in the Supersoft family range. Designed to maximise cost reduction and reduce environmental impact in line with the GCS Cap Green sustainability initiative, weighing just 4 gm, the closure is 20 per cent lighter than the previous version, which leads to a substantial reduction in carbon footprint. The weight optimisation and sophisticated high-cavity mould design enable the company to offer the closure at competitive price points. Manufactured with Zeller Plastikoriginated and renowned butterfly hinge technology, the closure suits the ND20.6 tube neck finish and is available in 2 mm, 3 mm and 5 mm orifice diameters. The contemporary, trendy in design closure comes in a wide range of matt colours and the flip-top can be embossed to suit customer requirements.
Nicholl adds smoothwall variants to foil tray range Nicholl Food Packaging has expanded its range of aluminium foil trays for the fresh and convenience food sector by adding five new smoothwall variants. Smoothwall trays feature a smooth rim, which allows each tray to be hermetically heat-sealed with standard film on high-speed machines. For extended shelf-life, gas flushing techniques are incorporated into filling and sealing phases of food production.
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Bosch launches SurePOUCH pack styles Bosch Packaging Technology has launched SurePOUCH – reclosable, flexible pouches with a wide range of applications from retail to food service. The packs are filled on the new SurePOUCH Clean-fill machine series (SPC) and roll-fed Vertical Form-FillSeal (VFFS) machines with a small footprint of 6 sq m. The pouch formats ‘retail’ for retail sales and ‘food service’ have filling volume size in the range of 100 ml to 5 litre. The SPC can produce four different pouch formats. The formats EZPouch, EZGable and EZSquare, with filling volumes from 100 ml to 5 litre, offer flexible applications for retail. For food
Epson announces seven-colour SurePress L-4033AW
service, the EZPillow can hold up to 20 litre, allowing for easy and quick refilling. All formats are produced, filled and sealed with the same machine. In addition to the SPC machine, Bosch supplies both spouts and the light-weight film or laminate structures for the SurePOUCH packs, guaranteeing seal and package integrity while ensuring easy handling, storage & dispensing of products. Due to its stable design, the package still stands up once vacant. Made from flexible materials, it allows high evacuation rates for increased utility as well as collapsibility for efficient disposal. The new flexible pack style also helps lower the product-topackage weight ratio as compared to rigid alternatives.
Epson has launched SurePress L-4033AW – a seven-colour, inkjet digital label press with white ink that makes high-quality, short-run label printing easier and more efficient, even on clear & metallic substrates. Delivering exceptional print quality and accurate colour reproduction on a variety of standard label substrates, the machine enables label converters and commercial printers to expand their service offering & improve profitability. In order to give a wide colour gamut for precise colour matching and accurate reproduction of spot/speciality colours, Epson’s SurePress AQ ink-set includes
green & orange inks. The difference is especially noticeable in the bright green-to-yellow and yellow-orange-red portions of the colour space, with higher colour saturation and lifelike shades that make labels more eye-catching. The ink-set now includes white ink for solid, opaque white printing on materials such as clear film and metallic substrates. The machine streamlines the production processes of label converters and commercial printers, ie, the machine is quick & easy to set up, with no plates or films to prepare. It also maximises uptime with automated print-head maintenance and hot-swappable ink cartridges, with no need to stop the press to change them during production.
The trays offer a robust, heavy-duty construction, reducing the weight of sleeves and cartons and total pack costs. These combine a quality, attractive appearance with user-friendly benefits, eg, easy handling, leak-proof seals and shatterproof when frozen, and retain their strength & rigidity at high oven & grill temperatures. Smoothwall trays are suitable for various product types, eg, ready-to-cook meat, poultry and fish, ready meals, barbecue products, vegetables, etc. The trays
are available in rectangular and round shapes with different depths & design enhancements, eg, ribbed sides & embossed squares on the base.
Modern Packaging & Design July-August 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. Weightless PET bottle The German Packaging Institute has now chosen the concept of ‘PET lite 6.6’, a 500-ml bottle developed using Krones’ NitroPouch process for the German Packaging Prize. This new bottle made from 6.6 gm of Polyethylene Terephthalate (PET) constitutes a milestone in the field of light-weight beverage containers. The NitroPouch concept, as the primary package, minimises material and energy consumption. The mouthpiece specially developed for this bottle dispenses with the otherwise customary neck ring, and weighs only 1.3 gm; the closure is as lightweight as 1.1 gm. Nitrogen is used to build up a defined pressure inside the bottle, so that it does not collapse during transport and handling. Manufacturer: Krones
A glass of wine
Airless bottle with dual wall Sunrise Pumps has introduced a new series of stylish dual-wall airless bottle ‘DA’. Developed by Sunrise, the 30-ml and 50-ml bottles feature a dual wall – the white plastic inner wall can be seen through the transparent outer one, providing two surfaces for decoration and branding. Made of styrene acrylonitrile, the opaque wall on the bottle offers a prestigious look that is perfect for upgrading an existing brand image, while the protective polypropylene inner bottle ensures perfect compatibility with all kinds of formula. In addition, the airless system reduces residual ingredients and ensures hygiene. Manufacturer: Sunrise Pumps
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Modern Packaging & Design July-August 2012
An entirely new packaging approach for wines that originated in France is now possible in plastics. The concept is finding favour with sophisticated wine makers who see new market opportunities for wine served in recreational and outdoor venues. Wine is bottled into a single-serve barrier plastic wine glass with a shelf life of one year. This saves 50 per cent of packaging waste. A significant technical challenge was to overcome in sealing of the lidding to the wine glass rim without spilling the wine. This innovation facilitates the entry of wine in the ready-todrink beverage category. Manufacturer: Copa Di Vino
DESIGN INNOVATION
A refreshing design Procter & Gamble (P&G) has revitalised an iconic brand through innovative new packaging. The new Scope Outlast mouthwash from P&G has been developed with Alpla, Tech Group and Webb deVlam Industrial Designers from USA. Dubbed as the ‘Genie’ bottle, the new design has outstanding stopping power and clearly separates Scope from private label and other offerings in the category. The new design of the Scope bottle has an additional benefit of significantly reducing packaging materials as PET usage was reduced by 20 per cent and allowing for higher efficiency when shipping. Manufacturer: P&G
Keeping it fresh and hygienic Innovative aluminium packaging
Exal Corporation’s new Coil to Can (C2C) aluminium bottle manufacturing technology, for the first time, features recyclable aluminium alloy and allows marketers to consider aluminium bottles for large-scale beverage applications. C2C aluminium bottles use less material and are manufactured at faster speeds to enable a 40 per cent weight reduction at a cost comparable to Polyethylene Terephthalate (PET) and/or glass. Apart from the benefits of the materials used, the design of the bottles ensures easy grip and ergonomic dispensing options.
Cryovac has introduced easy-to-open new design for fresh and processed meat & cheese, which yields improved convenience, safety and less waste of food. The packaging is not only lighter than conventional options, but also ensures ease of operation for the customer. The Cryovac Grip and Tear® bag combines the superior shrink, toughness and oxygen barrier properties of a conventional vacuum shrink bag along with an easy-open feature. A user simply grips the package and tears it open. Easily opened by pulling a tab, the bag’s knifeless design improves employee safety, reduces the risk of cross-contamination, eliminates mess and keeps the workspace clean. Manufacturer: Cryovac
Manufacturer: Exal Corporation
Modern Packaging & Design July-August 2012
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TECHNOLOGY TRANSFER
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Technology Requested
Technology Offered Air bubble packaging film A Korean company is offering its existing plant manufacturing air bubble film. This plant (model: YS1200, YS1000, YS1400) is equipped with modern facilities in accordance with excellent quality production. The consumption of air bubble sheet is a profitable business due to increasing demand in India.
Areas of application Packaging industry: It can also be used for agricultural applications instead of LDPE where additional thermal insulation is required.
Forms of transfer Equipment supply, turnkey
Bar code generating and printing A Thailand-based firm seeks to offer their services in bar code generation and printing. They use highly professional methods and their expertise will be useful depending on clients’ requirements. Other than consultancy, they provide training for barcode generation, which would help the manufacturer improve its prospects in the long term.
Areas of application
Adhesives, specialty additives and their intermediates A leading UK-based company is seeking 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 in high-quality performance products. The company seeks to acquire rights to novel chemistry products, innovative technologies, formulations, compounds and applications that are in synergy with its current range of activities, and that will increase the diversity of its manufacturing base. Patents or know-how would be desirable.
Areas of application Plastics rigid and flexible packaging, laminate printing and processing, etc
Forms of transfer Manufacturing, technology licensing, acquisition, joint venture and distribution
Printing industry, bar code auto ID section
Forms of transfer
Recycled PET bottle machinery
Consultancy, turnkey
An Indian firm is offering a green innovative technology – Coir Atlas. It is an eco-friendly and biodegradable substitute of wooden logs used by steel industry for shipment of flat products viz sheets/plates and coils.
A Poland-based company specialising in recycled PET polyester polyols manufacturing is looking for an alternative proposal of design and engineering of bigger (about 25 ktpa) production plant. It plans to start with good quality recycled PET flakes, which will be delivered in big bags. Hence, the company requires a complete package offer for this service.
Areas of application
Areas of application
Packaging and transportation
Beverage packaging industry
Forms of transfer
Forms of transfer
Joint venture, technology licensing
Others
Coir Atlas
Information courtesy: Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, Asian and ! "# %! ' * ! + / 33; ;3< = ;33">;?F >FQX / ;33">;?F >F3; Z [= ;33 " #<XQ <#F\ = ] ] ^! _ ` ' = +++_ q _ Z z! q +++_ \ _ + ! _ q q ] ' ' + '! and seekers of technologies across the globe. After submitting technology offer z! + ' ! z! + + + {
] q q q ] '! | { ! + ' before contacting APCTT for further assistance.
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Modern Packaging & Design July-August 2012
Share and Solicit Technology The mission of Modern Packaging & Design is to spread the technology culture. Here is an opportunity to be a part of this endeavour by sending your technology z! _ * ! ' + you are invited to furnish the techno-commercial details for publication. + "!q ' q + ' ! q ! z! qq and forms of transfer.
Contact: Modern Packaging & Design * 3X } ~ ` Â&#x20AC;!' Â ! Â&#x201A; Â&#x192; + Â&#x201E; / ` Â&#x201E;! ' \;; ;#X_ = ;##">;;> \<F3 Â&#x2026; Z [= ;##">;;> \\?? Â&#x2026; = q ^ 3X_
IN CONVERSATION WITH: Ajit Singh
key to introducing The
innovation is strong
R&D …emphasises Ajit Singh, Chairman, ACG Worldwide. Having served at the boards of several national and international associations for the pharmaceutical industry such as the Organisation of Pharmaceutical Producers of India (OPPI) and International Society for Pharmaceutical Engineering (ISPE), Singh highlights the need for research & development and innovations in India’s pharma packaging sector. A rare and exclusive interaction with Annabel Dsouza…
Photo: Mexy Xavier
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Modern Packaging & Design July-August 2012
Ajit Singh
How has the pharma packaging sector evolved in India over the years? The overall view of the pharma packaging and machinery industry is positive. Today, packaging is not just looked at as an aesthetic requirement, but also as a necessity for customer safety, brand protection and brand-building. Indian companies have matured to become complete solution providers with machines for tableting, encapsulation, coating, material handling for solid dosage manufacturing, blister packing, cartoning, pouch packing, case packing solutions for packaging and check-weigher as well as vision systems for online inspection.
To what extent does packaging contribute towards delivering worldclass solutions to the Indian pharma industry? The consistently upward trend of the Indian pharma industry has resulted in a strong and steady packaging sector over the years. Globally, India ranks third in terms of manufacturing pharma products by volume, and this gives immense opportunity to Indian equipment manufacturers, thereby expanding their horizons. With innovations being a crucial aspect in pharma packaging, companies like ACG have been successful in dealing with counterfeiting to a great extent. By employing innovative technologies such as Two-Dimensional (2D) coding & Radio-Frequency Identification (RFID), the packaging sector has helped pharma and non-pharma companies to protect their brand identity and ensure customer safety.
How is the uncertain global economic climate impacting the pharma industry in India? The industry has shown a mixed response to the economic slowdown. Many projects in Europe and US have been put on hold and that has inertly affected our exports to those markets. Nevertheless, there is a faint silver lining as European companies, who purchased only European machinery, are now considering Indian manufacturers
having global standards with competitive pricing edge.
What is your opinion on the competency of Indian companies as against their global counterparts? India is the worldâ&#x20AC;&#x2122;s fourth largest manufacturer of pharmaceutical formulations in the world by volume. However, in terms of turnover, the contribution of the Indian pharma industry is less than two per cent of the global total. This is a clear indication that the prices of medicines in India are the lowest in the world. The manufacturing facilities in India are being upgraded to the standards of the regulated markets. Today, India has the highest number of Food and Drug Administration (FDA)approved facilities outside the US. Packaging technologies that show great potential for growth are horizontal and vertical form-fill-seal machines for different goods, be it solids, granules or liquids. Global packaging giants like Alcan, Honeywell, Volpack, Sarong and Theegarten Pactec have partnered with companies in India to leverage on the potential of the Indian pharma companies.
How can Indian manufacturers deliver global innovations while maintaining a steady cost-quality ratio? The key to introducing innovation is to have a strong Research and Development (R&D) set up. Many good companies not only have a structured product development cell, but also invest in R&D. For example, ACG has its own R&D center (Scitech Center) exclusively for delivering innovative solutions. Research is a low-cost investment as compared to development cost overseas, and a large number of Indian designers are now capable of involving world-class standards in developing cutting-edge innovations.
What are the main challenges confronting this industry today? Customers today are looking for convenient, counterfeit-proof and informative solutions. Convenience coming from unit dose packs (single-use
cough syrup dose, etc), anti-counterfeit solutions such as Brandshield printing, specialised packaging films and track&-trace technology are gaining importance. All these pose a challenge for companies like ACG, and the R&D and innovation teams continuously work towards helping customers overcome these challenges.
What are some of the R&D initiatives taken by ACG? Anti-counterfeit solutions and methods of providing patients with safe & genuine medicine is the current focus. ACG has established end-to-end anti-counterfeiting capabilities. Beginning with Brandshield printing on capsules (in two and four colours) to unique blister packaging films (metalised with logo embedded) and, finally, the supply chain security solution, Verif-i from ACG Inspection, ACG is all set to cater to every need of the pharma industry.
How do you perceive the future of the pharma industry in India? Indiaâ&#x20AC;&#x2122;s pharma industry has approximately 3,000 active pharmaceutical ingredientmanufacturing facilities, nearly 5,000 formulation facilities and 2,000 other pharmaceutical facilities. Of these, 300 facilities are in the medium to large range. Some sub-sectors, including biotechnology, bioinformatics, contract research and manufacturing services, clinical research organisations and pharma machinery manufacturing, are growing in tandem with the larger pharma industry, as experienced human resources and investments spill over into these areas. Indian machines are manufactured and used in accordance with international standards and are not hazardous to inspection and approval of their facility. This is one of the many reasons that India has the highest number of FDA-approved facilities in the world. With more and more multinationals contracting out their manufacturing to India or setting up their own facilities in India, the demand for pharma machinery would only increase in the coming years. Email: annabel.dsouza@infomedia18.in
Modern Packaging & Design July-August 2012
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Dear Reader, â&#x20AC;&#x2DC;Modern Packaging & Designâ&#x20AC;&#x2122; 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 1500 words, while that of a product write-up should not exceed 100 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 â&#x20AC;&#x2DC;Modern Packaging & Designâ&#x20AC;&#x2122;. Authors whose articles are published will be sent a complimentary copy of that particular edition. Published by Infomedia 18 Ltd, â&#x20AC;&#x2DC;Modern Packaging & Designâ&#x20AC;&#x2122; is one of the leading bi-monthly magazines 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 worldâ&#x20AC;&#x2122;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, etcâ&#x20AC;Ś Look forward to hearing from you, soon! Yours sincerely,
Business Insights Technologies Opportunities
Manas R Bastia Senior Editor Infomedia 18 Limited â&#x20AC;&#x2DC;Aâ&#x20AC;&#x2122; Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India
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ANNIVERSARY SPECIAL
‘Pack’ing a punch with innovation Design CAD/CAM technology ................................................................................................................................ 28 Digital v/s offset printing .............................................................................................................................. 30 Interface: t Alpana Parida, President, DY Works ....................................................................................... 33 t Shyam Sundar B K, Chief Designer-Industrial Design, Tata Elxsi ........................................ 34 Roundtable: How do packaging designs influence consumer choice vis-à-vis the product? ...................... 35 Materials Food and beverage packaging ...................................................................................................................... 36 Flexible packaging ......................................................................................................................................... 38 Interface: APVS Chakravarthi, Managing Director, Ecobliss India Pvt Ltd ............................................. 42 Roundtable: Can India ride the wave of innovations in bioplastics packaging?........................................... 43 Machinery Robotic palletiser .......................................................................................................................................... 44 Conveyor technology ..................................................................................................................................... 46 Interface: t Avra Mitra, Senior Manager-Key Accounts, Business Unit-Web Fed, Bobst India Pvt Ltd ..............49 t Yatindra R Sharma, M D, KHS Machinery Pvt Ltd ............................................................... 50 Logistics Packaging for cold chain .............................................................................................................................. 52 Reverse supply chain .................................................................................................................................... 54 Interface: Frank Oliveri, Vice President-Marketing, Packaging Resources Group, MeadWestvaco ........... 56 Roundtable: How can the packaging industry overcome the logistic challenges posed by Indian infrastructure? ........58 Safety Fresh food packaging ................................................................................................................................... 60 High-speed packaging lines .......................................................................................................................... 62 Interface: t Krishnamachari Ravi, Managing Director, Hassia Packaging Pvt Ltd ............................................ 64 t Naushik Kabra, Director, Synthetic Packers Pvt Ltd................................................................ 66 Security Brand protection ........................................................................................................................................... 68 Package testing equipment ............................................................................................................................ 70 Interface: t Karl Vandenbussche, Director, Reynders Label Printing India Pvt Ltd .................................. 72 t Satyadeep Ray, Director, Holostik India Ltd ............................................................................ 73 Sustainability Packaging material ....................................................................................................................................... 74 Reducing carbon footprint ............................................................................................................................. 76 Interface: Pramthesh Pandya, Head-Unit & Business Development, Parikh Packaging Pvt Ltd .............. 78 Roundtable: Can recycling technology in India achieve competitive results for the market? ...................... 79
Modern Packaging & Design July-August 2012
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DESIGN: CAD/CAM technology
Integrated solutions for cost-effective designs Packaging is a complex subject and deriving an innovative design is a highly challenging task. Lionel Alva assesses how the advent of novel technologies such as three-dimensional modeling through CAD/CAM has spurred innovation in packaging designs.
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he rate at which a new product or its packaging variants reaches the market to achieve brand consistency across a variety of substrates as well as the wide & varied geographical spread of production units are quite rightly viewed as areas of additional attention for all major international brand managers. Energy management and waste minimisation are some of the key considerations while building packaging designs. Design optimisation is the key to achieve this, and conventional prototyping methods have several limitations when compared to Three-Dimensional (3D) modeling solutions, which is a more accessible approach. A Computer Aided Design (CAD)/Computer Aided Manufacturing (CAM) 3D modeling solution would not only give the designer a great degree of flexibility, but also enable him to create accurate and realistic images. With the conventional approach that is usually a highly timeconsuming and arduous process involving a keen scrutiny of various elements of packaging design and in comparison CAD/CAM solutions are quicker, more efficient and approachable as a design medium that completely integrates into the manufacturing function. An integrated CAD/CAM solution offers specialised software and hardware
Modern Packaging & Design July-August 2012
tools that add to the prowess of a packaging manufacturer in the value-added chain of printed packaging â&#x20AC;&#x201C; designers, brand managers, repro houses, printers and materials suppliers â&#x20AC;&#x201C; to ensure that brand objectives are met within the best possible timeframe. When broken down to its base elements, the CAD and CAM process is merely a geometric model of the product being designed. Activities of the CAD process include mass properties, finite element analysis, dimensioning, tolerance, assembly modeling, generating shaded images as well as documentation and drafting. Activities of the CAM process include Computer-Aided Process Planning (CAPP), Numerical Control (NC) programming, design of injection moulds, Coordinate Measuring Machines (CMM) verifications, inspection, assembly via robots and packaging.
Widening prospects â&#x20AC;&#x153;We have been working closely with manufacturers to understand their needs and have integrated these into the product solutions that we provide. It is important to understand the finer nuances of the manufacturing process before the product solution is made available to manufacturers so as to ensure complete integration while ensuring that the interface for our solution remains accessible, and we try & reduce
CAD/CAM technology
the learning curve to the maximum extent possible. Some of the key considerations for our solutions are that these should seamlessly work with the environment and automatically accommodate changes to design models while facilitating a smoother flow of the heterogeneous packaging process,â&#x20AC;? avers Sambit Pradhan, Business Development Manager, and Product Sales Asia Pacific, Geometric. In the Indian context, packaging manufacturers are increasingly exploring avenues that offer a suitable alternative to the time-consuming and expensive conventional prototyping methods. Considering the varied nature of packaging designs, the use of 3D modeling techniques appears to be the most pragmatic approach towards manufacturing. Indian CAD/CAM manufacturers ensure that the CAD/ CAM solutions they offer cater to the business dynamics of emerging economies while remaining accessible and costeffective. Since a CAD/CAM technology is a mix of hardware and software, the technology strives to achieve optimum and focussed product development characteristics. Recent developments in CAD/CAM solutions show that the best solutions help manufacturers increase productivity and profitability through best-in-class technologies and adaptable automation tools that maximise machining efficiencies. While being simple to use and eliminating the drudgery of CNC programming with intelligent machining through automation, the best advantage is perhaps that packages can be constructed from scratch within a few seconds. The constructions lead to data that can directly be used by other departments in a company similar to any production engineering unit (cutting, grooving, drafting, scoring, milling, laser, etc). The software simulates folding steps that enables the feasibility monitoring of oneâ&#x20AC;&#x2122;s new construction during the packaging design process. The automatic 3D display as wireframe graphics with hidden lines allows simulation and recall of folding steps for an easy, rapid and efficient packaging design.
Some of the major advantages are: Visualise an idea quickly and efficiently Modify modeled ideas to record and evaluate the consequences of their action Model concepts, such as nutritional analysis Represent ideas using real-time simulations, eg, virtual reality Use an outline specification proforma to aid product design Monitor and control production to ensure food safety and a consistent outcome, eg, hazard Hazard Analysis and Critical Control Points (HACCP) Ensure accuracy, especially precise weights and measurements
Challenges with software CAD and CAM are relatively new areas of technology that have come to fore in recent years. Understanding and implementing CAD and CAM can represent a challenge, especially since a keen scrutiny of the packaging manufacturing process is needed. Moreover, the hardware and software must fit the requirements or the integration could be a complete failure, further exacerbating the problems of the manufacturing process. There is also a steep learning curve associated with CAD/CAM software, and requires highly skilled and dedicated personnel. When two or more software packages need to communicate, there is always room for error. Sometimes it may be a minor problem, but often the problem becomes severe. Each software supplier writes its own code to handle complex geometry. In case of any differences in the way, one or the other describes a lofted surface, for example, one will not get exactly the same shape as was intended. However, with an integrated product, with both CAD and CAM, this possibility can be reduced to a great degree. Significant strides have been made in the training and implementation to help accelerate the processes. Once users pick up pace, they become self-sustaining and establish the best practices required to operate and maintain the system.
It is important to understand manufacturing process before the product solution is made available to manufacturers so as to ensure complete integration while ensuring that the interface for our solution remains accessible, and we try & reduce the learning curve. Sambit Pradhan Business Development Manager, and ! Â&#x2021;
With the range of machine tools, cutting tools and automated machines required, the initial setup cost could become expensive for Indian manufacturers. Moreover, there is a possibility that the CAD/CAM solution may not be compatible with new manufacturing processes introduced, thus requiring a complete overhaul of design.
Future of CAD/CAM technology Considering that the packaging industry is constantly evolving and finding new areas of application, CAD/CAM technology could go a long way in furthering the prospects of a packaging manufacturer. It is an excellent fit for high volume production where the focus is on shorter lead times, especially in the Indian context, since the retail boom and the demanding nature of the clientele in India requires an absolute optimisation of the manufacturing process. Email: lionel.alva@infomedia18.in
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DESIGN: Digital v/s and of offset fset printing printing
Weighin g the pros an d cons The ret a i centric l mar ket is dri designs ven by c Among t w o he vario ith varied visua nsumerit is the us desig l appea l. impor ta method of prin n consideration nt. Lione s ting use , and of l f s e t p r Alva explores h d that is inting disinteg ow digit c a r appr oac a t e d p a c k a g i n g o n s o l i d a t e s t h l h to crea e i n te appea d u s t r y w i t h a ling labe n l designs .
Courtesy: Avery Dennison
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o a large extent, the packaging industry, especially for the retail sector, is driven by the impulses of the consumer, and which is why the appealing nature of a design can make or break the success of a given product in a market. Such is the crucial nature of design, and thus it is extremely important that the technical aspects of the design philosophy have a sound basis. While often overlooked, the approach towards the nature of printing used can have an inordinate effect on the successful fruition of a strong design philosophy. When a consumer enters a retail store, he faces a kaleidoscope of colours and textures where a product that stands out on the shelf will arrest his attention immediately. This effectively underlines the powerful impact of colour in
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packaging design and the psyche of the customer. The question that most package and label converters in India ask themselves is whether they should opt for digital or offset printing. It is important to understand the strengths of each technique and the quality considerations of the design since choosing the wrong method could be detrimental to the organisation’s image and stand to compromise brand integrity and affect its equity in the market. In the end, a good design cannot fully live up to its potential if run on a poor print job. If a manufacturer is as careful and selective in choosing a print partner as he would be in choosing a design firm, one can ensure that the final product reaches the highest quality parameters.
Modern Packaging & Design July-August 2012
Economics of printing While assessing different print technologies an understanding of the terms ‘Cross-over’ or ‘breakpoints’ is important. This is when the comparable cost of a production run between, say, digital and offset, becomes the same. Moreover, as technological paradigms are constantly changing, so are the cost-value facets of digital and offset printing. Digital printing has all the advantages on the front-end, as setup is essentially free, but the price per label slowly rises with production. However, it is still too slow for large runs. Offset starts out as expensive with non-flexible and laborious setup, but as numbers increase, the unit cost per label declines. Flexo and offset presses run considerably faster than digital presses. Printers talk in terms of feet of paper per minute.
Digital v/s of fset printing
Digital printing technology constantly evolves requiring re-training of employees. Hence, currently, it is not feasible but is gaining increased interest due to more innovative design protocols and their immense potential. Shrikant Naik Director, Alpha Prints & Labels
For instance, digital production on a Hewlett-Packard WS-4500 at best is 50 ft/min. Offset can print hundreds of feet of substrate per minute. There is a point of ‘equal’ exchange or ‘crossover’ where, briefly, the costs equate. For the WS-4500, this translates into about a 5,000-case labeling run, which is a substantial figure. Thereafter, offset starts to be cheaper. “Currently, digital printing renders colours more accurately and on a
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comparative basis, creates more vibrant and appealing designs. Digital printing is also far more flexible for design changes that may happen. However, it is better used for smaller volumes and offset printing for larger volumes, since otherwise the economics just do not play out, especially in the Indian context as the market is quite cost-sensitive. The dimensions of the packaged product and several other factors are important, bearing weightage on the nature of printing used. Moreover, digital printing technology constantly evolves requiring re-training of employees. Hence, currently, it is not feasible but is gaining increased interest due to more innovative design protocols and their immense potential,” avers Shrikant Naik, Director, Alpha Prints & Labels. Different considerations will determine which method is the best, such as quantity, timing and size of the printed piece. Offset printing is commonly used for higher quantity, larger-format jobs, while digital printing is best applied to smaller-format, lesser quantity print runs.
Understanding the methods Offset printing, however, works as a more conventional publishing process from where the inked graphic from the completely ready plate is transferred to the rubberised blanket later, and lastly into a publishing spot such as cardboard or document. Offset printing is mostly employed in conjunction with lithography, which works to the reverse components with oil and liquid. The graphics to be published will get an oil-based toner through the offset machine’s wheels. A non-printing spot, nevertheless, extracts a small layer of liquid, which often prevents printer ink from flooding a non-printing spot.
Modern Packaging & Design July-August 2012
Handling the cost of digital printers is higher than that of offset printers, and thus gets a big portion of the business’s operating spending plan. Offset printers, however, generate high-quality replicates by applying low-cost and swift plates. “When done correctly, offset printing creates appealing designs, is more costcompetitive and poses lesser maintenance hassles since its intricacies are well understood by manufacturers. Digital printing is still a new form of technology and requires some time before it gains acceptance in the Indian scenario, which is the case with any new technology,” asserts Naik.
Merits and demerits Even though offset printers take advantage of basic oil-based toners, electronic equipment depend on costlier specific inks and toners. Furthermore, despite the fact that offset machines could print on all types of papers and other materials, eg, vinyl, lumber, textile and steel, digital printers require unique paper stocks, which are specifically made for digital printing. Obviously, these stocks cost more as compared to the standard types. Since digital printing is a new form of technology, it has brought about several advancements, more options and several features that have increased the printers’ interests. However, currently its application is limited since Offset printing is still a more cost viable technique for large volume production. Printers must, therefore, carefully scrutinise their project demands and digital printing can provide them with an added flexibility. Ultimately, everything is depends on the project demands, ie, whether a client should choose digital or offset printing. And, unless an even better approach to produce high-volume duplicates at low costs and effectively is created, offset printing is here to stay. Email: lionel.alva@infomedia18.in
DESIGN: Inter face - Alpana Parida
“Innovations in packaging design can drive market growth” …says Alpana Parida, President, DY Works. With an experience spanning over two decades in retail and marketing communications, Parida believes branding to be the new advertising. She emphasises that today’s packaging solutions must add value through innovative & functional designs, in an exclusive interaction with Annabel Dsouza.
Photo: Joshua Navalkar
How has packaging evolved into a branding tool today? This trend emerged when more advertising meant higher awareness, which meant more marketshare. Today, with incredible media clutter, brands need to make huge expenditure to garner awareness. Advertising, in a bid to differentiate them and be memorable, tells stories that are memorable but does little for the brand. Also, as categories, brands, variants and stock-keeping units proliferate, the consumer expects choices at the retail shelf. Here, packaging plays a huge role in causing conversions at the retail shelf and thus can expand marketshares.
What are the key design elements essential to successful packaging? The structure of packaging has to break the clutter and take the brand value forward. Further, the substrate and printing can indicate the brand’s values. For instance, the metallic substrate of Taj tea positions it as premium, and the special red colour used by Colgate ensures that there is no imitation.
Subsequently, the front of pack design must follow the messaging hierarchy for the brand. What does the consumer need to know first? What role does the image play? Finally, the back of pack design must convert the consumer. All information should be included at the back of the pack – Is it easy to use? What is the usage guideline or ingredients?
What are the current market trends in packaging design? Packaging must play a role in attracting attention, creating awareness, educating consumers and converting them to make a sale. Innovations in packaging design can drive market growth and brand penetration. These innovations can be of low cost but must be able to break the clutter in this highly populated multibrand retail environment. Some marketers are experimenting with substrates. For instance, the new Lakme skincare range created by us has various substrates, from regular to premium products. The use of metals is seen in categories such as food, personal care and household products.
In India, this clearly signifies a premium experience. Also, if value addition to a product is significant, consumers will pay for it. Innovations in packaging can command a premium and higher margins.
Which technologies are required to implement new packaging designs? Often, it is not technology, but an innovative mindset, both on part of the design agency and the client, that matters. For example, a bag of flour/rice with a zip lock, a stand-pouch with a gusseted bottom for sugar, a vertical pack for cereals, etc, none of these requires new technology.
How do you assess the Indian packaging industry vis-à-vis global developments? In India, the issue is not capability, but the tendency of Indian business to shun innovations. We still opt for the lowest cost, common structures. Only few brands invest in new structures or designs, eg, cigarettes that experiment with printing, substrates and textures. Email: annabel.dsouza@infomedia18.in
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DESIGN: Inter face - Shyam Sundar B K
â&#x20AC;&#x153;Creativity must be pushed beyond the comfort zone to achieve maximum expectationsâ&#x20AC;? â&#x20AC;Śasserts Shyam Sundar B K, Chief Designer-Industrial Design, Tata Elxsi. In an interaction with Lionel Alva, he describes his approach towards creative solutions while touching upon several key facets of the packaging industry and the trends driving it forward. What approach do you take towards creating innovative packaging solutions?
expectations without compromising on sustainability.
While developing a new pack, a designer can look towards numerous aspects of innovation. It could be a technological innovation that a brand needs to communicate or usability of the pack, which enhances consumer experience or a pack that challenges the trend in the category. Innovation could be driven by the design objective defined. If sustainability is the key objective, then the ideas that occur would be based on packs that reduce the amount of material used, its amenability for recycling/reuse, alternative cost-effective solutions, etc. Similarly, the aim could be user convenience, material change, cost reduction, etc. Inspirations and developments from other industries also facilitate new thoughts that can be induced to bring in innovation in the development of packaging solutions.
How do you see the future of the packaging industry and what are the major drivers shaping packaging trends today?
What is the scope and relevance of digital printing in the Indian market today? To be specific, digital printing has become an imperative for Fast-Moving Consumer Goods (FMCG) companies. Because of high quality of printing, more brands are now looking at this as an option. Innovative methods can help designers to quickly print, evaluate designs and develop artworks, thus helping to reduce the development time. Increase in private label with short runs, customising to target markets, etc are also some of the reasons that have given a boost to digital printing.
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How much emphasis does Tata Elxsi place upon environmental sustainability for packaging solutions? The solutions developed at the company are highly influenced by the client, and this gets articulated in the project objective. However, the concepts developed by us are evaluated on various parameters, and sustainability is an important aspect that is considered during the process. We have also carried out specific sustainability projects related to packaging.
What challenges are faced while designing a creative, yet sustainable and cost-effective packaging solution? Packaging should satisfy several expectations. In the process, it is a balance of various attributes versus sustainability that must be evaluated in order to take conscious decisions. Creativity must be pushed beyond the comfort zone to achieve maximum
Modern Packaging & Design July-August 2012
Innovations in technology are currently ruling this industry. Also, the influence of other industries is now fairly seen in packaging, such as the use of dual colour/ feel on packs; gadgets that help dispense the product; incorporation of electronic intelligence into packs, etc. The future of packaging will be defined by the cost to manufacture and cost to environment, as consumers become enriched as well as responsible. Packs that are easy to use and dispose as well as suitable for recycling will be more acceptable in the future.
What is your approach towards understanding consumer requirements while creating a fully integrated packaging solution? As rightly said, we have 4-5 different broad clusters of geography that probably have certain common taste and preferences. It is important to know that people trust the brand and value the product. Packaging becomes a functional and emotional carrier towards achieving this objective. Hence, an ethnographic study to understand the consumer needs can help gather insights in order to develop a successful product and its packaging. Although simpler in appearance, packaging becomes complex with diverse customer preferences, and there are numerous challenges every time to meet their expectations. Email: lionel.alva@infomedia18.in
DESIGN: Roundtable
How do
packaging designs
influence consumer choice vis-Ă -vis the product? The surge in supermarkets and retail stores has driven the need to better understand the consumer decision making process. Lionel Alva assesses how deeply packaging design affects the consumerâ&#x20AC;&#x2122;s decision making vis-a-vis other aspects such as quality and brand image.
Makdum Jahan Country Manager, Veripack Solutions India Pvt Ltd
The Indian packaging sector is perhaps the most dynamic one and driven by innovation. Only the most imaginative packaging designers can survive in a highly competitive and demanding environment. Those in the retail sector compete to build appealing, informative and cost-effective designs, which will ultimately affect the psychology of the customer, and thus influence his purchasing decision. Achieving and fulfilling design expectations is a difficult and challenging proposition. Therefore, it is vital to have courage to adopt various trends and factors driving the market today. We must address several facets such as graphic design, dimensions and nature of packaging as well as packaging quality considerations, which makes the science of packaging extremely challenging yet rewarding. The rapid rise of the retail sector in India has changed in its approach towards packaging, and even established brands now have to constantly strive to sustain bottomlines.
Manisha Joshi Director, Isha Enterprises
The packaging industry today is driven by creativity and innovation. This is in terms of design as well as nature of materials used for packaging where companies constantly strive to push the boundaries of possibilities. However, designers can merely take the brief from clients and give them different ideas based on their criteria. Then they conduct a market study to analyse the feasibility of the packaging design, dimensional considerations and overall costs. Understanding the psyche of the consumer can, at times, be a perplexing and tricky challenge. This is because taste is a subjective notion, and there is no such thing as a bad design, but figuring out what works and what does not is a challenging task. In the past, often, a design rejected by one organisation has been taken up by other organisations who have successfully integrated it into their product. Understanding the varied nature of consumer taste in India is undoubtedly the most challenging proposition.
M K Banerjee Director-Creativity & Innovations, Essel Propack
Innovative package design reflects the quality of the product packed inside. Often, the packaged product cannot be seen from outside, but from the graphics and packaging information, one can easily correlate the sentiment & seriousness of product manufacturer to ensure that the product quality remains intact throughout its designated shelf-life. Smart and innovative packaging design includes intrinsic properties of the packaging material as well as the look, feel and functionality of a complete package. Consumer convenience is also a great enabling factor as the packaged product should be easy to dispense, consume and retain for future use. ControlledAtmosphere Packaging (CAP) and Modified Atmosphere Packaging (MAP) designs preserve the filled product to its original freshness and texture. Todayâ&#x20AC;&#x2122;s consumer wants to know from the packaging if the product is genuine. Hence, the brand and packaging designer must incorporate anti-counterfeit measures into the basic packaging design.
Editorial take: Email: lionel.alva@infomedia18.in The dominance of the retail market has put a singular emphasis on understanding consumer wants and needs better. As companies strive towards innovation, the quality of products is also increasing with packaged products witnessing an improved shelf-life.
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MATERIALS: Food and beverage packaging & beverage packaging
Carving a niche in the Indian market Food processing and packaging technologies have undergone significant changes over the last decade, in terms of new methods of processing foods, packaging materials and techniques of manufacturing containers. Anwesh Koley delves deeper into the changes that have occurred in the area of plastics and other materials and the future of food & beverage packaging.
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ndian packaging industry is thriving, and of late, it has been the focal point of tremendous opportunities for manufacturers. Its exponential growth record in India varied by 22-25 per cent annually as compared to the global rate of 4-5 per cent. The dynamics of the industry are slightly fragmented and unstructured, but with terms such as global villages turning into reality, industry players are adapting to modern and advanced technology providing world-class products. Currently, the packaging industry is in a transition period due to increasing awareness among customers. Quality, hygiene and face value are making imprints in the minds of people. Packaging offers better shelf-life for products and helps retain the flavour for prolonged periods. This assists the consumers in their normal busy life. India being the world’s second largest and third largest producer of vegetables and fruits, respectively, is focussed more on packaging to meet stringent international standards. The growth parameter for the packaging industry is directly linked to the growth trends of the Fast-Moving Consumer Goods (FMCG) segments, which is
Modern Packaging & Design July-August 2012
highly influenced by consumer choice. High disposable income has enhanced the lifestyle of consumers who, today, have wider choices available in the market.
Latest innovations An increasing population and growing consumer demand for packaged foods has forced the Food & Beverages (F&B) industry to look at new technologies that provide flexibility, ease of operation and constant tracking of the production process. Suresh Singhal, Managing Director, Himalayan Group of Industries, says, “Manufacturers are working on guidelines for maintaining transparency in the production process for assuring consumers’ health and hygiene. This demands continuous monitoring and efficient traceability of the entire production process in the food processing plant. Innovation is an ongoing process, and we cannot rule out any possibility in developing new materials for new packaging.” Numerous trials are being conducted to make new materials suitable for better packaging and also make these more economical & environment-friendly Working on innovative ideas for cost-effective solutions, environment-
Food and beverage packaging
f riendly alternatives and appealing appearance vis-à-vis competing with international standards is the target of Indian convertors. Disposable packaging materials used to ship and protect purchased items as well as disposable containers used for F&B packaging are of particular interest today. New product avenues using the thermoforming process for fruits, vegetables and ice-cream will change the perception of packed food criteria. Packaging companies across the country are tracking these innovations and aggressively moving towards adding value to the packaging industry.
Rigid packaging technology Glass packaging had a global monopoly over F&B packaging for a very long time. Recent advancements in plastic materials such as Polyethylene Terephthalate (PET), Polypropylene (PP), Polycarbonate (PC), HighDensity Polyethylene (HDPE) and Low-Density Polyethylene (LDPE) are presenting strong competition to the traditional concepts of packaging. Universal standards and compliances for establishing non-toxic plastic products, has not only brought down the overall cost of packaging, but also made it viable for safe transportation. Another advantage that keeps rigid packaging ahead is its tamper-proof characteristics. Consumers still do not trust packaged food items manufactured in India, which is in complete contrast with globally manufactured and packaged food. But with steadily increasing awareness, the demand is slowly increasing. Emphasis on zero-toxic, Bisphenol A (BPA)free products is ensuring healthy and hygienic products. “Availability of goodquality raw material, fully automated machines and hygienic manufacturing process are making plastics packaging a more suitable option for F&B industry. These factors are helping to change the psychology of the Indian consumers to wipe out apprehensions about canned food products. Today, it can be said that the Indian packaging industry adheres to international standards, as
many of them are Original Equipment Manufacturer (OEM) suppliers to world-class companies,” adds Singhal.
Hygiene standards Much attention is being given to preserving health, safety and hygiene of the product. A major challenge for the packaging industry is to retain the essence of the packaged food products. As these products are carving a niche in the Indian market, innovative ideas are being implemented to keep the flavour intact. Production companies are taking numerous steps to produce the goods in controlled environment, which results in reducing contamination. Provision of clean rooms is an evident example of the importance given to hygiene. Tetra packs, PP jars and containers, and many others have replaced the kitchen shelf, as they are much easier to maintain and have better shelf-life. “Till date, the emphasis of hygiene was laid only on the pharma sector, but today, we notice similar compliance for F&B packaging as well,” mentions Singhal.
Availability of good-quality raw material, fully automated machines and hygienic manufacturing process are making plastic packaging a more suitable option for F&B industry. These factors are helping to change the psychology of the Indian consumers to wipe out apprehensions about canned food products. Suresh Singhal Managing Director, Himalayan Group of Industries
Tackling the competition Plastics packaging is facing tough competition from conventional style of packaging such as glass and metals. Singhal laments, “The stigma attached to plastics due to its chemical composition and supposedly toxic ingredients is taking time to change. However, when it comes to plastics packaging, the pros outweigh the cons and the consumer is realising its benefits.” Other packaging manufacturers are vehemently pressurising the Government to ban plastic products for environmental reasons and trying to malign the plastics packaging industry, but with modern technologies and stringent regulation, care is being taken to provide environment–friendly, recycled raw material and low carbon emissions from the manufacturing units. Plastics packaging is now accepted globally in every sector, particularly in F&B packaging. Email: anwesh.koley@infomedia18.in
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MATERIALS: Flexible packaging
Respon ding fle xibly to custome r deman ds The cons u changing mption pattern s better qu substantially wit in India are h i n c r e a s i ality and greater demand for ng. Anw convenie the cons umption e s h K o l e y g a u nce packagi ges of rigid n among c g a n d i t s f a s t and flexible onsumer accepta s. nce
Courtesy: Hi Tech Polyflex Pvt Ltd
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lexible packaging finds varied usage owing to its ability to provide strength, moisture resistance, aroma retention, gloss, grease resistance, heat retention, sealability, printability and low-odour properties. Flexible packaging has gained vast acceptability because of the protection it offers to the product against environmental threats such as moisture, heat and chemical reactions. Convenience in handling the product and the cost benefits it provides are some of the added advantages. Nonetheless, plastics, which is the most commonly used substrate in flexible packaging, faces unfavourable situations because of environmental protection and disposal concerns. These issues act as a major impediment for flexible packaging that will become an all-pervasive medium. Moreover, flexible packaging mandates additional capital requirements
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and technical know-how for efficient manufacturing operations.
Current market condition Growing at a compounded annual growth rate of 17 per cent, the Indian flexible packaging market is one of the most dynamic and fastest growing sectors in the country. Sandeep Jain, Director, Hi Tech Polyflex Pvt Ltd, says, “As advantages of flexible packaging such as ease of handling and lesser storage space are increasingly appreciated, conventional rigid packaging will take a backseat. Also, flexible packaging scores over conventional packaging for reasons such as keeping the product away from adulteration and moisture, convenience of disposal and cost savings on transportation.” For a company to be successful in the Indian flexible packaging market, it needs to understand the end-user requirements and provide packaging materials that
Modern Packaging & Design July-August 2012
offer better barrier properties. Flexible packaging offers the advantage of packing smaller quantities as compared to conventional packaging, and hence middle-class consumers, who comprise a major section of the Indian society, have the choice of purchasing just the required amount of products. The flexible packaging market has received a leg up from growth in the processed food, personal care and hygiene industries as well as the the retail sector. “The demand for smaller packaging and increasing consumerism due to higher purchasing power also bodes well for the market. However, there is a lack of quality consciousness among end users, who tend to gravitate towards low-grade products, thus hampering the sales of quality flexible packaging. Processors can dig deep into this fragmented market by making consumers more aware of the advantages of flexible packaging, offering
Flexible packaging
superior-quality product lines and pricing their products more attractively,” adds Jain. Additionally, the existence of more than 800 processors in the Indian market creates a fiercely competitive marketplace, fostering price wars. The use of new polymers, which enhance the packaging requirements as well as facilitate innovative techniques for faster packaging, will help companies grow in the Indian flexible packaging market. With the advent of metalised films and other novel materials, the industry is looking at increasing the quality of the products, and thereby per unit sales. In fact, the market is expected to treble its output in the next seven years from 1,000 kilotonne in 2007 to 3,100 kilotonne by 2014 owing to the greater demand from the processed food, pan masala and other retail products.
The Indian packaging machinery exports are rapidly growing and India has emerged as a key importer. India’s per capita packaging consumption is less than $ 15 against the worldwide average of nearly $ 100. “The large growing middle class, liberalisation and organised retail sector are the catalysts for growth in packaging, while the food & pharma packaging sectors are the key drivers,” adds Jain.
Corrugated box packaging market Multinationals are demanding corrugated boxes of international standards and the buying pattern is changing rapidly. Prices of corrugated sheet and converted boxes have remained low due to over-capacity, manual operations and low productivity. Besides, transport constraints and high freight costs have meant that small- to medium-sized corrugated box plants are located near the customers.
Benefits of paper packaging Although substrates such as plastics have gained vast acceptability, attractiveness of paper and paperboard consumption remains high. Currently, India is ranked 15th in the world for its paper and paperboard consumption and is expected to improve its rank in the future. Paper is the fastest growing substrate segment with a growth rate of 6-7 per cent. The total demand for paper is currently estimated to be about 6 million tonne, of which about 40 per cent is consumed by the packaging industry. If the demand for paper continues to grow at the same rate, total paper consumption is expected to double by 2014.
India vis-à-vis global market Laminated products including form-fillseal pouches, laminated tubes and tetra packs are growing at about 30 per cent per annum. There are about 600-700 packaging machinery manufacturers, 95 per cent of which are in the small and medium sector located all over India. Germany and Italy are the latest suppliers of packaging machinery to India, but the focus is now shifting on Taiwan, Korea and China. Indian packaging machinery imports are at $ 125 million.
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Flexible packaging
There is a lack of quality consciousness among end users, thus hampering the
packaging. Processors can dig deep into this fragmented market by making consumers more aware of the advantages superior-quality product lines and pricing their products more attractively. Sandeep Jain / Â Â? [ ] }
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Currently, India has over 4,000 corrugated board and sheet plants, which are highly labour-intensive and employ over half a million people â&#x20AC;&#x201C; directly and indirectly. The industry is converting about two million tonne of Kraft paper into corrugated boxes. Factories are spread out in all parts of India, even in the remote industrially backward areas. â&#x20AC;&#x153;This present scenario is already being challenged by the sweeping changes that are beginning to take shape. More and more in-line automatic plants are being set up, as corrugated box makers gear up to meet the new demands for high-precision boxes with attractive graphics and large integrated production capacities,â&#x20AC;? adds Jain. In-line, automatic board and box making plants will ease out the present semi-automatic production processes. Deployment of folder gluers, rotary die-cutters will be on the rise, besides the use of corrugated sheets for display/ promotional packs, package-on-package solutions and dispensers. Advancements in multi-colour, flexo printing will facilitate
Modern Packaging & Design July-August 2012
in-house flexo printing and eliminate the use of screen printing, contract printing on offset presses.
The way forward The growing Indian middle class, along with the surge in organised retail in the country, is driving demand in the flexible packaging industry. Another factor that has provided a substantial stimulus to the packaging industry is the rapid growth of exports, which requires superior packaging standards for the international market. Moreover, in terms of the ease of use, flexible packaging offers greater flexibility to the consumer, and this has been accepted in the market. â&#x20AC;&#x153;A package must protect what it sells and sell what it protects. Modern methods of consumer marketing would fail were it not for the message communicated on the package. The information provided on packaging allows the consumer to make informed decisions on the productâ&#x20AC;&#x2122;s purchase and use,â&#x20AC;? concludes Jain. Email: anwesh.koley@infomedia18.in
MATERIAL: Inter face - APVS Chakravar thi
“Innovation is the key for success in the packaging industry” …believes APVS Chakravarthi, Managing Director, Ecobliss India Pvt Ltd. In an interaction with Anwesh Koley, he explains various trends in the high-visibility packaging segment and the challenges faced by the industry in India. How is the pharma packaging industry shaping up in India? There is no distinction between the packaging industries about whether they belong to pharma packaging exclusively or otherwise. But, many packaging companies maintain their exclusivity, contributing towards the pharmaceutical sector. This can be individual or a combination of two or more segments such as blister packs, vials, tubes, caps and closures, flow-fill seals, bottles for suspensions, tubes, blow moulded containers, thermoforming blisters and bulk drug containers, besides the regular printed boxes, labels, flexible laminates, etc. Many of the above segments cater to non-pharma industries such as Fast Moving Consumer Goods (FMCG) and electrical/electronics, but the packaging industries supplying to the pharma sector maintain their uniqueness because of the high standards essential to this application. Pharma packaging industry in India is growing by about 15 per cent as against 5-6 per cent annual growth rate in western countries. Although we still lag behind in producing the basic packaging materials for pharmaceuticals, the converting and machinery industry is poised to reach global standards.
What innovations has this segment witnessed over the years? While tremendous improvements have been made in developing new drugs and molecules, the packaging industry in India is still to match the pace of
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innovations happening in product development. Nevertheless, many significant initiatives have happened of late in packaging. The use of heavy drums that contribute to massive transport costs when shipped empty to the manufacturing company is minimised abroad. Polypropylene collapsible bags, with corrugated board lining have been extensively used outside India for carrying bulk drugs or intermediates. This trend is slowly being adopted in India as well. Similarly, packaging supplied to formulation industries has seen a dramatic development in the recent past to keep pace with global requirements. Smart packaging using Radio-Frequency Identification (RFID) technologies is set to grow in future with demand from the user industry. India has undergone a radical change in the last decade, with a dramatic improvement in consumer awareness. This paved a new era in primary packaging industry for pharmaceuticals to produce better patient-interactive packaging.
What R&D initiatives have you undertaken over the years? We understand that packaging is essential in capturing that ‘first moment of truth’. It takes only seconds for a consumer to notice a product on the store shelf. And that moment presents an incredible marketing and selling opportunity. Nearly 70 per cent of all purchase decisions are made at the shelf. Almost half of all
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packaged goods are sold without any additional marketing support. Considering the way conventional medical shops have transformed into organised pharmacies, the above statement holds true for pharma packaging. Providing innovations and appropriate solutions is the key to success in the demanding and ever-changing market of blister and high-visibility packaging. We must stay updated on key developments in blister and high-visibility packaging and share this knowledge with our customers in order to achieve breakthrough packaging solutions. Keeping in view the demand from the industry, Ecobliss has taken steps in developing seniorfriendly, child-resistant, tamper-evident and patient-interactive packs. All products made by us are compliant with global standards.
What are the challenges you face in India? Cost has always been a major challenge for Indian pharma packaging manufacturers. While standards must not be compromised below global levels, pharma industries in general are not really prepared to spend at the same level in India. Hence, it is always a usual challenge to balance both factors. Moreover, like in the industry (pharma) it caters to, packaging also is witnessing imitations and counterfeiting. However, final decision making rests with the industry and its consumers. Email: anwesh.koley@infomedia18.in
MATERIALS: Roundtable
India ride the wave of innovations in bioplastic packaging? Can
Bioplastic packaging is fast gaining ground globally with manufacturers as well as consumers realising extensive environmental and application advantages. Anwesh Koley gauges the views of some industry experts on the current state of bioplastic packaging in India as compared to the international scenario. Bharat Rastogi Director, Mono Plastic Industries Pvt Ltd
Indian packaging companies no longer lag behind international players in bioplastics packaging. Bioplastic materials are defined as materials that are biodegradable, compostable and derived from both renewable & non-renewable sources. Since 2010, bioplastics technology is changing, with commercialisation of bioplastics produced directly from natural or genetically modified organisms and introduction of non-biodegradable, bio-derived Polyethylene (PE). These materials are expected to account for a quarter of total bioplastics packaging market demand by 2020 across the world. Polyhydroxyalkanoates (PHA) are forecast to achieve a compounded annual growth rate of 41 per cent and bio-derived PE a staggering 83 per cent over the period. The marketshare of conventional bioplastics packaging technologies based on starch, cellulose and polyester are expected to decline by 2020. Further, flexible packaging is expected to capture a growing share of the bioplastics packaging market in India over the next 5-10 years.
Neeraj Garg Proprietor, Suruchi Industries
Various bio-based materials and their innovative applications in food-related packaging have gained attention over the past several years. These new materials include starch, cellulose and those derived from processes involving microbial fermentation. Bioplastics development efforts have focussed predominantly upon starch, which is a renewable and widely available raw material. As a packaging material, however, starchbased bioplastics is extremely brittle. Starch alone cannot form films with satisfactory mechanical properties, eg, high percentage elongation, tensile and flexural strength, etc, unless it is plasticised, blended with other materials or chemically modified. Common plasticisers include glycerol and other low-molecular weight poly-hydroxy-compounds, polyethers & urea. Starch-based thermoplastic materials have been commercialised over the last several years and currently dominate the market of bio-based, compostable materials. Food-related applications include films for food wrapping and thermoplastics for food packaging and other food containers such as plates, cups & egg trays.
Ravi Kumar Director, Shiv Pooja Plastics
The use of biodegradable materials in the flexible packaging industry is fast gaining interest. Although their use in the industry is still limited, the need to move in the direction of more ecofriendly packaging is acknowledged by both the consumers and the industry and new developments are moving ahead. Producers of films, inks, adhesives and resins are actively involved in research on new materials from renewable sources that are compostable, and whose disposal can limit their environmental impact. The physical properties of raw materials derived from various vegetable resources are different from those of conventional films. This has a bearing on their machinability, which is of primary importance to a converterâ&#x20AC;&#x2122;s operations. This has prompted global players in the packaging domain to test and show the capability of their printing and laminating machines to print and convert profitably such new materials, while also continue to improve the efficiency of the equipment in terms of more efficient and sustainable operations.
Editorial take: Email: anwesh.koley@infomedia18.in The Indian bioplastics industry is witnessing heightened activity due to its numerous benefits. While manufacturers might find it more expensive to opt for biodegradable packaging, what cannot be ignored is that the future of packaging will see increased bioplastics usage.
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MACHINERY: Robotic palletiser
Reducing downtime, enhancing precision In this age of extreme competition, the demand for reducing overall costs and enhancing the quality of products, has increased the need for automation in manufacturing process. In this backdrop, Avani Jain highlights the advantages of robotic palletisers for precision and safety in packaging operations.
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utomation and usage of robotics in packaging is a growing trend, as it ensures better productivity and efficiency through a combination of speed & accuracy. Over the past few years, packaging technology has undergone a remarkable change, due to the rising awareness of the Indian consumer. The modern Indian consumer looks to buying quality products that are attractively packaged for hygiene and safety. This can be ensured by using robotics in packaging. With the introduction of new robot system technologies, manufacturing is continually undergoing major changes. One area, in particular, where measurable savings are seen is in the automated palletising of products in all shapes, sizes and weights. Khalil Nathani, General ManagerOEM, Rockwell Automation India Pvt Ltd, says, â&#x20AC;&#x153;In order to differentiate their products, manufacturers need to continuously innovate, which is impacting their product life cycles. Globalisation has thrown in several competitiveness challenges. Also, a surging middle class is driving demands, and manufacturers have to continuously scale up to seize this opportunity. Manufacturing assets that are highly productive and versatile to adopt
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changing products are the order of the day, and packaging industry is no exception to this. Speed, accuracy/consistency, flexibility to manage a variety of products are some of the common requirements across all packaging machinery. Thus, automation and robotics play a pivotal role in meeting all these requirements of modern manufacturing industries to enhance their business performance.â&#x20AC;?
Robotics in packaging Robotic palletisers have evolved rapidly over the last few years. Nathani avers, â&#x20AC;&#x153;Earlier, robots were used only to perform high-speed repetitive tasks to increase productivity. But, the evolution of vision systems and precision actuation systems, and the convergence of these technologies with kinematics have impacted the intelligence and application of robots across various industries. Further, flexibility in selection of pay load, reach and duty of the robotic arm combined with integration of vision system and selection of choice of end effector has opened up tremendous application avenues in packaging, as they handle infinite possibilities of product types and the need for orientation of product in packaging process. Further, reduced cost of acquiring the robotics technology
Robotic palletiser
is opening commercial feasibility for numerous applications.”
manufacturers to produce more in the same time, thereby impacting the efficiency of their manufacturing asset.”
Advantages of robotics Robotic palletisers alleviate the need for manual stacking of bags, cartons or drums onto a pallet. These are also used for increasing end-of-line productivity and improving the presentation of stacked pallets. These are suited to applications involving production from one, two or more lines where flexibility is required and space is premium. In most cases, a robotic palletiser provides a better alternative to manual palletising technology due to many factors such as increased output, continuous and automated monitoring of operations, safer working environment, less damage due to smoother bag handling, flexibility to handle a large range of products, adaptability to new processes, reliability and measurable Return on Investment (ROI) within two years. Nathani notes, “Robotic palletisers offer flexibility to change form and matrix of product to be palletised with least effort, thus ensuring flexibility to pack a variety of products with the lowest downtime to set the machine for product change. Further, higher throughput can be achieved as a result of optimum path control algorithms and higher speeds of operation. The robotic palletisers also ensure consistent delivery with high precision and ensure best-quality packing and reduced product rejections.”
Productivity enhancement In the last few years, the flexibility, speed, payload and reach of the robots has increased, and this has resulted in increasing the productivity. Nathani says, “Advanced optimum path control algorithms enable robots to travel optimally from one point to another with coordinated movements of multiple axes with the shortest path, which reduces the stroke length and, in turn, the cycle time for every pick & place. Moreover, the use of high-speed AC synchronous motors ensures faster traversing speeds, further reducing cycle time. This helps
Better precision and safety Of all benefits offered by a robotic palletiser, precision and safety assumes much importance. Nathani notes, “Robots use multiple close-loop AC Synchronous motors working in coordination to achieve a motion. Close loop motor offers capability to control the position precisely, ensuring that the product is placed on the pallets accurately in a programmed matrix consistently. Further, advancement in actuation technologies has generated capability in the end effectors, which grip the product to apply precise pressure consistently to avoid any damages to the product. Also, a vision system adds visualisation capability to orient the product and place it in a desired order on consistent basis.” He adds, “Manufacturers strive for risk-free work environment by ensuring safety to human, asset and product. Modern control systems used for controlling the robots integrate safety control features such as safe off, safe speed and safe networks ensure all safety requirements for a safe & productive manufacturing environment.”
Solutions for efficiency With advancements in robotics in the 21st century, many packaging companies are turning towards the use of a robotic palletiser. The obvious benefit is an improved efficiency, and therefore, greater profit. The robotics has been specially modified to approach the high-speed performance of conventional palletisers. Based on the robotic palletiser’s ease of operation, flexibility and repeatability, it can become a key factor in a plant’s ability to achieve the objectives of their project. The only requirement is having a trained systems integrator on staff with a background in robotics. The preliminary difference in the cost of the two systems (robotic versus non-robotic) is rapidly moderated by the repeatability, accuracy, handling of products and reduction in
Earlier, robots were used only to perform high-speed repetitive tasks to increase productivity. But, the evolution of vision systems and precision actuation systems, and the convergence of these technologies with kinematics have impacted the intelligence and application of robots across various industries. Khalil Nathani General Manager-OEM, Rockwell Automation India Pvt Ltd
on-going operating costs, making the robotic palletiser an obvious choice.
Future trends The usage of robotics in palletising will definitely increase in the future. Nathani concludes, “As manufacturers adopt highly productive technologies such as robotic palletisers, their next challenge will be to integrate this highly capable machine with proceeding and succeeding machines in the line to impact the overall equipment effectiveness. The line balancing system needs to provide capability to avoid flooding and starving of products by controlling the in feeds to individual machines by using advanced control algorithms. This is expected to reduce wear and tear due to sudden starts & stops of machines, running the machines to match with optimum line speed requirements, thus saving energy and creating a greener footprint.” Email: avani.jain@ infomedia18.in
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MACHINERY: Conveyor technology
Conveyi ng flexibilit y and speed With line c impor tan ontrol and autom c industr y, e in the bevera ation gaining ge pack integrate a has rec eived m d conveyor techn ging u present s ology ch atten c look at e enario. Avani Jain tion in the ff its advan icient conveyor t takes a closer e tages of speed an chnology and d flexibil ity.
Courtesy: KHS GmbH
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obility simplifies and improves our everyday life. Similarly, conveyor applications keep the industry moving right along. Whether used in a specific production process for further processing, storage or delivery, the focus is always the same, ie, conveyors need to span the distance efficiently and transport items as quickly as possible from one point to another. A reliable conveyor technology is the backbone of efficient packaging. So critical is its role that it can be compared with the structure of human body, where conveyors act as the arteries and veins of the production line and the filler is the ‘heart’ of the system.
Moving along the beverages segment The conveyor technology assumes much importance in packaging, especially beverage packaging industry. If utilised correctly, it can be exploited to raise line
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efficiency to a whole new level. Over the years, many developments have been made in the conveying systems so as to ensure flexibility and speed. Eike-Sebastian Hagen, Executive Vice President-Operations, KHS Machinery Pvt Ltd, says, “The choice of right conveyor system is essential to achieve the required line performance. Only the correct conveyor layout with proper buffers allows line running at its highest efficiency. Hence, the correct conveyor system is not a question of advantage or disadvantage, but it is essential for the required line performance.” He adds, “In the beverage industry, we use container conveyors [with belt or air conveyors for empty Polyethylene Terephthalate (PET) bottles], pack conveyors and pallet conveyors. All these conveyors connect the individual machines of a beverage line. Furthermore, conveyors work as a buffer to ensure that the line still runs
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in full speed when one of the integrated machines runs with a lower speed for a certain period.”
Evolution of the technology Over the years, conveying systems have undergone various changes. Hagen notes, “At present, conveyors run with low energy consumption thanks to variable centralised or decentralised drive concepts with high-efficiency drives (premium efficiency). At KHS, we also design low-noise conveyors. Advancements have also been made in developing conveyor systems for conserving resources with intelligent, energy-saving belt lubrication systems. Further, lot of changes are being made to ensure that the operation of conveyor systems can be consistent and practically maintenance-free. Also, long-lasting conveyor systems have appeared in the market, thanks to stable
Conveyor technology
waste, energy consumption and rejected packages. An ergonomic design enhances worker safety and reduces repetitive motion injuries and other hazards.
Enhancing speed and flexibility
The choice of right conveyor system is essential to achieve the required line performance. Only the correct conveyor layout with proper buffers allows line running at its highest Eike-Sebastian Hagen Executive Vice President-Operations, KHS Machinery Pvt Ltd
design and high-quality materials used in their manufacturing.â&#x20AC;?
One solution for multiple issues The use of integrated conveyor technologies offers numerous benefits and is equally important to address many of the general production issues and trends pertaining to packaging line changeovers. The larger-scale obstacles that can be addressed with conveyor add-on solutions include new packaging technology, new packaging materials and just-in time inventory management. With regard to changeover efficiencies, the conveyor plays a crucial role of transferring products from one location to another effectively, without causing harm to the product or workforce in the process. In the converting operation, there are many ways by which conveyors can aid processors in reducing changeover times. From an economic point of view, automation of conveying operations enables packaging solution providers to achieve the required throughput volume and competitive consistency. Advanced monitoring and control capabilities enable them to maintain higher up-time for their packaging lines and reduce packaging
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Conveying means transporting goods or products horizontally or vertically from one place to another. When spanning the distance, the goal is to move the objects as quickly and reliably as possible since transport time is actually unproductive time. Personnel safety is another important issue. If the conveying process is integrated into a uniform operator control and automation system, it is possible to achieve a markedly higher throughput at the end of the line. Hagen details, â&#x20AC;&#x153;All processes and components in a turnkey system must mesh perfectly to enable the machines to run at optimum ability. The integrated conveyor technology can help arrange the production to avoid inefficient stop-and-go operation in the filling or packing line and enable maximum system performance while, at the same time, minimising machine stoppages.â&#x20AC;? He adds, â&#x20AC;&#x153;KHS provides conveyor systems in a modular design. This allows us to provide the perfect layout for any customer and react flexibly to individual demands of each customer. The correct design of the line layout allows the customer to run his line with maximum flexibility and highest efficiency.â&#x20AC;?
Improving line efficiency There are two essential considerations for achieving good line efficiency. One is through the design of the conveyor layout as a people-friendly design essentially manages man and material movement & reduces stress for operators, while a machine-friendly design layout helps in supplementing machine performance. Further, the conveyor technology is important for line control and modulation. Line control and programming takes into account different scenarios based on inputs from performance of the machine and sensors placed at key points throughout the line.
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Hagen details, â&#x20AC;&#x153;Only components that are perfectly aligned with each other can turn the sum of individual machines into a reliable and, above all, high-performance and energy-efficient system. Acting as a reliable link between the individual production machines, conveyors provide continuous and flexible supply of the required containers. Combined with a specialised system control that helps to configure the production in order to avoid an inefficient stop-and-go operation, the conveyor systems developed by our company helps in achieving maximum performance with minimal machine downtime.â&#x20AC;?
Imparting total excellence A correct conveyor system design allows the bottler to reduce downtime, rejections, maintenance cost in spares and high wear & tear of parts. It gives bottlers the opportunity to truly automate their line, thus minimising the number of operations. Further, good conveyor systems help in achieving greater productivity and increased profitability with an integrated product portfolio and comprehensive solutions. These help in lowering operating costs through targeted minimisation of energy requirements. All these finally equate to a sizeable savings for the business. Thus, conveyors as a total system can, and is, as complex and equally rewarding as any other packer machine on any other line. Hence, bottlers must ensure that it always flows smoothly. This can be done seamlessly using the correct design, materials and smart programming.
Future trends The future trends would include decentralised control systems to ensure that the customer can arrange each individual transport segment separately, and that the customer has flexible control. Also, conveyor systems designed for optimum cleaning, with different hygiene designs that can adapt to all requirements, would be another trend that will surface in the time to come. Email: avani.jain@infomedia18.in
MACHINERY: Inter face - Avra Mitra
â&#x20AC;&#x153;The world leaders in flexible packaging machinery segment are entering Indiaâ&#x20AC;? â&#x20AC;Śopines Avra Mitra, Senior Manager-Key Accounts, Business Unit-Web Fed, Bobst India Pvt Ltd. In a candid conversation with Avani Jain, he underlines the growth and opportunities for the flexible packaging machinery segment in India, as well as the recent trends and challenges.
How is the demand for flexible packaging/converting machinery in India? With the demand for flexible packaging increasing in all segments of population, demand for primary flexible converting/ packaging machines is growing constantly in double digits. Due to various economic opportunities, which are enhancing the purchasing power of people, they are now buying from retail outlets demanding small sachets of oil and ghee, biscuit packets, etc. These sachets and pouches are a part of flexible packaging. This is one of the factors indirectly driving the demand for flexible packaging and the allied machinery segment in India. Further, the increasing disposable income of the rising middle class has increased the demand for flexible packaging. The growth of processed food industry has propelled the growth of flexible packaging market in India. Another factor driving industry growth is the fact that per capita consumption of flexible packaging is still lower in India as compared to other countries such as the US. Thus, there is a long way to go and the future of flexible packaging machinery segment is bright, although few negative factors such as a ban on
plastics usage in packaging of chewing tobacco will only affect one type of flexible packaging and machinery market. For the rest, there will be no change and the demand for flexible packaging machinery will increase significantly.
What are the recent trends in this segment? In terms of flexible converting/packaging machines, companies today are set to shift from conventional technologies to digital printing machines for flexible packaging. Another trend is that all leading technology providers are developing new technologies for energy optimisation in primary machines. Companies are also trying to move towards building energy-efficient systems for their machines. They are working on recycling of solvents and making the machines more compact.
What are the opportunities and challenges in this segment? The increase in domestic demand for flexible packaging is driving the growth of the flexible packaging machinery segment in India. Lower cost of labour is also a plus point. Today, the world leaders in flexible packaging machinery
segment are entering India and starting new projects or plants in the country. They are either starting a subsidiary or forming a joint venture to establish their operations in India. These companies are also bringing with them new technologies and experience. Medium-scale enterprises in flexible packaging are also investing in new technologies and machines and moving up the value chain. Fluctuation in the prices of raw materials, such as polyester, biaxially oriented polypropylene and polyethylene, is indirectly affecting the flexible packaging machinery business. Lack of skilled manpower to operate these machines effectively is another concern.
What is the future of the flexible packaging machinery segment? Looking at the current trends such as consistent growth of the processed food industry, flexible packaging is the cheapest & most convenient form of packaging. This will drive the demand for flexible packaging machinery. Also, with foreign direct investment in retail, the demand for flexible packaging and the allied machinery business will further increase exponentially. Email: avani.jain@infomedia18.in
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MACHINERY: Inter face - Yatindra R Sharma
“The demand for total quality solutions is increasing” …asserts Yatindra R Sharma, Managing Director, KHS Machinery Pvt Ltd. In a tête-à-tête with Avani Jain, he highlights various growth opportunities for the beverage packaging industry in India, while underlining the need for innovative packaging solutions in the beverages sector.
How is the demand for packaging machinery, especially in the beverages sector in India? The Indian market is growing at a rapid pace, particularly the beverage sector. Each segment of the beverage sector, ie, water, juices, soft drinks and beer, has seen double-digit growth in the last 4-5 years. Thus, there is volume growth, which means that the business of beverage packaging machinery is promising. Further, the food industry is growing at a fast pace, and this is boosting the growth of the allied packaging machinery.
What are the key growth drivers for the industry? The major growth driver of the packaging machinery industry is the demand for costefficient technology, with strong project management. All players in the food and beverage sector are currently looking for single-window solutions where they can give complete project to one provider along with full responsibility for execution. This phenomenon will become more prominent in future. Hence, companies in single machine manufacturing will have to graduate to the level of providing total solutions in terms of technology, operational capability, installation/
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commissioning project management, troubleshooting, etc. Thus, the packaging machinery manufacturers are looking for indigenous innovations and international partners to provide such solutions and execution capabilities at lower costs.
packaging machinery industry. Thus, the packaging machinery industry must look into these aspects and provide innovative solutions that are durable and economical.
What are the leading innovations in the sector?
The demand for total quality solutions approach is a challenge for packaging machinery providers who have to pay more attention to quality and workmanship of machines. They also have to compete with international players like China, Italy and Spain in terms of degree of automation & reliability of machines.
With regard to various segments in the beverage sector, eg, soft drinks, we are looking at some revolutionary solutions in the Polyethylene Terephthalate (PET) space, eg, light-weighting, highproductivity machinery, etc. Further, aseptic packaging of juices is now done in paper cartons, ie, tetra packs. Soon, we will see ultra-high temperature and flavoured milk in plastic bottles. The beer industry has undergone a revolution in using light-weight glass bottles, thus increasing the brew house production capabilities, thereby increasing capacity of their packaging lines from 18,000 bottles per hour to 36,000 bottles per hour. A lot of changes are happening in the spirits industry, with decoration of bottles gaining importance. Thus, each sector is expanding in terms of variety of products available and solutions. These changes are driving innovations in the allied
Modern Packaging & Design July-August 2012
What are the challenges facing the packaging solutions provider?
What are the recent Research and Development (R&D) initiatives in your company? We align ourselves with our global R&D capabilities. We are constantly involved in providing technologies, which are demanded by the Indian market. We are currently developing the aseptic packaging technology for milk, which will be on ground by 2013. We are also looking at high-capacity packaging solutions for various segments in the beverages sector, besides developing form-fill-seal technology for powders and liquids. Email: avani.jain@infomedia18.in
LOGISTICS: Packaging for cold chain
Innovations for effective storage and transport India’s logistics infrastructure, particularly its cold chain industry, has caught the attention of the packaging sector owing to a surging retail industry. As Indians demand better quality fresh foods and readyto-eat meals on the retail shelf, Annabel Dsouza probes packaging solutions complementing conventional cold chain systems in India.
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ackaging has a significant impact on the efficiency and effectiveness of retail supply chains, where efficiency can be achieved through adaptation and development of packaging solutions that are compatible with logistics systems. Packaging also affects supply chain effectiveness because it represents an interface between the supply chain and its main customer. This is especially evident in complex supply chains, which are fast putting fresh foods and perishables onto the retail shelf. Fresh and ready-to-eat convenience food products are an emerging trend in urban Indian lifestyle. Products such as pre-cut fruits & vegetables and ready-to-cook meals require an intricate cooling chain, exclusive distribution within a limited regional area or the use of Modified Atmospheric Pressure (MAP) technology. Although processed and packaged food is highly popular in the Indian retail space, the industry has to ensure futuristic processing and packaging solutions for quality & safety of the end-user. To ensure that products are not damaged or compromised throughout this retail supply chain, the food and pharma industries are increasingly adopting cold chain technology.
Modern Packaging & Design July-August 2012
RVS Ramakrishna, Group President– Signode India, China & MEA, ITW India Ltd, says, “Cold chain logistics system may be defined as a series of inter-related facilities for maintaining ideal storage conditions for perishables from the point of origin to point of consumption in the food supply chain. The chain starts at the farm level (harvest methods, post-harvest and pre-cooling) and continues till the consumer or retail level. A well-organised cold chain reduces spoilage, retains the quality of harvested products and guarantees cost-efficient delivery to the consumer. And, packaging forms an integral component of the cold chain industry.”
Cold chain technology Temperature control in the shipment of foodstuffs is a component of the industry that has continued to rise in sync with international trade. As India focusses its export economy on food production, the need to keep these products fresh for extended periods has gained importance. Increasing income levels create a change in diet and a growing appetite for fresh fruits and higher value foodstuffs such as meat & fish. Ramakrishna highlights, “With increasing purchasing power among India’s surging middle class,
Packaging for cold chain
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The proportion of products packaged for cold chain systems at Indian ports has constantly increaseddue to various trade liberalisation policies, increasing containerisation in general cargo commodities such as durables, engineering components, machinery, auto components, food products and apparels. Value-added goods are expected to increase, which will enhance the need for more secure containerised transport. Containerised transportation will also be driven by rising international trade, increasing investments in port infrastructure by the Government and through Public-Private Partnerships (PPPs). The cold chain industry is also expected to grow at double-digits owing to organised retail and growth in the processed food sector. Ramakrishna concludes, “Ever since its advent in India, packaging logistics has been dominated by small players with small capacities and poor deployment of handling, stacking & monitoring technologies. While it has received a lukewarm response from almost all sectors, the food and pharma sectors have welcomed innovations in packaging logistics, and have bolstered investment in cold chains & allied machinery.” Email: annabel.dsouza@infomedia18.in
tes y
The road ahead for India
Ever since its advent in India, packaging logistics has been typically dominated by small players. While it has received a lukewarm response from almost all sectors, the food and pharma sectors have welcomed innovations in packaging logistics, and have bolstered low investment in cold chains & allied machinery.
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Quilts: These are insulated pieces placed over or around freight to act as buffer during temperature variations and to maintain the temperature relatively constant. Thus, frozen freight will remain frozen for a longer period, often long enough not to justify the usage of more expensive refrigeration devices. Quilts can also be used to keep temperature-sensitive freight at room temperature, while outside conditions can substantially vary. Reefers: It is a generic name for a temperature-controlled container, which can be a van, small truck, a semi or a standard ISO container. These containers, which are insulated, are specially designed to allow temperature-controlled air circulation maintained by an attached and independent refrigeration plant.
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individuals with higher socio-economic status and more economic means are likely to consume vegetables and fruits, particularly fresh, not only in higher quantities but also in greater variety.” A core component of the success of an ideal cold chain is the type of container used and the refrigeration method. Factors such as duration of transit, size of shipment and ambient or outside temperatures are important in deciding the type of packaging required. These can range from small insulated boxes that require dry ice or gel packs, rolling containers, to large plastic trays with self-sustaining powered refrigeration unit. Some major cold chain packaging technologies are: Dry ice: Solid carbon dioxide, is about -80°C and keeps a shipment frozen for an extended period. It is used for shipping of pharmaceuticals, dangerous goods and foodstuffs. Dry ice does not melt, but sublimates upon contact with air. Gel packs: Large shares of pharmaceutical and medicinal shipments that are chilled products, must be stored at 2-8°C. Common method to provide this temperature is by using gel packs, or packages that contain phase-changing substances that can convert from solid to liquid and vice versa to control an environment. Depending on the shipping requirements, these packs can either start off in a frozen or refrigerated state. Along the transit process, they melt to liquids, while simultaneously capturing the escaping energy and maintaining an internal temperature. Eutectic plates: Its principle is similar to gel packs. Instead, plates are filled with a liquid and can be reused many times. Liquid nitrogen: An especially cold substance, of about -196°C, used to keep packages frozen over prolonged periods; mainly used to transport biological cargo such as tissues and organs. It is a hazardous substance for transportation.
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LOGISTICS: Reverse supply chain
Opening for reus avenues packagi able ng As the I advant a ndian industr y ges of realises r cost ef f iciency ever se logistic the s Annabel Dsouza t a n d s u s t a i n a b f o r innovativ i a e packa kes a closer loo l i t y, playing g k at in g desig a commerc vital role in the ns that are ial viabil s ity of this uccess and concept .
Courtesy: LINPAC Packaging
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s innovations in the packaging industry evolve with the demands of the Indian consumer, a leading trend is sustainability and resource conservation. Reverse logistics is among the most important practices that is driving innovations in the world of logistics. Reverse logistics can be defined as the process of planning, implementing and controlling the efficient, costeffective flow of raw materials, in-process inventory, finished goods and related information from the point of origin to the point of consumption in order to conform to customer requirements. Packaging and logistics have a longstanding relationship and contribute to innovations and commercial viability of one another. In the field of reverse logistics, packaging plays a critical role during asset collection. Whether consumers are shipping goods back to the manufacturer for return, repair or
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end-of-life disposition, packaging plays an important role in reducing the risks of damage and theft. Reverse logistics is more than just reusing containers and recycling packaging materials. Remanufacturing and refurbishing activities may also be included in the definition of reverse logistics. Redesigning packaging to use less material or reducing the energy and pollution from transportation are important aspects of the reverse logistics supply chain.
Profits through packaging Joseph Ringwood, Chief Operating Officer, Systech International, says, â&#x20AC;&#x153;With the credit crunch putting pressure on the bottom line, packaging manufacturers are adopting the practice of Returnable Transit Packaging (RTP). This is particularly true for defective or end-of-life electrical and consumer goods, which are quickly lost or become
Modern Packaging & Design July-August 2012
obsolete in the return supply chain. This minimises the opportunity to return them to the market place and forces them into global markets with long and complex distribution networks, or even, into the scrapheap. To what extent businesses are able to recover from these potential losses depends on the speed and effectiveness of their reverse logistics management.â&#x20AC;? It is estimated that as much as 70 per cent of the potential market value of these goods is lost as a result of poor management. This level of loss in the return supply chain is clearly not acceptable in the current economic climate, especially since it is easily preventable. Here, packaging plays a vital role in optimising efficiency. This calls for packaging systems that are: Locked to ensure against theft Sealed for quick visual inspection for signs of tampering Serialised or bar coded
Reverse supply chain
Configured with sufficient padding for laptops, CPUs or other data devices sent on site ahead of pickup for either do-it-yourself packing or for a service to prepare assets for shipping A package change may occur due to archaic design, or a change in the size of the product. This is particularly true with grocery items, where customers may be conditioned to a specific price for the product. Rather than increase the price of the package, manufacturers may keep the price constant by reducing the amount of product in the package, keeping the size of the packaging unchanged.
Reusable corrugated packaging The efficiency of a successful return supply chain depends significantly on the usage and impact of transportation packaging, pallets, drums, corrugated boxes, etc. Although sustainability is a cause of concern, returnable transport packaging offers more economic benefits than conventional methods. Reusable containers are generally more expensive than single-use packaging. However, if a reusable container is reused multiple times, the per-trip cost of the reusable container quickly becomes less expensive than the disposable packaging. Corrugated containers are light-weight, strong, easy to handle and inexpensive and have set the standard for all other packaging designs. However, the corrugated packaging industry in India finds itself at the crossroads. Increasing prices of kraft paper, non-availability of international standard papers at affordable prices, resistance of corrugated box user industry to offer sustainable prices, increasing competition, nonviability of automatic plants are proving to be hurdles in the growth path. Despite these adverse circumstances, the industry is at an advantage in overcoming India’s advancements in reverse logistics. As global companies set up their manufacturing bases in India to meet the growing demand for consumer and white goods, the need for
high-quality boxes is evident. Progressive corrugated manufacturers are setting up automatic board/box-making plants to increase production and enhance performance of boxes. In-house printing on corrugated board is becoming an imperative.
Advantages of returnable packaging One of the major reasons why companies consider reusable transport packaging is to save on the purchase and disposal costs of disposable packaging. In addition to a lower per-trip cost, reusable packaging may provide better protection for the products being shipped. It also provides the user with considerable future flexibility. Transportation costs are a major stumbling block to reusable containers, as these tend to be heavier than the corrugated materials that these replace. Ringwood asserts, “Because shipping costs can be weight-related, this translates into higher outbound transportation costs. If trucks ‘weigh out’, that is, they are filled to their maximum weight limit, the extra weight of reusable containers means that fewer units can be put on each truck, which also means higher shipping costs. Reusable containers often offer an ergonomic advantage over disposable containers. Most collapsible plastic containers offer a drop-down panel in one side of the container.” Given the high initial investment required for reusable containers, being able to get the containers back is critical. If a reusable container programme is designed to operate only within the area near a facility, getting the containers back is not difficult. Transportation costs should not outweigh the material savings from the programme. However, if the partners are far-flung, the reverse transportation costs may be prohibitively high, and hence render the programme uneconomical. Ensuring that the containers are returned may prove more difficult as the distance increases.
Forward turn As the Indian industry realises the
With the credit crunch putting pressure on the bottom line, packaging manufacturers are adopting the practice of Returnable Transit Packaging (RTP). This is particularly true for defective or end-oflife electrical and consumer goods, which are quickly lost or become obsolete in the return supply chain. Joseph Ringwood q Systech International
advantages of reverse logistics and its implications on the packaging industry, product manufacturers and packaging convertors are striving to overcome the hurdles in infrastructure and policy making. With the multidirectional supply chain as the focal point for delivery, consumption and packaging recovery is increasingly becoming the consumers’ home. This relationship has the potential to shift economic, environmental and social responsibility away from the industry towards the consumer. Ringwood concludes, “Industrial cooperation to implement the right conditions at the start of the packaging supply chain will assist the consumer to act with environmental responsibility. While the efficient handling and disposition of the returned product is unlikely to be the primary reason on which a company competes, the packaging industry can make a competitive difference.” Email: annabel.dsouza@infomedia18.in
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LOGISTICS: Inter face - Frank Oliveri
“We must look at packaging logistics to develop operative frameworks for optimal practices” …asserts Frank Oliveri, Vice President-Marketing, Packaging Resources Group, MeadWestvaco. He highlights the intense synergy between packaging and logistics systems in order to deliver value throughout the retail supply chain, in an e-interview with Annabel Dsouza. How does packaging contribute towards an efficient supply chain network? In the past 15-20 years, cost-effectiveness and environmental efficiency have received much importance in corporate decision making. In the field of logistics packaging, be it industrial transportation or consumer packaging, manufacturers make crucial decisions in order to determine the optimal packaging expenses. This decision situation practically means the one-way and reusable (disposable versus returnable packaging) mechanism between packaging systems. Globally, businesses are trying to integrate the difference between these two systems, and there are unique peculiarities. We must look at the factors effecting packaging logistics not only to provide us with a primary or definitive solution, but to develop operative frameworks for optimal practices. Environmental regulations in the last few years have increased the importance of efficient packaging and logistics systems.
What are the recent packaging innovations in the logistics sphere? Following are some of the major criteria for innovations in packaging logistics: Shrinkage - Pilferage, physical damage and theft
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Packaging cost - Optimum packaging levels, based on logistics conditions Inventory - Effective labeling and tracking for supply chain visibility Green supply chain - Applying the reduce–recycle-remove–renew template Yield levels - Product yield levels to consumers at the consumption point
How can packaging be designed for sustainable logistics? The design safety factor that we currently follow is at least 2-3 times higher than that in other developed or developing markets due to poor logistics conditions. This can be improved by better investment and logistics infrastructure. Packaging in India is historically designed for manual handling in a multilayer distribution model. Once a retailer-driven supply chain process evolves, organised logistics service providers will evolve and bring standardisation of practices and investments in logistics infrastructure. These will facilitate bulk/palletised shipments and help manufacturers optimise packaging design. Logistics service providers will be able to consolidate the minimum order quantity at Stock Keeping Unit (SKU) levels and aggregate the same from different manufacturers through effective
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milk run in clusters. Through effective use of supplier relationship management software tools supported by track and trace tools, an effective retailer-driven supply chain can be designed from the current manufacturer-driven operations. Shelf-ready packaging at source in manufacturing lines is another huge opportunity for removing pack duplications. If done at the last mile close to the retailer, this will help improve kitting and bundling cost & efficiency. The returnable, mix-load bulk packaging solutions can be improved between distribution centres and stores, thus reducing packaging & handling costs.
How do you perceive the progress of Indian packaging industry in the global arena? India is a dynamic market for the entire world across industries, particularly the retail market and its growth implications on advanced packaging. Owing to poor infrastructure and capacity constraints, Indian convertors have to adopt relatively higher safety margins. However, as the Indian consumer becomes more quality conscious and less price-sensitive, one can perceive immense growth opportunities in terms of innovations as well as volumes. Email: annabel.dsouza@infomedia18.in
LOGISTICS: Roundtable
How can the packaging industry overcome the logistic challenges posed by
Indian infrastructure? While the crucial relationship between packaging and logistics operations has been established in recent times, the vibrancy of both industries in India depends on infrastructure developments. Annabel Dsouza takes a closer look at the challenges and opportunities before the Indian packaging industry owing to India’s fast emerging infrastructure.
A K Kohli Executive Vice Chairman, Vikram Logistic and Maritime Services Pvt Ltd
The logistics industry in India is evolving rapidly and it is the interplay of infrastructure, technology and new types of service providers that will define this industry’s contribution towards economic development by reducing logistics costs and providing effective services. A key partner of the logistics sector is the bulk packaging industry. Logistics costs (inventory holding, transportation, warehousing, administration, etc) have been estimated at 13-14 per cent of India’s Gross Domestic Product (GDP). The logistics costs can be reduced through packaging innovations such as flexible bulk packaging and corrugated palletisation. Inadequate logistics infrastructure creates bottlenecks in economic growth. Effective logistics management can overcome the disadvantages in the short term, while providing cutting-edge competitiveness in the long term. This can be compensated by innovations in the packaging technology to adapt to the transient changes in Indian infrastructure.
Ian Heyting Operations Manager, Packaging Logistics International
Packaging has a significant impact on the efficiency of logistics systems and activities such as manufacturing, distribution, storage and handling throughout the supply chain. However, many packagingdependent costs in the logistics system are frequently overlooked by packaging engineers. The growth and competence of the global packaging industry depends on a two-pronged development strategy of converting innovations & dynamic logistics infrastructure. In shipping objects to another location, packaging ensures it arrives safely and intact. Irrespective of the medium of transport, ideal packaging depends on the product involved, nature of shipping and destination it is headed towards. The quality and durability of various packing materials used and the correct carton type & size will assure the client that there are no mishaps between sending and destination.
Sandeep Singh Director-Operations, CAS Packaging India Pvt Ltd
Logistics is a critical component relevant across agriculture, manufacturing and service sectors and has to be optimally managed for smooth functioning of production & distribution. With rising competition within these sectors, it has become even more important to enhance the efficiency of the system in increasing manufacturers’ competitiveness. Given India’s fledgling status in inf rastructure development, packaging innovations are a crucial value addition to the progress and prosperity of the logistics industry. The industry in India is dominated by the unorganised segment; the organised segment accounts for less than 10 per cent of the total logistics market in India. Various value adding services are available, such as packaging, labeling, cross-bundling, track and trace, which are common irrespective of the mode of transport, besides some special services such as express and cold chain systems.
Editorial take: Email: annabel.dsouza@infomedia18.in Packaging innovations compensate for lack of adequate infrastructure development in India and boost the competitiveness of the nation’s logistics industry. Bulk packaging innovations such as FIBC and corrugated palletisation will play a pivotal role in delivering value at the end of the supply chain.
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SAFET Y: Fresh food packaging
Aseptic solutions for the retail shelf The consumer shopping dynamics in the urban scenario has changed, with consumers now looking for convenient as well as cost-effective food packaging solutions. Lionel Alva assesses how aseptic filling and sealing solutions are setting a new paradigm in retail.
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ith retail shopping becoming the hallmark of the urban consumer lifestyle, there is a need to look at a viable solution for food packaging that allows it to remain on retail shelves for a long time without quality degradation. Especially for delicately processed foods and fresh food, it is essential to look at solutions beyond canning or bottling. While aseptic food packaging solutions are more expensive than conventional methods such as canning and bottling, it has an advantage because the process of sterilisation allows the packaged food to retain the colour, texture, taste and nutrition more than it does when subjected to more heat-intensive conventional methods used in canning & bottling. The products also offer more convenience, not only because they can be stored in the pantry unopened, but also because leftovers can be refrigerated in the same package without the risk of spilling, discolouration or the ‘tinny’ off-flavours caused when oxygen reacts with the metal cans. “Aseptic packaging solutions have lesser deterioration compared
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to conventional processes such as bottling and canning. While they may be comparatively more expensive to produce, they make up for it by offering better food preservation quality, while retaining the original flavour and nutritional characteristics of the food items. However, with the advent of thin-walled containers, it has become a far less expensive proposition to produce high-barrier, multi-layer films for aseptic packaging,” avers Neelesh Atasniya, Chief Marketing Officer, Avonflex.
Advantages of aseptic packaging Aseptic filling machines are designed to utilise minimal energy and ensure pre-sterilisation of the food before the filling process begins. The process ensures that the flavour and nutritional components of the packaged food are maintained. Following are the three main advantages of using aseptic packaging technology: Packaging materials that are unsuitable for in-package sterilisation are used. Light-weight materials consuming less space, offering convenient features and low-cost materials such as paper
Fresh food packaging
& flexible and semi-rigid plastics can be used gainfully Sterilisation process of HighTemperatureâ&#x20AC;&#x201C;Short Time (HTST) for aseptic packaging is thermally efficient and yields products with high quality and nutritive value as compared to those processed at lower temperatures for longer time Extension of shelf-life of products at normal temperatures by packing them aseptically The hygiene level of the packaging machine also enables a product shelf-life up to 12 months at ambient temperatures. In a well-designed aseptic processing facility, the monitoring should include periodic environmental filter examination as well as routine particulate and microbiological environment investigation and may include periodic sterile culture medium processing.
Package structure and composition Aseptic packaging must not only protect the product, but also maintain its quality. Hence, the structure as well as composition of aseptic packaging are more complex and vary depending on product application, package size & type. Factors such as seal strength and integrity, package shape, stiffness & durability, as well as barrier properties determine the choice and/ or combination of materials required. Generally, to achieve all required properties, aseptic packages incorporate more than one material in the structure that is assembled by lamination or co-extrusion process.
Aseptic packaging Aseptic packaging exposes food to detrimental factors such as heat for a shorter period than the conventional methods such as canning and bottling. This means that the food retains its inherent qualities without losing the nutritional value, colour, texture or flavour. They are also more environmentfriendly since they consume lesser material and the package can be easily recycled. Moreover, the production
process consumes lesser energy as compared to conventional methods, and this bears special relevance where there is an increased emphasis on reducing the green footprint. â&#x20AC;&#x153;Another important consideration for fresh food packaging is logistics. For items such as meat that should be kept frozen, a strong cold chain logistics must be in place. This means that the food has to be kept in a frozen environment right from the time of processing to transportation and even when it is stored on retail shelves. This is an expensive proposition and the latest technology in aseptic packaging is being developed that will eliminate the need to keep food in a frozen state and allow refrigerated products to save on logistics expenses,â&#x20AC;? asserts Atasniya. This bears special relevance in the Indian context because of the varying climatic conditions and the fact that India does not have a strong cold supply chain in place. Moreover, Indiaâ&#x20AC;&#x2122;s packaging market is huge and growing at a fast pace, and is estimated to represent almost 10 per cent of the global market in terms of unit volumes. Flexible packaging comprises the bulk of the packaging market, and aseptic packaging is all set to drive this market even further.
Future of aseptic packaging The focus will be on commercialisation of multiphase food products, aseptic bulk packaging, development of new validation tools (biological, chemical and electronic sensors), developments in heat exchanger design, rapid cooling methods and development of new filling & packaging equipment with higher line speed. Research is also focussed on developing novel packaging materials and techniques for advanced sterilisation. Aseptic packaging is the preferred method for packaging on retail shelves and technology augmentation & innovation will serve to enhance its prospects in this sector, particularly in food logistics & storage. Email: lionel.alva@infomedia18.in
Aseptic packaging causes lesser deterioration as compared to conventional processes such as bottling and canning. With the advent of thin-walled containers, it has become a far less expensive proposition to produce high-barrier,
packaging. Neelesh Atasniya Â&#x201E; { Â&#x2019; ] Â? [
Criteria for aseptic packaging materials Must be compatible with the product intended to be packed and comply with applicable material migration requirements Physical integrity of the package is necessary to contain the product and maintain sterility Must be able to withstand sterilisation and be compatible with the methods of sterilisation Must protect the product from oxygen and retain the aroma of the product
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SAFET Y: High-speed High speed packaging lines
Challen g convent ing i quality i on with nspectio
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Indiaâ&#x20AC;&#x2122;s sp packagin oradic retail rise is g productio manufacturers pressurising t market s n, while enhancin o accelerate ustenanc g capacit constant ly. Lionel e, besides innov y for ating automat Alva asse e s in packa d packaging lines ses how fully ging prod uction dy depict a shift namics.
Courtesy: Shuttleworth Inc
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he need for high-volume pac kaging production bears resonance for the manufacturing process in contemporary times, with FastMoving Consumer Goods (FMCG) volumes driving the countrywide retail growth. Packaging operations are under intense pressure to achieve production and quality objectives, while reducing costs, adapting to rapidly changing schedules, maximising asset utilisation and continually improving overall performance. This can be achieved by streamlining operations in high-speed packaging lines, but the overall process of troubleshooting, analysis and corelevel problem correction of performance in packaging environments is a highly challenging proposition. Moreover, even if the entire manufacturing process spans a large number of operations, packaging comprises a large percentage of the
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overall manufacturing cost. Thus, it is important to have a keen understanding of the entire manufacturing process down to its finer intricacies and the packaging ecosystem, which includes the materials, suitability of machines, factory environment and atmospheric conditions. Further, product design considerations must be scrutinised in a carefully in order to establish a cogent and highly evolved & integrated manufacturing setup that is streamlined and considered a natural progression of an established environment.
Key design considerations A modern packaging line is a combination of inf rastructure and investment, complex machines, conveyor belts, pipelines and people, all working together to achieve the goal of packaging specified products. The packaging lines can be protected to some extent against unexpected events by using the right
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combination of machines and conveyor speeds, besides occasional introduction of production buffers along the lines. This is the most effective production contingency that can be adopted. These production buffers are a core element of a line design, although these represent only a small part of the total investment. This is because, if dimensioned correctly and placed appropriately, these will ensure the right balance of the whole packaging line, allowing contingencies to be absorbed without impacting the final product throughput. Submitting provisional designs in the early engineering stages of the packaging lines for performance simulation can save considerable money and time, and help prevent flaws in the approach that remain undetected in the various details of a typical project. However, submitting actual performance of a high-speed packaging line after installation could be equally decisive to
High speed packaging lines
ensure that even the last bottle or can delivered by this final design is actually obtained f rom the line. Applying performance simulation to buffer design is a key factor to achieving success in the engineering as well as improvement process stage in the life of a modern packaging line. Suresh Shirwalkar, General Manager - Research & Development, Shruti Flexipack, avers, â&#x20AC;&#x153;For packaging line manufacturers, particularly high-speed automatic machines, it is important that the customer requirements are properly understood by the machine supplier at the machine design stage. The machine manufacturer must also suggest improvement in the process to customer, which can increase the overall output and enhance the process. Quality is a key consideration in high-speed packaging line. Checking the packed product regularly helps in detecting errors in the machine caused by various factors. Temperature changes can give weight variation and improve machine performance. An automatic checking system checks the packed product continuously and helps keep variations under control.â&#x20AC;? He elaborates, â&#x20AC;&#x153;The composition of raw material used for packing is important in high-speed machines. As the machine speed increases, time for each operation is reduced. Variation in raw material properties can give variation in packed product. The packing material supplier has to give assurance for the raw material supplied to customer. Training of the
machine operator and maintenance team is important in high-speed lines.â&#x20AC;?
Challenges to conquer For reliable packaging manufactures, order fulfilment and supply chain responsiveness are dependent on reliable, efficient, high-performance packaging operations. On a high-speed packaging line, this becomes a particularly challenging proposition. Owing to the emphasis on faster lead times, every minute that a line is down leads to loss in production. The fast nature of the operating setup leaves little time for operators to carefully scrutinise the cause of downtime. The manufacturing process becomes daunting if it is not well understood and also when used by a new operator. â&#x20AC;&#x153;Another problem is retention of skilled labour, for example, once the labour is trained sufficiently, he may migrate to another organisation offering a higher wage. Often, if manufacturers go for substandard machinery just because it is available at a lower price, the entire production might suffer. In the worst case scenario, it might even get derailed entirely. That is why machine quality is important. However, at present, one can opt for better technology, since the latest machines have servo motors that are brushless and do not require periodic maintenance. Besides, the machines have diagnostic screen that gives alarms and reasons for machine stoppage; hence, eliminating the need for constant maintenance as long as the manufacturer realises & fulfils the operating parameters,â&#x20AC;? asserts Shirwalkar.
Speeding up performance
Courtesy: Multivac
Packaging is a complex endeavour involving a matter of addressing shape, size, materials and marketing requirements quicker and with improved safety. A manufacturer with a highvolume production and an established manufacturing process would do well to opt for a high-speed fully automated packaging line. The manufacturer must
Quality is a key consideration in high-speed packaging line. Checking the packed product regularly helps in detecting errors in the machine caused by various factors. Temperature changes can give weight variation and improve machine performance. Suresh Shirwalkar General Manager â&#x20AC;&#x201C; Research and ] q ! Â? [ q {
bear in mind here that due quality considerations must be in check since unlike manual packaging manufacturing or semi-automatic packaging lines, there is a drastic change in approach in high-speed packaging lines and even slight deviations in material conditions, quality or composition could deeply affect the final product. Weight and size considerations must also be given due importance owing to stringent regulations in place. However, considering the burgeoning retail sector that is a reflection of the countryâ&#x20AC;&#x2122;s economy moving towards a financial crescendo, there is a need for a model approach towards high-speed and high-volume production in the current scenario. When properly designed and integrated in the desired manner, such machines can give the packaging manufacturer the required leverage to position himself in a pragmatic manner, while being available to market opportunities despite demanding requirements and dynamics. Email: lionel.alva@infomedia18.in
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SAFET Y: Inter face - Krishnamachari Ravi
“Manufacturers should focus on ownership cost rather than equipment cost” …asserts Krishnamachari Ravi, Managing Director, Hassia Packaging Pvt Ltd. He provides a unique insight into the varied nature of India’s packaging industry, while analysing the challenges and future trends. In an interaction with Lionel Alva, he highlights the growth prospects of this industry in India. What are the major technology trends in the Indian packaging industry today? We are currently engaged in two verticals, which include packaging in flexible bags and drilling & sealing of pre-formed cups. Today, the primary concern for the major brands in the food industry is product shelf-life. For food items available in malls, especially those that need refrigeration, a strong cold chain ref rigerated environment must be present throughout. Therefore, right from transportation to storage of such items in a retail setting, the cold chain is
an important aspect. Moreover, fresh food is stacked in a specific manner to achieve the desired shelf-life. Aseptic filling and sealing solutions are increasingly being used. Another development is significant growth and demand for pack sizes at the lower end, especially in Tier 2 & 3 cities. Thus, the spending is on high volume packaging machinery because the Indian market is mainly driven by price-point marketing.
machine quality, engineering expertise and reliability of components. Attention should be paid to the quality of packaging material. As the process becomes more automated, the tolerance for deviation in material becomes narrower, and slight deviations can influence product characteristics. Site conditions must also be given due attention.
What design parameters do you follow for building customised solutions?
ERP is extremely important in the Indian context as the packaging industry is quite small here. It is difficult to find an expert in this field, and since the Indian industry is growing fast, individuals from ancillary industries are hired immediately. Further, it is necessary that they quickly understand the intricacies of the packaging business. ERP is important here since everything is listed out and enhances the learning curve. It also expedites the routine work, thereby streamlining the entire packaging process.
We avoid using a 100 per cent customised design since it is a risky proposition. There is a possibility that if the design has not been tested in a factory setting to a complete extent, the parts and individual components may not function in cooperation. Moreover, it needs a keen scrutiny and minute factors may alter the commercial viability of the prospect. It heavily depends on customer changes where we offer standardised design and wherein modular engineering is possible, thus providing a comfortable middle ground.
How do you gauge client technology requirements? Our approach towards business is that the customer will stay with us if we offer a value proposition, which comes through a keen understanding of their business requirements. A market research in India had indicated that more than 50 per cent of the packaging machinery used in the country was considered a failure. For a packaging machinery to run successfully, it must have a combination of primary aspects, which include the
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How important is Enterprise Resource Planning (ERP) in the Indian context?
What is the scope for your solutions abroad? We have a strong market abroad since we have been exporting 30 per cent of our output. Our clients are present in several Asian countries such as Indonesia, Pakistan and Sri Lanka. We are the preferred supplier for several fast-moving consumer goods companies abroad since they require a good partner who offers them solutions that are comparable to the economies of emerging market and also maximise value for the consumer. Manufacturers should focus on ownership cost rather than equipment cost. Email: lionel.alva@infomedia18.in
SAFET Y: Inter face - Naushik Kabra
â&#x20AC;&#x153;The key is to innovate and compete in the global marketâ&#x20AC;? â&#x20AC;Śasserts Naushik Kabra, Director, Synthetic Packers Pvt Ltd. He highlights some of the developments in packaging technology while assessing the key implications of economic development and offers insights into the future of the Indian packaging industry, in an interaction with Lionel Alva. What is the potential of aseptic packaging solutions in Indian retail today? Aseptic packaging solutions are an integral part of the Indian retail sector. Aseptic packaging primarily consists of a
combination of three individual layers, ie, paper, polyethylene and aluminium. This combination of non-related materials yields an outcome that is more than just satisfactory in terms of maintaining high levels of sterility and retaining the nutritive value of the product that it carries. A crucial advantage as well as the primary objective of aseptic packaging is that it preserves the product it packages over a long period. Aseptic packaging solutions have simplified our lives to an extent where we could have a ready-toeat meal in less than a few minutes, as they have been preserved and packaged using such solutions.
What innovations do you consider as the most significant for the packaging industry today? With rapid growth in technology and increasing competition, innovations are integral for the consistent growth of any industry. The packaging industry being large in size and spread across the world comes up with several innovations from time to time. Not only are manufacturers promoting these products and creating awareness, but customers who use our films to pack their products also specifically suggest the application of these polymers and films for their packaging. A strong misconception is that the use of biodegradable polymers might decrease the required specifications and quality parameters of the films produced for packaging. We recommend the use of biodegradable polymer films to replace their existing packaging films at a low or insignificant cost, keeping in mind the benefit to society and indirectly assisting the industry. The presence of these polymers may induce the Indian Government to rethink some of its harsh
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decisions to ban certain plastics. Another important innovation in the Indian polyethylene industry is the development of competitive quality of agri-films such as greenhouse Ultraviolet (UV ) films and mulching films, which enable farmers to grow flowers, vegetables and fruits with better quality. These films allow only the required amount of UV rays to pass through and block all harmful UV rays, and that too at competitive costs by saving on water & pesticides.
What are the significant challenges for the packaging industry today? All industries face challenges in one way or the other. Challenges could be considered both negative and positive. However, the key to face a challenge in any industry would be to take it positively and prepare to fight back. One of the challenges before packaging industry is acute shortage of timely supply of the required polyethylene raw material in the Indian market. This is also because the industry heavily depends on a single domestic manufacturer. Thus, we import material from the Middle East and other sources across the world in order to be self-sufficient and not depend only on domestic market supplies.
How do you see the future of the packaging industry in India? The future of all industries in India along with the growth of the Indian economy is positive. In particular, the growth of packaging industry in the last few years has been encouraging. The key is to innovate and compete in the global market, towards which the Indian packaging industry is currently heading. Email: lionel.alva@infomedia18.in
SECURIT Y: Brand protection
Consumer confidence through package integrity The packaging industry is well aware that brand value may be attacked by product counterfeiting, parallel trading, product tampering and theft. Anwesh Koley looks into the various measures that provide protection to the brand image by employing the right checks and necessary actions.
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n a vast country like India, packaging security has a pivotal role to play in the purchasing decision of a consumer. The consumer of today’s India is a smart buyer, well versed with global trends and market information, immense product knowledge and highly alert about the product offerings. Consumers today are demanding and aware of counterfeiting threat across the globe.
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Consumers are looking for a well packaged product worth the money they spend, and are seeking the assurance & authenticity of the product purchased without incurring additional costs. Security features providing freshness, safety and authenticity of the product purchased is the customers’ expectation from packaging. Security benefits such as anti-counterfeiting, tamper evidence, track & trace and brand protection features are integral to the packaging industry. At the same time, the trend has opened numerous opportunities for brand owners who are increasingly looking to leverage packaging as a differentiator. Jitesh Mehta, Director Marketing,
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Label and Packaging Materials South Asia, Avery Dennison (India) Pvt Ltd, avers, “The needs of customers have led brand owners in segments such as pharmaceutical, food, home & personal care, white goods and automobiles to leverage packaging as a tool to offer security and brand protection features along with the functional advantages.” Further, brand custodians operating in key segments are actively looking to serve the rural market for better growth momentum. Counterfeiting becomes a major challenge for these custodians in the rural market. Brand awareness is trivial and customers tend to purchase products relying more on visual appeal. Hence, packaging security ensures counterfeit products do not reach the vulnerable rural consumers. Counterfeiting is one of the world’s fastest growing industries and is said to represent an approximately $ 600 billion market globally. It is a rapidly growing business and it is the top priority for Government and companies across the globe to curtail counterfeiting. Fraudulent products are easily sold in the market, which leads to lost revenue to the Government and brand owners, while potential product safety concerns
Brand protection
Director Marketing, Label and Packaging Materials South Asia, Avery Dennison (India) Pvt Ltd
Key trends in the packaging security domain
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Digital printing and water marking Sophisticated, covert holograms RFID identification at carton and unit level (supply chain) Layering (overt, covert and track & trace feature in a single solution)
ve ry
Global packaging companies are way ahead in terms of technology as compared to their Indian counterparts. The packaging companies serving the developed markets are at a matured stage in their learning curve, and this is through their sheer exposure and experience. For example, Radio-Frequency Identification (RFID) solutions for track and trace are rapidly accepted in the western markets at the carton & unit level, but such measures are at a nascent stage in emerging markets like India. To sum up, emerging markets are fast catching up with their global peers in terms of packaging security solutions. Email: anwesh.koley@infomedia18.in
Jitesh Mehta
:A
Indian companies vis-à-vis global counterparts
This is an opportunity for packaging companies to work as a team and meet the performance requirements of brand owners in terms of identifying unmet needs, being price competitive and offering commercially viable solutions.
tes y
Security labeling is an essential tool for combating counterfeiting. Today’s consumers look for overt security labeling to visibly guarantee genuine products, while covert and forensic solutions deliver an extra layer of protection by ensuring product integrity from the producer to the user. Therefore, brand owners need to find new and effective ways to protect their brand, customers, revenue and reputation. The fragmentation within the label and security technology supply channel is in direct conflict with the brand owner’s need for increased confidentiality, speed, flexibility, chain of custody control and secured site assurances coupled with a wide range of security options. “In times of tampering, counterfeiting and shoplifting, no area is immune from brand-damaging, sales-sapping activities. Fortunately, there are spectrums of safeguard options to protect products from harm, keep brand equity intact and put brand control back into brand owners’ hands,” adds Mehta.
While Government rules and regulations on anti-counterfeiting have been defined, they are not as effective, as brand owners would like. This puts the onus on the brand owner to incorporate packaging security features to ensure his product/brand safety. In an intensely competitive and complex market like India, the brand custodian needs to provide effective security solutions to ensure the authenticity of his product, and that it reaches the consumer without tampering. This may not be completely fulfilled as manufacturers are bound by cost implications. Often, packaging development managers face stiff resistance for upgrading and investing in latest security solutions, with only some incremental improvements made in the conventional security solutions. Typically, an effective security solution is a combination of security product and processes. “Highly specialised materials with a complex printing process can provide an excellent solution, which meets the brand owner’s requirements completely. This is an opportunity for packaging companies to work as a team and meet the performance requirements of brand owners in terms of identifying unmet needs, being price competitive and offer commercially viable solutions,” opines Mehta.
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Anti-counterfeiting solutions
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to consumers. “Such products destroy brands by impacting the credibility and brand equity in the market, and with counterfeiters constantly on the look out for new products and industries, it is becoming a major threat for authentic companies,” adds Mehta. Growing faster than genuine products, the global counterfeiting trade has doubled in size in just five years. Pharmaceutical, medical and cosmetics industries pose a particular high risk to the public among all industries. The International Commerce Commission (ICC) and Business Action to Stop Counterfeiting and Piracy (BASCAP) also estimated that by 2015, piracy will grow to become a $ 960 billion problem. “Brand protection is no longer a luxury, but a business necessity. In today’s market, we face brand piracy, counterfeit goods, market diversion and inf ringement of intellectual property/ trademark assets in alarming proportions,” believes Mehta.
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SECURIT Y: Package testing equipment
Reducin g in-trans it l
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Testing in role in e struments play a n l a i d d o suring strict q significant uality no wn by st andar d rms global i m p o r t a s. Anwesh Koley p a c k a g i n g n ever y st a c e o f p a c k a g e gauges the boosts p ge of the value t e s t i n g a t c ackagin g excelle hain, which nce.
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he market for testing equipment has been growing over the years and the current situation is quite positive. Gaurav Malhotra, Director, Presto Stantest Pvt Ltd, says, “Earlier, companies did not stress much on testing equipment, but gradually the packaging sector has become quality conscious, which is helping them to minimise transit damages. If the quality is checked for top-load and drop test, then we can ensure that minimum possible damage is made to packages during transit.”
Packaging testing market in India The industry has developed numerous specialised equipment, which simulate the conditions a product experiences during transportation. These include vibration tables and drop testers at specified height & angles. Top load testers that gauge the crumbling load or
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buckling load well in advance to check the sustainability of the packaging. Earlier, companies were reluctant to invest in packaging equipment because they thought they were well aware of this requirement. However, now with the advent of packaging testing equipment, they have realised considerable cost saving by reducing logistics damage Today, companies demand special purpose machines that are designed according to their specific requirements. These machines could be as simple as a tester for the scrubbing load of a label to test printing quality. “There are equipment that record the atmospheric conditions throughout the transportation period of the material. A data logger is kept in the shipment along with the packages. This gives an idea of the varied conditions that a package has to undergo if the distance is very large. There are software that
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help in logging this data at different time intervals,” adds Malhotra.
Innovations in testing industry Companies now rely more on automation as they do not want to risk human error. Extensive computerisation is required for this in order to reduce time and provide faster feedback. Earlier all data were recorded manually, which increased the possibility of error, whereas today, we can have all the information available. The computer interface does all calculations and can be mailed through Ethernet. Auto-triggers can be set, which help in conveying information to the party whose package is being tracked. Earlier, most companies had analogue burst testing equipment, which provided the bursting strength of a package as well as its Bursting Factor (BF). This is based on the weight of
Package testing equipment
the package, which is measured in Grams per Square Metre (GSM). Today, the analogue instruments have been replaced with computerised ones. This yields the BF directly through digital or computerised equipment. The techniques remain the same for all forms of packaging, be it plastics, metal or glass, with minor modifications as per specifications of the package and its capacity. Testing instruments are the only means of checking for quality at all three stages of manufacturing: Incoming QC: It is related to quality issues of raw material. If tested at this stage, a sub-standard product will not come into production at all. In-process QC: This is related to quality issues in the processing stage. If tested at this stage, the line can be halted and amends made to ensure no further losses happen. Final QC: It is related to quality issues of the final product. If tested at this stage, it ensures that a poor quality product does not reach the end customer. Testing instruments can help in significantly avoiding and decreasing rejection, thereby saving millions.
India vis-ĂĄ-vis global players The package testing industry in India is at par with international standards as far as technology is concerned. The
extent of growth achieved by Indian testing equipment manufacturers has been commendable. There are variations in the testing equipment available in the market. Essentially, the quality of services provided and the network span of companies determine market dynamics. Indian testing equipment players are receiving orders from big multinationals for setting up testing laboratories, which clearly shows the eagerness towards testing equipment to achieve global quality standards. The Indian testing instruments market is growing due to the realisation that there is more to gain than lose by investing in testing instruments. This not only enhances and improves the quality, but also ensures best value for money in terms of right procurement. It is now being considered as an investment rather than an expense. â&#x20AC;&#x153;Our strength lies in our ability to change and that too at a fast pace. Automation will be the key to the future as global levels of automation are at present higher than that of India but it would be just a matter of a few years before we catch upâ&#x20AC;? believes Malhotra. Earlier, these multinationals opted for imported testing machines only, as they were sceptical about similar products available from domestic manufacturers. However, with awareness spreading fast, they have seen similar results in quality testing from domestic manufacturers as well. This can be attributed to an efficient
Courtesy: FedEx
It is important to ensure quality up to the last level till the customer, and the vendors are an important part of this value chain. Hence, the large players in the industry must percolate the advantages of package testing to the last levels of distribution in order to retain product value. Gaurav Malhotra Director, Presto Stantest Pvt Ltd
service network offered by Indian manufacturers. With the development of technology, it is now seen that the cost of a computerised monitor is lower than a few analogue monitors available in countries like Europe.
Testing times While large companies have recognised the importance of employing testing equipment for packaging, we are yet to see medium- and small-level players take the initiative. Small vendors and dealers find testing equipment as merely a cost that does not yield much results or returns, which is not true. â&#x20AC;&#x153;It is important to ensure quality up to the last level till the product finally reaches the customer, and the vendors are an important part of this value chain. Hence, the large players in the industry must percolate the advantages of package testing to the last levels of distribution in order to retain product value,â&#x20AC;? says Malhotra. Email: anwesh.koley@infomedia18.in
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SECURIT Y: Inter face - Karl Vandenbussche
“India is the place to watch out for in labeling technology in future” …opines Karl Vandenbussche, Director, Reynders Label Printing India Pvt Ltd. In an interaction with Anwesh Koley, he describes the latest in labeling technology for the packaging sector and the essentials to consider for a long haul in this market. 24-25 per cent), but this growth is on a small scale.
What is the key to ensure efficient labeling solutions for packaging?
What are your views on the package labeling industry in India? The Indian labels industry is complex, dynamic and growing fast. Although the per capita consumption of labels in India is the lowest in any analysed region, it has the highest growth rate in the world, at 19 per cent. In India, wet glue labels although still growing in double digits, are fast making way for pressuresensitive and flexible film labels. The bar-coded labels market is growing by 30-35 per cent in India. This industry is making way for smart RadioFrequency Identification (RFID) labels across the globe. Narrow web flexo and combination presses are growing in India as compared to growth of digital label presses in advanced countries. Wet glue has been dominant in India because of its obvious ease of production and simplicity in application. Nevertheless, wet glue labels although huge in quantity and with continued double-digit growth were overtaken in value but not in quantity, by pressuresensitive labels in 2003-04. In contrast, the flexible, shrink and wraparound labels form the highest growth segment of the label industry (more than
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It all depends on the in-house prepress where the latest systems must be installed. This will give a head start printing plates of unusual sharpness, detail and overall consistency. The print offices should be equipped with state-of-the-art presses capable of combining several printing techniques (eg, flexography, screen print, hot and cold foil stamping) to obtain the highest achievable result. If a labeling company has efficient suppliers, it can obtain the largest range of printable materials and adhesives to tackle the most difficult applications in the most awkward conditions. Modern consumer product marketing believes that product packaging and the label should be attractive enough to sell the product on their own. This requires high value addition that is associated with the pressure-sensitive segment and, especially, its new varieties such as clear see-through pressure sensitive and, in some cases, shrink-wrap labels. It is estimated that flexible labels, pressuresensitive, wrap-around and shrink-wrap labels, will rapidly take away marketshare from paper-based labels. India has shown huge potential in terms of labeling solutions. It is a market that currently is ready to be explored.
At Reynders, what quality control initiatives have you undertaken? All steps in the process are supported by a Reynders Application System (RAS), which is a software especially developed
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for our group as per the pharmaceutical standards in Europe that gives a common platform to all production units in Europe and India. This allows us to create unique numbers for layouts and traceability of all processes up to arranging automatic communication with transport about the amount of boxes, weight & address and the communication between different production units regarding concept labels, materials and new developments. It is important to have a high level of quality control built on standardised procedures to ensure complete detection of non-conformities at every stage of production. A final inspection with a camera control will further eliminate defaults not visible to the human eye. Packaging is done with utmost care to guarantee the integrity of products both in transport and, later, when stored in the warehouse.
What are the challenges facing the package labeling industry in India? The label industry is facing many small hurdles that are hindering its growth. The first is that the printing industry as a whole has been unorganised and fragmented, lacking investment in specialised components & tools. There is a dearth of technology, research and development, standardisation, testing & certifying as well as training facilities. Environment, health, safety and best practices are some of the issues that must be tackled for the industry to address its customers’ needs. Foreign direct investment and organised retail growth are the key drivers for the packaging and labeling industries. Email: anwesh.koley@infomedia18.in
SECURIT Y: Inter face - Satyadeep Ray
“Higher research will ensure that holography finds wide-ranging applications” …opines Satyadeep Ray, Director, Holostik India Ltd. In an exclusive conversation with Anwesh Koley, he highlights the importance of holographic packaging in India where spurious products pose a constant threat to quality and consumer interest. What is the status of the holographic packaging industry in India? In India, previously, packaging was done primarily through the use of polyester, coupled with simple printing on the external packaging. With the advent of holography, manufacturers who faced the problem of duplication adopted this technique. Holography is a sophisticated technology using laser optics. It can never be duplicated, and thus provides vital security to packaged products. As holographic packaging emerged in India, companies were assured of their brand image and product authenticity. Various holographic materials are used as packaging materials, eg, holographic packaging films, hologram hot stamping foils, holographic aluminium foils, hologram labels, hologram tape/security tape, hologram stickers, etc. Holographic packaging also improves the aesthetic appeal of the product. It provides a higher visual treat to the potential consumer at the first glance as compared to ordinary printing.
How does holography provide security to packaging? Earlier, companies used conventional printing on laminates and pouches made of polyester. Today, on the same material, holography is used. Once the holography is done, duplication of the product becomes difficult, as it ensures a unique identity to each product. Holographic packaging is inexpensive as the procedure involves embossing holographics on
polyester or other materials. Embossing is a technique of applying heat and pressure, which transfers the holography from the metal plate to the polyester material. It is marginally expensive than ink printing but offers more advantages.
What are the advantages of this technology? Due to certain policies, manufacturers are moving towards paper packaging instead of plastics packaging in certain sectors. Even in paper packaging, holography is used through the same technique as used for plastics packaging. Customer perceives higher value addition, since holography provides differentiation and shelf appeal that brings product to the front on the shelf. In this era, where customers face the psychology of choice everyday, holography helps attract the attention of customers and move the product off the shelf. This is because holographic images can ‘move’ and ‘speak’ to consumers through optical motion, and packages with holograms attract attention of the customer.
What is the way forward for this industry? The large population of India ensures that the demand for packaging products is always on the rise. The problem of duplication is high in India and holography provides a vital solution for tackling this menace. Holography can be used on aluminium surfaces, paper and polyester. This technology has already entered the country and with the high levels of research and development, we can expect more enthusiasm from packaging companies towards anti-counterfeiting. However, the Government must be lenient and flexible towards holography. If this technology is made mandatory for the relevant sectors, it will go a long way in providing quality to the consumer as well as preventing spurious products from entering the market. This will increase the revenue for manufacturers and, in turn, for the Government. Similar to the information technology sector, we witness some new technology in holography every year, which is another reason for companies to adopt this technology. Email: anwesh.koley@infomedia18.in
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SUSTAINABILIT Y: Packaging material
More value with less resources With sustainability being one of the biggest challenges facing the packaging industry, downgauging packaging materials seems the most effective way for resource and cost reduction. Avani Jain looks at the current trends and methods adopted by companies in the segment for downgauging the packaging materials.
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oday, flexible packaging solutions represent the entire packaging industry. This is primarily due to the benefits offered by flexible films in terms of relatively low cost, good barrier properties against moisture and vapour, heatsealability, handling ease and convenience for the manufacturer, retailer and consumer. However, rising raw material prices have led the plastics packaging companies to move towards sustainable packaging and explore the possibility of downgauging the packaging materials for cost & resource reduction. Downgauging refers to reducing the amount of material in a product, while still maintaining or even improving the material properties. For example, just a few grams saved in the weight of a package can have a tremendous impact on the environment and lead to cost and resource reduction when factoring the net gain of millions of individual packages. Today, manufacturers of packaged goods are constantly challenged to reduce packaging for cost and resource reduction, while ensuring that it still serves the primary purpose, ie, protect the contents and help sell the product. Polyethylene, the most widely used flexible packaging material, has come a long way and
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packaging engineers have capitalised on designing flexible packages that are thinner & lighter than ever.
Towards sustainability In a study conducted by the Associated Chambers of Commerce and Industry of India (ASSOCHAM), it was found that the rising concerns over environmental hazards, carbon emissions, waste reduction targets specified by different countries and the trend towards green packaging are some of the factors propelling companies to take up the task of sustainable and green packaging. The study further stated that the green packaging industry is growing at about 25 per cent per year, faster than the overall packaging sector, which is growing at about 20 per cent annually, thus focussing on sustainable packaging as the latest trend.
Current trends In keeping with the demand for sustainable packaging, the packaging companies are increasingly adopting strategies to reduce the weight of product packaging materials. Approximately 5.6 billion two-litre plastic soda bottles are sold each year. When introduced in the late 1970s, these weighed 68 gm or less. Improved packaging technologies
Packaging material
have decreased the weight of the same type of bottle to as low as 49 gm or less, eliminating an estimated 200 million pound of Polyethylene Terephthalate (PET) each year. Also, plastic trash bags began appearing in homes and along curbsides around the world by the late 1960s. Since that time, plastic trash bags have been made thinner by 50 per cent, thus saving millions of pounds of polyethylene. Rajesh K Pandya, Vice PresidentOperations, Parikh Packaging Pvt Ltd, says, “In recent years, the weight of PET mineral water bottle has also reduced drastically, from 78-90 per cent to 28-32 per cent. In case of flexible packaging, the film thickness has been reduced by nearly 30 per cent than that used until a few years ago. A decade ago, the thickness of the film used for packaging milk was 60-75 micron. But now that thickness is reduced to 55 micron only. All these developments have led to cost and resource reduction.”
Advancing step by step With the sole aim of achieving sustainability, the plastics packaging companies have adopted various steps for downgauging of packaging materials. Pandya notes, “We have taken up the task of optimisation of film and laminates structures after proper stability study. We are also using newgeneration polymers and films to provide higher strength at lower thickness. With this step, we are able to reduce per pack weight, thereby leading to less material usage, less energy consumption and less cost incurred without compromising on the basic properties.” He adds, “In 2010-11, we developed a new light-weight packaging solution for a snack food company in India. We reduced the thickness of the laminate from 66-68 gm/sq m to 52 gm/sq m. This proved to be a benchmark of our efforts towards sustainable development. We are now manufacturing biodegradable and thin laminates.”
Future trends While considering the sustainability of
packaging, multiple factors must be taken into account, including the actual energy costs of production & transportation, quantity of raw materials used for manufacturing, toxicity and carbon emissions in production & decomposition as well as overall biodegradability of the finished product. Packaging companies are working efficiently towards fulfilling all these parameters, especially for conserving resources and reducing cost by material downgauging. Downgauging has become a buzzword among material suppliers and the processing community. It allows packagers to offer the same products with higher product-to-package ratios by using thinner materials. This approach to resin implementation has changed the way the industry does business. Pandya avers, “The future trends for conserving resources and reducing cost would include reusable packaging, elimination of secondary packing by developing sustainable inner/primary packaging, innovation in reducing number of layers in high-barrier laminates, thereby reducing material consumption, energy usage and production costs.” Besides downgauging of packaging material, various steps could be taken by the companies for ensuring sustainability. Pandya avers, “These steps include replacing old lowspeed high-wastage machinery with new-generation technology; this can be done by using alternative films and granules after studying the performance criteria of product & packaging needs for the same; using high-barrier non-traditional films with enhanced barrier properties to replace traditional films as an import substitute for food, dairy & pharma sector; optimising process & production costs; reducing wastage by deploying advanced technology for production, focussing on Research and Development (R&D) and new investments in R&D. Thus, in future, more efforts will be taken by companies for ensuring sustainability in packaging.” Email: avani.jain@infomedia18.in
The future trends for conserving resources and reducing cost would include reusable packaging, elimination of secondary packing by developing sustainable inner/primary packaging, innovation in reducing number of layers in high-barrier laminates, thereby reducing material consumption, energy usage and production costs. Rajesh K Pandya Vice President-Operations, Parikh Packaging Pvt Ltd
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SUSTAINABILIT Y: Reducing Carbon Footprint Reducing carbon Footprint
Rising energ y prices and enviro nment al consciousness are driving packaging companies toward s sustai nabili ty. An efficie nt way to ensure sustainability is through reducing carbon footprint by recycling. Avani Jain explores the significance of recycling for reducing packaging carbon footprint.
E
conomic growth and prosperity are essential components of sustainable development. The United Nations estimates that the population of the planet will grow to 9.2 billion by 2050. The efficient and productive industry engaged in truly sustainable practices is essential to meet the incredible increase in demand for goods and resources that this growth implies. Historically, increased use of packaging has accompanied economic growth. A goal of sustainable packaging is to facilitate economic growth by delivering the benefits of packaged goods without the negative impacts traditionally associated with packaging and related processes. Thus, sustainable packaging transforms the world into a greener and cleaner place, and safeguards the natural ecosystem.
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Tracking the footprint In an era of rising energy costs and scarce resources, companies need to work towards packaging that not only adds value to end products, but also conserves the environment, thus creating sustainability in packaging. One way of achieving this goal is reducing the packaging carbon footprint through recycling solutions. Carbon footprint is the overall amount of greenhouse gas emissions, consisting primarily of carbon dioxide, associated with an organisation, event or production. It is one of the most common measures of the effect of an individual, community, industry or country on the environment. An increase in greenhouse gas emissions, and therefore in carbon footprint, is the primary event associated with climate change that has led to global warming.
Modern Packaging & Design July-August 2012
The carbon footprint generated during packaging can be curbed by various methods such as downgauging of packaging materials with improvements in designs and raw material, development of fuel efficient machines & equipment, power generation from natural resources rather than fossil fuel and, most importantly, adoption of efficient recycling technologies. Cesar Rodriguez, Chief Executive Officer, MachinePoint Group, asserts, â&#x20AC;&#x153;Recycling is the key for carbon reduction, but at the same time, it is difficult to implement. It should be done in a correct manner in order to really achieve a carbon reduction.â&#x20AC;?
Recycling solutions Recycling reduces carbon emissions by reducing the need for raw materials, which generally require more energy
Reducing Carbon Footprint
to produce and transport than recycled materials. It helps in reducing waste in landfill and the consequent methane emissions. Recycling of packaging waste, both post-consumer and waste generated in the manufacturing process, is beneficial. An efficient and real-time recycling and returnable process should be implemented to capture & bring back waste to recyclers/packing companies for recycling. Recycling uses less energy and produces less pollution than making the products from scratch. For example, making aluminium cans from old ones uses one-twelfth of the energy than making them from raw materials. There are various strategies in the plastics industry which can be adopted by the companies for reducing their carbon footprint through recycling. Rodriguez notes, â&#x20AC;&#x153;Reducing packaging wall sizes with multi-layer products will make them lighter but stronger, and thus, help reduce carbon footprint by reducing energy required for transportation. Another way is to develop mono-polymer products, where a bottle, cap and label are made from the same material. The recycling of this bottle is easier, as no product separation will be required as the polymers used are not different.â&#x20AC;? Various machines are available in the market, which can enable easy recycling of plastics. â&#x20AC;&#x153;Size reduction machinery and re-pelletising machinery can help in reducing carbon footprint because these
machines are mainly used in industrial recycling. Further, the recycling process usually consists of the leftovers of the process to input them back in the process, making this method of recycling the most efficient one in terms of carbon reduction,â&#x20AC;? suggests Rodriguez.
Challenges posed The market for sustainable development and awareness about reducing carbon footprint through recycling is increasing in India. However, the technology and machinery needed for recycling are still not fully developed in India. The companies operating in the Indian market have to import machines and technology from overseas, which makes sustainable packaging a costly affair. Thus, the recycling technology solutions providers have to spread their wings to help their customers in the best possible manner. The main challenge lies in the correct separation of the waste to be recycled. Rodriguez opines, â&#x20AC;&#x153;For this reason, industrial recycling where waste separation has proved to be easier is economical and environmentally more interesting than post-consumer recycling, where the correct separation, cleaning & sorting of all materials is a challenge.â&#x20AC;?
Future trends Adopting more efficient recycling technologies will result in increased energy efficiency and economies of
Reducing packaging wall sizes with multi-layer products will make them lighter but stronger, and thus, help reduce carbon footprint by reducing energy needed for transportation. Another way is to develop mono-polymer products, where a bottle, cap and label are made from the same material. Cesar Rodriguez [ ! ] Â&#x2019; MachinePoint Group
scale. Rodriguez avers, â&#x20AC;&#x153;The new trends would include the development of mono products. At the same time, multilayer products can go for a weight reduction, as these are more difficult to recycle. However, the real challenge remains the development of technologies for separation process employed during recycling.â&#x20AC;?
Green footprint Packaging sustainability will be the way to the success of a business model and place industrial development on the â&#x20AC;&#x2DC;green routeâ&#x20AC;&#x2122;. Cutting back on amount of waste seems a daunting task, but applying these practices to oneâ&#x20AC;&#x2122;s manufacturing processes is the need of the hour. Thus, it is important for the industry to learn to adapt to the packaging 3Rs â&#x20AC;&#x201C; reuse, reduce & recycle â&#x20AC;&#x201C; which can help achieve sustainable packaging through reducing carbon footprint to a large extent. Email: avani.jain@infomedia18.in
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SUSTAINABILIT Y: Inter face - Pramthesh Pandya
“Today, the renewablerecyclable-compostable trend is seen in the industry” …opines Pramthesh Pandya, Head-Unit & Business Development, Parikh Packaging Pvt Ltd. In an interaction with Avani Jain, he discuses the growth and demand of sustainable packaging in India, while outlining the challenges and opportunities facing the segment. Why is there a need for sustainable packaging in India? With global plastics consumption expected to reach a mammoth 300 million tonne by 2015, the global packaging industry is set for a strong growth in the future. The Asia-Pacific market will be the key market driving this growth, with India and China collectively making a sizeable contribution. The factors influencing this growth are development of new-age plastics, emergence of new applications and focus on green chemistry due to legislative & environmental requirements, all leading to development of sustainable packaging in the country.
What are the principles governing sustainable packaging? Sustainable packaging works on four principles – effective, efficient, cyclic and clean. Effective means that the packaging system should add real value to the society by effectively containing and protecting products as they move through the supply chain and by supporting informed & responsible
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consumption. Efficient indicates that the packaging system should be designed to use materials and energy as efficiently as possible throughout the product life cycle. This includes material and energy efficiency in interactions with associated support systems such as storage, transport and handling. Cyclic means packaging materials used in the system should be cycled continuously through natural or industrial systems, minimising material degradation. Clean states that packaging components used in the system, including materials, finishes, inks, pigments and other additives, should not pose any risks to humans or the ecosystem.
What are the key growth drivers for sustainable packaging industry? The Indian sustainable packaging category, which is currently recording annual growth of 25 per cent, was valued at $ 3.19 billion in 2011. Factors such as high consumer awareness, increasing popularity of smart & sustainable packaging among leading companies and adoption of environment-friendly technology in sustainable packaging production have contributed to the increase in demand for active, smart & sustainable packaging. Further, rising concerns over environmental hazards, carbon emissions and waste reduction
targets specified by different countries, are the factors likely to boost the market for sustainable packaging solutions.
What are the leading innovations making headway in the segment? Some new concepts in sustainable packaging segment include reduction in the usage of plastics at source, biodegradable laminates, paper-based packaging materials, eco-friendly flexi-tube for cosmetics & pastes, slider zipper with diaphragm and nonplastic laminates for mouth freshener industry. One of the most visible trends in sustainable packaging is the focus on environment-friendly materials. Today, the renewable-recyclable-compostable trend is seen in the industry, from grocery aisles to shoe stores, shipping containers to the retail shelf.
What steps has your company taken to ensure packaging sustainability? We constantly work to reduce product waste, waste to landfill and solvent usage across the manufacturing process; preventing over-packaging, improving energy efficiency through various methods and usage of biodegradable materials to offer sustainable solutions to our customers. Email: avani.jain@infomedia18.in
SUSTAINABILIT Y: Roundtable
recycling technology in India achieve competitive results for the market? Can
In recent years, the demand for sustainable packaging has increased and so has the demand for recycling technologies. Avani Jain speaks to some industry experts to explore whether companies in the country are willing to take up recycling on priority and whether recycling technology can achieve competitive results in future. Sunil Jain President, Rajoo Engineers Ltd
The demand for sustainable packaging is low in India and not many companies are willing to invest in it. Further, technologies are not sufficient to support sustainable packaging initiatives such as recycling. There is lack of investment in developing recycling technologies in India. However, the multinational companies in this segment have begun recycling plastic waste and using recycled plastics for packaging. But these are few is number as against the domestic players in the market. The major reason is that most companies believe that recycled plastics is a lowend product and the manufacturing process is messy. Thus, in order to motivate companies to undertake recycling, it is important to change their perception, upgrade technology and invest in developing recycling technologies, as this will become the future of the plastics and allied packaging industry. Since the demand for plastics is growing, recycling is required to meet the growing demand. Thus, recycling technologies in India can achieve competitive results for the market in future.
Umesh Sharma Managing Director, Julison Packaging India Pvt Ltd
The market for sustainable packaging has not yet matured in India and only a few companies have taken up to this task. The major reason behind this is lack of technology, infrastructure and funds. These reasons remain the same as only few companies involved in recycling plastic materials. Apart from this, the perception of people is an issue, as people think that recycled material is not a good option. Moreover, plastic materials can be recycled when the volumes are large, but in India, this is not the case. Unlike other countries where the production and consumption is huge and recycling is considered as a feasible option, but this is difficult in India where a large number of small & medium enterprises with lower capacities also operate in this segment. Also, recycling means adopting compatible converting technology, which, at present, is not adequate in India. Thus, recycling technology in India can achieve competitive results for the market, provided there is adequate fund, infrastructure and, above all, willingness of companies to adopt these futuristic trends.
Vineet Desai Head-Sales & Marketing, Unnati Speciality Films
Today, few companies have taken up the task of recycling plastic waste and are using recyclable plastics. The major reason is that recycling plants are expensive and not everyone can afford to buy these lines. Further, in India, the technologies related to recycling are not adequate as compared to other nations. The usage of recycled plastics is also limited here. However, the scenario is changing and companies are considering their own recycling lines for plastic wastes. This is because of the increasing environmental consciousness. Awareness is also spreading about the fact that production of recycled resin uses 90 per cent less energy and emits 78 per cent less greenhouse gases than producing virgin resins. Recycling of plastics saves much more energy compared to burning it in an incinerator. Thus, employing recycling technologies by companies in this segment has several benefits.
Editorial take: Email: avani.jain@infomedia18.in With the general outlook shifting towards sustainable packaging, the demand for recycling technologies will increase in future. Although not many companies are currently willing to invest in recycling, these technologies will certainly define the future of the surging plastics and the allied packaging industry.
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FACILIT Y VISIT: Uflex Engineering Ltd
] Â? [ ' q { With a paradigm shift in the food packaging segment, India is moving towards more consumer-friendly flexi-packaging solutions. This has seen Uflex Engineering Ltd emerge as a prominent player in this field globally. Anwesh Koley tracks the journey of the company as it has transformed flexible packaging through its innovative concepts.
U
flex Engineering Ltd is one of the largest companies offering flexible packaging solutions in India with large manufacturing capacities of plastic film and packaging products. Headquartered in Noida, National Capital Region (NCR) - New Delhi, and listed on Bombay Stock Exchange and NSE, the company has a strong manufacturing base in India ( Jammu, Noida and Gwalior), Mexico, Dubai and Egypt, providing end-to-end solutions to clients across 100 countries. It caters to global markets such as USA, Canada, South America, UK, Europe, Russia, Commonwealth of Independent States (CIS) countries, South Africa and other African countries, the Middle East and South Asian countries. It also has offices in the UAE, Europe and North America, and enjoys a formidable market presence in over 85 countries.
Manufacturing facility Uflex works with a vision towards creating total flexible packaging solutions for the
world. Its strategic locations across the globe have helped the company to cater to global demands with solutions that keep its goals in focus. The Uflex facility enjoys ISO 9001 and ISO 14001 certifications, besides Food and Drug Administration (FDA) & German Federal Health Office (BGA) approvals for its products. Being a multi-faceted organisation, Uflex has integrated its operations from the manufacture of polyester chips, films [Biaxially Oriented Polyethylene Terephthalate (BOPET), Biaxially Oriented Polypropylene (BOPP) and Cast Polypropylene (CPP)] â&#x20AC;&#x201D; both in plain and metalised form â&#x20AC;&#x201D; coated films, laminates, pouches, holographic films gravure cylinders, inks and adhesives to all types of packaging & printing machines. Uflex is committed to the industry by providing technical know-how and being the trendsetter in the flexible packaging space. Being on the cutting edge of innovation, it develops advanced products that cater to the changing demands of the packaging industry.
Printing machine in action
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Business divisions Uflex is a one-stop shop for flexible packages. It provides complete integrated packaging solutions, right from design to delivery. Catering to the specific needs of customers for laminates and pouches by constantly redefining cost-effective packaging options is its tradition. With almost two decades of experience in flexible packaging and significant investments, Uflex has perfected its processes and technology to produce high-quality flexible packaging materials on time and within budgets. Sanjay Malik Sabharwal, Vice President-Marketing, Uflex Engineering Ltd, says, â&#x20AC;&#x153;Our in-company divisions and group companies located nearby produce all critical inputs, such as the BOPET and BOPP films, inks, adhesives & substrates, holographic films, metalisation facility, blown film and other such raw materials. Through our innovations in packaging, we enable our customers to resolve various problems.â&#x20AC;? Uflex is a pioneer in providing converting machinery to the packaging
Uflex Engineering Ltd
industry. Its Converting Division, engaged in the business of packaging and converting machines, was established in Noida in 1984, and it is one of the best-in-class facilities manufacturing packaging machinery in India.
Diverse portfolio Boasting of a wide range of machines for flexible packaging, Uflex has a solution for every packaging need. From semi-automatic to high-speed automatic machines incorporating the latest in automation technology, the company has a customer-specific approach through efficient engineering. There are machines that provide a wide ambit of tailor-made packaging printing and allied machinery as per customer specifications. Uflex has also introduced the concept of reusable carry bags with Pilfer-Proof Seal Rope Handle for packaging rice. Packaging machines are broadly classified in three categories: formfill, seal-wrapping and special-purpose machines. Vertical and high-speed horizontal form-fill-seal machines are single- and multi-track machines to pack granules, powders and liquids. Wrapping machines such as flow wrap, over wrap and candy wrap machines are used to pack solid products such as candy, biscuits and electrical switches. Semi-automatic machines such as vacuum nitrogen flushing and sealing machines are used for flexomatic for packaging liquids & band sealers. Printing and allied machines include both Electronic Line Shaft (ELS) drive and Mechanical Line Shaft drive
Assembly hall area
(MLS) drive lamination machines (dry and solvent-less lamination), inspection, slitting & doctoring machines as well as pouch making machines.
Research and Development (R&D) The companyâ&#x20AC;&#x2122;s R&D sets standards for quality machines globally. The company boasts of several facilities with sophisticated equipment to meet customer demands. The company believes that launching new and upgraded concepts with a single-minded commitment to quality is the key to success. The access to a large pool of engineering skills, in-depth and product understanding is the secret to the companyâ&#x20AC;&#x2122;s constant stream of innovative concepts.
in the manufacture of a wide variety of packaging and converting machines, the crux of its expertise lies in its ability to respond requirements.
Management strategies
Sanjay Malik Sabharwal
Uflex has been receiving the constant support of its customers by extending quality services. The company has been following different management strategies to become the leader in the current competitive packaging scenario. â&#x20AC;&#x153;Uflex has joined forces with customers to achieve European quality at Indian prices. With the world getting smaller through the rapid spread of knowledge and technology, it is important to understand the customersâ&#x20AC;&#x2122; needs and work accordingly,â&#x20AC;? adds Sabharwal.
Vice President-Marketing
Innovative marketing for the future In the relentless pursuit of its vision, the Uflex Group strives to offer total packaging solutions to its customers. This includes thorough understanding of customer requirements, in-house development of
solutions and offering the customer a costeffective packaging solution. Sabharwal opines, â&#x20AC;&#x153;We believe that before and after-sales service is a major determining factor for success or failure. Repeat orders can come only from satisfied customers. We recommend the correct method and machinery to all our customers. Although Uflex specialises in the manufacture of a wide variety of packaging and converting machines, the crux of its expertise lies in its ability to respond to customer-specific requirements. At Uflex, we follow a process of constant innovation to match customersâ&#x20AC;&#x2122; specifications.â&#x20AC;? Photo: Amit Kumar Email: anwesh.koley@infomedia18.in
Pouch making machine
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INSIGHT & OUTLOOK: Consumer-friendly packaging
Enhancing customers’
experience
The responsibility of packaging today has moved on from being service-oriented to promotional and a means of communication with the customer. The best way to differentiate one’s products on the market shelves is value addition, and thereby paving the way for consumer-friendly packaging. factors. The responsibility of packaging slowly moves from a utilitarian to promotional and communicative and from service oriented to symbol oriented. Packaging that encompasses various inter-related functions has also moved to be more expressive from the traditional functional aspects. Consumerism has thus become the watchword for package designers and marketers, as today they have to address the consumer eating habits, fast diminishing family sizes, average consumer pattern becoming mosaic, monolithic functionalism shifting to hedonism, variations in consumer goods and shifts in distribution & marketing changes.
Understanding consumerism
P V Narayanan
P
ackaging has become a revolution today, bringing in fundamental changes, massive expansion and exponential developments. The context is indeed
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social, economical and technological changes. The changing trends, consumer preferences and causes are built around convenience features, quality & quantity assurance, preference to branded products, product & use information, price stability, value addition and dosage
Modern Packaging & Design July-August 2012
The social and societal changes underline and differentiate more than just consumer-f riendliness. It is not mere convenience but includes significant additional responsibility. What a consumer-convenient pack should also address is satisfactory health and hygiene, besides pilfer-evidence, as well as tamper identification to ensure that the consumer gets the right product. The consumer demographic groups are of kinds – ‘what a child cannot access’ and ‘what an elderly can access more easily’. The urban consumer is fundamentally different from the conservative budget shopper of earlier decades. This is augmented equally by the increasing exposure to western lifestyles and habits.
Consumer-friendly packaging
The consumer demographics is evolving in smaller towns and rural areas where a shift in shopping patterns & buying habits is motivated by consumers’ desire to emulate urban lifestyle. Consumers and technologies will drive the inventions and innovations. It is no more generalistic, but scientific, with the world becoming increasingly uncertain with respect to brands with consumer thrusts. Consumer expositions with increasing literacy will demand novel concepts. Consumer expectations will undergo a sea change. They will continue to be cost centric, but value-for-money propositions to higher value offerings will surface strongly. Packaging will become the vital opportunity to build new brands, reinforce and add value even for an existing brand. The package becomes the resource for the entire marketing chain and interacts directly with brand and the consumer. Thus, markets and consumers will be the drivers for new products, convenience factor, brands and supply chain activities.
Packaging convenience Consumers of today look for a package that is easy to handle, portable, easy to open and reseal and also satisfy other demands & needs. Typical user-friendly packages identified by a consumer survey include: Packaging of liquid soap and readyto-use packs Packs with top-slide zippers as the most desirable closures Ease of use of plastic jars Following are typical packages that are uncomfortable to handle: Packaging and labels that are difficult to read or understand Finding contents spoiled after opening a package Spilling on first pour Roll-on Pilfer Proof Caps (ROPP) caps continue to rotate instead of breakage of the steps A well-defined consumer-f riendly package should address the target
audience, consumer insights and consumer convenience. Understanding of the target audience for the product plays a crucial role in developing the pack. The needs of the consumers vary within the groups. Packaging of toys should be more appealing to the children’s category than any other consumers. Consumer insights when taken into account at an early stage of package development can help in the right innovation and design. One can explore the ideas by the consumers. These ideas can relate to the shape, colours, typography, feel, touch and texture of the package. A survey into the feel of the consumers will open up new doors for product and package developments in terms of requirements of the user. Considering these requirements will help in designing a package that can meet the convenience factors of the end user. The task of understanding the consumer is a joint research between the marketing, manufacturing, purchase and supply chain teams. Understanding the consumers also revolves around questions such as – ‘who are they?’ ‘what are their needs?’ ‘what are their practices?’ and ‘what are their habits?’ Also, understanding the consumers with respect to other aspects should analyse use and consumption pattern as well as consumption & use frequency. The demand for consumer-friendly packaging is essentially the market driver enabling introduction of product categories and adoption of different technologies. The strategy is indeed based on a global scope catalysed by leadership and specialisation. The major business segments and, indeed, consumer goods & food services, personal care, healthcare and pharma products, open up opportunities for a wide range of package types, eg, shapes, sizes, technologies and many to suit specific customer groups and varying end-use applications. Reversing loop innovations could succeed, as consumers today are willing to experiment, adopt new products and experiences. This can also become more successful if the ‘new’
can articulate aspirational needs and seek solutions, with affordable price, better quality and high reliability being the new buzzwords. Consumer-friendly packaging offers a curiosity factor, value addition and opportunity exploration. Innumerable examples can be cited for such a packaging – press-in pill dispensers, caps for controlled dosage, spouted pouches, wine pouches with tap, single-serve tea pouches, stand-up pouch with screw-on spoon, twin-compartment pack, cartons with tear-off ribbons, three/two-in-one coffee/tea pouches, etc.
Infusing value to the pack Today, every company is willing to differentiate their products f rom others in the point-of-purchase shelf. A value-added pack is the best way to differentiate the product on the shelf. The concept of value addition in the pack is different from manufacturer to manufacturer. For some, the concept of value-added pack may mean providing an offer pack, while for some it may be providing the pack with a reusability feature and, for yet others, it may be through inbuilt consumer-friendly user features & security measures. The development of consumerf riendly packaging is important since everyone wants to offer some or other advantages to consumers through their product-package combination or in isolation of either. However, the path to consumerf riendliness is indeed challenging as many different parameters must be considered individually and collectively. 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
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PROJECT S
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers such as 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.
Battery manufacturing and packaging facility Procter & Gamble Duracell Project type Expansion Project news Duracell is making a $36 million investment to expand its Cleveland, Tennessee facility. P&G Duracell, the manufacturer of high-performance alkaline batteries, will expand its capacity and create about 60 jobs, thereby bringing its workforce to more than 500 personnel. Project location United States Project cost $ 36 million Implementation stage Ongoing Contact details: Procter & Gambles Duracell Berkshire Corporate Park Bethel, Connecticut- T 06801 United States Tel: +1800-551-2355 Email: trevor.johnson@PGDuracell.com
Integrated textile park The North India Printers Association (NIPA) Project type New facility Project news Proposed integrated Green Field Textile Park is being set up as part of the associationâ&#x20AC;&#x2122;s efforts to focus mainly on the US market. This textile park, claimed to be the countryâ&#x20AC;&#x2122;s first privatelyheld textile park, would have weaving,
processing, spinning, stitching, packaging and dispatching facilities at one location. Project location India Project cost ` 2000 million Implementation stage Implementation stage
Contact details: Paharpur Industries Ltd 2-A, Paharpur Business Centre 21 Nehru Place Greens New Delhi Tel: 011-6207727 / 28 Fax: 011-6452736 Email: pilcorp@pilpack.com
Contact details: The North India Printers Association C/o. Preeti Art A-55, Royal Indl. Estate Naigaum Cross Road Wadala, Mumbai, Maharashtra Tel: 0161-2404221, 2404093 Fax: 0161-2406434 Email: info@nipa.in
Printing institute cum testing laboratory project
Packaging machinery and technology Paharpur Industries Ltd Project type New facility Project news Paharpur Industries Ltd (PIL), a wholly owned subsidiary of Paharpur Cooling Towers Ltd and manufacturers of a wide range of packaging products, will invest around $ 22.5 million over the next five years in acquiring new machinery and technology. The company is working on a five year rolling plan to invest around ` 80-100 crore to acquire new technologies and machinery starting with a coater laminator that would cost around $ 4.5 million Project location India Project cost $ 22.5 million Implementation stage Implementation stage
The North India Printers Association (NIPA) Project type New facility Project news Glasgow Metropolitan College (GMC) and NIPA have signed an agreement under which GMC will provide syllabus and other technical know -how to the students. The need for such an institute has emerged with the changing technology and installation of sophisticated computerised machines, which has made it necessary to up-scale the printing and packaging industry in India. Project location India Project cost Not known Implementation stage Planning Contact details: The North India Printers Association C/o. Preeti Art A-55, Royal Industrial Estate, Naigaum Cross Road, Wadala, Mumbai, Maharashtra Tel: 0161-2404221, 2404093 Fax: 0161-2406434 Email: info@nipa.in
Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India = ;## #X<<<3>\ Â&#x2026; Z [= ;## #X;3>X3F Â&#x2026; = q _ ^ _
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TENDERS
Latest LatestPopular PopularTenders Tendersbrought broughttotoyou youbybywww.tendersinfo.com www.tendersinfo.com Bottling line for hot fruit juices
Automatic shrink packaging machine
Org
Org
TRN Desc BOD LOC BT
: The Maharashtra Agro-Industries Development Corporation Ltd : 11528580 : Consultant for setting up bottling line for aseptically packaging hot fruit juices : 10 July, 2012 : India : Domestic competitive bidding
TRN Desc BOD LOC BT
: Indian Railway Catering and Tourism Corporation Ltd (IRCTC) : 11499075 : Automatic shrink packaging machine : 20 July, 2012 : India : Domestic competitive bidding
Automatic wrap around labeling and rinsing Packaging of lubricants in HDPE containers Org TRN Desc BOD LOC BT
: : : : : :
Indian Oil Corporation Ltd (IOCL) 11509036 Packaging of lubricants in HDPE containers. 12 July, 2012 India Domestic competitive bidding
Packaging of lubricants in small pack containers Org : Indian Oil Corporation Ltd (IOCL) TRN : 11509093 Desc : Packaging of lubricants in smaller size HDPE containers. BOD : 13 July, 2012 LOC : India BT : Domestic competitive bidding
Filling and corking of drugs Org : Borisovskiy Zavod Meditsinskikh Preparatov TRN : 11569178 Desc : Supply of line for filling and corking of liquid drugs in 30/50/100 ml bottles with cleaning station and tunnel for drying bottles BOD : 16 July, 2012 LOC : Belarus BT : International competitive bidding
Pharma packaging Org : Ministry of Health TRN : 11545580 Desc : Supply of liquid filling machine with accessories for pharmaceutical services department at Al Sabah Hospital BOD : 16 July, 2012 LOC : Kuwait BT : International competitive bidding
Org TRN Desc
BOD LOC BT
: Indian Railway Catering and Tourism Corporation Ltd (IRCTC) : 11499074 : Automatic wrap around labeling and rinsing with filling and capping machine : 20 July, 2012 : India : Domestic competitive bidding
Packaging line for 500 ml PDW bottle Org TRN Desc BOD LOC BT
: Indian Railway Catering and Tourism Corporation Ltd (IRCTC) : 11498608 : Packaging line for 500 ml PDW bottle : 20 July, 2012 : India : Domestic competitive bidding
Procurement of conveyor roller spares Org : Western Coalfields Ltd TRN : 11468354 Desc : Procurement of conveyor roller spares BOD : 20 July, 2012 LOC : India BT : Domestic competitive bidding
Supply of conveyor belt Org TRN Desc BOD LOC BT
: : : : : :
Northern Railway (NR) 1518096 Supply of conveyor belt 20 July, 2012 India Domestic competitive bidding
Org: Organisationâ&#x20AC;&#x2122;s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type. Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India = ;## #X<<<3>\ Â&#x2026; Z [= ;## #X;3>X3F Â&#x2026; = q _ ^ _
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EVENT LIST
National
Ahmedabad
Pune
Chennai
Ludhiana
Indore
Aurangabad
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Gujarat Oct 5-8, 2012
Maharastra Nov 2-5, 2012
Tamil Nadu Nov 22-25, 2012
Punjab Dec 21-24, 2012
Madhya Pradesh Jan 11-14, 2013
Maharastra Feb 1-4, 2013
Uttarakhand Feb 23-26, 2013
Indiaâ&#x20AC;&#x2122;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. = ;## >;;> \<Q3 Â&#x2026; Z [= ;## >;;> \\?? Â&#x2026; = [q ^ 3X_ Â&#x2026; ` '= +++_ " [q _
PackPlus South 2012 This will be an opportunity to focus on the emerging opportunities in the fast industrialising markets of South India. The packaging sector of this region will be represented through its latest trends and technologies, especially by SMEs; July 6-9, 2012; at Hyderabad International Trade Exposition Centre (HITEX), Hyderabad For details contact: Print-Packaging.Com Pvt Ltd F101, 1st Floor, Tower 7, International Infotech Park, Above Vashi Railway Station Vashi, Navi Mumbai - 400705 Tel: 022-27812093/2619/2657 Fax: 022-27812578 Email: info@packplus.in Website: www.packplussouth.in
Compack 2012 This is among the leading trade exhibition for the entire packaging process such as bagging, sealing, strapping, filling, conveying, dosing, etc. Compack 2012 will provide the Indian packaging industry with an excellent opportunity for all industry players to meet on a common platform; July 13-15, 2012; at Chennai Trade Centre, Nandambakkam, Chennai For details contact: Narendar Bafna Smart Expos New No 116, Mount Road
86
Guindy, Chennai - 600 032 Tel: 044-22501986/1987 Mob: 09952966752 Email: compackexpo@smartexpos.in Website: www.compackexpo.com
Print & Packtech 2012 This exhibition will reflect the marketâ&#x20AC;&#x2122;s evolutionary with special focus on the integration of printing and packaging processes and its supply chain. This event will enable both industries to claim market leadership and future opportunities; August 24-27, 2012; at Palace Grounds, Bengaluru For details contact: Cyril Pereira 25, 3rd Floor, 8th Main Road Vasanthnagar, Bengaluru - 560 052 Tel: 080-4330402, Mob: 09886789641 Fax: 080-22352772 Email: info@printandpacktech.com Website: www.printandpacktech.com
PackPlus 2012 In order to showcase the opportunities and growth potential within the Indian packaging industry, PackPlus 2012 will provide a global platform to the leaders of this industry, who will present some of the latest innovations and developments from macros the world. Strong growth in sectors like fast moving consumer goods, pharmaceuticals, liquor, and cosmetics has had a positive rub off on the packaging
Modern Packaging & Design July-August 2012
industry.; December 7-10, 2012; at India Expo Centre, Greater Noida, Delhi NCR For details contact: Print-Packaging.Com Pvt Ltd F101, 1st Floor, Tower 7, International Infotech Park, Above Vashi Railway Station Vashi, Navi Mumbai - 400705 Tel: 022-27812093/2619/2657 Fax: 022-27812578 Email: info@packplus.in Website: www.packplussouth.in
Printpack India 2013 This edition will focus on disseminating information on technology, market perspectives and various developments taking place around the world, relevant to the Indian printing, packaging, converting and allied machinery manufacturing industries; February 23 to 28, 2013; at India Expo Center & Mart, Greater Noida, Delhi NCR For details contact: Indian Printing Packaging and Allied Machinery Manufacturersâ&#x20AC;&#x2122; Association (IPAMA) Plot No C - 54 Sector-62, Institutional Area, Noida - 201 307, UP Tel: 0120-4292274/75, 2400110 Fax: 0120-2400109 Mob: 9717199385 Email: admin@ipama.org, info@ipama.org Website: www.ipama.org
EVENT LIST
International PPMA Show 2012 This is among the leading trade shows endorsed by PPMA. It offers enormous opportunities to engage with manufacturers, processors and engineers looking to source processing & packaging machinery & equipment to enhance their operational productivity; September 25-27, 2012; at National Exhibition Centre, Birmingham, UK For details contact: Graham Earl Exhibition Manager Reed Exhibitions Ltd Gateway House, 28-The Quadrant Richmond, Surrey, TW9 1DN, UK Tel: +44 (0)20-89107890 Fax: +44 (0)20-89107877 Email: graham.earl@reedexpo.co.uk Website: www.ppmashow.co.uk
Paper Arabia 2012 This event will feature a broad range of industry verticals within paper packaging, such as tissue manufacturing, paper converting machinery and chemicals, processing & recycling solutions. It is the right platform to reach out to decisionmakers, traders, printers and packaging designers in the Middle East; October 1-3, 2012; at Dubai International Convention & Exhibition Centre, UAE For details contact: Rajesh Nair Exhibition Manager Al Fajer Information & Services PO Box: 11183, Dubai, UAE Tel: +971-4-3406888, Fax: +971-4-3403608 Email: nair@alfajer.net Website: www.paperarabia.com
Tokyo Pack 2012 This is among the largest international packaging shows in Asia. It provides strong support for expansion of business opportunities owing to emphasis on innovative product design and packaging; October 2-5, 2012; Tokyo International Exhibition Center, Tokyo, Japan
EMBALLAGE 2012
For details contact: Japan Packaging Institute 10F Togeki, Bldg 4-1-1 Tsukiji, Chuo-ku, Tokyo - 104 0045, Japan Tel: +81-3-35431189, Fax: +81-3-35438970 Email: tokyopack@jpi.or.jp Website: www.tokyo-pack.jp
Packaging Innovations 2012 This conference is for packaging designers and brand owners to ideate on convenient & sustainable solutions. From the latest materials to create customer recognition, design agencies to create a brand representing the product, to mock-up agencies producing the newest concepts: for producing branded packaging is represented here; October 4-5, 2012; at Business Design Centre, London, UK For details contact: Adrian Harrow easyFairs UK Ltd 8 Oak Lane, Twickenham TW1 3PA United Kingdom Tel: +44 (0)20-88438800 Fax: +44 (0)20-88921929 Email: Adrian.Harrow@easyFairs.com Website: www.easyfairs.com
For details contact: Flora Liegey Marketing Manager Comexposium 70 avenue du GĂŠnĂŠral de Gaulle F - 92058 Paris-La DĂŠfense Cedex Tel: +33 (0)1-76771424 Fax: +33 (0)1-53309521 Email: flora.liegey@comexposium.com Website: www.emballageweb.com
ALLPACK Indonesia 2012
PACKEX 2012 Among the leading packaging trade shows in North America dedicated to innovations in processing and converting, this event will offer hands-on access to the latest in flexible packaging, cartons, labels and tags, custom automation equipment, contract services, printing, converting, processing, materials, material handling, software, etc; November 14-15, 2012; at Montreal, Canada For details contact: Jim Beretta UBM Canon 11444 W. Olympic Boulevard Los Angeles, CA 90064-1549 USA Tel: +310-445-4200, Fax: +310-996-9499 Email: jim.beretta@ubm.com Website: www.canontradeshows.com
This is an interactive platform focussing on new packing design, exclusive conferences on food safety, eco-design, recycling, sustainability, etc. This event will offer exhibitors and visitors an opportunity to learn about the packaging industryâ&#x20AC;&#x2122;s current development techniques, new strategic stakes & marketing management policies; November 19-22, 2012; at Paris Nord Villepinte Exhibition Centre, France
This international packaging exhibition will feature the latest technology, machinery, materials system and supplies for the food & beverage industry, pharma & cosmetic packaging, bottling, canning & refrigeration solutions, automation & material handling, quality control and testing systems; November 21-24, 2012; at Jakarta International Expo, Kemayoran, Indonesia For details contact: Krista Exhibitions Blandogan Street No 28 D/G - Jakarta 11220 Tel: +62-21-6345861/62 Fax: +62-21-6340140 Email: info@kristamedia.com Website: www.allpack-indonesia.com
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
Modern Packaging & Design July-August 2012
87
EVENT PREVIEW: PackPlus South 2012
Emphasising on India’s packaging prowess India’s packaging industry is estimated to be a ` 8,000-crore industry and is growing at a brisk pace. With an aim to capitalise on this potential, PackPlus South 2012 promises to bring myriad innovations from the packaging industry under one roof, while pushing business opportunities to create further new avenues and possibilities. Some of the prominent participants at the event include Hilda Automation Ltd, KP Tech, Saurabh Flexipack Systems (P) Ltd, Superpack Packaging Machines (P) Ltd, Reynders Label Printing India (P) Ltd, Cyklop Packaging Systems India (P) Ltd, Bhavmark Systems (P) Ltd, AKR Plastic Industry, Hassia Packaging (P) Ltd, Ecobliss India (P) Ltd, AVP Papers, Maharshi Udyog, MarkemImaje India (P) Ltd, Electronics Devices, Inpack Fabrications (P) Ltd, Jay Instruments & Systems Pvt Ltd, SV Modular Conveyors (P) Ltd, Uflex Ltd and Interlabels Industries (P) Ltd.
Lionel Alva
C
onsidered as the beginning of a new epoch for the packaging industry, 2012 is undoubtedly a landmark year bringing in new prospects and possibilities. Industry growth projections have been extremely positive with estimates depicting a remarkable growth rate of 14-15 per cent in the coming years. The market driver for the rapid rise of the packaging industry is the retail boom, with market statistics registering record growth rates for the retail sector. PackPlus South, to be held on July 6, 2012, at HITEX, Hyderabad, promises to showcase some of the industry’s biggest and brightest names, and give a birds’ eye view of the potential of the Indian packaging industry.
A global platform With a strong and consolidated growth across segments, unprecedented business opportunities lie ahead for the packaging
88
A decade of evolution
industry. Growth in consumer goods and organised retail mainly drives demand for packaging. For an investor, the packaging sector offers promising growth and high returns. PackPlus South aims to provide a global platform to the leaders from this promising industry who will display some of the latest innovations and developments from the industry. The exhibition is expected to set the bar even higher than the remarkable edition of the previous year. “With the third edition of the PackPlus being organised in Hyderabad, the foothold has strengthened further. We have surpassed the last year’s records, with 250 exhibitors signed up for the show, and there are two more months to go. The show will outshine all previous records to create new landmarks,” avers Neetu Arora, Director, Print-Packaging. Com (P) Ltd, the organisers of the show.
Modern Packaging & Design July-August 2012
The packaging industry has always adopted a degree of sophistication in terms of underlying complex dynamics of manufacturing since it is a largely innovation-driven industry. The science of packaging has evolved rapidly. This edition of PackPlus South 2012 promises to showcase the latest trends in technology, especially in CAD/ CAM software and non-woven fabrics, thus earmarking trends that provide a panoramic view of the enormous possibilities in this sector. Along with the huge value addition and employment involved in these activities, packaging has served the Indian economy by preserving quality and prolonging the shelf-life of products such as milk & biscuits, drugs & medicines, processed and semiprocessed foods, fruits & vegetables, edible oils and electronic goods, besides domestic appliances, industrial machinery and other hardware that require transportation. Email: lionel.alva@infomedia18.in
BOOK REVIEW
Plastics Packaging Authors : Susan E M Selke, John D Cutter and Ruben J Hernandez Price : ` 6,473
Food and Package Engineering Author : Scott A Morris Price : ` 10,919
Most of those outside the field of packaging pay little attention to packaging; although without it the food and other commodities would be unsafe, untransportable and often unusable. This is a good book on plastics packaging, which includes properties, processing, applications and regulations. The authors stress on the relationship between chemical structure and properties of packaging materials. The book is well structured into 16 main chapters, which begin with basic concepts and definitions, polymer structures and properties, major plastics in packaging, additives & compounding. It continues into processes such as adhesion and heat sealing, extrusion, converting, lamination, casting, flexible packaging, thermoforming, injection moulding, blow moulding and bottles. It covers foams, cushioning and distribution packaging as well as mass transfer-related systems & considerations. The language is lucid, with clear and relevant illustrations. It is a good read for students and teachers of Packaging Technology and Plastics Engineering. However, the book has a chapter on Regulations and Environmental Considerations that deals with the subject in the US, and this is irrelevant for other countries. Thus, as a core book on the subject, it is a must for the library in institutions and will provide immense benefits to students.
This book explores the interconnected, globally integrated nature of the food packaging industry. It draws on nearly every aspect of science, technology, business, social science and engineering. Rather than present a traditionally linear view of these topics, the author takes a â&#x20AC;&#x2DC;Packaging Cycleâ&#x20AC;&#x2122; approach by guiding readers through the life of the package, from raw materials and conversion, operations, distribution, retail, all the way to recycling or disposal by the consumer. The book consists of 12 chapters covering the evolutions and future developments in food packaging technology and is intended for readers with varying levels of experience, Food and Package Engineering provides multi-level accessibility to each topic, allowing both students and professionals to find useful information and develop technical expertise. Rather than being a simple exposition of technical knowledge, the book provides real-world examples as well as challenging problems that require consideration at different levels. The subject is dealt well, but in many places, a more detailed explanation could have been given. The coverage is wide, but lacks depth in certain topics. Although it does not qualify as a core book, it is useful for additional reference. This is a valuable book for packaging and food engineering institutions and will serve as a good reference to teachers and students alike.
Reviewer: Prof C S Purushothaman, Chair Professor Director, SIES School of Packaging Mumbai. Avaliable at: SCI-TECH Books & Periodicals, 414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai 400 053 = ;##"#<F> Q#<;|<<?F ;Q;F Â&#x2026; [= ;##"#<F> Q\#\|Q#<; Â&#x2026; = ' { ^ _
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Modern Packaging & Design July-August 2012
` `
` `
PRODUCT S
Looking For A Specific Product? Searching and sourcing products were never so easy. Just type MPD (space) Product Name and send it to 51818
eg. MPD Wrapper and send it to 51818
Invospeed
It is a continuous operating high-speed shrink wrapper with single- or twin-lane tray packer module. It has an all servodriven machine capable for speeds up to 100 cycles/min. It is available in various configurations (Film only, Pad+Film or Tray +Film). The machine can handle different types of containers, eg, bottles, cans, cups, jars, cartons etc. The solid construction, the almost wear-and-tear free and easily accessible design, ensures a low maintenance cost. Invospeed requires no change parts when moving from one size to another. Clearpack India Pvt Ltd Mumbai - Maharashtra Tel: 022-28596422 Email: sales@clearpack.com Website: www.clearpack.com
Sleeve wrapping machine Lantech revolutionary SW series high-speed sleeve wrapping machine eliminates many of the common shrink wrapping problems that result in poor package quality. The machine significantly improves productivity levels by reducing rework as a result of poor package quality and reduces downtime due to time consuming changeovers. The SW series is available in SW-1000, SW-2000, SW-3000 and SW-5000 models. Features include simple, intuitive mechanical adjustments that make it easy for operators to set up systems, extra large operating sweet spot for time, speed and temperature control significantly improves quality, etc. Durapak Chennai - Tamil Nadu Tel: 044-43033533 Mob: 09840050066 Email: hitendra@durapak.in Website: www.durapak.co.in
Automatic extrusion blow moulding machine
Co-extrusion blow moulding machines have co-extrusion die heads to combine up to six different materials, incorporating highefficient melting screws, linear function for swift & steady production. The die-head ensures quality-melted material of non-scorch. Blow pin units and deflashing units have innovative designs for perfect neck and bottom deflashing.
This machine is used for making view stripe/ window line for lubricant field. The blow moulding machine is incorporated with a view of stripe extruder to produce various bottles and containers with the window line. Carriage movement is under the linear movement with German parts to provide swift performance, adopting a special brake system to ensure swift and stable movement of the mould carriage. Mould clamping is improved in design with column bars for strong and equal clamping performance.
Full Shine Plastic Machinery Co Ltd Tainan County - Taiwan Tel: +886-4-22765071 Email: fulshine@ms7.hinet.net Website: www.full-shine.com
Full Shine Plastic Machinery Co Ltd Tainan County - Taiwan Tel: +886-4-22765071 Email: fulshine@ms7.hinet.net Website: www.full-shine.com
Co-extrusion blow moulding machines
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PRODUCT S
Thermoform-fill-seal machine The Veripack Rollstock thermoformfill-seal machine is designed keeping the end customer in mind. This machines is well ahead in terms of flexibility, robust construction and high-end electronics. All models can handle flexi and rigid packaging films and carry out special skin-type pack formats; also, changeover from one format to another is simple and fast. Veripack Solutions India Pvt Ltd Mumbai - Maharashtra Tel: 022-66971133 Mob: 9967752336 Email: makdum.j@veripackindia.com Website: www.veripackindia.com
Thermoforming moulds High output is achieved by maximum cool capacity in combination with the right form air technology. The mould is constructed with a tool layout for minimum scrap. Optimal material distribution helps save material by downgauging.
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Modern Packaging & Design July-August 2012
Elpie Engineers Pvt Ltd Rajkot - Gujarat Tel: 0282-294522, Mob: 09712973716 Email: jjaghera@elpie.in
Vacuum packaging machine The mini counter-top vacuum packaging machine has standard features such as high-quality seethrough lid and all stainless steel body. This machine size overview is chamber 325 x 300 x 80 mm. seal beam 300 x 3 x 1 mm, and overall size of 670 x 385 x 370 mm, hot air chamber size at 325 x 300 x 80 mm, seal bar of length 300 and width 3 mm; number of seal bars and chambers: one, power grid voltage: single-phase 220 V, pressure: 2-5 mbar, pump speed: 4 m3/hr, vacuum pump power 0.4 hp single phase, etc. Saurabh Engineers Ahmedabad - Gujarat Tel: 079-22911288, Mob: 09824040137 Email: saurabh@indvacindia.com Website: www.indvacindia.com
PRODUCT S
Vertical form/fill/seal machine This PK 70 Storm vertical form/fill/seal machine has output of 80-120 pouches/minute, dimensions is 1,893 mm (L) x 1,222 mm (W) x 1,820 mm (H), power is 8 kW and the packaging material is polyester and metalised polyester films. It has an optional attachment such as multi-head scale, auger filler, volumetric cup filler, nitrogen gas flushing system, nitrogen gas flushing system and poking device.
soft stop, self-lubricating air cylinders, safety guarding, standard fault detection features and extended blank magazine. Clearpack India Pvt Ltd Mumbai - Maharashtra Tel: 022-28596422 Email: sales@clearpack.com Website: www.clearpack.com
Textile packaging boxes Pakona Engineers (India) Pvt Ltd Mumbai - Maharashtra Tel: 022-22854138 Email: info@pakona.com Website: www.pakona.com
Case erector Model 330 is a heavy-duty case erector built for high continuous production. It is designed for simple control, top flexibility and minimal maintenance. Its continuous motion drive performs case forming and case sealing operations at speeds of 35 cpm. Using electronics to control the operations and document their performance on the machine, it is also operator-friendly with touchscreen controls. Its features include
To ensure scratch-free and safe handling of sensitive articles, Nilkamal offers textile partitioned boxes. These boxes are useful in automotive industry for transportation and handling of sensitive components like lamp assemblies, fenders, etc. Being a licensee of Conteyor NV, Belgium, for their world-class Fitbox Technology, Nilkamal textile packaging provides an edge over others and is a costeffective solution for all industrial needs. Nilkamal Crates & Bins Mumbai - Maharashtra Tel: 022-26818628, 26818888 Mob: 8980011640 Email: pallets@nilkamal.com Website: www.nilkamal.com
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PRODUCT S
Linear weigh fillers Required accessories are double-stage reciprocating-type air compressor, threephase 15-kVA servo stabiliser and Z-type bucket elevator. Optional systems can be batch coding device, nitrogen flushing system, static charge eliminator and extra collars and trays. The machine can fill and pack products like rice, pulses, sugar, whole spices, seeds, grains, etc as well as nonfree-flowing & irregular shaped products. Inpack Fabrications Pvt Ltd Hyderabad - Andhra Pradesh Tel: 040-2724 3869 Email: ifpl2004@rediffmail.com
Flushing and sealing machine Nozzle Type Flushing and Sealing Machine is ideal for 'Pillow Packing' of fragile food products like potato wafers, banana wafers, certain fine noodles, etc, to maintain aroma, freshness, crispness for long time and protect fragile products from breakage/damage. It is easy to operate with food switch, has fully automatic sequence of operation & low cycle time. The standard seal length offered is 350 mm and width 12 mm (serrated). Saurabh Engineers Ahmedabad - Gujarat Tel: 079-22911288 Mob: 09824040137 Email: saurabh@indvacindia.com Website: www.indvacindia.com
Induction cap sealer Water-cooled Fluxosealer AFX3000 is a heavy-duty induction cap sealer for high-speed sealing and special applications. Bottles with neck diameters ranging from 10-150 mm can be sealed with ease. Standard features include no foil detection system, which consists of sensors to detect induction seal inside the cap, easy line relocation and plug & play system. The enclosure is made of MS powder coated/SS304. Arshad Electronics Pvt Ltd Mumbai - Maharashtra Tel: 022-24451709 Email: amoolji@arshadelectronics.com Website: www.arshadelectronics.in
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PRODUCT S
Blow moulding machine The complete XBLOW X07 series with platen widths of 350-700 mm is offered. The new single- and double-station machine is available with all-electric (EBLOW ) and hydraulic (HYBLOW ) drives. No modifications are required to use existing Bekum customer blow moulds on these machines. Continuity of the machine operation, apart from certain extended capabilities is considered. The machine platens are designed for good accessibility and ease of maintenance. Bekum Maschinenfabriken GmbH Berlin - Germany Tel: +49-30-74900 Email: c.richard@bekum.de Website: www.bekum.de
Labeling machine The automatic BOPP Labeling machine has fully automatic linear operation for 200-2,000 ml bottles. Maximum production speed of 60/90/120/200 bottles/minute. The machine is built fully in stainless steel. Height adjustments can be made to suit various
bottle sizes. It requires no cleaning of the nozzle or glue unit, before production (less maintenance & saves time) and is fitted with PLC. Hilda Automation Navi Mumbai - Maharashtra Tel: 022-2764 1585, Mob: 9821334822 Email: hildaautomation@yahoo.com Website: www.hildaautomation.com
Packaging machine The Corazza automated packaging machine is used for processed cheese, butter and soft soup cubes. This machine is versatile for a wide range of applications, for products in any required shapes having delicate consistency and requiring high-speed dosing, wrapping and cartoning, eg, processed cheese, fresh & cream cheese, dosed hot or cold. The machine has greater sealing coverage with patented tear tape offering far superior protection of the product. Tricon Pune - Maharashtra Tel: 020-25652205 Mob: 09890192832 Email: triconfood@gmail.com
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PRODUCT S
Blow moulding machine These blow moulding machines are targeted to produce plastic containers such as bottles, drums, tanks and other types of containers with volume in the range of 20 ml to 220 ltr. Also available in continuous type, this blow moulding machine is used for containers below 25 ltr. The accumulator die head-type blow moulding machine is used for containers above 25 ltr. Chen Way Machinery Co Ltd Tainan City - Taiwan Tel: +886-06-2434077, 2434079 Email: chenwaym@ms35.hinet.net Website: www.chenway.com.tw
Food packaging equipment
Automatic wrapper The model WM-4000-B automatic wrapper is good for packing house. It has a 10.4' colour LCD touch panel, automatic film changing, detachable and washable in-feed table and lifts. This automatic wrapper also includes automatic tray identification and centering, freearm labeling and has the capacity of 35 packs/min. The CCD camera automatically identifies the tray as soon as it is placed on the in-feed table. Wrapping conditions and tare weight are set automatically and any fluctuation in commodity tray placement is corrected by the centring conveyor. Ishida India Pvt Ltd Gurgaon - Haryana Tel: 0124-3854392, Mob: 09971449821 Email: sales@ishidaindia.co.in Website: www.ishidaindia.co.in
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The food packaging equipment includes jar filling machines for pickles and insulated bottle filling tanks. These machines are useful for bottle and highweight PET bottles filling for mango, lemon, mix pickles suitable for bottle and jar filling machines. Jar filling equipment with 125 kg filling hopper have provision of suitable nozzles. Regulated speed motor is provided with auger filler. Blended pickle and fruits do not get damaged. Weight filling is done by these machines and final weight is achieved by oil topping. Varada Engineers Pune - Maharashtra Tel: 020-26989087 Mob: 09823076601 Email: omvarada@gmail.com Website: www.foodequipmentvarada.com
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
LIST OF PRODUCT S
Looking For A Specific Product? Searching and sourcing products were never so easy. Just type MPD (space) Product Name and send it to 51818
eg. MPD Wrapper and send it to 51818
Product
Pg No
Product
Pg No
Product
Pg No
Auto sealer series .......................................................96
Flushing and sealing machine.......................................... 96
Pneumatic bagging machines ........................................... 47
Automatic extrusion blow moulding machine ................. 93
Food packaging equipment .............................................. 98
Polyethylene ....................................................................... 6
Automatic wrapper........................................................... 98
Gaskets ...................................................................... 3
Pre-engineered metal buildings........................................ 57
Automation controllers .................................................... 23
Gearboxes ......................................................................... 95
Pressure guage .................................................................. 59
Bearings ..................................................................... 4
Goliath crane.................................................................... 95
Pressure sensor for wet packaging application ................. 31
Blow moulding machine ............................................. 97,98
Goods lift ......................................................................... 95
Profile controller............................................................... 97
Bottle/container filling machines ..................................... 98
Guided compact pneumatic cylinder ............................... 41
Bottle testing equipment .................................................. 94
Hand-type impulse sealer ...........................................96
Breath analyser ................................................................. 95
Heavy industrial steel structures ...................................... 57
Cable carrier ............................................................... 4
HMI ................................................................................. 23
Cable connector ................................................................. 4
Horizontal FFS ............................................................. FIC
Cartoning machine.................................................. 98, FIC
Horizontal flow wrap machine ........................................ 47
Case erector ...................................................................... 95
Horizontal form-fill-seal machines .................................. 98
Chain.................................................................................. 4
Hydrogen gas detection system........................................ 94
Chain pulley block ........................................................... 95
Induction cap sealer ...................................................96
Chiller .............................................................................. 67
Induction motors.............................................................. 23
Co-extrusion blow moulding machines ........................... 93
Invospeed.......................................................................... 93
Semi-automatic filling system .......................................... 47
Cold form sections ........................................................... 57
JIB crane ...................................................................95
Sensors ............................................................................. 51
Compact pneumatic cylinder ........................................... 41
Labeling .................................................................. BC
Servo motors .................................................................... 23
Concrete block & paver machines ................................ FIC
Labeling machines ...................................................... 40,97
Shrink film ................................................................40, BC
Connector........................................................................... 4
Linear weigh fillers .......................................................... 96
Shrink wrap sealer series .................................................. 96
Container filling lines ................................................... FIC
Liners ................................................................................. 3
Shrink wrappers ............................................................... 40
Conveyer belts .................................................................. 15
Long bar sealer................................................................. 96
Single-stage monoblock vacuum pump ........................... 96
Coolant pipe..................................................................... 59
Material testing instrument........................................94
Single-stage vacuum pump .............................................. 96
Crabs/end carriages .......................................................... 95
Metallocene polyethylene ................................................... 6
Skin wrapping ...........................................................BC, 40
Crane ................................................................................ 95
Monoblock high-vacuum pump ...................................... 96
Sleeve wrapping machine ................................................. 93
Digital temperature controller ....................................97
Monorail trolley ............................................................... 95
Solenoid valve .................................................................. 59
Dosing/sealing systems .................................................... 98
Motorised chain pulley block........................................... 95
Drives ................................................................... 13, 23, 97
Motors .............................................................................. 19
Dry vacuum pumps .......................................................... 96
Multilevel steel car parks ................................................. 57
Dual channel with modbus .............................................. 97
Nitrogen extrusion sealer ...........................................96
Dynamic controller .......................................................... 97
Non-nozzle-type vacuum sealer ....................................... 96
Eco wrap bagging machines .......................................47
Nozzle-type vacuum sealer............................................... 96
Electric actuator & gripper .............................................. 41
Oil cooler ..................................................................67
EOT/HOT cranes ........................................................... 95
Oil seal high-vacuum pump............................................. 96
Exhibition - International Packtech India 2012................ 8
Packaging machine ....................................................97
Expanded polyethylene capseals......................................... 3
Packaging solutions .......................................................... 65
Expanded polyethylene seal liners...................................... 3
Palletisers ................................................................. FIC, 98
Two-stage vacuum pump ................................................. 96
Extra heavy-duty bagging machines ................................ 47
Panel cooler ...................................................................... 67
Universal controller....................................................97
Filing & packaging ....................................................39
PET bottle testing equipment ......................................... 94
Vacuum pumps ..........................................................96
Fill and seal machines ...................................................... 40
Plastic film & sheet.......................................................... 40
Vertical FFS .................................................................. FIC
Flame-proof hoist ............................................................ 95
Plastic masterbatches .................................................... BIC
Vertical form-fill-seal machines ...................................... 98
Flexible packaging material.............................................. 40
PLC.................................................................................. 97
Wire rope hoist ..........................................................95
PU tube ............................................................................ 59 Pumps............................................................................... 96 Push fittings ..................................................................... 59 PVC flexible braided hose ............................................... 59 Refrigerated compressed air dryer...............................41 Roofing & cladding sheets............................................... 57 Roots vacuum pumps ....................................................... 96 Rotary pumps ................................................................... 96 Sachet pacer...............................................................47
Structural floor decking sheets......................................... 57 Temperature controller ..............................................97 Testing instrument ........................................................... 94 Textile packaging boxes.................................................... 95 Thermoform-fill-seal machine ......................................... 94 Thermoforming moulds ................................................... 94 Thunder continuous motion bagging machines .............. 47 Transfer trolley ................................................................. 95 Tubular bag form ............................................................. 40
FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
Modern Packaging & Design July-August 2012
99
LIST OF ADVERTISERS Advertiser’s Name & Contact Details Benison & Co. Ltd.
Pg No 40
Advertiser’s Name & Contact Details Joyam Engineers & Consultants Pvt Ltd
Pg No 96
Advertiser’s Name & Contact Details Shanghai Dase-Sing Packaging
T: +886-3-322-5531
T: +91-79-26569533
Technology Co., Ltd
E: benison@benison.com.tw
E: joyam@joyamvactech.com
T: +86-21-3365-8333
W: www.benison.com.tw
W: www.joyamvactech.com
Bharat Bijlee Ltd
23
KHS Machinery Pvt. Ltd
T: +91-22-24306237
T: +91-79-2644-0331
E: vishwajyoti.vengurlekar@bharatbijlee.com
E: partho.ghose@khsindia.com
W: www.bharatbijlee.com
W: www.khs.com/india
Bonfiglioli Transmissions (Pvt) Ltd
13
Messe Dusseldorf India Pvt Ltd
T: +91-44-24781035
T: +91-11-26971745
E: sales@bonfiglioliin.com
E: sharmaS@md-india.com
Cognex Sensors India Pvt Ltd
51
T: +91-20-40147840 E: sales.in@cognex.com
6
T: +91-44-42152387
E: info@mifasystems.com
Ultraplast Chainbelts Pvt. Ltd
Pakona Engineers India Pvt Ltd
Prayag Polytech Pvt Ltd
E: info@ultraplast.in W: www.ultraplastindia.com United Steel & Structurals Pvt. Ltd
FIC
E: admin@unitedstructurals.com W: www.unitedstructurals.com Universal Corporation BIC
T: +91-11-47262000
E: samson7@vsnl.com
E: delhi@prayagmb.com
W: www.samson-grp.com
W: www.prayagmb.com
Vora Packaging Pvt Ltd
31
Presto Stantest Pvt Ltd
94
T: +91-129-4085000
E: pankaj@vorapack.com
E: info@ifm-electronic.in
E: gaurav@prestogroup.com
W: www.ifm-electronic.in
W: www.vorapack.com
W: www.prestogroup.com 4
Reynders Label Printing India Pvt Ltd
T: +91-80-39127800
T: +91-149-3305400
E: info@igus.in
E: india@reynders.com
W: www.igus.in
W: www.reynders.com
Infomedia India Ltd.
89
Roechling Engineering Plastics (I) Ltd
Wraptech Machines Pvt Ltd
47
41 T: +91-22-27614316 E: abm@wraptechmachines.com W: www.wraptechmachines.com 98
Wu Hsing Electronics Co. Ltd.
T: +91-22-30034650
T: +91-22-4217 8787
T: +886-4-2271-1498
E: b2b@infomedia18.in
E: binit.mishra@roechling-india.com
E: wuhsing@ms17.hinet.net
W: www.mphonline.in
W: www.roechling-india.com
W: www.sealers-web.com
Our consistent advertisers
3
T: +91-22-24012330
T: +91-2312672770
Igus India Pvt Ltd
59
T: +91-22-23436320
E: info@heatandcontrol.com
IFM Electronics India Pvt Ltd
57
T: +91-44-42321801
T: +91-44-42103950 W: www.heatandcontrol.com
15
T: +91-129-4113187 65
W: www.pakona.com 17
19
E: iecmktg@indianelectric.com W: www.indianelectric.com
E: bhushan@pakona.com
W: www.freezetechequip.com Heat And Control
97
T: +91-22-22826751
E: info@freezetechequip.com
W: www.technoind.com
T: +91-20-24456062
W: www.nichrome.com 67
E: info@technoind.com
The Indian Electric Co
E: marketing@nichrome.com
W: www.exxonmobilchemical.com Freeze Tech Equipments Pvt Ltd
8
T: +91-79-26870825
Nichrome India Ltd
95
T: +91-79-25830742
T: +91-20-6601101
T: +86-21-2417-3999
W: www.dasesing.com Techno Industries
W: www.mifasystems.com
W: www.cognex.com Exxonmobil Chemical
Mifa Systems
BC
E: leo@dasesing.com 39
W: www.md-india.com
W: www.bonfiglioliindia.com
Pg No
96
FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
COMPLETE ENGINEERING UNDER ONE ROOF @ www.eng-expo.com
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Modern Packaging & Design July-August 2012