Modern Packaging & Design - November-December 2011 by Infomedia18

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Modern Packaging & Design

November-December 2011

EDITORIAL

And the change continues… undreds of billion dollars worth rescue plans to tide over sovereign debt default, seeking alternative avenues to cope with volatile energy costs and rising demand for financial inclusion among several strata of society across the globe, irrespective of the stage of a country’s economic prosperity. These mega challenges confronting the world today are not just highly unprecedented but were also almost unthinkable a few years ago. More importantly, this reflects the reality of a fast-changing global phenomenon and a time of challenging opportunities to annul the risks effectively.

Change is inevitable for an organisation of any size or industry. The distinguishing point would be how the progressive ones bring about a significant difference by effectively managing change in a sustainable manner. Some of the real-life scenarios include implementing the latest hardware and software, mergers and acquisitions, relocation of facilities, adopting processes that enable to do more with less resources, etc. On a more sophisticated level, it can involve implementation of a strategic planning process, a specific quality management programme, process re-engineering, among others. A few months ago, we also embarked on a similar journey to ‘challenge and change’ ourselves, to make our brands better. In this exciting and innovative sojourn, we revisited & thoroughly analysed not only the content but also every practical aspect of our motto of providing information empowerment to you - our audience. Although we have put our best efforts towards perfecting the products and practices further, we would submit that the best practices for managing change are still elusive. The result is there for you to see in this new avatar of ‘Modern Packaging & Design’. From the brand new sections to focussed features, emphasis has been laid on ensuring more analytical, in-depth and contemporary first-hand information. Of course, all these are presented in a lucid and elegant manner; thanks to an optimum combination of applying mind over matter as well as some of the latest publishing software.

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

We would appreciate getting your valuable feedback on these initiatives. Suffice to say, it will help us in our constant endeavour to help you in terms of receiving superior value on a sustained basis. Let there be more information empowerment towards better decision-making in business. Happy business hours!

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

R Krishnamurthy Director-Marketing & Operations Orient Press Ltd

Manas R Bastia manas@infomedia18.in

S Das Managing Director Nordson India Pvt Ltd

Modern Packaging & Design November-December 2011

CONTENT S

43 Pharmaceutical packaging ........44

Special Focus Automation in packaging ..... 28

Insight & Outlook R&D in pharma packaging ...48

Automation index ................ 34

In-line quality control .......... 52

Small assembly robots .......... 36 Courtesy: Denso Robotics

Modern format retailing ...... 54 SWOT analysis of screen printing...................... 58

Modern Packaging & Design November-December 2011

27 Modern Packaging & Design November-December 2011

Automation Trends

Bottling line solutions: Conveying outstanding performance Courtesy: Clearpack India Pvt Ltd

Energy Management

Material conservation: Reducing consumption, augmenting growth

Policies & Regulations

ISO guidelines for biodegradable plastics: From formulation to implementation

In Conversation With

Ashok Chaturvedi, Founder Chairman & MD, UFLEX Ltd

KHS Machinery Pvt Ltd: Complete solutions under one roof

Strategy

Sustainable plastic packaging: Road to recyclability

Tips & Tricks

Safety in pharma packaging: Focussing on the hygiene factor

Facility Visit

Details on pg no. 76 Cover photo courtesy : ABB Ltd

Highlights of Next Edition Special Focus: Cosmetics Packaging Insight & Outlook : Filling, Strapping & Sealing Machines Note: ` stands for Indian rupee, $ stands for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise

REGU L AR SEC T ION S Editorial ................................. 9 Book Review ........................ 76 News, Views & Analysis ...... 14

Products................................ 77

Technology & Innovation .... 20 Projects ................................. 73

List of Products.................... 91

Event List............................. 74 List of Advertisers ................ 93

Modern Packaging & Design November-December 2011

Business Insights •Technologies•Opportunities

FOUNDER & EDITOR, NETWORK 18 Raghav Bahl

GROUP CEO, NETWORK 18 Haresh Chawla

PRESIDENT & EDITORIAL DIRECTOR, TV 18 Senthil Chengalvarayan

GROUP COO, NETWORK 18 B Sai Kumar

SENIOR EDITOR Manas R Bastia EDITORIAL TEAM Annabel Dsouza, Vishakha Avachat-Naware, Swati Sharma, Michael Anthony, Abha Mishra, Paskaline Sebastian, Anwesh Koley (Delhi), Avani Jain (Ahmedabad) ASSISTANT ART DIRECTOR Varuna Naik DESIGN Sharad Bharekar CHIEF PHOTOGRAPHER Mexy Xavier PHOTOGRAPHY Neha Mithbawkar, Joshua Navalkar BUSINESS CONTROLLERS Pukha Dhawan, Lovey Fernandes, Akshata Rane, Deepak Bhatia, Shwetha ME, Jayashree N, Sugandha Kulkarni, Shefali Mahant

PRINTING

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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 November-December 2011

NEWS, VIEWS & ANALYSIS

Burgopak innovations awarded at Pentaward competition

Globally renowned packaging designers, Burgopak has received a Bronze Pentaward at the 5th edition of the annual Pentaward Worldwide Packaging Design Competition for its designs for Aura Health & Wellbeing’s range of health and lifestyle products. Resembling origami style structures of intricate folds and precise structural design, the cardboard packaging as well as the logo motif are designed around an abstract representation of a tealeaf,

Ocean Extrusions on an expansion drive Ahmedabad-based Ocean Extrusions is all set to launch its new extrusion coating lamination machine. It is different from others as it will be a fully automatic machine using one extruder and two dies. The company claims that this machine is completely new in the Indian market, as the machines available earlier used two extruders & two dies. Since two years, the company has been working on the new machine, which is now

Green packaging industry shows positive development A study on domestic green packaging industry by The Associated Chambers of Commerce and Industry of India

repeated three times to represent inner strength. With nearly 1000 entries from 5 continents, this year’s Pentaward winners were selected by a jury of international marketing specialists and designers chaired by Gerad Caron, founder of Carre Noir (France) and with other members f rom companies including BIC Corporation (USA), Procter & Gamble (Belgium), etc. Burgopak’s designs showcase a wonderfully colourful and minimalistic branding aesthetic as well as the clever integration of logo and structural design to create a central and uniform identity. Dane Whitehurst, Creative Director, Burgopak, said, “This award demonstrates Burgopak’s commitment to offering packaging design solutions that consider the brand, consumer and retailer as well as being designed realistically for production.” Annabel Dsouza

almost complete. According to the company, it is entirely an indigenous product and has been conceptualised, designed and manufactured in-house. The new machine finds application in the woven sacks industry. In future, the company also plans to build a two-layer blown film plant. The budding company will also be participating in Plast Eurasia Istanbul 2011, an exhibition to be held during October 27-30, 2011, in Tuyap Fair Convention and Congress Center, Istanbul, Turkey. Avani Jain

(ASSOCHAM) 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. It stated that the Indian flexible packaging market is currently worth about ` 14,000 crore and is likely to reach ` 22,950 crore by 2015, with more domestic companies opting for eco-friendly packaging for their products. ASSOCHAM interacted with nearly 1,000 representatives, eg, chairmen, managing directors, chief executive officers & directors of food & beverage companies, consumer packaged goods, shopkeepers, wholesalers and retailers in cities like Delhi, Mumbai, Chennai,

Modern Packaging & Design November-December 2011

Mamata Machinery sets new standards in pouch making Mamata Machinery has established an Application Center in Bradenton, Florida, combining their pouch-making expertise with a US-based design team to develop a truly innovative and unique horizontal form-fill-seal pouching machine. Apurva Kane, Senior Vice President, Mamata Machinery Pvt Ltd, said, “This will help strengthen our position in the US.” VegaPack M-200 is designed to meet the needs of consumer packaged goods companies in the food, homecare and personal care markets. This new-generation machine balances high line speed with a small footprint and brings the flexibility of being able to process both laminated and co-extruded films with easy-tooffer repeatable no-fuss changeovers (less than 20 minutes). State-of-theart servo technology & design deliver unmatched operational efficiency and lowest per-pack costs in the business. Its hygienic design makes it ideal for applications requiring washdown and USDA food packaging specifications. Kane added, “Almost a million dollar has been invested in making this machine, which is different from others. This machine will use 100 per cent recyclable film and not laminates, which are generally non-recyclable.” Avani Jain

Kolkata and Bengaluru (200 in each city) to ascertain the impact and advantages of sustainable packaging on the highly fragmented Indian packaging industry. Nearly 45 per cent of manufacturers were found to be increasingly adopting renewable packaging technologies, eco-friendly light materials and costeffective methods, which would increase consumer awareness. About 75 per cent of the respondents stated that they were gradually reducing the use of nondecomposable plastic bags and seeking support of local grocery stores, vegetable & fruit vendors and hawkers to promote paper bag usage. Avani Jain

NEWS, VIEWS & ANALYSIS

Grafica appoints RH Solutions as supplier for North America

Sonoco’s Trident division alliances with Janoschka

After setting up base in UAE and Europe, Grafica Flextronica has recently appointed US-based RH Solutions Llc as supplier for North America. RH Solutions will distribute and service Grafica’s wide range of screen printing machines, screen making set up and UV curing machines in the US market. Following its alliance with Grafica, RH Solutions Llc is actively setting up major distribution channels throughout North America with established installations, after-sales support, engineering and sales, mainly derived by regional distributors. Bhargav Mistry, MD, Grafica Flextronica, said, “Screen printing is a versatile process has huge demand in industrial printing, textiles, graphics and packaging. Screen printers in the Americas can explore the power and secrets of screen printing for value addition, the way we have successfully explored in India. Hence, I

see a great potential for Grafica’s products in the Americas.” RH Solutions had also displayed Grafica’s Nano series screen printing machine and equipment at the 2011 SGIA Printed Electronics & Membrane Switch Symposium. Ron Hayden, Director, RH Solutions LLC, said, “Industrial-quality built machines and equipment are very important as well as the support behind it and that’s why RH Solutions has formed a strategic alliance with Grafica which is very well known for its excellent products, responsive technical support and after sales service.”

Sonoco’s Trident division, which provides print tooling and global graphics management, has entered into a strategic alliance with Janoschka, a German-based global supplier of pre-press solutions and tooling, to provide global consumer products goods companies and rotogravure printers with the widest coverage area available in the market.While several global consumer product companies currently produce graphics at a single supplier, no one supplier has been able to supply (and support) rotogravure print tooling to global print suppliers. This alliance will close that gap. Bob Carroll, General Manager, Trident, said, “The two companies will share technologies and communication systems to provide global consumer goods companies with fast, effective and consistent management of all their rotogravure tooling requirements.”

Annabel Dsouza

Avani Jain

Ron Hayden

Amcor claims breakthrough green coffee packaging

Wisdom Adhesives forays into India Wisdom Adhesives, North America’s top mid-sized manufacturer of high performance, environmentally safe industrial Jeff Wisdom adhesives, recently opened Wisdom Adhesives India as part of the firm’s global expansion plan. Headquartered in Mumbai, Wisdom Adhesives India provides a full range of hot melt and water-based product offerings for the packaging, converting, bookbinding and graphic arts industries in India. Key product lines include Wisdom Adhesives North America’s popular metalocene-based Clearbond and polyethylene-based Polytak hot melts as well as water-based Wizbond adhesives. The Wisdom Adhesives India team is a venture started by Advance Chemicals under the leadership of Kunal Jhaveri, who brings years of experience in adhesive development and adhesive market. Jeff Wisdom, CEO, Wisdom Adhesives, says, “We have been amazed at the strong welcome and positive response we have received from customers in India within two months of opening Wisdom Adhesives India. Our India team offers strong technical and marketing support, providing us with a bolt-on platform for expansion into the rapidly growing Indian marketplace. We look forward to providing Indian customers with our exceptional brand of industrial adhesives.” Annabel Dsouza

Amcor Flexibles Europe & Americas has launched NaturePlus Renewable, a three-ply laminate based on renewably sourced materials, which Amcor has produced and converted with Belgian company Beyers Coffee. The new product launch, in association with Beyer’s premium BénéCafe brand, will see NaturePlus Renewable used in a coffee bag format containing 58 per cent carbon based on the ASTM D6866 method to test carbon-neutral CO 2 emissions. This is a standardised analytical test method for determining the bio-based (carbon) content of solid, liquid and gaseous samples using radio carbon analysis, and has been incorporated into reporting protocols used in the European Union (EU), Australia and the US. Amcor has claimed that the bag has strong barrier properties and seal integrity, which allows coffee to retain its freshness and aroma. Nathalie Vanderkindere, Sustainability Product Manager, Beyers Coffee, said, “Providing responsible packaging means that we must meet our stakeholders’ expectations to deliver innovations that have the potential to reduce packaging’s environmental impact utilising our expertise as a global packaging leader to make a positive contribution to society.” Anwesh Koley

Modern Packaging & Design November-December 2011

NEWS, VIEWS & ANALYSIS

Canvironment Week 2011 sees more global participation

Atit Bhatia

After the global success of Canvironment Week 2010 which brought together leading can makers, trade association and different bodies to promote the sustainability of metal cans, Hindustan Tin Works (HTW) launched Canvironment Week 2011 earlier this year at Metpack and Interpack in Germany. Following are some of the activities planned for this year’s edition of Canvironment Week: The Italian can maker ASA plans painting competitions for school children in Italy Empac, representing the European metal packaging industry plans to donate T-shirts promoting Canvironment Week to the under privileged in Belgium in association with HTW Brasilata in Brazil will inaugurate a metal can recycling center in Brazil during the week HTW is planning to use art, fashion and glamour to promote sustainability of cans in India. It will also be producing a TV show on a youth oriented channel to promote canned food with celebrities. Health camps for rag pickers – the people who are the major cog in the recycling wheel of India will also be conducted. Atit Bhatia, Canvironment Week President and Senior VP, HTW said “Canvironment week is a global attempt to spread the message about the exclusive benefits of usage of cans, every industry stake holder should celebrate this event and promote metal cans as a package.” Annabel Dsouza

Indian packaging segment to reach $ 41 billion in 2015 The Indian packaging industry is expected to reach $ 41 billion by 2015, to become the sixth largest market in the world, according to a study by ICD Research. In line with the growth in the overall industry, the packaging machinery category is expected to record robust growth to reach $ 2.3 billion by 2015 from its current estimated value of $ 1 billion. Fundamental drivers indicate strong long-term growth prospects that are attracting foreign companies. Despite this growth, India’s per capita packaging consumption is estimated to reach only $ 31.4 by 2015, which is significantly lower than the average

of the top 14 packaging markets. Key packaging end-user markets such as retail, pharmaceutical and processed food industries have grown steadily, focussing on both domestic demand & exports. Following the strong Gross Domestic Product (GDP) growth over the last two decades, a huge middle class with high disposable income has emerged. This has led to new patterns in lifestyle and consumption, which is driving the demand for packaged products. Key growth areas for packaging-related imports include wood pulp, specialty paper, aluminium foil and tinplate. The Indian market also relies on imports for high-end packaging machinery. Anwesh Koley

Gerresheimer plans expansion into the US market Pharmaceutical packaging firm Gerresheimer has plans for acquisitions in the US to enter the North American plastic drug packaging sector, as well as emerging markets. The company has a presence in the US pharma glass primary packaging market but is planning to expand its focus to the plastic systems business for pharma and healthcare customers in North America. Gerresheimer currently operates in the US medical plastic systems market through a technical centre in Atlanta, Georgia. Hans-Jurgen W iecha, Chief Financial Officer, Gerresheimer, said that the German-based company plans to extend its market position as a successful partner to the pharma industry both in

Alternative energy from non-recycled plastics A new study conducted by the Earth Engineering Center (EEC) of Columbia University and sponsored by the American Chemistry Council has found that if all non-recycled plastics that are currently dumped into landfills each year in the US were converted to energy by using currently available technologies, they could provide at least enough energy to fuel 6 million cars annually. “Plastics have a significantly higher energy value than coal,” said, Prof Marco

Modern Packaging & Design November-December 2011

the western world and emerging markets like China, Brazil and India. Wiecha said, “There are very few companies in the US that are genuinely focussed on plastic packaging products for the pharma industry. Most of them are technology providers, ie, they have good plastics technology for various end-markets like the pharmaceutical, automotive or consumer goods sectors.” The company also plans to join hands with companies whose pharma business accounts for more than 50 per cent of their total business. Anwesh Koley

J Castaldi, Earth and Environmental Engineering Department, Columbia University, and Associate Director, EEC. He explained, “Capturing the energy value of non-recycled plastics and municipal solid waste in general, makes good sense because it provides a good domestic form of energy while minimising impacts on the environment.” The study also estimated that if all non-recycled plastics discarded in the US annually were diverted to modern waste-to-energy facilities, they could produce 52 million MWh of electricity. Anwesh Koley

NEWS, VIEWS & ANALYSIS

New film laminate from Avery Dennison

Markem-Imaje introduces printing & labelling solutions

Kabra Gloucester showcases first five-layer film plant

Avery Dennison has introduced Global MDO – the latest addition to its innovative Machine Direction Oriented (MDO) film product line. The new film laminate bridges the gap between the highperforming MDO film range and PE85 film and features major productivity and sustainability improvements, eg, significant reduction in web breaks, up to 50 per cent less ooze, an inherently printable film and double the amount of labels per roll, balanced with the on-shelf label clarity required for Home and Personal Care (HPC) applications. Kent Stobbart, Product Marketing Director, Avery Dennison Label and Packaging Materials Europe, said, “Earlier, the thinner label material available lacked rigidity. For conformability one had to give up clarity. One need not make such compromises with Global MDO.” The company claims that the clear, inherently printable face stock offers high-grade printability with on-press corona treatment and delivers stable print registration, resulting in consistent highquality print work. Global MDO is ideal for label printers and brand owners looking for operational excellence. The exceptional strength of the label stock, which has a 50micron MDO film and 23-micron polyester liner, virtually eliminates line shutdowns due to web breaks.

Markem-Imaje has launched its 2200 Series, an ultra-efficient range covering a broad choice of interchangeable applications, optimised operational intervention and unparalleled label application rates. The new 2200 Series enjoys the advantages of a range that has already demonstrated its reliability, efficiency and ease of use. With thousands of units installed in demanding environments and its capacity to operate round the clock, the 2200 Series has proved to be highly reliable. “We have evaluated the 2200 Series in the most representative applications and estimate that production line stoppages will be reduced by at least two days per year as compared to our competitors,” claimed Mike Kirk, Product Manager, Markem-Imaje. He elaborated, “In terms of sustainable development, we have reduced the power consumption to 135 watt at maximum throughput, well below the market standard, and the machine has been designed to be 95 per cent recyclable.” The 2200 series is capable of printing and applying labels at rates in excess of 125 boxes per minute. Label application is consistent due to an optimised label path, automatic label tension and an integrated label pad sensor.

KAGE is the brand name for film plants manufactured by Kolsite Group, utilising the engineering designs and technology of Gloucester Five-layer film plant Engineer ing Co. KAGE lines are specifically engineered to meet diverse challenges of the film plant industry, and the first five-layer fully loaded line is all set to be delivered to Prropyl Packs Ltd, Kerala. KAGE plants are designed to produce barrier film at rates and quality levels that not only meet the markets requirements, but also result in enhanced operational efficiency and higher flexibility for plastics manufacturers. The five-layer 2,200-mm film line has an installed capacity of 4,000 tonne/year and output up to 600 kg/hr. This five-layer film plant can be used to pack oil, and in other barrier applications; it is also used for production of high-quality lamination films. Prropyl Packs will introduce the barrier film mainly for oil packaging, vacuum packaging and packaging that needs enhanced shelf life. As India has mandated edible oil to be sold in packaged form only, barrier film packaging shall not only meet government standards, but also improve the shelf life of packaged oil by protecting it against oxygen & moisture and ensuring its cleanliness.

Annabel Dsouza

Anwesh Koley

Annabel Dsouza

Pro Mach acquires Matrix Packaging Machinery Pro Mach Inc has recently acquired Matrix Packaging Machinery will join its Primary Packaging Business Unit expanding Pro Mach’s primary packaging solutions. The Matrix management team will remain with Pro Mach, which provides machinery solutions and consumables for many of the world’s most recognized food, beverage, and consumer goods companies.

Matrix, founded in 1988, provides flexible packaging machiner y for companies worldwide that require high quality, versatile pouch and bagging solutions. Matrix solutions include machines for pillow, gusseted, zipper, stand-up, and bag-in-bag packaging. Matrix’s strength in vertical form fill seal packaging allows Pro Mach to reach new markets worldwide with its diverse brands of high

Modern Packaging & Design November-December 2011

performance equipment and integrated solutions. “We are excited to welcome the Matrix team to Pro Mach. We look forward to continuing the Matrix tradition of excellence and serving their outstanding customers as well as providing their solutions to all the customers of Pro Mach,” said Mark Anderson, President & Chief Executive Officer, Pro Mach. Anwesh Koley

NEWS, VIEWS & ANALYSIS

Packaging companies get a glimpse of latest technological developments in Gujarat India Package Meet 2011 that concluded on September 10 focussed on technological developments in the packaging and package printing industries. The event – held in Gujarat by Print-Packaging.Com (P) Ltd – attracted more than 150 visitors at Vapi, over 250 visitors at Ahmedabad and over 200 visitors at Rajkot. The event comprised a half-day conference focussed on technological developments in packaging and package printing and a day-long table top exhibition showcasing products and services from more than 30 exhibitors at each venue. “At one level, the meet took the packaging event to the grassroots, where the packaging is made and consumed and, at another level, it served to whet the attendees’ appetite to visit international events organised in Mumbai, Delhi and Hyderabad,” said Anil Arora, President, Print-Packaging. com Pvt Ltd.

Ashok Shukla, President, Vapi Industries Association lighting the lamp as other dignitaries look on

The technical sessions at each venue were carried out by distinguished speakers from the industry, including KVA Naidu, Cyklop Packaging Systems (India) Pvt Ltd; Rakesh Shah, Windmoller & Holscher India Pvt Ltd; Kishor Butani, Robatech India Pvt Ltd; Mohan Pailwan, Creed Engineers Pvt Ltd; Ignatius Selvaraj, Pepperl + Fuchs (India) Pvt Ltd; P V Sivaram, B&R Industrial Automation Pvt Ltd; Lalit Jain, Siemens Ltd; Harveer Sahni, Weldon Celloplast Ltd; Avinash

Bangale, Bosch Ltd; and Deven Mehta, Rajoo Engineers Ltd. “Vapi, being a small industrial cluster, does not see many trade events organised in this area. The speakers were cooperative in helping us understand the technical aspects of their presentations,” said Jatin Shah from Shah Print & Pack Industries. The table top exhibition at each venue showcased products and services from the providers of machines, materials and services to end users, package converters and corrugated box makers. “The event provided us with a unique opportunity to reach our customers from the industrial clusters of Gujarat,” said Ignatius Selvaraj, Pepperl + Fuchs (India) Pvt Ltd. Further, Arora commented, “The huge response of India Package Meet has added to our enthusiasm. The focus now shifts to our main exhibitions – India Converting Show in Mumbai and India Packaging Show in New Delhi.” Vishakha Avachat-Naware

Modern Packaging & Design November-December 2011

TECHNOLOGY & INNOVATION

Twist-off Natralock packaging for Berkley’s NanoFil fishing line

MeadWestvaco (MWV) Corp has redesigned its Natralock® packaging solution to create a new reusable package for the new Berkley® NanoFil fishing line. A secure and more sustainable Natralock® packaging solution is used to create the glare-free surfacing and standout foil graphics for NanoFil. For the first time, an innovative twist-off feature is added to Natralock paperboard-based blister packaging, creating a reusable design, which allows the consumer to store the product in the package. In keeping with consumer purchasing habits and the product’s applications, MWV’s design team developed and introduced the new twist-off concept to help fishermen keep their lines organised in between uses. Once the seal is broken on the blister, the card twists right off for easy accessibility and reusability. NanoFil is the world’s first unifilament fishing line that pushes the limits for minimum diameter & maximum strength, as well as effortless casting. Berkley® NanoFil, packaged in MWV’s Natralock twist-off packaging, is available in retail stores.

New flatbed printer for optimum productivity on rigid substrates The latest addition to Agfa Graphic’s Anapurna family of wide-format UVcurable inkjet printers is a dedicated Flatbed (FB) engine, designed to accommodate the growing market needs for printing on rigid substrates. The Anapurna M2540 FB is a new time-saving machine featuring a revolutionary quick-change vacuum bed technology, six colours (CMYKLcLm) and white ink.

Syntac T-max boosts blister pack moulding Syntac T-max from Trelleborg is a new syntactic material designed to offer greater control over the thermoforming mould process used in the blister packaging market. The Polytetrafluoroethylene (PTFE)-impregnated material is claimed to reduce process cycle times and enhance finished quality through its superior slip and release properties. The new solution features increased strength as compared with other epoxy

syntactic systems. It provides improved clarity, eliminating swirl and chill marks, as well as uniform material distribution, low void content and easy high-speed milling with little dust production. Designed for use in both roll sheet and heavy-gauge thermoforming processes, no special tools are required to machine Syntac T-max, and a high service temperature of 232°C is attainable. The material is available off the shelf in machinable blocks, sheets and rods.

Thermal transfer coder by Allen Coding Allen Coding Systems has launched its 53XL thermal transfer coder. It features a large print area up to 53 mm x 80 mm, allowing users to easily print fixed and variable text, data & graphics, as well as reproduce bar codes, real time, sell-by dates, batch numbers, prices and source codes. Also capable of printing Julian data and 2D DataMatrix codes, the affordable new 53XL is ideal for food, cosmetics and pharmaceutical applications. It is available in intermittent motion for easy integration with a wide range of packaging equipment including vertical & horizontal form-fill-seal systems, primary labellers, thermoformers and overwrapping equipment. It offers reduced maintenance and type changes, resulting in lower cost of ownership. Besides a larger print area, the 53XL provides many of the advanced

features of more expensive thermal transfer units, but at a fraction of the cost. These include 300 dpi print resolution, cassette ribbon loading, 600-m ribbon capacity, print speeds up to 400 mm per second and a best-of-breed thermal print head. With its standard Ethernet connection capability, the 53XL can be accessed using the plant-wide network to remotely changeover, monitor and diagnose the print operation and centralise the control of multiple printers. The standard PR5 handset enables operators to recall images from memory and simple editing functions at print time. The handset’s USB port enables easy uploading of label designs.

With a maximum print speed of 45 m2/hour, Anapurna M2540 FB can print sizes up to 2.54 x 1.54 m, with substrates up to 4.5-cm thick and 80 kg weight. The machine’s 11 retractable register pins simplify quick and accurate positioning, particularly when working on double-sided jobs. The excellent adhesion of the UVcurable ink and its fast & efficient curing mean that glass, ceramics and wood can also be printed, making it suitable for architectural & interior

decoration as well as exterior signs, displays and publicity. The new printer will appeal to not only display producers and signmakers but also other market sectors driven by the need for high-quality, durable full-colour output using UVcurable ink technology. It is as suitable for packaging prototypes, promotional goods’ manufacturers as it is for industrial specialists who need fast throughput and the ability to work with a vast range of rigid substrates.

Modern Packaging & Design November-December 2011

TECHNOLOGY & INNOVATION

New barrier system for PET bottles Tet APPE, the packaging division of La Seda de Barcelona, has launched a new barrier system for Polyethylene Terephthalate (PET) bottles. The new ActivSeal system is an oxygen scavenger with a catalyst in the bottle wall and a hydrogen activator in the closure, which work in combination to prevent oxygen reaching the drink and reduce vitamin C loss. ActivSeal is based on the HyGuard oxygen scavenger previously launched by ColorMatrix. A minute amount of the ActivSeal catalyst is present in the container wall, while a hydrogen activator is built into the closure. Once the container is full and the closure applied, there is a controlled release of hydrogen. As oxygen enters through the container wall, it binds with the

hydrogen on the surface of the catalyst to form negligible amounts of odourless and tasteless water. This prevents oxygen from entering the container. The advantage of the closure incorporating barrier technology is that clarity is maintained even in smaller bottle sizes, as no extra barrier material needs to be added to the container wall. ActivSeal bottles can be used for food contact applications again when they are recycled. It can match the typical shelf life for juices packaged with current barriers, and offers an extended shelf life. Another advantage of the system is that the oxygen scavenging process does not start until after filling and capping, so empty bottles can be stored for longer periods with no loss of barrier effectiveness.

Modern Packaging & Design November-December 2011

Stretch film for direct food contact Duo Plast has produced new stretch film for securing loads in the food industry. Duo Food Contact is specifically developed for direct food contact and can be used as primary packaging for all types of food. The stretch film corresponds to the latest provisions of EU Regulations. It is a blown stretch film having outstanding technical properties such as extreme elongation and tear strength. As a result, the film thickness can be reduced and significant material savings can be realised. Excellent adhesion properties and restraining forces increase transport security considerably. It offers the added value of being used as a primary packaging. Primary packaging used so far can be reduced or even completely replaced. With Duo Food Contact, every food producer is on the safe side in terms of hygiene and sustainability.

IN CONVERSATION WITH: Ashok Chatur vedi

“India is an emerging country in terms of flexible packaging” …asserts Ashok Chaturvedi, Founder Chairman & Managing Director, UFLEX Ltd, who has pioneered the growth of the flexible packaging industry in India. Demonstrating innovativeness and entrepreneurial skills, he applied latest international technologies to design packing material, which adapted to customers’ needs, winning markets globally. In a tête-à-tête with Vishakha Avachat-Naware, he highlights the promising future of the flexible packaging industry in India. What are the key driving factors that led to inception of UFLEX Ltd? With an objective of catering to the masses, UFLEX Ltd came into existence in 1985. After pursuing a degree in science, I wanted to start a new venture on my own. The mass appeal that this industry had at the time and the guidance that I received from industry experts led me to choose this industry. After observing the consumer needs and demand drivers in this industry, I invented the portion pack – a package meant for one-time use. The first product to be packed in such portion packs was spices. The idea behind the invention of portion packs, which are not only utility based but also affordable, was that instead of buying big packs for spice powders, people would prefer smaller portions.

In 1985, the concept of flexible packaging was new to India. How did you convince yourself and others associated with the company to start a new venture for flexible packaging? I belonged to a non-business background and needed to be firm on my decision to start this venture. Back then, although flexible packaging was at its nascent stage, it had huge potential to expand in future. So I was convinced of the lucrative growth prospects of this industry. Also, the need for flexible packaging among the masses made my decision even stronger.

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Modern Packaging & Design November-December 2011

Ashok Chatur vedi

As a first-generation entrepreneur, what challenges did you face during the company’s inception and later? Two major challenges that every business aspirant has to face are funds and manpower. The challenge for me at that time was to convince people to join this company and assure them of a good career in this field in the future. Making people aware of flexible packaging and its demand in our country was a big and challenging task. Finding appropriate financial resources was a tough task, as we started as a micro-scale company. We began our venture in Noida with a small, modest shed spanning 100 sq yard. Today, we have come a long way, from that small shed to having established a presence in more than 100 countries.

To whom would you attribute your success to? I attribute my success to the product that we invented – the portion pack. It was received successfully in the market and that motivated me to do a lot more in this field. I believe that this product has removed the discrepancy between the rich and poor due to its cost-effectiveness.

You have been associated with this industry for the past 26 years. How would you describe the progress of flexible packaging in India and worldwide? The packaging industry is the world’s third largest industry, the first and second being the crude oil and Fast Moving Consumer Goods (FMCG) industries, respectively. The flexible packaging industry has a growth potential of 6-8 per cent in the near future globally. India is an emerging country in terms of flexible packaging and expected to grow at a faster rate of over 20 per cent annually. As compared to the western world and Asian countries like China, the per capita consumption of goods packaged using flexible packaging is less in India. There is a huge potential in this field, as flexible packaging will also improve the hygiene in our country. In order to

maintain the hygiene, it is important that the product is packed at the same place where it is manufactured. India can become the largest consumer of flexible packaging goods in the world, if companies here start packing the following products in this way: sugar, wheat flour (less than 1 per cent is currently sold in packed form), rice, pulses, spices, tea and coffee. Among liquid products, packaging milk in cartons and flexible laminates will help increase the use of flexible packaging. Edible oils can also be packed in a similar way.

which make the pouches such that maximum filling area can be achieved.

What are the challenges faced by the flexible packaging industry, in India as well as globally?

What are your future expansion plans?

As we see a high growth potential in the flexible packaging industry, the only challenge is to continue updating and improving the technology used in it. In glass or metal packaging, the growth potential is either stagnant or in negative. Flexible packaging has less weight, uses less energy, produces less carbon dioxide and leaves smaller carbon footprint. Also, it is convenient to both - consumers and manufacturers. The awareness is increasing among consumers. A product is packaged so that it reaches in its original and fresh form to the consumer. If the quality is not good, the consumer can file a lawsuit against the manufacturer.

What are the latest developments and innovations in this industry? This industry observes new developments every day. Flexible laminates – made from raw materials such as Polypropylene (PP), Biaxially Oriented PP (BOPP) and Polyethylene Terephthalate (PET) – are becoming thinner day by day due to the latest technology used. The thin laminates ensure lower cost for both the manufacturers and consumers. The preform pouch or Three-Dimensional (3D) pouch, which has a large amount of filling area, is a new trend in the industry. Today, good filling machines are available,

What has been the toughest business decision you have ever taken? Until the decision is converted into success, every decision made is difficult. During the global meltdown in the years 2007 and 2008, we had plans to expand our company to Jammu in India and to other countries like UAE and Egypt. People constantly advised me to reflect on this decision, but I was convinced that as long as food and consumer products are being packed, this industry will not see a fall.

We are currently present in over 100 countries and plan to further spread in countries where there is a market for flexible packaging. Two of our plants are under construction in the US and Poland. The Poland plant, located in Poznan, will produce high-quality polyester packaging films and is expected to start operations in May 2012. The plant in the US, located in Kentucky, is expected to begin operations in December 2012. We also plan to start manufacturing plants in other countries for manufacture of high-grade packaging Polyethylene (PE) and BOPP films in the near future. With the ` 15,000 crore domestic packaging industry growing at 15-18 per cent annually, we are eyeing a $ 1-billion turnover by the financial year 2013. This will make UFLEX a preferred supplier of packaging materials in India and globally. UFLEX Ltd has become synonymous with the flexible packaging industry in the country, with a revenue of $ 750 million and gross capital investment of $ 700 million worldwide.

Your message to aspiring and upcoming entrepreneurs My message to all aspiring entrepreneurs would be to enjoy work like they enjoy holidays. One must be passionate about the work and not consider it as a burden. Email: spedit@infomedia18.in

Modern Packaging & Design November-December 2011

Business Insights •Technologies•Opportunities

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

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SPECIAL FOCUS

Automation in Packaging Automation in packaging Flexible futuristic solutions .................................................................................. 28

Automation index Boosting the bottom line...................................................................................... 34

Small assembly robots Reducing downtime, enhancing precision ........................................................... 36

Modern Packaging & Design November-December 2011

SPECIAL FOCUS: Automation in packaging

Flexible futuristic solutions Courtesy: Baumuller India

The tech-savvy and gadget-friendly consumers demand quality products that are attractively packed, hygienic & safe. As growth of the packaging industry is directly proportional to consumer demands, the stiff competition in the market necessitates manufacturers to adopt fast, efficient yet cost-effective packaging processes. Vishakha Avachat-Naware explores the scope of automation technology in the Indian packaging scenario.

utomation in packaging is a growing trend as it ensures better productivity and efficiency through a combination of speed and 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 forward to buying quality products that are attractively packed, and yet are hygienic and safe.

Automation advantage The entire packaging industry, inclusive of pharmaceutical, food & beverages and confectionary packaging, has witnessed the benefits of automation. Automation has influenced packaging processes, in terms of high rate of packaging (line speed), accurate filling, perfect sealing, flexibility in product selection, quality of packaging, etc. “With the advent of ultra-modern automation technology, the packaging process is now completely integrated with manufacturing process at the end of the line. Today’s packaging

machines are safe as well as offer hygienic conditions for packaging,” asserts Sunil Mehta, General Manager - Technical, Messung Systems Pvt Ltd, and Assistant General Manager, Automotive Business Unit, Messung Group of Companies. Winds of change are flowing in the packaging machine industry. Driven by end customers, the packaging machinery Original Equipment Manufacturers (OEMs) are being driven to bring in innovative technology in the machines they intend to supply in the market. Manufacturing efficiency and flexibility are the buzzwords in the market today. Decreased product lifecycle and rising costs are driving manufacturers to push OEMs to deliver competitive machines while meeting efficiency and flexibility requirements. “While globalisation has created new opportunities for OEMs outside their home markets, it has increased competition for OEMs from suppliers across the world, necessitating faster response to manufacturers’ machine requirements with appropriate product offerings for their survival,” says Khalil

Modern Packaging & Design November-December 2011

Nathani, General Manager - OEM, Rockwell Automation India Pvt Ltd.

Meeting manufacturers’ demands The packaging machine manufacturers see re-use of technology modules in the machine application together with standards adoption or compliance, proliferation of development and software tools, ready availability of training and access to knowledge & skills as major factors that influence design and/or development and adoption of technology. “Off-the-shelf products, modular machine design concepts and reusable engineering content should help reduce costs involved in machine development continuum,” states Nathani. Manufacturers are looking for machines that are information-enabled to keep a tab on their manufacturing facilities in order to help them realise higher efficiency from their set-ups as they continuously upgrade their manufacturing line layouts. This necessitates OEMs to deploy technology that is future proof and meets the performance requirements

Automation in packaging

With the advent of ultra-modern automation technology, the packaging process is now completely integrated with manufacturing process at the end of the line. Sunil Mehta General Manager - Technical, Messung Systems Pvt Ltd, and Assistant General Manager, Automotive Business Unit, Messung Group of Companies

for their machines and gain competitive advantage for their machines. As the manufacturing sector witnesses changes in its demographics, OEMs need the capability to extend support at manufacturing locations across the globe while meeting regional compliances at the end-user location. The rising costs of energy & raw materials and increased awareness towards social and environmental responsibility by manufacturers are driving OEMs to optimise resource management, ie, reduce waste, carbon footprint & costs and consider machine & operator safety in their machines. Thus, automation enables the capability of packaging machine OEMs to meet the demands of manufacturers by deploying a control system that brings in flexibility, delivers productivity and meets regulatory compliances.

Potential in Indian scenario

Off-the-shelf products, modular machine design concepts and reusable engineering content should help reduce costs involved in machine development continuum.

With regard to the potential of automation in the Indian packaging industry, Mehta says, “The packaging market is primarily driven by growth of Fast Moving Consumer Goods (FMCG) companies, which are witnessing a double-digit growth (~15 per cent year on year). Further, there is an ever-growing need to automate packaging process, as this will lead to cost-effectively manage each packaging unit, automate manual processes and increase the level of automation of semi-automated processes. It also means re-evaluating current automation solutions in light of new, faster and more economical automation technology.” Hence, the advent of fast and more accurate Variable Frequency Drives (VFDs) and Servo Drives (Servos), feature packed Programmable Logic Controllers (PLCs) with singleaxis to multiple-axis control capacity and integration with vision systems and high-speed sensors is being observed.

Technology advancements

Khalil Nathani General Manager - OEM, Rockwell Automation India Pvt Ltd

“At Rockwell Automation, we understand the needs of OEMs and bring together three fundamental elements of machine automation, ie, technology, resources

Modern Packaging & Design November-December 2011

and people. Integrated architecture, a multidiscipline control platform that is a scalable, information-enabled product portfolio, and meets regulatory compliances. These are standard off-theshelf offerings, which is a future proof technology delivering OEMs’ capability to meet the demands of manufacturers,” says Nathani. Resources that facilitate granularity in their offerings and tool sets accelerate the design, development & delivery of engineering solutions that include Mechatronic Design Tools facilitating reliable equipment with optimal sizing of power elements, software engineering tools with consistent programming framework and reusable codes library, templates for Manufacturing Executions System (MES) integration & Overall Equipment Effectiveness (OEE) matrix availability and diagnostics that is proactive and preventive, thus increasing lifecycle of the equipment. Technical consultants, who are machine domain experts, work with OEMs with set-ups to enhance the competency of OEM engineers and establish proof of concepts. On similar lines, Mehta informs about the automation products of his company. “Messung, as a pioneer in industrial automation and the first indigenous PLC manufacturer in India, has been a dominant player in the field of automation solutions for packaging industry since 1981.” Messung has always taken a lead to provide innovative, costeffective and cutting-edge solutions for packaging. For example, solutions like 6axis to 12-axis blister packing machines or single-axis form-fill-seal machines have been customised to application needs, optimised in performance and economical in nature.

In a nutshell The result of employing good automation technology is less manual intervention, reduced wastage of raw material, increased speed of production, flexible product change and increased uptime, safety & energy efficiency. Email: anwesh.koley@infomedia18.in

SPECIAL FOCUS: Automation index

Boosting the

bottom line As developing economies result in new consumer markets, new sources of low-cost labour and increased manufacturing competition, the pressure on packaging convertors to increase their level of automation will most likely continue to grow as well. Annabel Dsouza analyses the key trends and innovations making headway in the world of packaging automation.

anufacturers have always faced the challenge of constantly finding new ways to reduce the cost of their packaging processes. In todayâ&#x20AC;&#x2122;s globally connected world, however, the game is tougher and the stakes are much higher. To meet the new challenge of sharply increased global competition, manufacturers are now being forced to cut costs more drastically than ever before.

The shift to automation By automating manual processes and increasing the level of automation of semiautomated processes, packaging convertors are gaining a competitive edge in the market. Packaging has traditionally been the realm of fixed automation, often supplemented by manual labour to carry out machine tending and other intermediate process steps. For some continuous, high-speed, high-volume processes, fixed automation remains the best solution. Increasingly,

Courtesy: Marchesini Group

Modern Packaging & Design November-December 2011

however, manufacturers are turning to the use of industrial robots, which offer several advantages over fixed automation. Farook Merchant, Chairman & Managing Director, Messung Group of Companies, says, â&#x20AC;&#x153;In the Indian automation scenario, the packaging industry is playing a pivotal role. With regard to stringent safety & hygiene standards, particularly in the food and pharma packaging sectors, demand for latest automation solutions is on the rise. Automation is the future of the packaging industry in terms of consistency and quality control.â&#x20AC;? The requirements for packaging machines are just as diverse as the properties, formats and materials of the products to be packaged, apart from hygiene & freshness (especially in packaging of food), aesthetics, presentation, design and logistics of goods, all of which play a crucial role. Packaging design is subject to ever-changing fashion trends, so packaging machines must also be highly flexible. In addition to demand for small production lots and higher production speed, traceability and complete electronic process documentation & validation must be ensured. Packaging, palletising, depalletising and order picking are logistical tasks characteristics of the packaging industry. These could previously be performed only by employing huge manpower. Today, automation technology is being inducted in manufacturing plants at a faster speed and more flexibly than ever before. Unlike dedicated machines and systems that are tailored for a specific product, automatic intelligent packaging lines can be adapted to changing products types. Due to rapidly

Automation index

Courtesy: Motion Control Robotics

changing product variants, hard automation is no longer a cost-effective solution.

the set-up controller can access the complete packaging line and simultaneously monitor the procedure. Jitendra Devlia, Managing Director, Engel Machinery India Pvt Ltd, says, “In the simple view, the sequence of operations on a packaging line is displayed in the form of a circle. Individual actions are visualised graphically in their temporal sequence, creating a clear and simple view of the automatic operations. Furthermore, the operator can control the several processes at the same time.”

Process optimisation and control Computer-aided design is making headway into packaging processes. Most companies are turning to designing solutions before finally adding new assembly lines. With increasing use of technology, companies are working on simulation techniques before the actual process, to test physical parameters, reduce iterations and cycle times. EtherCAT-based control technology is considered as an ideal solution for automation of the entire process chain for individual packaging machines and complete packaging lines. For the packaging machine, there are high-performance automation systems with motherboards, especially designed for industrial applications, compact embedded controls, a wide range of electronic input/output terminals, versatile servo drive technology, cost-effective stepper motor technology, the high-speed EtherCAT fieldbus & motion control software and control panels as operating display units. With regard to computing power, complexity and cost, a scalable control solution can be created for any packaging machine from the integrated modular product range. More functions like motion control, condition monitoring, robotics, etc are moving over into the software and controlled by an interactive control system, making the control architecture lean. In addition, hardware is becoming increasingly compact, thus decreasing space requirements in the control cabinet. However, automation control offers even more advantages; eg, integration of condition monitoring in the controller improves diagnostic options and simplifies error handling, which results in optimised machine efficiency. At the press of a button,

Computer-based control The universality and openness of computerbased control technology, in terms of both hardware and software interfaces, help machine manufacturers to adapt their systems to diverse and ever-changing requirements without high implementation costs. EtherCAT integrates Programmable Logic Controller (PLC) and motion control functions and controls the individual process steps of the packaging machines with high performance. A wide range of software modules for different packaging tasks such as cam plates, synchronisation and interpolating movement of several axes help manufacturers reduce downtime and enhance productivity.

With regard to stringent safety & hygiene standards, particularly in the food and pharma packaging sectors, demand for latest automation solutions is on the rise. Farook Merchant Chairman & Managing Director, Messung Group of Companies

Future focus The demand for automation in packaging in India is not comparable with that in Japan, the US or European countries, as they adopt an extremely high level of automation in their processes. This demand in India is rising, but Indian companies need to first streamline their processes and then move to a higher level of automation. Clear command structures, a readily comprehensible program design and extensive help functions make today’s robots easier to program. Another cost-saving measure is using integrated motors and drives. Devlia concludes, “In keeping with rigorous cost-to-quality margins of packaging machinery, today’s packaging automation industry is witnessing a trend for highly integrated production cells, supplied as single source, turn-key systems.” Email: annabel.dsouza@infomedia18.in

In keeping with rigorous cost-to-quality margins of packaging machinery, today’s packaging automation industry is witnessing a trend for highly integrated production cells, supplied as single source, turn-key systems. Jitendra Devlia Managing Director, Engel Machinery India Pvt Ltd

Modern Packaging & Design November-December 2011

SPECIAL FOCUS: Small assembly robots

Reducing downtime, enhancing precision Packaging manufacturers often face the challenge of reducing production costs. Although traditional, fixed-automation solutions are in use, rising competition has forced a majority of packaging manufacturers to employ small assembly robots. Here, we find the reasons for the success of these more flexible alternatives in the manufacturing world.

hroughout most of the 20th century, propelled by the dynamic growth of the consumer society, packaging has greatly benefited from dedicated, fixed-automation machines, which offered previously unachievable scales of economy. Yet, fixed automation has its drawbacks, as each machine has to be specially built to handle a specific product. Furthermore, changing a productâ&#x20AC;&#x2122;s shape or size means buying expensive new tooling, or even a whole new machine. This has other limitations, such as high maintenance & service costs, bulky size and open mechanical designs, which present a danger of injury to employees. Also, the high cost of fixed automation limits its use mainly to high-volume operations with few or no product changes. Until recently, the advantages of fixed automation outweighed the disadvantages. Manufacturers had a solution that worked, and without the fierce new competition f rom off shore manufactur ing that globalisation would bring, there was no compelling reason to do anything differently. Today, however, the situation has dramatically changed. To stay in business, manufacturers must find new, less costly and more flexible alternatives to fixed automation.

The solution: Small assembly robots A class of robot arms often referred to as small assembly robots provides just such an alternative. Despite their name, small assembly robots can carry out a wider variety of tasks than just assembly. These include various material-handling and other functions involved in upstream packaging processes, eg, pick & place, loading & unloading, package forming, product insertion, etc, as well as secondary operations such as labelling, testing and inspection. In terms of size, small assembly robots have a payload capacity up to 20 kg (44 pound) and reach up to 1,300 mm (51 inch).

Four-axis SCARA versus 6-axis articulated robots Assembly robots are of two basic types: four-axis Selective Compliance Articulated Robot Arm (SCARA) robots and six-axis articulated robots. A SCARAâ&#x20AC;&#x2122;s arm segments, or links, are compliant, ie, they can move freely, but only in a single geometrical plane. The first two links of a SCARA swivel Courtesy: Denso Robotics

Modern Packaging & Design November-December 2011

Small assembly robots

left and right in the horizontal plane. The third link consists of a metal rod called a quill, which holds the robot’s end effector, such as a gripper. The quill moves up and down in the vertical plane and rotates around its vertical axis, but cannot tilt at an angle. This unique design gives four-axis SCARA robots a high degree of rigidity, which allows them to move fast and with high repeatability. In packaging applications, four-axis SCARA robots excel at high-speed pick & place and other material-handling tasks. Six-axis articulated robots have two additional joints than four-axis SCARA robots, and hence more freedom of movement. The first link swivels in the horizontal plane like a SCARA, while the second two links move in the vertical plane. Also, six-axis articulated robots have a forearm and two wrist joints, which help them perform the same types of movements that a human forearm and wrist can do. The additional joints of six-axis articulated robots mean that they can pick up a part no matter how it is oriented off the horizontal plane, and insert it into a package that may require a special angle of approach. They can perform many other operations that might otherwise call for the dexterity of a human operator.

Advantages in packaging operations The most important benefit of small assembly robots in packaging operations is their lower cost. Hence, robots have a lower initial cost – and thus a quicker Return On Investment (ROI) – their high degree of flexibility, small size and low maintenance requirements give them a lower overall cost. Both fixed automation and robots can carry out packaging tasks more efficiently, consistently and cost-effectively than manual labour. Robots have the added advantage of being able to fill in automation gaps – manually performed tasks that may still exist in an otherwise automated line – usually because a fixed-automation solution would be expensive.

Unlike fixed automation, which must be specially designed for a particular process, robots are modular, off-the-shelf automation systems that can be adapted to a process with relative ease, greatly reducing the need for costly design engineering. Also, robot workcells have a smaller footprint than fixed automation machines. When necessary, a robot can be moved to an entirely different process and repurposed, thus reducing equipment investment. Robots do not require expensive new tooling when the product changes. Often, a relatively simple modification of the software program and, if necessary, a different end effector are needed. This can be particularly beneficial to manufacturers and contract packagers with small lot sizes requiring frequent, fast changeovers. W hen equipped with a multifunctional gripper or automatic tool exchanger, a single robot can perform more than one function, such as loading & unloading a product, presenting the product for inspection & labelling and then inserting it into a packaging container. It can also handle multiple product sizes and shapes, all on the fly, without interrupting production. Vision systems and other options such as conveyor tracking can be easily installed, extending the robot ’s capabilities still further. Another important advantage of robots is that their internal mechanisms are sealed inside protective coverings. This gives them lower maintenance requirements than fixed automation machines, whose motors and mechanical parts are usually left open and can get damaged from dirt & debris.

Offering big gains Small assembly robots save workers f rom tedious assembly line jobs, lower maintenance and help increase production, which is faster, more efficient and precise and provide cost savings. Courtesy: Denso Robotics

Modern Packaging & Design November-December 2011

10 things to look for when choosing a robot 1. Experience and reputation of manufacturer: Manufacturer must be an established industry leader whose robots have stood the test of time. 2. Documented MTBF: Robots are often required to operate 2-3 shifts per day, every day of the year so they must be reliable. Manufacturers can furnish documentation of the robots’ Mean Time Between Failures (MTBF). 3. High maximum allowable moment of inertia: The higher the maximum allowable moment of inertia, the more easily the robot can lift and move a given size of payload, putting less strain on its motors and resulting in a longer working life. 4. Continuous-duty cycle time: When comparing robot cycle times, ask if the figures given are for continuous duty or only shorter bursts of an hour or less. If the latter, the robot will have to operate at a slower speed in normal operation. 5. Compact, efficient robot design: A compact robot design with small footprint makes integration easier and saves valuable factory floor space. Designs with concealed air and electrical lines keep the lines from interfering with other equipment, and protecting them from wear & damage, reduce overall costs. 6. Robot controller features: Small size & weight; fast processing speed; modular expandability, to accommodate additional peripheral equipment without having to purchase a new controller; ease of integration with a vision system, Programmable Logic Controller (PLC) or other devices; and ease of servicing. 7. Affordable offline programming software: The offline programming software being offered must not include unnecessarily expensive, advanced features. 8. Low energy consumption: Efficiently designed, lightweight robot arms require less power, so their motors draw less electrical current. This can result in significant long-term cost-savings. 9. Safety codes: To protect employees and limit the company’s liability, verify that the robot meets or exceeds all current safety codes. 10. Short training: Unnecessarily long training can result in excessive unproductive employee time and travel costs. Source: Denso Robotics

FACILIT Y VISIT: KHS Machiner y Pvt Ltd

Complete solutions under one roof Massive influx of consumers into the urban food market has resulted in a swift and sustained increase in beverage processing and packaging operations. Moreover, the industry in India has witnessed a significant international participation, leading this growth to a higher level. Among such companies is KHS Machinery Pvt Ltd, a market leader in this segment. Avani Jain tracks the company’s journey so far and the milestones it has achieved.

he food and beverage industry in India has blossomed from an unorganised sector to an economic powerhouse, which has been led by significant national and international participation. This development has resulted in an increase in demand for beverage packaging. As a market leader in the food & beverage packaging industry, KHS Machinery Pvt Ltd can provide the right platform to enter this burgeoning industry, which is expected to grow at 34.3 per cent to reach $ 226.4 billion by 2012. Yatindra R Sharma, Managing Director, KHS Machinery Pvt Ltd, says, “There is a huge demand for packaging in the beverage sector. Sectors like soft drinks, juices, etc, are growing in volumes year after year. This is a positive sign for this industry.” KHS is a global leader and solution provider of the first choice in the packaging industry, catering to mainly beverage and food applications with a focus on complete turnkey solutions.

Photo: Vijaykumar Soneji

Headquartered in Germany, the company has manufacturing facilities across the globe, with several plants in Germany, the US, Brazil, Mexico, China and India.

Cutting-edge infrastructure KHS started its operation in India to cater to the needs of Indian as well as neighbouring markets. Eike-Sebastian Hagen, Executive Vice President Operations, KHS Machinery Pvt Ltd, says, “This step has brought us closer to our customers and saved the shipping cost, taxes and time.” Previously, the company had a facility in Vatva Gujarat Industrial Development Corporation (GIDC) in Ahmedabad, but with rising business demands, the facility was shifted to the present location in 2007. The present stateof-the-art manufacturing facility with a production space of 25,000 sq m is built over a sprawling landscape of

Modern Packaging & Design November-December 2011

110,000 sq m, complete with a modern technology centre to cater to all training needs of the esteemed customers and other stakeholders. The facility has three main production halls and a material storage area right in front of these halls to reduce time & energy required to get the materials from faraway places. It also has a packaging unit, a spare part shop, paint shop with two cabins for small & big items, blasting area and a quality assurance department.

Unique shop-floor practices The production halls have a well organised system of working. “All production floors are divided into five zones indicated by proper floor markings. One employee is assigned to each zone. Thus, in case of any difficulty, we contact the zone incharge to resolve the problem,” notes Hagen.

KHS Machiner y Pvt Ltd

Offering complete solutions

Research & development

The company provides full-line packaging solution to customers. Hagen details, “The complete packaging solution provided for glass line where returnable glass bottles are packed in returnable crates include the following: depalletiser, crate conveyor, crate washer, unpacker, bottle conveyor, bottle washer for cleaning the bottles, filler with cleaning system, pasteuriser, labeller, packer and palletiser. All these enable gentle handling, accurate & fast stacking of finished goods.” The company also provides packaging solution for Polyethylene Terephthalate (PET) bottles, eg, blow moulder, filler & capper, bottle conveyor, labeller, shrink packer, pack conveyor, palletiser and pallet conveyor. “We also manufacture carton, erector, carton packer for unfolding the carton and carton sealer. There is a difference between packaging solution for PET and glass bottles. In case of packaging solution for PET, everything else is manufactured in India, but the blow moulder comes from the parent company in Germany,” notes Hagen.

The company is constantly involved in research. “We will soon be entering the milk and aseptic juices market with the help of our German partners, where we will design low-capacity & highly efficient aseptic plants. The second area of innovation will be the flexible packaging space,” informs Sharma. Although the company is mainly involved in assembling activities as per the design given by the parent company, it has the freedom to do some engineering work keeping in mind the requirements in India. “We receive most of the designs from Germany, few from our partners in Brazil and the pouching technology comes from Florida. Hence, we are majorly involved in assembling of machines. Most parts come from local markets or Germany. In case of special demands from Indian customers, we are allowed to make few changes to adapt to local needs,” notes Hagen.

Quality assurance The company is quality conscious and has taken various steps to check the quality at every level. Hagen notes, “We often visit our vendors and train them to ensure that they deliver good quality. After the products reach the factory, they are tested first so that only good products reach our production floor. The quality assurance department checks the quality at every level till the machine is made. After all internal tests, we invite the customer to check the machine. The machine is dispatched only after the customer accepts it.

The paint shop

Employee development With a workforce strength of over 300 employees, the company has taken every possible step for their development. Hagen says, “The company organises workshops for employees where they are encouraged to think of new ideas through which they can further improve, save time and money. These ideas are collected & implemented and, the employee who gives the best idea or solution is rewarded.”

In future, the beverage industry will go for bigger capacities, with a focus on energy efﬁciency and carbon footprint reduction. Accordingly, we will have to adjust technology solutions. Yatindra R Sharma Managing Director

“Our achievements include setting up of a global level facility. Not many companies take the initiative to start as a 100 per cent outsourcing model, but we have done it and have been successful too.”

Future focus

The company has grown tremendously well over the years. Sharma notes,

The major focus of the company is on the local market followed by international markets. Sharma concludes, “We are looking forward to sell KHS technology in wider markets. In future, the beverage industry will go for bigger capacities, with a focus on energy efficiency and carbon footprint reduction. Accordingly, we will have to adjust technology solutions.” Email: avani.jain@infomedia18.in

Labeller for putting labels on bottles

Production hall

Major achievements

Photo: Vijaykumar Soneji

Modern Packaging & Design November-December 2011

INSIGHT & OUTLOOK

Pharmaceutical Packaging Pharmaceutical packaging Delivering smart solutions ...................................................................................... 44

R&D in pharma packaging Cutting-edge solutions for drug safety .................................................................. 48

In-line quality control For a true zero-fault packaging ...............................................................................52

Modern format retailing Enhancing product visibility ...................................................................................54

SWOT analysis of screen printing Innovating for superior image quality .....................................................................58

Modern Packaging & Design November-December 2011

INSIGHT & OUTLOOK: Pharmaceutical packaging

With the Indian pharmaceutical industry witnessing a steady growth, thanks to efforts of Indian pharma companies, India has become the preferred destination for pharma investments. Anwesh Koley analyses how Indian companies are working towards delivering the best packaging solutions to their end-consumers.

he Indian pharmaceutical packaging business is evolving into a specialised industry. This is supported by an increasing confidence of developed countries in domestic pharmaceutical companies. Moving away from mainly focussing on generic products, pharmaceutical companies do not emphasise much on the quality and consistency of the primary packaging material as well as product branding. This has led to the pharma packaging industry evolving into a specialised sector. With advancements in technologies, the type and form of pharmaceutical packaging are also changing at a rapid pace. Drug packagers are working to reduce cost of packaging and, consequently, the industry is also expanding.

Courtesy: Helvoet Pharma

specialised chambers and temperaturecontrolled divisions for transporting pharmaceutical cargo, which is of high importance in terms of quality and timeliness. AVPS Chakravarthi, Managing Director, Ecobliss India Pvt Ltd, says, â&#x20AC;&#x153;The segmentation can be individual or a combination of two or more in segments like blister packs, vials, tubes, caps & closures, blow-fill seals, bottles for suspensions, tubes, blow-moulded containers, thermoforming blisters, bulk drug containers apart f rom regular printed boxes, labels, flexible laminates, etc.â&#x20AC;? Although most of the above segments cater to non-pharma industries like Fast Moving Consumer Goods (FMCG), electrical/electronics, etc, the packaging industries supplying to pharma industries maintain their uniqueness because of the high standards they need to adhere to.

Pharma versus non-pharma packaging

Areas to work on

Generally, there is no distinction among packaging industries about whether they belong exclusively to pharma packaging or other industries. However, many packaging industries maintain their exclusivity, contributing towards the pharma sector. Currently, logistics companies in India and worldwide have

While the Indian pharma industry is highly advanced, with the highest number of US Food and Drug Administration (USFDA)-approved plants outside the US, it has yet to embrace the pressuresensitive technology like most other countries. More than 60 per cent of the labelling in India is still wet glue

Modern Packaging & Design November-December 2011

Pharmaceutical packaging

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. AVPS Chakravarthi Managing Director, Ecobliss India Pvt Ltd

As traceability becomes the need of the hour, the new track-&-trace and 2D coding will bring in the next level of security for tertiary, secondary & primary packs, thus giving companies and government traceability of products, which will ensure patient safety. Dr A K Sinha Vice President-Formulation, Morepen Laboratories Ltd

– the conventional form of labelling. Innovations are happening more rapidly in the self-adhesive and pressuresensitive label technology, which have been adopted by most other industries like healthcare, personal care, durables industry, automobiles, etc. The pharma industry is not far behind today. The need for advanced labelling requirements with respect to regulations, applications and functionability are increasing with each passing day and major players in the packaging and labelling industry are able to address these needs with products like low migration labels, hanging labels, booklet labels, blood bag labels, syringe labels, etc. Dr A K Sinha, Vice PresidentFormulation, Morepen Laboratories Ltd, says, “A step in this direction is through the barcoding industry. The barcoding industry received a fillip with the onset of the retail evolution in India and is gaining ground across all formats of sale and a cross section of industries. As traceability increasingly becomes the need of the hour, the new track-&-trace and Two-Dimensional (2D) coding will bring in the next level of security for tertiary, secondary & primary packs, giving companies and government traceability of products, which will ensure patient safety. Also, government regulations on track & trace have given the barcoding industry an excellent growth opportunity.”

Witnessing improvement While there has been a tremendous improvement in developing new drugs and new molecules, the packaging industry in India is still to catch up with the pace of innovations that happened in products that the packages need to contain. However, off late, there have been significant initiatives in packaging as well. “Most countries have minimised the use of heavy drums, which contribute to massive transport costs when shipped empty to the manufacturing facility. Polypropylene collapsible bags,

Modern Packaging & Design November-December 2011

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,” adds Chakravarthi. Similarly, packaging supplied to formulation industries has seen a dramatic development in the recent past to catch up with global requirements. Smart packaging using Radio-Frequency Identification (RFID) technologies is set to grow in the coming years with demand from the user industry. Driven by an increasing demand for quality, innovations in pharma packaging have also been pushed in the same direction. Manufacturers of pharma packaging have started to invest in more modern machinery in order to maximise outputs and reach a higher quality level. This trend is also supported by pharma companies that export their products to other countries and regions as well as upcoming biotech companies. For these companies, stable supply and a high product quality are key success factors as far as packaging is concerned. This also has an impact on the producers of the raw materials and glass tubing, which is used by converter companies to produce pharmaceutical containers.

Ensuring highest drug quality Pharma packaging products represent the starting point of the value chain. The quality of the packaging product affects all subsequent steps within the process and its steady supply is a prerequisite to make medical products available when required. In a time when countries across the globe are investing heavily in their pharmaceutical industries to ensure consumer satisfaction, India has also shown improvement in terms of quality. However, there remain areas where India needs to gear up and adopt more advanced labelling and barcoding methods in order to counter the manufacture of spurious drugs and ensure stringent quality practiced worldwide. Email: anwesh.koley@infomedia18.in

INSIGHT & OUTLOOK: R&D in pharma packaging

Cutting-edge solutions for drug safety As regulatory requirements become more stringent, the Indian packaging industry is preparing aggressively to enter the global pharma sector and compete with international players. Anwesh Koley highlights the R&D initiatives undertaken by pharma packaging companies to ensure the highest quality and safety standards. Courtesy: Nelipak

onstant efforts by the global pharma industry to improvise in terms of quality and higher productivity have made Research & Development (R&D) an important step for the Indian pharma industry. Sundeep Prabhu, Assistant Vice President-Sales & Marketing, Schott Glass India Pvt Ltd, says, “Our R&D initiatives are focussed on improving the quality of our glass tubing products. This includes aspects like dimensional quality & tight tolerances and high cosmetic quality. Our approach is to assure the quality of our products at each step. R&D efforts examine the entire process from glass composition and processing to final packaging for shipment.”

R&D in pharma Packaging needs of pharma companies are evolving continuously, and this has

prompted packaging providers to devise innovative methods to ensure higher packaging safety & product efficiency. “To ensure best cosmetic quality, we have introduced a non-stop optoelectronic monitoring process so that the glass tubing supplied to our customers has no design flaws. We are also optimising the packaging of our products. A scratchresistant coating of the tubing and other sturdy packaging products ensure high cosmetic quality of our glass tubing during shipment,” adds Prabhu. Besides ensuring design quality and innovation, companies need to focus on dimensional accuracy to enable converters supply the pharma industry with packaging solutions that offer excellent performance on high-speed lines by ensuring low breakage risk and constant filling levels. Prabhu says, “Through scientific services that we offer, customers can benefit from

Modern Packaging & Design November-December 2011

our experience in glass production. With our individual consulting services, we cover fields such as process evaluation & fault analysis and offer advice on specifications & regulations.” Ashish Moghe, Market ManagerPharma, Avery Dennison (India) Pvt Ltd, says, “The labels industry has also started evolving with this movement of pharma industry, though slower than expected. With constant R&D being undertaken in this sector, the cut & stack labelling is slowly fading away. As regulatory laws become stringent, awareness is increasing of pressure-sensitive technology, adaptability to global packaging trends and requirement for high productivity, speed, accuracy & appearance.” Currently, companies in the pharma packaging space have to deal with high quality requirements form pharma companies as well as ensure cost-effectiveness through

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R&D in pharma packaging

economies in production. Some specific areas of development have been focussed on, such as better patient safety through low migratory packaging, higher adherence to medical standards through booklet labels, higher functionality of packaging materials through hanger labels and anti-counterfeit and tamper evidence through luminescent labels, Infrared (IR) tags, etc.

Challenges on the way The pharma packaging space has several limitations, which make it difficult to move away from the conventional methods. “The key challenge we are faced with is educating our partners along the entire value chain about processing of glass with all its facets. This includes special topics like drug-container interaction, adsorption, chemical resistance, stability of packaging and freeze-drying (lyophilisation) of certain pharmaceutical agents,” says Prabhu. Moghe elaborates, “In India, historically, the medium for decoration and labelling has been wet glue, so bulk of the market still includes wet glue. The technology has its limitations in terms of of speed, efficiency, tracking, traceability and hygiene. Also, the awareness of the importance of and the technology behind Pressure-Sensitive (PS) labels is limited, creating an urgent need for educating the end-users.” Most companies have undertaken various initiatives to educate consumers as well as prospective packaging companies. “Launched in India in 2010, our FIOLAX® Academy programme serves as a complete technical and scientific customer advisory service to our partners in the pharma industry,” informs Prabhu. Another challenge is the awareness & application of these technologies among printers, but large companies are taking the lead in educating the printers and end-users about new trends and technologies. The Government has taken the initiative to move towards track and trace solutions. This will give way to advanced platforms such as PS labels in the near future.

Where does India stand? India is one of the key and emerging markets identified as a growth country among the BRIC countries (Brazil, Russia, India and China). The biggest opportunity for Indian companies arises from patent expiries estimated at $ 80 billion in revenue in the next two years. Moghe asserts, “With the ultra-modern manufacturing infrastructure entering at a fast pace in pharma companies, expert human resources, wide range of products across all therapies, investments in R&D and growing recognition of quality in international markets, the Indian pharma industry is all set to catapult into the global pharma space.” Adding to this is the expanding domestic market with a huge population and more aware citizens, higher reach and wide availability of medicines, increasing medical insurance and growth of chronic diseases. With increased presence of global multinational companies in the country, the demand for high-quality and convenience-based products will also increase. “The Indian pharma packaging market is roughly divided into 75 per cent of rigid packaging and 25 per cent flexible. Future growth in the flexible industry will be higher as more and more manufacturers are moving in this direction,” says Prabhu. In developed countries, the percentage of flexible packaging is much higher. The packaging business is an emerging industry in India and will grow in terms of quality, innovation and consistency of the product due to the global exposure.

Great expectations Globally, the pharmaceutical packaging market is expected to grow by an average of 6.9 per cent each year to reach a total volume of $ 69 billion by 2015. In contrast to emerging markets like India, China and Russia, where an increased demand for packaging is mainly based on the strong growth of the pharmaceutical market, new application solutions such as syringes and injection systems with safe & user-friendly features are promoting the growth on an international level. Email: anwesh.koley@infomedia18.in

The key challenge is educating our partners along the entire value chain. This includes drugcontainer interaction, adsorption, chemical resistance, stability of packaging and freeze-drying (lyophilisation) of certain pharmaceutical agents. Sundeep Prabhu Assistant Vice President-Sales & Marketing, Schott Glass India Pvt Ltd

In India, the medium for decoration and labelling has been wet glue, so bulk of the market still includes wet glue. The technology has its limitations in terms of speed, efﬁciency, tracking, traceability and hygiene. Ashish Moghe Market Manager-Pharma, Avery Dennison (India) Pvt Ltd

Modern Packaging & Design November-December 2011

INSIGHT & OUTLOOK: In-line quality control

For a true zero-fault packaging Quality is a prerequisite for any manufacturer supplying packaging to pharma companies, and thus the packaging industry must follow strict specifications. Various technical developments made today will help the packaging industry offer innovative products and services with added value to customers.

Marco Lideo

ntil some years ago, companies supplying packaging to the pharma industry delivered their cartons several days or weeks before they were needed. The cartons would be stored at the packing and filling plant, where Quality Control (QC) personnel would ascertain whether they met with brand specifications. These activities have changed with the advent of lean, just-in-time manufacturing. Today, the same packaging is delivered straight to the filling line, and is done not in advance but when actually needed. There is no time for a detailed analysis of the package received, so minimal checks are done by QC personnel from packer-fillers. Thus, the delivery must be not only ‘on time in full’, but also ‘zero fault’.

In-line production monitoring Packer-fillers have put the onus on the packaging maker for carrying out most of their own Quality Assurance (QA) process. The packaging manufacturer

is required to supply Certificates of Analysis and Certificates of Conformity, along with batch samples, before their delivery is accepted. Thus, the packaging manufacturer must prove that every carton they supply is perfect. This means that the packaging maker must have a robust QA throughout production, along with thorough testing before dispatch. In manufacturing terms, this means that the plant’s folder-gluer lines are the process that the cartons go through; hence, these are the last line of defence against manufacture of products that do not conform to the given specifications. Folder-gluers are machines at the end of a carton manufacturing process, which fold and glue the printed, foiled, hologrammed, embossed and die-cut blank into a recognisable carton, making it ready for the filling line. Typically, a folder-gluer runs at several hundred metres a minute, often churning out in excess of a hundred thousand straight-line cartons, or tens of thousands of crash-locks, in each hour of production. Long before ‘zero fault’ packaging contracts became popular, folder-gluer lines were supplemented

Modern Packaging & Design November-December 2011

by simple detection systems, which monitored correct application of the adhesive used to glue the carton flaps prior to their folding. These systems allowed operators to rectify a problem and remove any poorly glued or unglued cartons. Over the years, these glue detection systems became more sophisticated, allowing the user to identify small variations in gluing patterns or the amounts applied, on a wide range of substrates. These adhesive monitoring systems have also proved to be the perfect platform on which additional QC checks can be supported. Add-ons to adhesive monitoring systems have been developed, which can check that two cartons are not fed together; the carton has correct pharma codes and barcodes printed on it; it has a film window; and check its print-to-cut registration if the sheet was not die-cut on a machine with a dynamic register system. Modern folder-gluers integrate or interface with such systems, and many lines offer ‘flipper ejectors’ that instantly remove non-conforming cartons from the line without affecting production speed.

In-line quality control

Technology advancements Two latest developments in the addon systems are Braille scanning and print quality checking. Both are key determinants in ensuring that every carton reaching the filling line is in compliance with the specifications laid down by the brand owner. Systems like Braille-Scan read every carton passing through a foldergluer and check the Braille applied against a reference sample, ejecting any non-conforming samples. Capable of scanning every single carton in a run, even at high running speeds of modern folder-gluers, Braille-Scan also translates the Braille on the carton into the operator’s own language, displaying it on a monitor so that operators can double check its correctness. The latest development in the inline QC is scanning and checking of the print on cartons as they pass through the folder-gluer, way beyond the simple checking of bar codes. This offers the prospect of independent, automatic

and auditable checking of the print on every carton that leaves the plant. Automated QC is the last chance for the packaging manufacturer to remove faulty products without resorting to hand sorting. Bobst – a leading Swiss manufacturer – produces systems that check the print on each sheet produced by the flexographic presses it manufactures for printing corrugated boards. The company has developed iQ300 devices, creating sophisticated register control systems for its web-fed gravure presses. Using two high-definition Registron® cameras, the iQ300 systems on flexo presses manufactured by Bobst can scan the entire printed sheet. The analysis system, which is designed for the ultra high rate of data flow received from the cameras during production, checks for differences between the scan and the reference image for that job. Depending on the settings defined for the run – the high and low priority areas of the sheet, size and type of defect that are

permissible, etc – the defective sheet can be automatically ejected in real time, without affecting production.

True ‘zero fault’ packaging Taking a technology that is designed to scan a 2100 mm × 1300 mm sheet running at 12,000 sheets per hour and adapting it to scan an extremely small pharma carton, but one that runs 10 times faster, is a huge challenge. Nevertheless, Bobst is all set to deliver fully featured print scanning QC modules that can be retro-fitted to most of the huge installed base of folder-gluers in the field. This will bring even closer the packaging manufacturers’ ultimate aim of supplying truly ‘zero fault’ packaging to their customers. A nuclear engineering graduate, Marco Lideo joined Bobst in 2001. He is currently Marketing & Sales Director for folder-gluer products worldwide. Email: marco.lideo@bobstgroup.com

Modern Packaging & Design November-December 2011

INSIGHT & OUTLOOK: Modern format retailing

Enhancing product visibility The rising purchasing power of the growing middle class in India, increasing youth population and changing customer taste are transforming lifestyles and spending patterns. This trend is slowly giving way to a modern, more organised form of retailing. With buyers today more open to experimentation, organised retailing has opened up opportunities for packagers as a one-stop shop for an array of products. Thus, packagers must follow modern format retailing to maximise their shelf visibility.

Changes in the offing

P V Narayanan

he Indian market is witnessing rapid urbanisation and, by 2020, nearly 140 million people are expected to enter the urban life and overall 700 million will urbanise. Between now and 2020, the Indian per capita is all set to quadruplicate. Currently, 50 per cent of Indiaâ&#x20AC;&#x2122;s population is less than 20 years of age and 64 per cent below 34 years. This has two features. First, the current population group is a strong market mover and, second, 3-4 decades later, the market needs will probably change and package designers may have to address to a different population segment, innovation for an elder-friendly population.

Although modern retailing is still growing in single digit, this growth is expected to increase considerably. An analysis of the organised retail pie would clearly differentiate the package type needs. Though food and grocery is more visible at 14 per cent, it is the apparel sector that accounts for 36 per cent of the retail pie, closely followed by jewellery & watches. Irrespective of the end population (market) segment, the modern format retail will have a direct influence and impact on packaging. Bulk packaging for fresh food, food raw materials for food processing and efficient movement to food processing centres will be a challenge in itself. Package design for consumer packs of fresh food, fruits, vegetables, poultry, meat, eggs, etc will demand a different approach. Supply chain efficiency & control will see tighter tolerances and quality standards for speed and efficiency of larger volume processing and packing lines. Inventory

Modern Packaging & Design November-December 2011

management tools like bar code and Radio-Frequency Identification (RFID) will have a greater role and will be used more extensively.

Array of pack sizes Major changes are expected in packaging trends, one of which will be a considerable increase in the use of various pack sizes. The modern large retail format consumer will have little use for the singleuse pack and prefer multi-unit packs. Family size packs will witness large sale volumes, with contribution from factor of economy. Product Stock-Keeping Units (SKUs) will also witness multiplication with branded ones. In the competitive situation, they need to occupy more shelf space. More SKUs will offer wider choices. The implication will be increased number of shorter runs and demand for more innovative designs and, simultaneously, major changes in packaging trends. The package design for the supermarket shelf should emphasise on:

Modern format retailing

Package form and graphics modification to maximise shelf presence Shelf display packaging that should multiply its impact as point-ofpurchase display material Shelf-ready packaging will be tailored to maximise occupation of shelf height in a single movement from CFC secondary carton to shelf, eg, tall visible packs with maximum impact and pre-stacked consumer packs in dispensing packing/easy removable bonding More use of ready-to-cook and readyto-serve foods will increase variety of food service packing. Same will be true for fresh and frozen food packaging Growth in modern retail format will witness introduction of more private labels who will aggressively compete with established brands. Opportunities for contract packers will also rise. Typically, private labels are highly price conscious in their purchase, so offer a price advantage to customers

Trendsetters Large form sectors will enter into processing, reducing waste and improving delivery & returns. The rapidly growing middle class will further add to the market. A shift from saving to spend attitude due to increasing disposable personal income with high propensity to spend will boost the modern format retailing. Consumer awareness on good health is a major factor, searching for branded, well packaged and presented product. A large percentage of the population is adventurous, looking for changes and willing to experiment, and thus demands product diversification and new products. In contrast, consumer packaging market is still in single digits in respect of labels, caps & closures, metal cans, printed folding cartons, rigid plastics and flexible packaging, which hover at 17-21 per cent. Glass is probably somewhere in between, with 10 per cent. The developments seem more in the areas of flexible, folding board cartons and rigid plastics.

Growing Indian consumer market Currently about 250-300 million strong, the Indian middle class is estimated to touch 700 million soon. The World Bank defines the middle class with Purchasing Power Parity (PPP) of $ 10-20. The National Council of Applied Economic Research (NCAER) defines it in terms of income range of ` 2.0-10.0 lakh. The population dissection based on household income is placed at 22 per cent maximum and 13 per cent minimum. About 21 per cent of the population is considered well off and 19 per cent as not so well off; 52 per cent of the urban population falls under the highest income group and 48 per cent in rural. As 91 per cent of poor income sector comes from rural group, the rural market is considered as the robust potential market.

A shift from saving to spending attitude due to increasing disposable personal income with high propensity to spend will boost the modern format retailing. The processed food industry offer huge growth potential for packaging and increased product introduction are in flexibles. A primary reason for growth in the food sector is increasing health consciousness and a shift towards branded products. For example, drinking water in Polyethylene Terephthalate (PET) bottles; cooking oil in PET/High-Density Polyethylene (HDPE) bottles; alcoholic beverages, ketchup, herbs, spices in glass bottles. Nearly 50 per cent demand (unit packs) are from single-serve packaging, eg, fruits, vegetables & grain mill products, dairy and baked products, etc.

The chota sachet market This concept has revolutionalised the Indian consumer market and more than in any other part of the world. Probably

Modern Packaging & Design November-December 2011

many of such unit dose consumer sachets in India are a first in the global market. Cost-effective consumer-convenient and preferred mode have made such packs successful, as the consumer continues to be cost driven. Smaller sachets are most suitable due to low unit prices and fits into the requirements of travelling urban consumers, eg, shampoo, squeeze toothpaste, edible oils, jams, pickles, etc.

Fast Moving Consumer Goods (FMCG) volume growth This has had a catalytic effect on packaging. Double-digit growth, lower prices, discounts, reduced input cost and recovery in consumer demands have resulted in a net revenue growth of 10 per cent. The trends in modern retailing are influenced by consumer consciousness and convenience, brand association, satisfying quality claim, besides value addition. The overall retail trends have resulted in a wide range of package types, sizes, shapes, materials and technologies to suit a wide range of consumers. The inventions and innovations are driven by consumers and technologies. The market is under increasing uncertainty and consumer thrust is moving towards brands.

Seeking novel experience Consumer expectations have undergone a sea change. Though they are cost-centric, value for money propositions to higher value offering has set in. Buyers today are willing to experiment and adapt to new product experiences. Quality and reliability are the buzzwords, but cost is important. Modern format retailing as a one-stop shop for a cross-section of products must work closely with the above and packaging could well be the tool to realise this dream. 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: peeveen@gmail.com

INSIGHT & OUTLOOK: SWOT analysis of screen printing

Innovating for superior image quality Screen printing has evolved considerably over the years and offers ample scope for innovation. It plays a major role in the printing industry with the availability of advanced machines and new special effects inks. Hence, to create a lasting impression, we need to analyse the strengths, weaknesses, opportunities and threats in the screen printing industry.

Bhargav Mistry

ith advancements taking place at all levels, screen printing has evolved as an indispensable and versatile printing process. Screen printing today is faster, cheaper, produces better quality images and offers numerous special applications. But simply having advanced machines in place is not sufficient to run a profitable screen printing business. In order to truly master printing of high-quality images using the screen printing process also takes longer, as there are several variables involved. Hence, here is an evaluation of the current screen printing scenario in India through a quick SWOT analysis â&#x20AC;&#x201C; an acronym for Strengths, Weaknesses, Opportunities and Threats.

Strengths Automation and Ultraviolet (UV ) technology: Many screen printers have seen their business double or triple over the years ever since they switched over to automation along with UV. Thus, semiautomatic and fully automatic screen printing machines are making inroads into the Indian screen printing industry.

In recent times, a big shift has taken place from a predominantly manual printing process to semi-automatic and now fully automatic printing machines. A steep increase has occurred in the number of screen printing machines (and UV curing machines) sold in the last few years than it was 5-10 years ago. A noteworthy transformation here is the quantum leap in the number of visitors to our pavilions at various printing industry exhibitions than it was 5-10 years ago. Screen printing not only involves low investment, which is a big advantage for those wishing to join the screen printing business, but there has been widespread applications of this versatile process and greater awareness about the immense benefits of and need for automation.

Modern Packaging & Design November-December 2011

Courtesy: DMI

Quality improvement: With automatic precision machines, it is now possible to achieve results that would have been a dream years ago. The screen printing process of today is faster, better and cleaner. Combination of processes: There is a growing trend of offset printers/ packaging companies setting up in-

SWOT analysis of screen printing

house screen printing units instead of outsourcing. Many digital printers have set up screen printing units to meet the market demand for ‘total print solution’. Screen printing is the perfect complement to offset and works in tandem to generate more business.

Weaknesses Education – lack of knowledge: Knowledge is the key to success for any business. However, the screen printing industry lacks not only ‘knowledge’, but also ‘knowers of knowledge’. Despite this, over the years, screen printers in India have drastically improved with hard work and through learning from self-help, by reading technical articles, attending exhibitions, seminars, etc. Technical education think tanks in India should analyse the printing education offered in various institutes, which lack in ‘advanced screen printing’. These institutes touch upon only some basics and outdated elements of screen printing. This is necessary as Indian screen printing is adopting automation in a big way and will thus need more trained screen printing professionals. According to Narendra P, Pragati Press, Hyderabad, people must change the old mindset that ‘screen printing business can easily be started with an investment as low as ` 500-1000 to print visiting cards, letterheads, etc’. That is because technological development in screen printing has moved way ahead of this thinking. In screen printing, each step is a ‘science’, and without learning this ‘science’, nothing can be printed qualitatively.

Opportunities Unlimited applications: Screen printing is an excellent technology used by many industries with numerous old, new and not yet discovered applications – for flat [plastics, cloth, metal, thin to thick papers, sunpack/sunboard, rubber, leather, wood, glass, Printed Circuit Board (PCB), etc] as well as non-flat substrates, using appropriate machinery

and inks. It is widely used in packaging, labels, smart-cards, etc. Value addition with UV special effect inks/varnishes: What started as Spot UV (matte and gloss), today, with the availability of various UV special effects, screen printers have a better opportunity to delight the consumer. Extensive range and variety of effects is available, providing the marketer, print buyer and designer with endless exciting possibilities. Use of non-paper substrates: Continuous advancements and developments in polymer technology, cost-effective manufacturing, plastic substrates, etc are replacing traditional materials in many fields. These include Polyvinyl Chloride (PVC), Polypropylene (PP), High Impact Polystyrene (HIPS), lenticular films, polycarbonate, etc. PP sheets are extensively used for blister packaging, cardboard boxes and making disposable containers, embossing, gift boxes, freight packaging, etc. PVC and PP sheets are best suited for screen printing. Great shift - Indian screen printers: At FESPA Munich 2010 Workshop titled ‘The Future of Screen Printing Goes Through Innovation: A comparison between Western and Asian Countries’, Michel Caza – an international screen printing expert – had stated that ‘Graphics and signage constitute only 20 per cent of screen applications, while 35 per cent lies in textile printing and 45 per cent in industrial applications’. This sums up the potential and the future of screen printing. During a presentation at the show, titled ‘how European countries are moving towards screen printing and Indian screen printing industry is also progressing with the latest trend’, Caza mentioned that due to industrial production shifting to Asian countries, screen printing is gaining greater attention in this region. Rewarding printers: A growing number of entries and award winners are participating in two major international competitions – SGIA/FESPA – besides national competitions such as Screen

Print India Award, SPAI-FESPA India and PrintWeek India. This will increase the zest for quality improvement on various counts – complexity, image definition, precision & sharpness, colour, applications, creativity, etc. But, most printers still hesitate to participate in such competitions due to various reasons.

Threats Manual screen printing: Screen printers catering to industrial printing should discontinue the use of manual screen printing tables. Because the industrial screen printing demands strict quality and delivery requirements, which is not possible by manual operation. Many screen printers have shifted to automation since manual screen printing is tedious, laborious, time-consuming and wastage-ridden. Use of outdated methods: Wooden f rames, nylon white fabric instead of polyester yellow fabric, lack of standardisation in screen making, etc. Some other threats include use of poor quality raw materials, use of solvent despite UV being available for many applications. Thus, in India, more and more Original Equipment Manufacturers (OEMs) are setting up their own screen printing units, whereas earlier, they outsourced their requirement.

For a vibrant future Today, different systems have been designed to help screen printers achieve better results. But these require standardisation of the screen printing process, after which one can expand the applications for screen printing with confidence and get full benefit from the synergy of screen printing with other processes. Bhargav Mistry is Director of DMI, and MD of Grafica Flextronica, manufacturer of fully automatic and semiautomatic screen printing machines. Email: bhargav@graficaindia.com

Modern Packaging & Design November-December 2011

AUTOMATION TRENDS: Bottling line solutions

Conveying outstanding performance The importance of line control, modulation and integration on conveyors in beverage and bottling plants could not be more significant today. Jams and stoppages on these conveyors impact the function of the filler, and thereby the entire line. Here arises the need for a conveying solution that can help avoid glitches such as this and improve overall line efficiency.

reliable conveyor technology is the backbone of efficient packaging. The conveyor and transport systems manufactured by most companies today are customised as per the quality of goods conveyed. 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 â&#x20AC;&#x2DC;heartâ&#x20AC;&#x2122; of the system.

Why have a conveyor system? A common user of conveyors does not pay much attention to their purpose. For him, it is merely a system to move a product from one point to another.

However, if utilised correctly, it can be exploited to raise oneâ&#x20AC;&#x2122;s line efficiency to a whole new level. Over the years, significant development has been made in the art and science of conveying systems. 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 operators. All these finally equate to a sizable savings for the business, especially if the bottling line has an output of more than 300 bottles per minute.

Improving line efficiency There are three essential considerations for achieving good line efficiency. The first 30 per cent of a good conveyer system would be attributed to the design of the conveyor layout. Two immediate benefits of the same need to be observed. o People-friendly design essentially manages man and material movement. This reduces stress for operators o Machine-friendly design layout supplements machine performan Another 30 per cent would be the quality and make of the conveyor. The components, quality of raw materials and finish of the conveyor determine

Courtesy: Clearpack India Pvt Ltd

Modern Packaging & Design November-December 2011

Bottling line solutions

the durability of the conveying system. Details like selecting wear strips, materials of chain, rating of motors, design of return rollers and guides need to be considered. It is common for bottlers and suppliers to save cost and investment by choosing non-branded and inexpensive material. Often, these materials have very short life and drastically increase friction in conveyor chains. This increases the load on the conveyor motor, significantly reducing its life. Hence, this requires investing in frequent replacement of the wear strip, conveyor chain and motor. The remaining 40 per cent of the conveyor solution is attributed to the line control and modulation. This is the major reason why top companies invest heavily to ensure that their line never stops. Line control and modulation is the programming that takes into account different scenarios based on inputs from performance of the machine, sensors placed at key points throughout the line.

Role of a conveyor system Consider a scenario of a bottling line rated at 400 bottles per minute. If the case packer stops due to a fallen bottle, the operator needs to go to the machine, take care of the bottle and restart the system; this whole exercise may take about 30 second. In that time, 200 more bottles may have accumulated between the packer and the up-stream machine. Thus, when the case packer starts, it now has to ensure that it can take care of the 200 bottles that have accumulated besides the 400 bottles that come out of the filler every minute. So, it now has a total of 600 bottles at hand. Usually, downstream machines have 20 per cent higher capacity than conventional machines, so the maximum speed of the case packer here would be 480 bottles per minute. Thus, it will take 2.5 minute for the case packer to clear the accumulation of 200 bottles over its current capacity.

Here, the conveyor has to ensure that it can ramp up faster than the speed of the case packer to ensure that it is not starved at a speed of 480 bottles per minute, while also ensuring no significant back-pressure building up on the machine from the force of bottle accumulation at a speed of 400 bottles per minute. The conveyor also needs to communicate to up-stream machines to slow down to prevent further accumulation.

Imparting total excellence Conveyors as a total system can, and is, as complex and equally rewarding as any other blow-moulder, filler, labeler, packer machine on any other line. Hence, bottlers must ensure that it always flows smoothly. This can be done seamlessly by using the correct design, materials and smart programming. Courtesy: Clearpack India Pvt Ltd

ENERGY MANAGEMENT: Material conser vation

Reducing consumption, augmenting growth An unstable economic condition coupled with rising environmental awareness has forced the packaging industry to re-evaluate its performance in terms of materials, methods and machinery. Annabel Dsouza analyses the trends and technologies that are reducing material consumption while promoting alternative solutions for the converting industry in India.

s India’s retail industry gears itself towards new horizons of innovations and growth, it is necessary to analyse the overall performance of the packaging industry in terms of materials, methods and machinery. The importance of packaging and the need for advanced packaging technology is proven by the Freedonia report, which expects the global market to grow to $ 23 billion in 2015, at an estimated Compound Annual Growth Rate (CAGR) of 8.2 per cent from 2010 to 2015.

Cost-efficient technologies As Indian convertors face an increasingly competitive global business environment, they seek opportunities to reduce production costs without negatively affecting product yield or quality. Uncertain energy prices in today’s marketplace negatively affect predictable earnings, a concern for publicly traded companies in the packaging industry. Successful, cost-effective investments in energy-efficient technologies and practices meet the challenge of maintaining the highquality output despite reduced production

costs. Energy efficiency is an important component of a company’s business and environmental strategy. End-of-pipe solutions can be expensive and inefficient while energy efficiency can often be an inexpensive opportunity to reduce carbon emissions. Energy efficiency can be an effective strategy to work towards the socalled ‘triple bottom line’ that focusses on the social, economic and environmental aspects of a business.

Innovative trends In recent times, flexible packaging solutions have come to represent the entire packaging industry. This is primarily due to flexible films advantages in terms of relatively low cost, good barrier properties against moisture & vapour, heat sealable, easy to handle and convenient for the manufacturer, retailer and consumer. However, rising raw material prices have led to Indian convertors exploring alternative packaging materials like Polylactic Acid (PLA), thermoplastic starch, bio-polyamide (nylon), Polyhydroxyalkanoate (PHA), etc. Uday Shah, Director, Star Technocrates Pvt Ltd, says, “The packaging industry should work

Modern Packaging & Design November-December 2011

towards thicker flexible packaging solutions. Higher micron laminates are more beneficial to the recycling mechanism and help eliminate wastage. As an alternative, biodegradable plastics should be made more affordable and market-friendly.” The recent economic situation coupled with rising environmental awareness has forced many consumers to look for greater value in all their purchases. This has given rise to more emphasis on refurbished or upgraded packaging materials, resulting in greener choices of packaging materials. Consumer preferences are instigating manufacturers to opt for the reformulation, re-branding and re-pricing of products to beat the competition. Here, packaging serves as an important differentiator. Although maximum focus is on quality and value, consumers are attracted to innovations in products, packaging, advertising and branding.

Stretching profitability Minimising waste by preventing film breaks and stretch wrap damage is essential to seamless packaging operations. Mechanical film handling systems also wrap at a

Material conser vation

higher tension without distorting the load so that pallets previously wrapped with 22-24 revolutions now need only 12 spins to provide the same level of containment. Fewer wraps per load reduces film usage and waste up to 50 per cent. Another waste reduction technique involves converting to non-destructive leak testing equipment. Todayâ&#x20AC;&#x2122;s leak testers are equipped with non-contact laser scanning technology, which detects flaws as small as 10 micron.Integrated quality control systems reduce waste by identifying flawed product or packages. For example, a built-in cap inspection sensor on the packaging line rejects any unsealable container before it reaches the sealing head. Automation solutions also offer efficient methods that help convertors and original equipment manufacturers (OEM) to integrate waste-eliminating machine vision inspection.

Utility conservation Conserving utilities is not only positive for the environment, but also improves

the bottom line. As a result, there is an increased interest in packaging machines that require less water for cleaning, monitor utility consumption and operate at higher speed. Dry decontamination system on integrated blow moulding, filling & capping line reduces energy, chemical and water consumption by using hydrogen peroxide vapour and sterilising the smaller preform rather than the larger bottle. The system can run 36 hours between sterilisation cycles and is compatible with light-weighted containers. With motors and drives consuming an estimated 68 per cent of all energy used in industrial settings, packaging lines require a multifaceted conservation approach, which is called 4EE: Energy-efficient components, Energy recovery, Energy on demand and Energy-efficient design. Shah concludes, â&#x20AC;&#x153;We use energy-efficient motors and drives to ensure that our machines work at higher speed. This gives us an added advantage to market our products in the competitive packaging machinery industry.â&#x20AC;? Email: annabel.dsouza@infomedia18.in

The packaging industry should work towards thicker flexible packaging solutions. Higher micron laminates are more beneficial to the recycling mechanism and help eliminate wastage. As an alternative, biodegradable plastics should be made more affordable and market-friendly. Uday Shah Director, Star Technocrates Pvt Ltd

Modern Packaging & Design November-December 2011

POLICIES & REGULATIONS: ISO guidelines for biodegradable plastics

From formulation to implementation The government is making steady progress towards creating a plastics-free society. However, not all plastics harm the environment. A case in point is biodegradable plastics, for which the industry wants the ISO guidelines to be implemented strictly to avoid misleading the customers and manufacturers. Anwesh Koley finds out how proper implementation of these guidelines and raising the awareness levels of people on the same can help save our environment.

n an age where sustainability is one of the biggest issues facing the packaging industry, the use of bioplastics seems the most feasible option considering the rapid increase in pollution levels caused by petroleum-based plastic materials. The major difference between biopolymers and hydrocarbon polymers is that biopolymers, due to their physical & chemical structure, can be decomposed by microorganisms and assimilated in the soil again. This property of biodegradable plastics has made it popular across the globe. However, the guidelines that regulate the usage of bioplastics are not well defined in India. “In India, the ISO 17088 guidelines rule the use of bioplastics, but have not been implemented properly,” says Manish Pathania, Sales Director, Greendiamz Biotech Ltd. The journey towards starting a bioplastics initiative has been fraught with challenges and, above all, negative sentiments, from the plastics lobby and the government.

In India, the ISO 17088 guidelines govern the use of bioplastics, but have not been implemented properly. Manish Pathania Sales Director, Greendiamz Biotech Ltd

They perceive the initiative as a threat to their industry and livelihood. But, the sentiments of people today are different from the government’s perspective and are proactive in their support for bioplastics.

Use of oxo-biodegradable plastics The use of oxo-biodegradable plastics is now widely accepted across the country and there are valid reasons that show why companies are moving towards it. Mahendra Jain, Director, Symphony Polymers Pvt Ltd, says, “Oxo-biodegradable packaging starts breaking down in the presence of oxygen, and the process is accelerated by heat, Ultraviolet (UV) light & stress, followed by biodegradation. This results in a slow carbon-release favourable to the environment as a nutrient for plants.” This type of packaging should help reduce major environmental problems caused by littering of non-degradable packaging, which clogs drains, sewers and rivers. It can also be recycled with other oil-based plastics in a normal recycling process.

Modern Packaging & Design November-December 2011

What do the guidelines imply? The ISO 17088 guidelines specify procedures and requirements for identification and labelling of plastics and plastic products suitable for recovery through aerobic composting. This specification is intended to establish the requirements for labelling of plastic products & materials, including packaging made from plastics, as ‘compostable’ or ‘compostable in municipal and industrial composting facilities’, or ‘biodegradable during composting’. The labelling has to conform to any international, regional, national or local regulations. The current market for bioplastics is restricted as compared to other countries where they have high utility. “Oxobiodegradable plastics are essentially A2W additives, which ensure that the material breaks down into particles when kept under the soil for more than 180 days,” adds Pathania. The government is clear in terms of guidelines issued for anti-solid waste management.

Stumbling blocks Adoption of oxo-biodegradable packaging

ISO guidelines for biodegradable plastics

Oxo-biodegradable packaging starts breaking down in the presence of oxygen, and the process is accelerated by heat, Ultraviolet (UV) light & stress, followed by biodegradation. This results in a slow carbonrelease favourable to the environment as a nutrient for plants. Mahendra Jain Director, Symphony Polymers Pvt Ltd

for the industry faces some hurdles. Oxo-biodegradable packaging is more expensive and requires continual exposure to microorganisms in an industrial composting environment; hence, this rules out the problem of littering of plastics. Composting is an artificial process with a shorter time-scale than natural biodegradation, which results in rapid, unfavourable carbon release into the atmosphere. “These cannot be recycled in the normal recycling process and have to be segregated from the waste stream and treated separately, which considerably increases the cost. Furthermore, it is difficult for manufacturers to physically distinguish between hydro-biodegradable and normal plastics,” adds Jain. The government has made it mandatory that plastic bags of thickness less than 40 microns cannot be manufactured for packaging purposes. But similar standards are yet to be implemented for bioplastics. “Today, our customers are skeptical about the long-term viability of plastics, be it classical plastics or biodegradable ones. If the government does not demarcate

Modern Packaging & Design November-December 2011

between classical and bioplastics, a huge share of the market will not achieve full benefits of bioplastics,” says Pathania.

Future forward Hydro-biodegradable and oxobiodegradable plastics have their own unique merits and should compete fairly in the market for interested customers to decide on the best one based on product characteristics and their requirements. “Although oxo-biodegradable plastics do not decompose as much as conventional biodegradables, it is a step forward to moving away from the use of classical plastics, which take millions of years to decompose,” adds Pathania. Government policies and guidelines are the most important factors determining market acceptability for biodegradable plastics. While the industry is well aware of their benefits, simpler norms and more support will ensure that the guidelines are well implemented across the country, thus saving the environment through continuous awareness. Email: anwesh.koley@infomedia18.in

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STRATEGY: Sustainable plastic packaging

Road to recyclability In an era of rising energy costs and scarce resources, companies need to adopt a clear strategy to develop packaging solutions that not only add value to end products, but are also environment-friendly. Manufacturers are increasingly adopting renewable packaging technologies, eco-friendly light-weight materials and costeffective methods. Avani Jain explores some of the strategies adopted by industry leaders to ensure sustainability in plastic packaging.

ackaging is a crucial necessity for every sector. It helps the manufacturer to transport products to consumers, increase shelf life, minimise breakage, reduce handling costs, safeguard public health, provide product information and create consumer convenience. Plastic packaging accounts for over 50 per cent of the total packaging in India. From toiletries to food products, plastics are present everywhere. The global outcry towards reducing wastes has forced companies in the this segment to move towards sustainable packaging. Apurva Kane, Senior Vice President, Mamata Machinery Pvt Ltd, says, “Sustainability in packaging can be defined as reducing the amount of materials used in packaging and, secondly, using only materials that are completely recyclable.” Recently, a study conducted by the Associated Chambers of Commerce and Industry of India (ASSOCHAM) found that due to rising environmental concerns, several domestic companies are opting for eco-friendly packaging. The study 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. It thus focusses on the fact that sustainable packaging is the latest trend.

Strategising the concept At present, most manufacturers are increasingly adopting renewable packaging technologies and using environment-friendly light materials. Pavan Parikh, Director, Parikh Packaging

Pvt Ltd, says, “We are manufacturing biodegradable and thin laminates, as these help in attaining sustainability in packaging. For instance, to pack one tonne of biscuit, 300 kg of laminates is needed. But we have developed laminates that are thinner but provide similar types of barrier. Therefore, we now use only 220 kg of laminates. With this, one can save almost 22 per cent of valuable raw material and energy as well as transportation cost. We also recycle our polyfilm waste and regain granules

Modern Packaging & Design November-December 2011

back for reuse, saving material as well as the environment.” Companies are working towards developing technologies that enable sustainable packaging. Kane details, “The company focusses on developing a technology that allows customers to process biodegradable and recyclable films. This is because normal machines, which make bags and pouches, are unable to process these films. The technology that we are offering to the market helps in making thinner films.”

Sustainable plastic packaging

Further, sustainable packaging might not necessarily mean biodegradable packaging. It means that all methods by which carbon footprint can be reduced, including source reduction. For example, instead of using 5 gm of plastics for packaging a particular product, if it can be reduced to 4 gm, it contributes to being green. Yatindra R Sharma, Managing Director, KHS Machinery Pvt Ltd, says, “Plastic bottles used for beverage packaging have a huge carbon footprint. Our company is basically looking at light weight solutions. We are looking for ways to produce bottles, which would require less amount of plastics as compared to others. This way we are trying to reduce the carbon footprint as well.”

Hurdles encountered Even after adopting various measures to ensure sustainable plastic packaging, the processors in this segment are faced with few challenges. Kane says, “The major challenge for the plastic packaging industry is to change the perception of the people who think that plastics is an extremely polluting material. This is not correct; in fact, plastics does not pollute, it is the habit of people to throw it on the roads, which makes it a polluting material. Unlike paper, plastics is made from man-made cellulose, which means that there is no need to cut trees for that. Moreover, plastic packaging is better than paper packaging because to pack 25 kg of material in a paper bag, one will need a very thick paper bag but in plastic packaging, that thickness can be reduced drastically.”

Mapping the future In future, rising environmental concerns about carbon emissions, dearth of natural resources together with increased health awareness and waste reduction targets will be the key growth drivers for green packaging innovations in India.

Kane says, “We have developed a new product, ie, form-fill-seal machine. This is a patented technology, which uses recyclable films and not laminates. With regard to flexible packaging, at present, most processors are using Polyethylene Terephthalate (PET) laminates, which is a combination of two or more different materials. One must understand that polyethylene and terephthalate alone are completely recyclable. The problem begins when polyethylene and terephthalate are combined because after this the two materials cannot be separated and neither can these be recycled easily. Although there are ways by which PET can be recycled, these are expensive and the practice would become economically almost non-viable. Therefore, most companies do not recycle PET. As laminates are non-recyclable, the recent ban on gutka pouches, which use these, is a right decision.” He further adds, “We have never manufactured machines that make gutka pouches or jhabla bags. We make machines for industrial bags used for packing salt, detergent, shirt, stationery items, etc and pouches for packing hand wash, shampoo, etc, which use sustainable films & not laminates. This is our basic strategy for future growth and the way to address the rising environmental concerns. Moreover, the zeal to ensure green packaging should come from within the processors and be a voluntary exercise. Companies need to realise their roles and responsibilities in a proper manner and take the green foot forward without actually being forced by the government or any other regulatory body.”

Plastics does not pollute; it is the habit of people to throw it on the roads, which makes it a polluting material. Apurva Kane Senior Vice President, Mamata Machinery Pvt Ltd

We also recycle our polyﬁlm waste and regain granules back for reuse, saving material as well as environment. Pavan Parikh Director, Parikh Packaging Pvt Ltd

The great shift The plastic packaging industry has thus begun to carry out extensive research in order to become sustainable and economical. The key to attaining sustainability in packaging consists of three Rs – reuse, reduce and recycle – which are vital to safeguard a better environment for future generations. With the general mindset shifting towards procuring ecofriendly products & packages, sustainable packaging will provide manufacturers with social, economic and environmental benefits in the future. Email: avani.jain@infomedia18.in

We are looking for ways to produce bottles, which would require less amount of plastics as compared to others. Yatindra R Sharma Managing Director, KHS Machinery Pvt Ltd

Modern Packaging & Design November-December 2011

TIPS & TRICKS: Safety in pharma packaging

Focussing on the hygiene factor The current trend in pharmaceutical packaging companies is the increasing reliance on enabling technologies to achieve higher levels of productivity and efficiency. Manufacturing companies face numerous challenges like regulatory compliances, safety & hygiene, environmental issues and high customer expectations. Of these, safety & hygiene claim top priority. Here are some pointers on how to ensure safety & hygiene in pharma packaging. Anwesh Koley

he pharma packaging industry places particular attention to hygiene and while safety was always the key element, cleanliness within the manufacturing premises as well as for individual products has gained ground of late.This is a challenge

as time and distance are factors that often negate the efforts by companies to ensure packaging quality and product safety. Overcoming these challenges necessarily implies extensive use of technologies, which can not only sense, but also anticipate variables and provide actionable real-time information. Such collaborative manufacturing IT solutions

Incorporating sustainable design at the beginning of package development creates an opportunity to find ways to reduce consumption. It involves understanding of exact needs of the consumer and d e ve l o p i n g a solution that meets safety standards surrounding manufacturing efficiency, consumer usage and product hygiene.

Technology advancements are creating new options for more effective and sustainable packaging. These include smart packaging applications, which can record and transmit realtime data, or use sound & light to communicate with the consumer. These technologies support consumersâ&#x20AC;&#x2122; adherence to their medication regimen, improve patient outcome and lead to long-term wellness.

It is important to create the efficient forms of packaging to minimise environmental impact and maximise each step in the supply chain. For instance, pre-filled medication packages benefit pharmacists, consumers and the environment. Such a packaging helps expedite pharmacist hand ling, providing time for consumer consultation and ensures that consumers receive right medication.

play a major role in tracking the ever-dynamic production and business processes and in generating the required information. The data captured and information generated by collaborative manufacturing IT solutions help companies gain sustainable competitiveness. Email: anwesh.koley@infomedia18.in

Efficient transportation contributes to a smaller carbon footprint. Increased efficiency can be achieved by reducing the weight of the overall package, eliminating tertiar y packaging and optimising shipping routes & loads. Blister packages, for example, are shipped as fully loaded packages, ready for immediate distribution by pharmacists.

Well-designed packaging should be implemented to existing equipment, which can be achieved by using state-of-the-art technology. Equipment can be often recalibrated or enhanced to run more efficiently and with increased precision towards safety & cleanliness of the finished product.

-- With inputs from Rajabahadur V Arcot, Vice President and GM (South and South East Asian operations), ARC Advisory Group

Modern Packaging & Design November-December 2011

EVENT LIST

National

Pune

Chennai

Indore

Aurangabad

Maharashtra Nov 18-21, 2011 Auto Cluster Exhibition Centre, Pimpri-Chinchwad

Tamil Nadu Dec 8-11, 2011 Chennai Trade Centre, Nandambakkam

Madhya Pradesh Jan 6-9, 2012 Poddar Plaza, Nr Gandhi Hall

Maharashtra Feb 17-20, 2012 Garware Stadium, Chikkalthana

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

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

Indo-German Conferences This will be a special conference on the latest innovations in the world of printing technology. Experts and industry authorities will highlight the latest trends & developments in the field of packaging printing and issues like brand protection and anti-counterfeiting; November 22-23, 2011; at Hotel Novotel, Juhu, Mumbai For details contact: Kiran Prayagi Graphic Arts Technology & Education 2-B, 202, The Neighbourhood CHS Lokhandwala Township, Akurli Road Kandivali (E), Mumbai - 400 101 Tel: +91 22 66997437 Mob: +91 9820441799 Email: kprayagi@gmail.com Website: www.gate.co.in

India Converting Show 2011 This will be a platform to showcase the latest converting solutions in advanced machinery and best-in-class practices. The concurrent India Flexo Show and India Corrugated Show will offer a further insight into the strategic moves required by the Indian industry in order to keep pace with the global market trends; November 23-26, 2011; at Bombay Exhibition Centre, Mumbai

F 101, Tower No 7, First Floor International Infotech Park Vashi - 400 705 Tel: 022-27812093/27812619 Fax: 022-27812578 Email: info@packplus.in Website: www.indiaconvertingshow.com

India Packaging Show 2011 Among India’s most exhaustive packaging events, this brings together seven established niche shows dedicated to distinct segments. The show aims to bring together the worldwide manufacturers and providers of machinery, materials and services for food, pharmaceuticals and packaging industry from India and neighbouring countries; December 7-10, 2011; at NSIC Exhibition Centre, Okhla Industrial Estate, New Delhi For details contact: Prateek Kaushik Print-Packaging.com Advant Navis Unit No A1101B Noida-201301, Uttar Pradesh Tel: 0120-3075400 – 04 Fax: 91-22-27812578, Mob: 09899981610 Email: info@packplus.in Website: www.indiapackagingshow.com

Intelpack 2012 For details contact: Neetu Arora Print-Packaging.com

In its 12th edition, this exhibition will showcase the cutting-edge technology and converting applications. With concurrent

Modern Packaging & Design November-December 2011

events like Foodtek and Pharmapack, visitors will find innovations & solutions to make their business more efficient and profitable; February 23-25, 2012; at Bombay Exhibition Centre, Mumbai For details contact: 113, New Sonal Link Industrial Estate Building No 2, Link Road Malad (W), Mumbai - 400 064 Tel: 022-28803977/28803978 Fax: 022-28819008 Email: intelexpo@vsnl.net Website: www.intelexpo.com

N PRINTECH TODAY 2012 This exhibition will highlight the next generation printing solutions encompassing all the innovations & latest technology for the packaging and converting industries. From small print shops to full-scale packaging-printing companies, there is no doubt that the digital revolution has transformed printing industry to a new dimension with emphasis on quality, speed and efficiency; April, 20-22, 2012; Chennai Trade Centre, Chennai For details contact: Buysell Interactions Pvt Ltd No 5, Shanmugam Street, Royapettah Chennai - 600014 Tel: 044 28353739 Fax: 044 28350839 Email: ravi@buysellint.com Website: www.nprintech.com

EVENT LIST

International Saudi PPSG 2011 This a specialised event dedicated to packaging, converting, screen and digital printing industries in the Middle East. This bi-annual trade exhibition will be an ideal business platform to showcase the latest packaging/printing technologies, products and services in Asia’s growing converting market; November 28-December 1, 2011; at Riyadh International Convention and Exhibition Centre For details contact: Riyadh Exhibitions Company P O Box 56010, Riyadh 11554 Kingdom of Saudi Arabia Tel: +966 1 2295604 Fax: +966 1 2295612 Email: info@recexpo.com Website: www.saudisigngraphics.com

China Foodtech 2011 This show will emphasise on the food processing and packaging industry in Asia. In collaboration with all major global packaging industry associations, this trade show will offer unique advantages to the Asian market. It will be a chance to discover machinery and technology solutions from the Far East as well, November 30-December 2, 2011; at China International Exhibition Centre (CIEC), Beijing, PR China For details contact: China Council for Promotion of International Trade 1 Fuxingmenwai Street Beijing 100860, PR China Tel: 86-10-8807 5769/5729 Fax: 86-10-68030747 Email: BCNweb@bizchinanow.com Website: foodtech.ciec-exhibition.com.cn

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

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

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

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

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

PCD 2012 This edition of PCD (Perfumes, Cosmetics & Design) will be dedicated to packaging innovation for the cosmetic packaging. This exhibition-cum-conference will highlight issues relating to preservativef ree products, new designs and functionalities from packaging experts in different special fields (materials, surface treatments, forming, processing, artwork, etc); February 8-9, 2012; at Porte de Champerret, Paris For details contact: Oriex 25, rue André Joineau Le Pré saint Gervais Paris - 93310, France Tel: +33 1 48.91.89.89 Fax +33 1 48.43.49.94 Email: congress@oriex.fr Website: www.pcd-congress.com

IPACK-IMA 2012 This exhibition will show case the latest innovations and trends in the world of packaging, processing and material handling technology. It will be a common platform for technology suppliers and end-user companies to increase business, create value, share knowledge and expertise within the packaging professional community; February 28 – March 3, 2012; at Fieramilano, Milan, Italy For details contact: Ipack-Ima SpA Corso Sempione 4 20154 Milano, Italy Tel: +39 02-3191091 Fax: +39 02-33619826 Email: ipackima@ipackima.it Website: www.ipackima.it

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

Modern Packaging & Design November-December 2011

BOOK REVIEW

Formulating, packaging, and marketing of natural cosmetic products Editors : Nava Dayan and Lambros Kromidas Price : ` 6,000

Innovations in food labelling Editors : Janice Albert Price : ` 9,000

This book is a collective work of 44 contributors from companies at the forefront of cosmetic business and research universities in Europe and the US. It can be used as a reference by all associated with the cosmetics industry.The book is divided into six groups: Market and Trends gives the history, natural progression and current status of the largest natural & organic personal care companies, besides current trends, regulations and governmen & non-governmen standards followed. The chapter Regulatory Aspects describes the regulations to be followed for natural claims, flavours & colour additives; natural food claims to cosmetics, fragrance ingredients, treatment of organic claims and certification; government regulations; and advertising claims. Safety Aspects introduces the assessment of plant-derived ingredients in cosmetics, threshold of toxicological concern, approach to assessing consumer safety of botanical ingredients, preservation of cosmetics, microbial risks, eco-friendly packaging and major risk factors. Use of Natural Ingredients discusses formulation of cosmetics with natural oils, fats, butters & waxes; natural antioxidants; measuring antioxidant capacity; clinical studies; use of quercetin and curcumin in skincare consumer products; and ayurvedic ingredients in cosmetics. Ancient Indian discipline of Ayurveda provides a pre-existing resource that documents the traditional uses of various plants for therapeutic benefits, besides traditional Chinese medicinal herbs & herbal formulae. Analysis of Naturals talks about scientific chromatography techniques for analysing natural products in cosmetics and use of nuclear magnetic resonance spectroscopy to identify biomarkers for quality control of plant extracts. Biodegradation explains biodegradability evaluation of cosmetic ingredients & finished products, biodegradable packaging, methods and current trends.

Increasing numbers of food consumers today are seeking information on products that affect their health & safety and environment, besides technical and socioeconomic conditions under which products are processed. Increase in global food trade and the information provided on packages must not mislead consumers. Continuous developments are taking place to harmonise food labels. Moreover, labels function as a marketing tool. From this perspective, this book has arrived at the right time and with authoritative information. Besides historical account of food labelling, it includes the topic of Codex Committee on Food Labelling. The main shift is from a strict ‘prevention of fraud’ scenario to providing consumer information and health policy through labelling. International trade agreements and key international human rights questions of relevance of labelling and consumer protection considerations are explained. Governments in different countries are developing policies to encourage standards for a true and informative system. Food companies depict nutritional information in graphical forms, which are explained in the forms of policies and key trends. The book explains the importance of geographic origin and identification labels, associating food quality with location. The last chapter describes new technologies in food labelling. The book contains useful tabulated information for immediate application and numerous references at the end of each chapter.

Reviewed by: Kiran P Prayagi, Graphic Arts Technology & Education and pmIndia

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

Modern Packaging & Design November-December 2011

PRODUCT S

This section provides information about the national and international products available in the market Hot-melt coating machine

Parallel gripper system

Shanghai Huadi Machinery offers RT-20 hot-melt medical plaster coating machine. It is used for producing medical plaster, band-aid, medical spring bandage, non-woven fabric glue sticker and other products. It adopts slot die, can-coating 100-1,000 g/mÂ˛ with the width between 200-800 mm and the speed is 20 m/min. The uniformity is controlled within 5 per cent. The machine adopts servo motor drive, can setting and adjusting precisely with steady speed. Other important advantages include: realises lowtension control of the elastic substrate; manufactured by stainless steel as per the usage standard in medicine industry; and realises precise metering, dosing, double-screw mixing and coating at moment.

Neejtech India offers parallel gripper system from Gimatic SPA, Italy. Its feature include flat profile, robust guide, high gripping force, small weight, high dimensional accuracy, spring closed (-NC) or spring open (-NO) option. Excessive forces or torques can damage the gripper, cause functioning troubles and endanger the safety of the operator. F s, Mx s, My s, Mz s, are maximum permitted static loads. F d, Mx d, My d, Mz d, is the maximum permitted dynamic loads. M, is the maximum permitted weight of each gripping tool, when the gripper works without speed adjustment. If the weight is over the permitted value, it is necessary to decrease the speed of the jaw by using flow controllers. The operating position can be checked by magnetic sensor(optional), detecting the magnet of the piston, or by inductive sensors (not supplied), detecting the ball (SY ) in the appendix (Y ). Two adjustable appendixes can be mounted on the jaw using the supplied screws (TY ). The pneumatic circuit must be pressurised progressively inorder to avoid uncontrolled movements.

Shanghai Huadi Machinery Co Ltd Shanghai - China Tel: +86-21-5779 4228, Fax: +86-21-5779 4222 Email: huadi@huadi.us

Pick & place case packer Clearpack India offers RCP series pick & place case packer from APSOL that are extremely flexible machines designed to pack a variety of products into cases, display boxes or trays. Thes case packer is available with various feeding or picking systems at speeds up to 25 cycles/min with 1 to 4 picking heads. Simple and clean design of the case packers makes it particularly suitable for applications in food, beverages, and home care & personal care industries. The machines is equipped with a touchscreen HMIs, which allows easy access to all functions, including creation of new packing programs. Main features include: pick & place section based on a flexible & efficient 2-axis robot; compact structure with mechanical parts mounted overhead, particularly designed to maximise accessibility & cleanability; quick & tool-free changeover; modular design, which allows integration of various feeding & collation systems for products in rigid or flexible packaging. Clearpack India Pvt Ltd Mumbai - Maharashtra Tel: 022-2859 6422 Fax: 022-2850 9391 Email: sales@clearpack.com

Neejtech India Ahmedabad - Gujarat Tel: 079-2656 1312 Mob: 098250 40231 Email: sales@neejtech.com

Multilayer stretch film Krishna Packaging offers multilayer stretch film. The multilayer stretch film is specifically manufactured in such a manner that they provide complete protection of ferrous and non-ferrous metals against corrosion. The multiple layers help to protect the metal with vapour phase and avoid the contact from corrosion inhibitors. In addition to this, the multilayer stretch film absorbs moisture from package through desiccant action for better functionality. It is widely used in various industries. Krishna Packaging Ahmedabad - Gujarat Tel: 079-2217 1041 Mob: 094260 53814 Email: k_krishnapackaging@yahoo.com

Modern Packaging & Design November-December 2011

PRODUCT S

Electric injection moulding machine Neejtech India offers horizontal injection moulding machine from Niigata, Japan. This machine is generally known as green machine because it saves more than 60 per cent power consumption than the similar size hydraulic/toggle machine, the machine is absolutely free from oil, due to which it is eco-friendly. Due to no oil in usage it reduces maintenance & repair cost of the hydraulic system. It ensures enhanced accuracy and reliability and also provides great cost savings and contributes to environmental preservation. This machine runs silent & without vibrations. Machine is very precise due to no deviation through oil viscosity, compressibility, through drifting hydraulic valve action time. By switching over from hydraulic to electric injection moulding machine one can save greater cost on power consumption, cooling water consumption, hydraulic oil elimination, housekeeping and maintenance cost. It will increases up time and decrease the material wastage. This machine is ideally suitable for medical, automotive, pharmaceutical and packaging moulding segment industry. Neejtech India Ahmedabad - Gujarat Tel: 079-2656 1312, Mob: 098250 40231 Email: sales@neejtech.com

Twin bagger Hassia Packaging offers 'Flexi Bag 180T' twin bagger. This machine provides high output per unit of packaging space. Resultant total speed is higher for any product, due to optimised speed on each lane. This machine is an excellent solution for high volume applications like snack food, salt, detergents, milk powder and small packs on any product. It is an ideal solution to reduce floor space, feed points, power consumption and manpower by 50 per cent as it replaces two single-lane machines. Advantages of this machine are: two independent systems for each lane, one-touch isolation of any lane, resultant dependability on each lane of only 50 per cent; highest range of format size in the category 50-180 mm; and wide range of fillers both volumetric and weighmetric offered with this bagger to suit every product application/need. Hassia Packaging Pvt Ltd Pune - Maharashtra Tel: 02137-302 802-06 Fax: 02137-302 819 Email: info@oystar.hassiapackaging.com

Modern Packaging & Design November-December 2011

PRODUCT S

Candy wrapping machine Bosch Packaging Technology offers Miniwrap BVK 1200 candy wrapping machine. This is a cost-effective and proficient solution for customers seeking higher production speed and increase in Overall Efficiency Equipment (OEE), especially in the B and C segment markets. With an output speed of 1,200 candies/min and attributes like servo drive to achieve drive pattern, it is ideal for wrapping candies. Also, the touch-screen panel offers easy operator interface, making troubleshooting and operation simple. This machine can be used to wrap a range of products like hardboiled and deposited candies, dragees, coated balls, chicklets, chewing gum, coated chewing gum, etc. It can be used for products shaped round, oval, square, rectangular and spherical. All machinable heatsealable materials can be processed on this machine. The machine is available with optional accessories like: second reel carrier, coding device, rejection system and vacuum discharge of empty packs. This can be used to make packages, which can be single or multiple-unit packs or with dimensions independent of the product dimensions. Bosch India Ltd, Packaging Technology Division Bengaluru - Karnataka Tel: 080- 4176 8218, Fax: 080-4176 8106 Mob: 098805 96101 Email: narendra.s@in.bosch.com

Modern Packaging & Design November-December 2011

PRODUCT S

Powder filling machine

Auger filler

Ace Technologies offers semi-automatic powder filling machine. This is suitable for all powders and granules. The machine has high filling accuracy due to unique design feature. Wide table design helps accommodate more containers. It requires minimum change parts. All contact parts are of SS 316. Microprocessor-based control, zero dripping, and accurate slippage control are other important features.

Saurabh Flexipack Systems offers Smart-EX auger filler. This vertical form-fill-seal machine is cost-effective and designed for entrepreneur, mid-scale and large-scale manufacturers. It requires very little floor space. The machine is intelligent, PLC-controlled, with pneumatic operations. It is suitable for packaging pouches of size in the range of 0.5-500 g, with good speed and weight precision. The machine is good for free-flowing fine powders like turmeric, mehandi, besan, atta, talcum powder, ground spices, herbal powder and all kinds of fine powders. Specifications of the machine include: filling capacity 0.5-500 g, filling speed 1,000-4,000 pouches/hr, PLC control, pneumatic mode of operation, weighing accuracy 0.5 per cent of set volume, weight of the machine 50 kg (approximate), dimension can be 1,000 x 950 x 2,450 (approximate), power requirement 220 V single-phase or 420 V three-phase, and compressed air requirement 6 CFM with pressure 6 bar. The machine is available in a variety of models: 0.5-10 g, 5-50 g, 10-100 g, 50-250 g and 100-500 g. Packaging material used are laminated films.

Ace Technologies Mumbai - Maharashtra Tel: 022-2854 0743/0645, Fax: 022-2870 0281 Email: acetechnologies@vsnl.com

HDPE/PP woven sack Kanpur Plastipack offers HDPE/ PP woven sack. Some of the salient features of this sack include: circular woven fabric; laminated and/or unlaminated; printed and/or unprinted; all types of small sack, such as valve, bale wraps, liner sack, gusseted sack, etc; and reel-to-reel printing with corona treatment UV stabilised option. The comprehensive range of sack is utililsed in many industries such as fertilisers, agri products, cement, sugar, fibre, plastic polymers, chemicals, sand, seeds, salt, minerals, etc.

Saurabh Flexipack Systems Pvt Ltd Pune - Maharashtra Tel: 020-2749 2722, Fax: 020-2749 1347 Email: saurabhpackaging@hotmail.com

Vacuum packaging machine Kanpur Plastipack Ltd Kanpur - Uttar Pradesh Tel: 0512-269 1113 Fax: 0512-269 1117 Mob: 098381 01789 Email: info@kanplas.com

Air bubble film Tender-Care International offers a wide range of air bubble films that are lightweight, chemically neutral, transparent & attractive, non-hygroscopic sealable & weldable, strong & firm, flexible and tenacious. Large size air bubble films are ideal for heavy and midsized items, test equipment, motors, receivers, machineries, spares, furniture, carton lining, void fill, etc. Medium-sized air bubble films and smaller diameter air bubble films are also available. Tender Care International Mumbai - Maharashtra Tel: 022-2685 4908, Fax: 022-2685 5930 Email: airplast@mtnl.net.in

Modern Packaging & Design November-December 2011

Monarch Appliances offers vacuum packaging machine, which is used to pack food products. Vacuum packaging increases the shelf-life of products. The machine vacuums the product along with the shape of the product that comes out with the pack. The advantage of this chamber machine is that even the space surrounding the product outside the package is vacuumed. These chamber machines can also be used to pack products with a modified atmosphere. Very low residual oxygen figures can be obtained by first pulling a vacuum before the injection of gas. Vacuum packaging machine is useful for packing cheese, meat, fish, dairy products, peanuts, dry fruits, sea foods, coffee beans, pillows, PCBs, spices, instant food, bakery products, chemicals, electric components and pharma products. Monarch Appliances Rajkot - Gujarat Tel: 0281-246 1826, Fax: 0281-301 9788 Mob: 098252 15733, 093767 77277 Email: monarchrajkot@gmail.com

PROJECT S

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

Bottling plant Coca-Cola

Project type New facility

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

Project location Negeri Sembilan, Malaysia

Project cost $ 302 million

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

Project location Naidupeta, Andhra Pradesh

Project cost ` 400 million

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

Glass manufacturing complex Hindustan National Glass (HNG)

Project type New facility

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

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

Packaging materials Tetra Pak New facility

Project news

Industrial packaging Time Technoplast

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

Not known

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

Implementation stage Construction

Project cost

Project type New facility

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

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

Project location Chakan, Pune

Project cost ` 600 crore

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

Modern Packaging & Design November-December 2011

PRODUCT S

Digital colour mark sensor

Cleaning and washing system

Lubi Electronics offers â&#x20AC;&#x2DC;Sunxâ&#x20AC;&#x2122; LX-100 series digital colour mark sensor. This can detect any marking because the sensor is equipped with red, green and blue LED element. In order to expand the functionality, the sensor comes with dual mode, ie, mark mode (ultra highspeed response) & colour mode (high-precision mark colour discrimination) to suit any application. This sensor comes with Mode Navi technology for enhancing features and is easy to use. It is provided with a four-digit digital display, 12-bit A/D converter, D-code, key lock, timer, NPN or PNP outputs, IP67 protection, etc. It is used in many applications/ industries, especially in packaging, food, pharmaceuticals, textile, plastic & many more.

Scanvik Packaging offers a wide range of Flexo Wash cleaning/washing systems for anilox rolls, gravure cylinders, printing plates and parts for both narrow web and wide web presses. Flexo Wash uses a safe and gentle cleaning method that does not harm even the most delicate rolls. With this system one can both deep clean the rolls and wash them on a daily basis without harming even the finest rolls. Simply place the roll in the anilox roll/ plates in the cleaning machine and press start. The whole cleaning process starting with liquid spraying, rinsing with high-pressure water and at the end drying by means of air will run through automatically in one cycle. There is no need to do manual cleaning or drying thus ensuring minimum manual handling of rolls/plates. The quick and gentle system is fully automatic and leaves the anilox roll/cylinder/ plates 100 per cent clean & dry ready for use in a very short time.

Lubi Electronics Ahmedabad - Gujarat Tel: 079-2220 547 Fax: 079-2220 0660 Mob: 093274 97006 Email: info@lubielectronics.com

Scanvik Packaging Mumbai - Maharashtra Tel: 022-4010 6327 Mob: 098204 28338 Email: scanvik@gmail.com

Modern Packaging & Design November-December 2011

PRODUCT S

Vibratory bowl feeder Elscint Automation offers a special vibratory bowl feeder for large caps having diameter of more than 100 mm. Plastic caps require feeding for automatic capping machines as well as other special pharmaceutical and consumer goods feeding machines. These caps have to be oriented in one direction, which can either be open side facing sky, open side facing ground or even the open side facing centre of the bowl or away from it. The feed rate achievable in case of such large caps is about 60-80 caps/min depending on the size of the plastic cap. As most of the caps come out in ‘open side facing sky’ orientation, they need to be twisted to change the orientation to ‘open side facing ground’. A versatile tooling along with feeder can twist caps of any diameter in 180o or as required. Elscint Automation Pune - Maharashtra Tel: 020-2712 2059 Fax: 020-2712 2994 Email: sales@elscintautomation.com

Vertical form-fill-seal machine Wraptech Machines offers high-speed vertical form-fill-seal machine for producing centresealed pouches handling all types of f ree-flowing/non-f ree-flowing powders/granules/solids. The machine handles a single-reel film stock of maximum reel diameter 530 mm on 76 mm core. The machine has the facility to be provided with a variety of filling heads. Draw down of the film is through vacuum pressed draw-down belts, controlled through a servo-motor drive. The length of the bag is controlled by print registration system, which is PLCbased. For unprinted film, the bag length can be adjusted from a singletouch keypad provided on the front panel. Filling range of the machine is 25-2,000 g depending on bulk density of products & fill weight that the maximum pouch size can accommodate. Output can be up to 120-140 packs/min depending on product flow properties, pack size, type, quality and thickness of laminate being used. Wraptech Machines Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-2787 1743 Fax: 022-2761 2807 Email: marketing@wrapmachines.com

Modern Packaging & Design November-December 2011

PRODUCT S

Horizontal flow wrapping machine Bosch Packaging Technology India offers for the horizontal flow wrapping machine Pack 201. This mid-range speed machine is easy to maintain and is designed for delicate product handling. It is ideal for wrapping bakery goods, trays, candy bars, wafers and non-food products. Easy format changes for packaging various sized products are made possible through the adjustable folding box, allowing for maximum machine efficiency and improved package quality. The simple and smart design incorporates minimal parts to increase reliability, streamline maintenance and allow for greater adaptability. All data is stored on a flash card. The on-board UPS protects data in case of power loss. The logical structure and the use of graphics simplify the use of the operator screen. The screen displays parameter entry, errors and production statistics. The Pack 201 is available in full stainless steel, it ensures a long lifecycle while safeguarding against leakage, spoilage, cleaning and humid environment. Bosch Ltd (Packaging Technology Division) Verna - Goa Tel: 0832-669 2042, Fax: 0832-669 2028 Mob: 091588 81011 Email: boschpackaging@in.bosch.com

Modern Packaging & Design November-December 2011

PRODUCT S

Extrusion melt-pressure transducers & transmitters

Film production line

Adinath Controls offers extrusion melt-pressure transducers & transmitters from OneHalf20, Canada, a liquidfilled capillary design. This tried & proven design provides an electronic signal which is proportional to the measured pressure and allows the transducers to operate at process temperature up to 400oC. The electronic of each transducer are a Wheatstone bridgebonded strain gauge design, ensuring high accuracy, reliability and repeatability. These are available in two distinct accuracy grades, generalpurpose grade accuracy (non-linearity) of batter than 0.5 per cent FSO, laboratory grade feature accuracy (non-linearity) of batter than 0.5 per cent FSO. All these melt pressure transducers and transmitters are fully compatible with the industry standards wiring pattern and colour coding, as well as offering 100 per cent mechanical compatibility with existing pressure transducers utilising the six pin bayonet connectors. Pressure range 0-1,500 PSI to 0-15,000 PSI, outputs available 3.3 mV, 4-20 mA, 0-10 DC. The execution voltage available can be mV/V 10 V DC, 4-20 mA and 24 V DC.

Bori Machinery offers 'BR-L' ser ies laminating pouch film, thermal lamination film production line. This machine is equipped high-precision full-seal original imported die head, which ensures high quality lamination. The speed can be up to 260 m/min. High-precision PLC (Siemens, Mitsubishi) is used for controlling, with the full automatic constant tension control for reeling, unreeling and every tension point. This machine is suitable for base materials such as BOPP, BOPET, BOPA and aluminium foil for resins: LDPE, LLDPE, HDPE, PP, EVA, EAA, EMA and other coating grade resin to produce pouch film and thermal lamination film.

Adinath Controls Pvt Ltd Gandhinagar - Gujarat Tel: 02764-286 573 Fax: 02764-286 574 Email: info@adinathcontrols.com

Pharma print cartridges & felt pads/rollers Process Instrumentation & Controls offers pharma print cartridges & felt pads/rollers. These are made for blister packaging machine, FFS machine and coding machine. The absorbing material used is poly porous in various microns varying from 1 to 25 micron, depending upon the requirement of customer. The absorbing capacity of these cartridges is quite high and the cartridges are hard, so that the impression is good as there is cotton cloth knitted sleeves (covering), which is used to avoid direct contact of stereo with roller. The cartridges are made in various ID, OD and length depending on customerâ&#x20AC;&#x2122;s requirement. The maximum OD can be 85 mm and length up to 300 mm. Inner diameter of the bore can be adjusted as per the specific coding/marking requirement. These inking rollers are used extensively in coding and batch printing machines for marking/stamping of 'batch no', 'mfg date', 'exp date', 'retail price', etc. Process Instrumentation & Controls Vadodara - Gujarat Tel: 0265-235 7228, Fax: 0265-235 5429 Email: batchprinting@yahoo.com

Modern Packaging & Design November-December 2011

Bori Machinery Imp & Exp Corp Zhejiang Province - China Tel: +86-579-82050435 Fax: +86-579-82050430 Email: bori@bori.cc

Proximity sensors Omron offers a wide range of inductive proximity sensors to solve sensing application needs. The industry standard inductive sensors provide high reliability for machine parts and metal object detection from short to long distance, in special environment, for special mounting conditions and special applications. The new 'E2GN' proximity sensor offers exceptional value without compromising on quality. It is available in both shielded and non-shielded M12 & M18 model. Come in pre-wired and connector type, this proximity sensor offers 2 mm, 5 mm and 8 mm sensing distance, respectively. Also available in DC 3 wires, it has built-in power source circuit reverse polarity protection, output reverse polarity protection and short-circuit protection. The 'E2GN' series meets IEC60529, IP67 degree of protection and EN60947-5-2 EMC compliance. It is an ideal choice for machine makers and end-users who seek value for money yet quality product in this tough time. Omron Automation Pvt Ltd Bengaluru - Karnataka Tel: 080-4072 6400 Fax: 080-4146 6403 Email: in_enquiry@ap.omron.com

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PRODUCT S

Digital paper moisture meter Cole-Parmer India offers the ‘Delmhorst P-2000’ digital paper moisture meter. This electrical resistance-type moisture meter comes with three separate scales: paper, baled scrap paper and reference. The moisture scale range for paper is 4.3 to 18 per cent, for baled paper the range is 5 to 40 per cent, and for the reference scale it is 0 to 100 per cent. The meter measures through built-in pins and optional pin electrodes. The contact pins mounted on top of the meter provide 0.8 cm (5/16’’) penetration for testing paper tubes or corrugated stock. The meter also features an audible out-of-range alarm, internal calibration check, 100 data point memory, and average/maximum readings. This meter is provided with a 9V battery and hard plastic carry case. Optional and replacement electrodes & accessories are also available. The paper moisture meter is ideal for testing paper materials such as paperboard, corrugated stock and paper tubes. It finds applications in the print & paper, packaging, food & beverage and manufacturing industries. Cole-Parmer India Mumbai - Maharashtra Tel: 022-6716 2222 Fax: 022-6716 2211 Email: response@coleparmer.in

Plate making machine Innovative Flexotech offers photopolymer plate making machine for pharmaceutical batch printing. It performs exposure, washout, drying and treatment in complete functions. The exposure unit comes with instant lightup Philips high-intensity lamps, unique digital timers for back/main exposure, good quality lamps cooling/exhausting system and quick vacuum draw-down pump with an indicator. The features of washout unit include: easy access design, special bristle good for all kinds of plates washout, suitable for Perc+NBA & green chemicals and good result for 175 LPI one per cent reproduction. Drying unit comes with features such as drying drawer with uniform heat distribution, temperature adjustable by a precise controller, unique air circulation and exhaustion design and over-heat sensor for safety and protection. Features of treatment unit are: chemical-free operation, digital timer for light finishing control and Philips UVC high-intensity lamps equipped with powerful air exhausting for large size models. Innovative Flexotech Pvt Ltd Ahmedabad - Gujarat Tel: 079-2685 2439 Email: info@flexo.co.in

Modern Packaging & Design November-December 2011

PRODUCT S

Contact coder Process Instrumentation & Controls offers online highspeed contact coder. This is a small intermittent motion reciprocating contact coder with ink cartridge enclosed in its container for label printing. It is mountable for online marking on sticker labelling machines in pharma/food industry and is widely used for coding and marking on labels at high speeds. It is used to print various statutory information like batch number, date of manufacturing, expiry date, price and any other information on various packing like tins, containers, cartons, lids, stickers, laminated flexible pouches, films, metal containers, etc. It is specially used for high-speed coding application viz, self-sticker labelling & multi-track packing line, FFS, blister pack, and strip pack machine. This machineâ&#x20AC;&#x2122;s compact design makes it easy to install where space is limited. It can be mounted in any angle: vertical, horizontal, or side mounting. It has a versatile controller with inbuilt cyclic timer and five different input modules to achieve or optimise printing at speeds up to 180-200 impressions per minute with easy operation. Process Instrumentation & Controls Vadodara - Gujarat Tel: 0265-235 7228 Fax: 0265-235 5429 Email: batchprinting@yahoo.com

Web guiding system ATE Enterprises offers web guiding system of low noise level (62-63 dB), manufactured by Erhardt+Leimer (India). Important features of this system include infinitely adjustable control sensitivity by regulating air signal pressure, adjustment of the operating pressure with the aid of a pressure gauge, adjustment of the cylinder positioning speed to optimise control circuit, and high-powered blower provides fast system response with almost nil signal transmission delay. This system is suitable for a wide range of webs including thin films, maintenance & wear-free blower, easy fitting of an additional hydraulic port for external uses, etc. Further, it is easy-to-maintain due to compact & modular construction, and is also operator-friendly. ATE Enterprises Pvt Ltd Mumbai - Maharashtra Tel: 022-6676 6100 Fax: 022-2673 2463 Email: pps@ateindia.com

Modern Packaging & Design November-December 2011

PRODUCT S

Blue LED display Kwality Photonics offers a wide range of blue LED displays which include: single-digit, multi-digit, dotmatrix, lightbars, etc. The expanded range now includes: single-digit, seven segment displays (SSDs) from 7.6 to 200 mm character height; dual, triple and quad SSDs in 7.6, 10 and 14 mm variants. Blue dot matrix displays are available in a wide range of alternatives with the traditional 30 and 50 mm, 5 x 7 modules proving particularly popular. There is a choice of intensity and wavelength in the range, with new variants being constantly introduced. The brilliant, 470 nm wavelength LED displays are visible in the brightest ambient lighting, but draws less than 0.5 W (85 mA) from a single +5 V supply, which is less than most standard red LED displays. The KLSXXXB series LED digital meter displays are offered as units to employ silicon carbide super bright blue LEDs. Kwality Photonics Pvt Ltd Hyderabad - Andhra Pradesh Tel: 040-2712 3555 Fax: 040-2712 4762 Email: kwality@kwalityindia.com

Aluminium profile section Kirpekar Engineering offers a variety of aluminium profile sections along with all the connecting accessories a designer requires. These sections and profiles allow the designer various options and possibilities of frames to be manufactured for industrial applications like Fifo storage racks, display boards, enclosures, machine guards & fencing, robotic & automation systems, conveyors, work-test & assembly line benches and tables, assembly in packaging machines and many more. These specially extruded aluminium profiles are designed and manufactured with very close tolerances and maximum strengths, anodised to a depth of 15 micron ensuring the structures are accurate and resistant to corrosion. These have a ling life and can be used for any application. The standard sizes available are 30 x 30, 40 x 40, 40 x 80, 80 x 80 and 80 x 160. Kirpekar Engineering Pvt Ltd Pune - Maharashtra Tel: 020-6674 1600 Fax: 020-6674 1601 Email: sales@kirpekarengg.com

Modern Packaging & Design November-December 2011

PRODUCT S

Temperature controller

Retro-reflective area sensor

Procon Technologies offers PXR series temperature controller from Fuji Electric. This 1/16 DIN temperature controller comes with a LED display that is 1.6 times larger than other previous models with dust-proof front display and operational section that is waterproof and conforms to NEMA-4X (IP66). It is available in 24 x 48 mm, 48 x 48 mm, 48 x 96 mm and 96 x 96 mm sizes. Fuzzy control is a standard feature suppressing overshoot without lengthy start-up time and improving the response to external disturbances by quickly reverting to set points. It is provided with 16segment ramp/soak & menu driven auto/manual mode of operation. By using the digital input option, the operator can change between two set points using a remote, start/stop the control action, start/reset the ramp/soak, start/stop the auto tuning, cancel the alarm latch or start the incorporated timer.

Pepperl+Fuchs offers RLG28, a new series of retro-reflective area sensor. With a total of six light beams, this sensor generates a constant 60 mm detection field over a sensing range of 0-4 m. This complete solution offers a resolution of 12 mm and is designed to fit aptly in situations where single-beam retro-reflective sensors reach their limitations or where expensive light grids are needed. Housed in a standard photoelectric senor housing, the RLG28 is mechanically and electrically compatible with all common photoelectric sensors available in the market. Users facing problems in detection of targets can easily use this technology without changing the control concepts within their control loop. This sensor reliably detects objects of all shapes. The sensors are used primarily for the reliable detection of the front edges of objects, as well as the consistent detection of different objects with no defined shape or position, such as pallets, bags, deformed blocks, etc.

Procon Technologies Pvt Ltd Ahmedabad - Gujarat Tel: 079-2749 2566, Fax: 079-2743 2871 Email: dhaval@procon.co.in

Pepperl+Fuchs (India) Pvt Ltd Bengaluru - Karnataka Tel: 080-4211 1198, Fax: 080-2837 8031 Email: info@in.pepperl-fuchs.com

Photoelectric gap sensor Lubi Electronics offers ‘Sunx’ RT-610 series photoelectric gap sensor. It is ideal for gap sensing, mark sensing and address reading. In this sensor, the beam axis alignment is not required, as the emitter and receiver are integrated in a single body. It has a sensing range of 10 mm, 20 mm and 50 mm. The models with a sensing range of 10 mm and 20 mm are available in red LED type and green LED type for mark sensing. This sensor provides high reliability, as the housing material is made of die-cast aluminium. It can be used effectively in typical applications such as packaging, pharma and machine tools industry. Lubi Electronics Ahmedabad - Gujarat Tel: 079-2220 5471 Fax: 079-2220 0660 Mob: 093274 97006 Email: info@lubielectronics.com

Modern Packaging & Design November-December 2011

Rotary coder Bhavmark Systems offers RM-2 , a compact rotary coder with instant dry thermo fusible ink. This coder can print date, batch number, price and other information. It is applicable to most soft and flexible packaging materials, eg, cellophane, PP, PE, aluminium, cardboard, etc. Maximum speed can be up to 35 m/min and maximum printing area 30 x 35 mm. It is easy to install on all types of continuous motion packaging machines such as flow pack units and form-fill-seal machines. Important features include: driven by high-speed stepping motor, self-test, quick configuration, automatic temperature control, LED display, and quick replacement of modules. Bhavmark Systems Thane - Maharashtra Tel: 022-2819 8722, Fax: 022-2818 0455 Email: sales@bhavmark.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 Business Insights •Technologies•Opportunities

LIST OF PRODUCT S

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

Pg No

AC drive............................................. 19 AC variable frequency drive ................... 19 Acrylic bending machine ........................ 57 Air bubble film ....................................... 80 Air cooled sealer ..................................... 22 Aluminium profile section ...................... 87 Ammonia liquid chiller ............................. 8 AS-interface system ................................ 45 Auger filler .............................................. 80 Auto sealer ............................................. 78 Automatic rescue device ......................... 19 Automation & storage system ................ 45 Batch counter ..................................... 81 Battery....................................................... 7 BBL brake motor.................................... 23 BBL/KEC flame proof motor ................ 23 Bearing .................................................... 69 Bio-mass dryer ........................................ 79 Blade bending machine .......................... 57 Blue LED display system ....................... 87 Bottle / container filling machine........... 83 Bottle uncrambler ..................................... 5 Brake pad .................................................. 7 Brewing technology ................................ 61 Bulk milk cooler ....................................... 8 Butterfly valve ........................................... 8 Cable ................................................. 45 Cable carrier............................................ 69 Cable connector ...................................... 69 Cable handling & processing system...... 45 Candy wrapping machine ....................... 79 Capacitive and magnetic sensor .............. 45 Capping machine ...................................... 5 Cartoning machine ........................5, 31, 83 Case erector .............................................. 5 Case packer ............................................... 5 Case sealer................................................. 5 Chain ...................................................... 69 Cleaning and washing system................. 81 Clutch plate & cover assembly ................. 7 Coding ............................................... COC

Sl No Product

42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82

Pg No

Cold-aseptic filling system...................... 61 Compact pneumatic cylinder .................. 39 Concrete block & paver machine ........... 31 Connector ............................................... 69 Connector accessory................................ 45 Contact coder.......................................... 88 Container filling line............................... 31 Contrast/colour scanner .......................... 37 Controller ................................................ 19 Convertor ................................................ 81 Conveyor ................................................... 5 Conveyor belt .................................... 82, 88 Conveyor system ..................................... 89 Conveyor technology .............................. 61 Counter ................................................... 81 Counter & power supply ......................FIC Crimp contact & tool ............................. 45 C-slot and T-slot pneumatic cylinder .... 17 Custom-made cable ................................ 45 Cutting machine ..................................... 57 Cylindrical sensor ................................... 37 Dairy machinery ................................... 8 Data cable ............................................... 45 Design concept ....................................... 29 Digital colour mark sensor ..................... 81 Digital panel meter ................................. 12 Digital paper moisture meter.................. 87 Digital temperature controller ................ 83 Dosing/sealing system............................. 83 Double sheet monitoring system ............ 37 Drive ....................................................... 83 Drying and heating system ..................... 79 Dual channel with modbus .................... 83 Dynamic controller ................................. 83 Electric actuator & gripper ................. 39 Electric injection moulding machine ...... 78 Electronic brake ...................................... 19 Elevator controller .................................. 19 Encoder .................................................FIC Exhibition - Complete Packaging Expo ...33 Exhibition - Engineering Expo ........ 42, 49

Sl No Product

83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121

Pg No

Exhibition - Food & Bevtech 2012 ....... 65 Expanded polyethylene capseal............... 32 Expanded polyethylene seal liner............ 32 Extrusion melt-pressure transducers & transmitters ............................................. 84 Factory production display .................. 81 Fastback revolution seasoning system ..... 89 Fiber-optic controller .............................. 17 Fibre-optic amplifier ............................... 37 Fill and seal machine .............................. 79 Filling and closing technology ................ 61 Filling machine ......................................... 5 Film production line ............................... 84 Filter .......................................................... 7 Finished package ..................................... 29 Flange mounting motor .......................... 23 Flexible packaging material .................... 79 Flow rate indicator & totaliser ............... 81 Flow wrapping machine ........................... 5 Forked photoelectric sensor .................... 37 Gasket ............................................... 32 Gasoline system ........................................ 7 Gear pump ................................................ 7 Geared motor .......................................... 23 Glue spreader .......................................... 79 Gripper.................................................... 33 Guided compact pneumatic cylinder ...... 39 Hand-type impulse sealer ................... 78 HDPE/PP woven sack ........................... 80 Heat treatment plant .............................. 79 High capacity bag palletiser.................... 87 Horizontal FFS machine .......................... 5 Horizontal flow-wrapping machine ....... 83 Horizontal form-fill-seal-packaging machine ............................................. 55, 83 Horn ......................................................... 7 Hot- melt coating machine .................... 77 Identification system .......................... 45 Induction sealing..................................... 22 Inductive switch ...................................... 37 Industrail connector ................................ 45

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

Modern Packaging & Design November-December 2011

LIST OF PRODUCT S

Sl No Product

122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170

Pg No

Industrial automation.......................... 6, 78 Industrial control & sensing device ......FIC Industrial pump ...................................... 66 Inspection and monitoring technology... 61 Instrumentation made cable ................... 45 Invertor/variable frequency drive ..........FIC Isolator .................................................... 81 Kamlok & drylok coupling ................. 66 KEC AC motor ...................................... 23 KEC DC motor ..................................... 23 KEC slipring crane duty motor .............. 23 Labelling ...........................................BC Labelling and dressing technology ......... 61 Labelling machine.................... 5, 79, COC Length counter ....................................... 81 Level controller .....................................FIC Lighting system ........................................ 7 Liner ....................................................... 32 Load cell indicator .................................. 81 Loading arm ........................................... 66 Long bar sealer ....................................... 78 Lubricant................................................... 7 Marking system ............................. COC Measuring & monitoring relay .............FIC Measuring sensor .................................... 37 Mini sensor ............................................. 37 Motion control......................................FIC Motor ...................................................... 23 Multilayer stretch film ............................ 77 Nitrogen extrusion sealer .................... 78 Non-nozzle type vacuum sealer .............. 78 Nozzle ..................................................... 66 Nozzle-type vacuum sealer ..................... 78 OEM controller ................................. 81 Oil cooler ................................................ 79 Oil heater ................................................ 79 Online B2B marketplace .................. 47, 91 Overwrapping machine ............................ 5 Packaging development engine ........... 29 Packaging solution .................................. 21 Packing and palletising technology ........ 61 Palletiser .................................................. 31 Palletising robot ...................................... 87 Paper impregnation line.......................... 79 Paperless recorder.................................... 12 Parallel gripper system ............................ 77 Pharma packaging machinery .............. BIC Pharma print cartridges felt pads/ rollers 84 Photo electric sensor .................FIC, 45, 90

Sl No Product

171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219

Pg No

Pick & pack case packer ......................... 77 PID temperature controller .................... 81 Plastic film & sheet ................................ 79 Plate heat exchanger ................................. 8 Plate making machine ............................ 87 Plug valve .................................................. 8 Pneumatic & hydraulic cylinder ............. 33 Pneumatic valve ........................................ 8 Powder filling machine ........................... 80 Power controller ...................................... 19 Pressure regulator .................................... 33 Pressure sensitive paper & film label ...... 21 Pressure sensor ....................................... 17 Process controller .................................... 12 Process tank .............................................. 8 Process technology .................................. 61 Product handling equipment .................. 89 Profile controller ..................................... 83 Programmable logic controller ........FIC, 83 Programmable terminal ........................FIC Protective-conduit system ....................... 45 Proximity sensors ..................................FIC Proximity sensors .................................... 84 PVC & fabric coating plant steam heater ..79 Rail tanker ........................................... 8 Receptacle ............................................... 66 Refrigerant pump...................................... 8 Refrigeration ............................................. 8 Refrigrated compressed air dryer ............ 39 Relay ......................................................... 7 Retro-reflective area sensor ..................... 90 RFID ....................................................FIC Rinser and pasteuriser ............................. 61 Robotic palletiser ...................................... 5 Rotary coder............................................ 90 Rotary encoder ........................................ 45 Safety light curtain .......................... FIC Scanner ................................................... 81 Screw commpressor .................................. 8 Screw power controller ........................... 19 Sealer....................................................... 22 Self adhesive tape.................................... 88 Sensor...................................................... 45 Shrink bundler .......................................... 5 Shrink film ...................................5, 79, BC Shrink film packaging machine .............. 87 Shrink sleeve applicator ............................ 5 Shrink wrap sealer ................................. 78 Shrink wrapper ....................................... 79

Modern Packaging & Design November-December 2011

Sl No Product

220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257

Pg No

Shrink wrapping machine......................... 5 Sight flow meter ..................................... 66 Skin wrapping machine .........................BC Soft starter & digital starter ................... 19 Solenoid valve ......................................... 33 Spark plug ................................................. 7 Starter motor ............................................ 7 Stretch blow-moulding technology ........ 61 Stretch film packaging machine ............. 87 Stretch wrapping machine ...................... 87 Surface inspection system ....................... 10 Switching relay......................................FIC Swivel ...................................................... 66 System engineering ................................. 61 Tank & silo .......................................... 8 Temperature controller........12, 83, 90, FIC Thermoforming machine .......................... 5 Timer ..............................................81, FIC Transmitter.............................................. 81 Tray sealing machine ................................ 5 Tubular bag form system ........................ 79 Twin bagger ............................................ 78 Ultrasonic flow meter ......................... 12 Ultrasonic sensor ............................... 37, 45 Universal controller ................................. 83 Vacuum packaging machine ................ 80 Variable frequency drive ......................... 19 Ventilator ................................................ 88 Vertical cartoning machine ..................... 53 Vertical FFS machine ....................5, 82, 83 Vibratory bowl feeder ............................. 82 Vision sensor ...................................FIC, 10 Vision software ....................................... 10 Vision system .......................................... 10 Washer ............................................... 61 Web guiding system................................ 88 Wiper blade .............................................. 7 Wood seasoning kiln............................... 79

Looking for a speciďŹ c product? We will ďŹ nd the product for you. Just type MPD (space) Name of the Product and send it to 51818 eg, MPD (space) xxxx and send it to 51818.

LIST OF ADVERTISERS Advertiser’s Name & Contact Details ACG Worldwide

Pg No BIC

Advertiser’s Name & Contact Details

Pg No

Cognex Sensors India Private Limited

Advertiser’s Name & Contact Details IFM Electronics India Pvt Ltd

T: +91-22-26780127

T: +91-80-4022 4118

T: +91-231-2672770

E: shabbir.badami@acg-world.com

E: sales.in@cognex.com

E: info@ifm-electronic.in

W: www.cognex.com/handheld-barcode-

W: www.ifm-electronic.in

W: www.acg-world.com

scanners.aspx Avery Dennison India Pvt Ltd

Confederation Of Indian Industry

Igus India Pvt Ltd

21 65

T: +91-124-2215581 T: +91-22-24931790

Pg No

T: +91-80-39127800 E: info@igus.in

E: lpm.in@ap.averydennison.com E: saurabh.rajurkar@cii.in

W: www.igus.in

W: www.enhanceyourbrand.com W: www.foodbev.in Benison & Co. Ltd.

IndiaMART InterMESH Ltd Enercon Asia Pacific Iss Pvt Ltd

T: +1800-200-4444 / 91-120-3911000

T: +886-3-322-5531

T: +91-09600344430

E: benison@benison.com

E: pr@indiamart.com

E: skumar@enerconmail.com

W: www.benison.com.tw

W: www.indiamart.com

W: www.enerconaciapacific.com Industrial Thermal Engineers

Beumer Group Gmbh & Co Kg

47, 91

Engineering Expo

42, 49, 57 T: +91-79-25833806

T: +49-2521-240

T: +91-9819552270

E: vt@beumer.com

E: engexpo@infomedia18.in

W: www.beumer.com

W: www.engg-expo.com

E: industrialthermal@gmail.com W: www.intherm.in

Bharat Bijlee Ltd

E: vishwajyoti.vengurlekar@bharatbijlee.com

Fluid Energy Controls Inc

E: info@jeltron.com W: www.jeltron.com

W: www.fecindia.com Bosch Limited

7 Heat And Control

T: +91-80-22999269

W: www.boschindia.com Clearpack India Pvt Ltd

KHS Machinery Pvt. Ltd

E: info@heatandcontrol.com

E: partho.ghose@khsindia.com

W: www.heatandcontrol.com

W: www.khs.com/india

IDMC Limited

Krones Ag

T: +91-22-42532222

T: +91-2692-225399

T: +49-9401-700

E: anthony@in.clearpack.com

E: idmc@idmc.coop

E: info@krones.com

W: www.clearpack.com

W: www.idmc.coop

W: www.krones.com

Our consistent advertisers

T: +91-79-2644-0331

T: +91-44-42103950 E: sanjay.chakravarty@in.bosch.com

T: +91-40-23401159

T: +91-44-42083536 E: sales@fecindia.com

W: www.bharatbijlee.com

Jeltron Systems (India) Pvt.Ltd.

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

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

Modern Packaging & Design November-December 2011

LIST OF ADVERTISERS Advertiser’s Name & Contact Details M & M Technologies Pvt Ltd

Pg No 78

T: +91-22-27781580 E: mkp@mmtechnlogiesindia.com

Advertiser’s Name & Contact Details Omron Automation Pvt. Ltd.

Pg No FIC

Packaging Technology Co., Ltd

E: in_enquiry@ap.omron.com

T: +86-21-3365-8333

W: www.omron-ap.com Pakona Engineers India Pvt Ltd

T: +91-22-22826751 E: bhushan@pakona.com

E: manish.sahay@leuze.in

W: www.pakona.com

W: www.leuze.in

Pepperl+Fuchs(India) Pvt Ltd.

Markem-Image India Private Limited

COC

E: leo@dasesing.com

T: +91-80-40854444

Pg No

Shanghai Dase-Sing

T: +91-80-40726400

W: www.mmtechnologiesindia.com M+V Marketing - Leuze Electronic

Advertiser’s Name & Contact Details

W: www.dasesing.com Smart Expos

T: +91-44-28603086/4087

E: compack@smartexpos.in W: www.smartexpos.in

T: +91-80-28378030 E: info@in.pepperl-fuchs.com

Sreelakshmi Traders

W: www.pepperl-fuchs.com

T: +91-44-24343343

T: +91-120-4099500 E: salesindia@markem-imaje.com Plastic Technologies

E: sreelakshmitraders@gmail.com

W: www.markem-imaje.co.in T: +91 9322215410 Mifa Systems

W: www.sreelakshmitraders.com

E: pvs.prasad@plastictechnologies.com

T: +91-79-26870825

W: www.plastictechnologies.com

E: info@mifasystems.com

Procon Technologies Pvt Ltd

W: www.mifasystems.com

T: +91-79-27492566

The Indian Electric Co

T: +91-20-24474303 12 E: icemktg@indianelectric.com W: www.indianelectric.com E: info@procon.co.in Multispan Instruments Co

Ultraplast Chainbelts Pvt. Ltd

W: www.procon.co.in T: +91-79-22770865

Reynders Label Printing India Pvt Ltd

E: marketing@multispanindia.com W: www.multispanindia.com Nichrome India Ltd

E: info@ultraplast.in

E: india@reynders.com

W: www.ultraplastindia.com

W: www.reynders.com

Vora Packaging Pvt Ltd 83

T: +91-22-42178706

E: marketing@nichrome.com

T: +91-129-4113187

T: +91-149-3305400

Roechling Engineering Plastics (India)

T: +91-20-66011001

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

E: yogesh.sawatkar@roechling_india.com W: www.nichrome.com

W: www.vorapack.com W: www.roechling.com

Noida Fabcon Machines Pvt Ltd T: +91-120-4225550

S P Engineers T: +91-9890990234

Wu Hsing Electronics Co. Ltd. T: +886-4-2271-1498

E: nishantb@fabcon-india.com

E: sp_engineers@yahoo.co.in

E: wuhsing@ms17.hinet.net

W: www.fabcon-india.com

W: www.spengineerspune.com

W: www.sealers-web.com

Modern Packaging & Design November-December 2011