17 minute read
WATER PROCESSING TECHNOLOGY
Dry preform sterilisation enhances aseptic production flexibility
Nongfu Spring’s latest additions to its beverage portfolio required a hyper-flexible and safe aseptic solution, able to process high- and low-acid, still and carbonated products in PET, while enabling impactful bottle designs.
WITH FOUR DECADES of supporting sensitive beverage producers worldwide, Sidel recently engineered and installed a complete aseptic packaging line, integrating the Versatile Aseptic Combi Predis. The line helped the leading Chinese beverage player launch a breakthrough in the domestic market: sparkling ready-to-drink (RTD) products, aseptically bottled in PET.
Founded in 1996 in Hangzhou, Nongfu Spring is one of the key players in the soft drinks market in China, maintaining leadership in the packaged water market over the past eight years.
The company bottles not only high-quality natural drinking water, but also vegetable and fruit juices, functional beverages, teas and other high-quality soft drinks. Its portfolio includes plant protein yoghurt, premium water for elderly people and vitamin water. Its strong focus on innovation and premium brand positioning are contributing to the steady customer base increase, even within beverage categories.
The popularity of these RTD tea and coffee products reflects a large, overarching trend across Chinese consumers, as they continue to show a growing preference for better-for-you products that either exclude sugar or include functional ingredients.
DRIVEN SUPPLIERS ARE KEY FOR PREMIUM BEVERAGE PLAYERS
Nongfu Spring offers high-end, unique product propositions from bottle design to drink quality and recipe formulation to Chinese consumers and aims to enrich the product portfolio on a yearly basis. Sidel can thus fulfil Nongfu Spring’s mission as one of the strong partners that can combine forwardlooking technologies with professional support.
FLEXIBLE ASEPTIC BOTTLING THANKS TO DRY PREFORM STERILISATION TECHNOLOGY
The beverage processor was already familiar with aseptic bottle decontamination technology in a standalone configuration. It also validated Sidel aseptic dry preform sterilisation solution in the past few years. This is efficiently supporting Nongfu Spring in the expansion of its portfolio, while ensuring reliability and product integrity. For further flexibility, the dry preform sterilisation technology solves the challenges presented by different bottle shapes, as the sterilisation takes place at the preform stage.
Additionally, Nongfu Spring decided to equip the Combi with Sidel’s patented active base mould system, the Base Over Stroke System (BOSS), in order
They appreciated the support throughout project execution, starting from the validation of the new container shapes – with and without the BOSS base. In addition, Sidel’s liquid packaging interaction scientists performed various flavour tests for the new drinks Nongfu Spring were evaluating, thus
to differentiate some of its bottles and expand its marketing opportunities. In fact, the technology can be selected depending on the container’s shape. BOSS is a piston activated system in the blowing phase that strokes the base, thus raising and lowering it during the bottle-forming process, independently from the opening and closing of the two half-shells of the mould.
Nongfu Spring visited Sidel facilities in France and was impressed by the high-quality services and the long-standing expertise of the packaging team.
1,2,3 Dry form sterilisation systems offer cost-efficiency and sustainability benefits to beverage manufacturers defining the carbonation level and the sugar residue in the bottle. Once the line was installed, food technologists handled the microbiological validation of both high- and low-acid products, which successfully achieved zero contaminated bottles in 30 000 units on the first attempt, as per the protocol specifications. To ensure this success, Sidel experts and project managers made sure to closely support Nongfu Spring’s operators.
“For Nongfu Spring, it was critical to operate a simple and safe solution, while being able to manage the sheer variety of products in the future,” adds Mark Li, technical sales manager sensitive products at Sidel. “The cost efficiency and sustainable benefits offered by our dry preform sterilisation technology were also key factors for them: using no water and very few chemicals, while pushing the boundaries of the lightweighting potential, represented a very valid argument with this leading company. Lastly, we were able to secure a very competitive lead time,” Li enthuses.
The new aseptic complete PET line at Nongfu Spring’s plant in Xin’anjiang (Eastern China) is running at 36 000 bottles per hour (bph). Aside from the Versatile Aseptic Combi Predis, it was also equipped with Capdis, the dry cap sterilisation technology from Sidel. The line also includes Tetra Pak Processing Systems technologies, an easy-to-handle Sidel RollQUATTRO roll-fed labeller – for wrap-around labels – and Roll Adhesive labeller and a cooler with optimised water consumption.
The End-of-Line solution integrates a wraparound case packer and the modular PalKombi palletiser for medium to high speeds. Thanks to Sidel’s expertise in line design and engineering, deriving from its long-standing heritage in aseptic complete solutions for PET, the team at Sidel were also able to successfully and quickly cope with a very challenging line layout. It took merely three days to install the key pieces of equipment at Nongfu Spring’s plant.
PARTNERSHIP LEADS TO REPEAT ORDERS
To quickly reach the committed line efficiency and maintain consistent volumes and quality of production, Sidel also ensured that two dedicated shifts of field engineers were working alongside Nongfu Spring’s personnel for 18 months.
Due to this fruitful cooperation, Nongfu Spring quickly decided to turn to Sidel again and invest in two additional Versatile Aseptic Combi Predis, installed in the company’s factories in Hubei and Zhejiang, respectively. Both equipped with BOSS and running even faster at up to 49 500 bph, those pieces of equipment have already been fully validated. Last autumn, Nongfu Spring acquired another Versatile Aseptic Combi Predis Combi from Sidel with speeds up to 54 000 bph. •
Your packaging speaks to your customers before your product does
Long after your merchandiser leaves, your packaging takes on its most important sales task - attracting the consumer to your product before any competitor. Your product package is responsible for most of your off-the-shelf sales.
DURING THE PRODUCT development stage, special attention needs to be given to labels and overall packaging presentation. It represents how your product or brand interacts with consumers. More than this, it showcases the product’s heart and soul while communicating key promises and information to your consumers. Use of colours and high-resolution images, placement of information and your consumer’s first reaction to your product is key to attracting customers. Connecting with your consumer on a personal and emotional level achieves something money can’t buy – brand loyalty.
Product communication attributes are constantly evolving, creating challenges for brand owners to keep up with popular market trends. Factors such as industry regulation, product improvements, variety of flavours and package delivery can hinder go-to-market strategies making it harder to compete. Digitally producing your packaging, although more expensive when costing per unit, offers significant benefits to your organisation: • Flexibility to offer more variants, flavours, and packaging sizes • Lower packaging stock commitment, saving costs by reducing waste • Lightning response to topical opportunities • Control of production deadlines • Live packaging response testing • Personalised connections that promote brand loyalty • Limited and premier edition opportunities
PRINT FOR YOUR OWN USE IN-HOUSE OR OUTSOURCE?
“Some prefer to leave it to the traditional packaging developers and that is OK. We know the digital options are daunting and “drop-off” salespeople are plenty,” NSI LABEL’s business development director Shawn Bezuidenhout says. Minimum order quantities and slow turnaround of new product orders will however remain a challenge.
Going digital should be as complicated as desktop document printing - design-to-print at the click of a button. The right supply partner that is focused on your success, rather than short-term gain, is more important than the physical hardware solution. It doesn’t matter how expensive your machine is or how many amazing features it has. If your supplier isn’t committed to your success for the long term, it may all be for nothing.
“Some have burned fingers by making the wrong choices. Hopefully, those burned have learned a valuable lesson that did not include giving up.
“The Industry emphasis is shifting towards product packaging lifecycle and recyclability. There is a big move towards being more environmentally compassionate with regards to product packaging across all industries. Paper trumps traditionally hard to recycle films.
Using bright colours and high-resolution images is a key factor in attracting customers
“Even clear labels are no longer beyond the reach of the small producer as label media manufacturers in the digital space are constantly developing and improving substrates in line with diverse user preferences, environmental concerns and industry influence,” Bezuidenhout concludes. • NSI LABEL – www.labelandpack.africa Interroll – www.interroll.co.za
Unpacking tamper-proof labelling in Africa
Food fraud has been around for over 200 years, and the more connected we become through social media and web-based media platforms, the more incidents of food fraud come to light. It is a broad term that encompasses fraudulent and intentional substitution, dilution or addition to a product or raw material, or misrepresentation of the product or material for financial gain.
AFRICAN CONSUMERS APPRECIATE the technology and see tamperproof labelling as a necessity. Brand owners operating in Africa rely heavily on tamper-proof technology to ensure that the packaging contents are safeguarded against counterfeiting. Without compromising the brand identity, tamper-proof label technology must evolve to keep growing illicit trade at bay. Anti-counterfeit labelling solutions are designed to ensure an original look for products and provide package traceability, effectively countering sales fraud and illegal distribution.
It has become evident that brand owners are looking for labelling solutions beyond the norm. Standard off the shelf tamperproof solutions isn’t adequate to fight the “Brand owners operating in Africa rely heavily on tamper-proof technology to ensure that the packaging contents are safeguarded against counterfeiting”
battle against highly developed tech-savvy criminals. With the use of specialised technology and materials and, in some cases cutting edge traceability software, it is now possible to counter a variety of illicit activities.
It is estimated that 10 of the most common foods consumed are faked to one degree. Whether it is the entire product that is faked, or parts of the product substituted
The Combi labelling system is a fully automatic industrial labelling system customised to the customer’s application need
2020/2021
by fake components, the fake food phenomenon is growing fast.
BiDiLase is a complete solution that provides a unique passport to each package; it is the most innovative and disruptive laser coding solution for coding and marking in the world for its unrivalled speed of 1 000m/ min, perfect quality offering class A high definition and micro-precision, personalise your brand experience with unique QR codes for every one of your end consumers
A breakdown of what constitutes food fraud thanks to Integra Promo & Serialisation software and premium scan ability offers excellent readability through smartphoneoptimised dot size. Unique QR codes enable interaction throughout the complete value chain, enabling traceability from production to end customer and allowing customer engagement through promotions, nutritional information, games, etc.
An all-in-one labelling machine for jars, bottles and food containers, the Combi labelling system is a fully automatic industrial labelling system customised to
BiDiLase is a complete solution that provides a unique passport to each package
the customer’s application need. With the Combi, it is possible to create more than one application: top, enveloping, front/back or sealed on elliptical, round, rectangular or quadrangular products such as tanks, bottles, food containers or tray, the Combi can be used in stand-alone (offline), or it can be integrated with existing production lines. •
Tracepack – www.tracepack.co.za
A Division of MITAS Corporation (Pty) Ltd
TAMPER-PROOF LABELLING IN AFRICA
Contact TracePack to find out about labelling solutions that are beyond the norm.
+27 10 020 7221 www.tracepack.co.za
Labels are getting smarter!
Transparency regarding food and beverage products has become an urgent issue, in part by COVID-19. People are asking questions around healthy choices and food safety with a desire for more insights into the product journey from farm to table.
WHEREAS OTHERS WISH to make smarter purchasing decisions with regard to minimising their impact on the environment. “The higher consumer demand for information and education is driving the need for labels to not only deliver ingredient data, but also facts about sustainability and traceability from raw materials to end product,” explains Henk Jacobs, GM of Lebone Paarl Labels. “Even though labels may be a small part of the packaging, they also play a role in ensuring the safety of the food contents within and keeping the environmental footprint as low as possible.”
In South Africa, there are stringent safety regulations regarding the manufacturing and labelling of food to protect the consumer. “One consideration in the production of food labels is the migration of substances from labels to packed food that might impact consumer health and safety,” says Jacobs. “For the food and beverage industries, we
offer the printing of pressure sensitive labels using low migration inks, which are designed to dramatically reduce migration of chemicals from the ink printed on the packaging to the product contained within.” He adds, “Lebone Paarl Labels is also Foundation Food Safety System Certification (FSSC) 22000 certified, confirming the food safety management system is compliant for food products.”
“We are seeing clients taking into account the environmental impact of their labels in the design and its production,” Jacobs highlights. “From substrate selection to production, using the right and less resources can have a significant contribution to improving the sustainability of the project.” Advancements in technology allows for the development of new label substrates to help brands mitigate their environmental impact, focusing on lighter weight materials, alternative fibres, certified papers, recycled content, solventfree adhesives, wash-off and fossil free solutions. “TreeFree” paper is made from renewable sugar cane bagasse, is an example of a more green label material option that doesn’t compromise on quality and performance.
“In the design of responsible sensitive pressure sensitive label must also take into consideration existing recycling streams,” Jacobs notes. “Clear plastic and glass containers are far better for recycling than coloured so the label provides the opportunity to colour and decorate the surface of the container whilst avoiding colour contamination of the main material.” Consideration must be given to a label’s removability during recycling or matching right labels with right packaging material to optimise the recycling process.
Company experts can offer excellent advice for the selection of the right substrate to meet each labels requirement in terms of functionality, visual and environmental objectives. “Our commitment to delivering the high quality pressure sensitive labels with the least impact on our world is demonstrated in our globally recognised Forest Stewardship Council FSC-C160814 CoC (Chain of Custody) certification,” Jacobs highlights. “Self-adhesive labels printed on FSC certified substrates can request to carry the FSC trademark, thereby informing consumers that the materials used originate from environmentally and socially responsible sources.”
With consumers embracing virtual working, socialising, learning and shopping, it is easier to inform them through connecting labels with the virtual world. “Some of the labels we produce include a QR code, through which consumers with smartphones can access to online information on ingredients, production chain and packaging recyclability,” advises Jacobs. “These tools empower the consumer to have visibility across the supply chain, from the raw materials used down to how they can be recycled.”
Digitally printing unique QR codes integrated with blockchain technology can provide a digital certificate of authenticity, designed to assure buyers that their product is genuine and not counterfeited. “This points to a coming future when tamperproof labels with digital authentication attached will become a new standard in offering consumers full traceability, while offering brands protection against counterfeiting,” he concludes. •
Lebone Paarl Label - www.lpaarllabels.co.za
FAST FACT
EcoFloat helps consumer goods companies to reach recycling targets in the US.
CCL Label, the global converter of pressure sensitive and extruded film materials for decorative, functional and information labels, can now supply a sustainable sleeve solution for plastic packaging.
CCL DEVELOPED ECOFLOAT - a floatable polyolefin shrink film with high shrinkage - to meet new market demands and to assist brand owners to reach their sustainability and recycling targets.
This hybrid polyolefin film facilitates easy separation of labels from PET bottles and other types of plastic containers in the recycling process to enable bottle-to-bottle circularity, an important goal for global consumer goods brand owners.
“We see EcoFloat as the sustainable decoration solution of the future – for a whole range of packaging in the beverage, dairy, home care and other industries,” says Guenther Birkner, president of Innovia and CCL’s food & beverage business. “We are proud that this has been verified by receiving the recognition of APR.” EcoFloat shrinksleeves have been engineered to perform ideally in the sink/float separation process of PET recycling plants for PET containers. This enables smooth bottle-to-bottle recycling to achieve high yields of high quality PET flakes. The products has also been endorsed by the European PET Bottle Platform EPBP in their evaluation earlier this year. As it is a polyolefin film, the material is also an ideal match for HDPE bottles and PP cups as certified by recycling organisation Interseroh with their ‘Made for Recycling’ accreditation.
“Our investment is part of our commitment to boost plastic recycling and take steps towards a circular economy as stated when we signed the Global Commitment of the New Plastics Economy led by the Ellen MacArthur foundation last year.
“In future we expect more regulations to set a target for the recycling rate in municipal waste, for example. Reaching these will not be feasible without investing in new technologies for packaging materials that support design for recycling. As a floatable, low density polyolefin film, EcoFloat fulfils the requirements for sleeves as defined in packaging design guidelines,” Birkner concludes. •
CCL reaches next milestone for EcoFloat sleeve material in the US market
CCL – www.ccl.com
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