Packaging Europe Issue 10.5 by packagingeurope

VOLUME 10.5 – 2015

FACHPACK 2015 EXTENDED SHOW GUIDE LABELEXPO EUROPE PREVIEW THE FUTURE OF PRINT THE POWER OF PACKAGING DESIGN Laminated with Cosmo Films’ scuff free matte thermal lamination film

SPOTLIGHT ON THIS AUTUMN’S EVENTS

Contents

VOLUME 10.5 – 2015

The cover of this edition has been laminated with a BOPP-based scuff free matte film supplied by India based global group, Cosmo Films Ltd. which is a leading provider of lamination solutions & polypropylene films. The scuff resistant matte film is one of the many premium laminating films with luxe touch that the company offers. Thermal lamination of this film is possible on all kinds of printed and non-printed paper and film is extensively used on perfume, liquor & cosmetic mono-cartons; manuals; shopping bags and diaries. Various decoration printing techniques can be performed on the surface post lamination. For further info, write to enquiry@cosmofilms.com

3 4

Editorial Tim Sykes Interview The power of packaging design

14 16 18 20 22 26 28 36

FachPack 2015 FachPack Essentials Floor plan FachPack Overview Marking & labelling Multi-channel communication Headline events Lectures and forums Exhibition highlights

54 56 58 61 62 63 66 70 72 75 78 80 82 86 89 92 95 98 101 104 108 111 114 118 120 122 124 127 130 131 134 138 139 142 146 149

FachPack 2015 Profiles RoitherMaschinenbau Presses, balers and more Somic The very best end-of-line packaging machines Appec Group Aiming high Graco Invisipac™: Next generation hot-melt Ferag Skysorter – The new gravity conveying system Multivac Myriad packaging alternatives Bak Ambalaj European quality from Turkey Alpma Quick change, hygienic design Optel Vision Inspection technology visionaries Constantia Flexibles Passion for packaging Bischof + Klein Leading the way in flexible packaging Bischof + Klein Dramatic savings Elif We are packaging for life KTP Kunststoff Palettentechnik Innovative solutions for transport and storage Jindal Films Committed to knowledge Haloila Stretch wrapping machines from Finland Boehl Upward spiral SCA Sustainable Packaging Truly environmentally sustainable Purus Plastics Boxing clever Carré Karton A perfect fit Gregor Hofbauer Case by case know-how Pattyn Packing Lines Global player in box lining solutions Sonoco and Weidenhammer An Uncanny Combination Paramelt Global growth in hot melt adhesives Hell Pioneer in image processing and direct engraving KBA-Metronic KBA-Metronic at FachPack Bluhm Systeme Labelling and coding systems A. Hatzopoulos A cut above Denso Security meets innovation: Secure QR code designed by Denso Hitachi High-tech coding and marketing equipment Quadpack Premium wood packaging Herrmann Ultraschall New ultrasonic top seal module TSM 35: The fast way towards series production Bizerba Weighty success NiceLabel Innovation in labelling systems Nitro-Chem An explosion in flexible packaging Simco-Ion Fast-moving static technology

Scanpack 152 Lighting up Northern Europe’s packaging industry 158 161

Scanpack Profiles Storopack Protective packaging perfection Tyler Packaging Consumer trends in packaging

164 168 176

Label Expo Strengthening focus on package printing Exhibition highlights Smart packaging lab

178 181 184 187 190 193 196 199 202 204

Label Expo Profiles ITW Foils Originate, emboss and laminate ITW Dynatec Application excellence Futec Bringing Japanese inspection quality to Europe IGT Testing Systems Research in their blood Emax Label Solutions The labeling solution engineers from the Netherlands Berhalter High-tech die-cutting on a low budget Goss International New web solutions TTS Transfer to more Flexomaid Introducing Aeromaid – The high-performance anilox cleaning system Recyl Ensuring optimum performance for printers

Commentary 207 Print The future of print 214 Inkjet State of the art or sci-fi fantasy? 224 Events 230 FKuR Devoted to nature 234 Corbion Purac Bio logical 238 Design opinion When packaging becomes art 241 Closures Caps & closures: Uncapping the trends 243 Traditional labellers move into packaging 244 247 250 253 260 263 266 270 274 279 282 285 288 292 296 300 304 308 312 314 319 320 327 330 334 338 346 349 352

Industry Profiles Fabo Italian leaders in tape Imballaggi Prottettivi Bringing in the new Lamican The value alternative in aseptic carton packaging Delta Print At the forefront of carton design Elitron Your automatic packaging partner Iggesund Sustainable emotion, Iggesund’s underlying advantage Primera Technology Fast, flexible and reliable printing PakTech We can handle it Linpac Lightest weight film and tray portfolio InduSoft Leading the way in automation Petainer High performance and sustainable Systech Safeguarding supply chains Dentas Paper Industry Packaging solutions for fragile products FlexLink Revolutionising production flow Pillar Technologies Focus on customer success OCME Moving solutions Envaflex Passion for print D2 Printing Passion for prestige packaging Sidel PET bottle labelling – today and tomorrow Collano Adhesives Smart Bonding Amaray Making good things, better European Bioplastics The voice of bioplastics TBMA Valves with value Neri Labels Positive labelling DS Smith Customised packaging solutions Cartiera dell’Adda A strategic alliance Neograf Aiming for new heights Logoplaste Rigid plastics specialist IMFA Making the most of sustainable mould-fibre packaging

Advertisers Index A

Agrana A. Hatzopoulos Alpma Alvey Manex AmbaFlex Ambrogio Appec Group Asahi Austropressen AVT

323 43 41 5 37 342 41 169 15 227

B Bak Ambalaj Belfast Foiling Company Berhalter Bianco Federico Trasporti Bischif and Klein International Bizerba Bühnen bwh Spezialkoffer

49 258 165 343 79 19 15 43

C Cartiera Torre Mondovì Cerutti CMII Comexi Group Constantia Flexibles Cosmo Films

340 69 342 67 47 10

Fatra Ferag FKuR Flexibles, Parkside FlexLink Flexomaid Flux-Geräte Futec Europe

L 29 25 233, 325 240 295 202 52 166

7 355 291 9

E EasyFairs Electronic Technologies International Elif Elsto Drives & Controls Emax Label Solutions ESI Euromac

219, 222 298 82, 84 329 171 ii 155

R 355 157 345 322 317 340 21

G GEA Food Solutions Germany Global Vision Goss International Graco Gregor Hofbauer

12 217 172 17 29

H Hach Lange Haloila Hapa Harrington Signal H. Bohl Hell Hermann Ultraschall Herwarth Jackstädt Hitachi HP HSM Hudson-Sharp

344 41 209 299 42 31 33 107 47 237 49 69

Marchi Industriale Matthews Brand Solution Memtronik Innovations Mitsubishi Electric Mitsui Chemicals Europe Moba Eurotubi Modern Grab Monomatic Multivac

343 35 298 11 316 221 307 255 15

25 340 9

SA Giuseppe Cristini SCA Senstronics Metrology Simco-Ion Soem Somic Sonoco Stelioplast Stora Enso Storopack Scandinavia Systech

341 35 318 27 342 57 117 25 258 13 10

NatureWorks Nitro Chem Noxon

324 51 53

O OCME Oleodinamica Sabatini Optel Vision Ourus Plastic OWS

303 341 33 37 324

T Technotraf Tecnowerk Plast Thermal Printer Support Thermal Transfer Solutions Tipa Toyo & Deutsche Aerosol Triniflex Tubettificio M. Favia

137 215 171 173 322 221 51 239

ICR Ioannou 213 Impresa De Mitri 345 Inkspec 202 Integrated Timber Solution 259 ITW Dynatec 171, 317 ITW Foils 167

P PakTech Paramelt Parkside Flexibles Pattyn Packing Lines Poligal Posimat Prati

239 23 240 21 307 351 167, 333

Q K Karton-pak KBA-Metronic Kodak Komori-Chambon

316 19

Jindal Films

Rahn Robatech Roland Stengel Kunststoffverarbeitung Rolls To Roll RPC Containers

S M

D Denso Dentaş Paper Industries Diper Dow

Lacasse & Weston Laetus Lannutti Lanxess Deutschland Laufenberg Laviosa Chimica Mineraria Logopak

Quadpack 348 45 6, 356 256

137

Valco Melton VST Paper & Board

337 345

W Weber Marking Systems Woodside Haulage

23 258

Editor Tim Sykes Deputy Editor Victoria Hattersley News Editor Elisabeth Skoda Journalists Libby White Profile Writers Emma-Jane Batey Alessandra Lacaita Felicity Landon Romana Moares Barbara Rossi Piotr Sadowski Abigail Saltmarsh Marco Siebel Julia Snow Vanja Svacko Philip Yorke Art Director Gareth Harrey Art Editor Paul Abbott

Designers Claire Bidle Rob Czerwinski Leon Esterhuizen IT Support Jack Everson

Tim Sykes

EDITOR

Web Development Neil Robertson Production Manager Kamila Kajtoch Administration Amber Dawson Kayleigh Harvey Senior Account Managers Kevin Gambrill Jesse Roberts Features Managers Mauro Berini Jamie Gibson Clayton Green Matthew Howe Dominic Kurkowski

Art Administration Tania Balderson

Packaging Europe

Alkmaar House, Alkmaar Way, Norwich, Norfolk, NR6 6BF, UK Telephone: +44 (0)1603 414444 Fax: +44 (0)1603 779850 Email: Editorial: editor@packagingeurope.com Studio: adcopy@packagingeurope.com Advertising: jr@packagingeurope.com, kg@packagingeurope.com Website: www.packagingeurope.com Facebook: www.facebook.com/PackagingEurope Twitter: www.twitter.com/PackagingEurope

utumn is expo season for the packaging supply chain and we dedicate our September edition to the events that will feature the biggest innovations and spotlight the most important trends of the year. The premier focus of this magazine is FachPack, which is set to be Europe’s most important general packaging exhibition of 2015. As part of our collaboration with the show, which takes place in Nuremberg on 29 September to 1 October, we present a dedicated guide to the fair, featuring all the practical information you require about the exhibition and its programme of events, commentary on its central themes of marking / labelling and the rise of the multichannel, snapshots of key product launches, and in-depth interviews with some of the most exciting exhibitors. We also look ahead to Labelexpo Europe, this year’s must attend event for the printing and labelling segment. In addition to our extended show preview, Jules Lejeune, managing director of FINAT, discusses the move of traditional label printers into the packaging printing space, while participants in the Labelexpo’s Smart Lab share their views on the future of the rapidly developing market for smart packaging and labels. Remaining in the field of print, we also take a first glimpse at some of the anticipated hot topics of next year’s drupa, with Gareth Ward offering his view on the future of print amid a bewildering flurry of technological advance and Sean Smyth asking when we will reach the long predicted digital future – and what it will look like. Among the other major events we preview are PPMA, the stalwart of the UK’s packaging and processing machinery market, Scanpack, the leading exhibition for the northern European region, the ever more relevant European Bioplastics Conference, and Fakuma, the signature event for plastics processing. Our diaries will be full over the couple of months. In addition, Guy Douglass of Brand On Shelf discusses the enduring power that packaging design can bring to brand owners in the face of a shifting retail landscape, Luca Desiata reviews an exhibition in Rome which emphasises the potential overlap between packaging and art, and Kevin Heap comments on developments in caps and closures. We look forward to getting a first-hand look at the trends and advances featured in this edition, as well as meeting a lot of our readers, in Nuremberg, Brussels, Birmingham and Berlin over the coming weeks. See you there! Tim Sykes ts@packagingeurope.com @PackEuropeTim

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Interview

The Power of Packaging Design Guy Douglass, managing director at BOS Design (Brand On Shelf), will be speaking at Packaging Innovations and Luxury Packaging London 2015, taking place at Olympia London on 16-17 September. The 2015 exhibition will provide key industry speakers from Liberty, Thorntons, Müller, Diageo, Harrods, Hotel Chocolat, Funkin Cocktails and Sauvelle Vodka, just to name a few, all sharing their packaging secrets across the two days. On day one of the show Guy Douglass, Managing Director at BOS Design, will be discussing ‘The power of packaging design’. Disclosing how brands can defend against the hostile on-line shopping environment and the power of the discounters’ copycat designs through the power of packaging design.

These products are very often either bought on line or in Argos, where the packaging plays no role until post-purchase. It may also be delivered inside someone elseís brand (e.g. Amazon) so it has to work hard to make a strong brand statement to break through the initial Amazon packaging and branding. Therefore every face of the pack is equally important and there is the opportunity to Think Big and utilise the brandís real estate on pack.

What are the main considerations in packaging design for FMCG products?

Are there new opportunities for the designer, e.g. getting more involved in the design of secondary packaging used in home delivery?

The rate of change in the retail environment (and the catalysts for that change) has created a couple of real challenges for FMCG brands. Packaging now has to work in a variety of different selling environments (on line and off line); a small thumbnail on a computer screen is a difficult place to utilize packaging design to entice the consumer through beautiful, tactile and engaging packaging - so omni-channel is one of those challenges. The other one is the rise of the discounters. The own-brand products in the discounters are shamelessly creating ‘me-too’ designs (sometimes referred to as copycats) so brands have to work harder to create strong brand equities that can’t be copied easily.

As a brand you would hope so. However, the conduit through which you brand is delivered is very often either a traditional retailer (such as Tesco) or a purely on-line retailer (such as Amazon). In both cases they will deliver your brand inside their brand, which is a worry; “that’s a nice vacuum cleaner”. “Thanks. I got it off Amazon”. Therefore your packaging has to work hard to make an impact when it is unpacked, thereby overshadowing the Amazon or Tesco outer branding.

What are the implications for packaging designers in the face of the omni-channel reality? Does it mean having to find sweet spots between a larger number of variables? It has always been the case that packaging has had to work in numerous consumer-facing environments, so any design team worth their mettle will always have considered the different opportunities to communicate with the consumer, way beyond just creating shelf impact in store. What’s changing is that the “first moment of truth”, the point at which the consumer interacts with your packaging for the first time, is no longer necessarily going to be in store. | 4 | Packaging Europe

Can you give examples of packaging design for brands that has successfully countered the challenge of me-too design? Is this primarily about adding functionality? Brands have to defend against copycatting by creating depth of personality; a brand purpose where they stand for something more than just the functional features of the product. Packaging design can help with this in as far as brands need to Think Big; create pack designs that make the most of the pack, whether through enhanced functionality or a deeper level of communication right around the pack, creating brand equities that extend beyond the physical pack and consistently support the purpose of the brand. We also have a theory that a brand that has only one or two key visual equities is harder to copy than one that relies on a number of equities that fight for attention. The redesign

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This pack builds a strong brand story all around the can, referencing the tasting notes and the detail that goes into the creation of such a special, craft cider.

of PG Tips is a good example of a brand relying on one or two strong equities that would be very difficult to imitate.

The notion that the on-shelf role of packaging will become more subtle is an interesting idea. Are there any examples of packaging that is already less orientated towards shelf impact than other functions? Method is a brand that is a good example of this. The Method brand has a strong purpose and a transparency and honesty that lives well beyond the store shelf. The packaging has to work well in the home environment as well as in store (it is often kept on show in the consumer’s home). Consumers who buy Method probably buy it because the brand’s purpose resonates with their own personal beliefs. The pack designs reflect the honesty and transparency of message of that brand at the expense of strong shelf standout.

How can brands best use packaging design to engage with shoppers? Brands have to work hard to build a strong relationship with their consumers through engaging them in a conversation. Having a front face that catches the eye in store is no longer enough; who knows which face of the packaging will be the one the consumer sees first if his shopping is delivered to his kitchen? Brands need to ‘Think Big’ and consider how the packaging will work throughout the product’s life-cycle from point of purchase to point of disposal (recycling).

What are the implications for a branded packaging design agency? What will packaging of the future look like and will there be a future for packaging design? I remember saying that I would never buy clothes on the internet because I would want to try them on, feel the quality. I remember going to Blockbusters to rent a video, Comet to buy a kettle and Jessops to get my films developed. It’s taken some time, but internet shopping has finally taken off. The appearance of fibre optic cable, smart ‘phones and tablets has put everything so much more at our fingertips that the acceleration of remote shopping is only going to increase. In the next few years we are going to face massive changes. But packaging will remain. The massive changes that we will see will present big opportunities for brands to use their packaging in new and interesting ways. | 8 | Packaging Europe

Packaging will still need to protect the product but the on-shelf promotion job that it does currently will be more subtle. The shelf will no longer be the retailer’s shelf, but the consumer’s shelf in the cupboard, in the larder or in the bathroom cabinet. Packaging will not have to have a “front face”, it won’t necessarily have to have “shelf impact” and there will be more opportunity to build a conversation with individual consumers.

Indeed, if the product is ordered on line by a named consumer what’s to stop the packaging using that name? Why not “Guy’s Marmite” or “Colin’s Dr Pepper”? “Beyond the till” is an expression we use a lot to describe the importance of the role of packaging after the product has been bought. “Beyond the click” might be a more relevant expression in the next couple of years and it’s this area that is really very exciting. The future of packaging….Bring it on!

Interview

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Labeling and printing solutions for food packages Flexibility and speed drive GEA’s product development.

wo important add-on functions for food packaging machines are labelling and printing. This is driven by increasing legal and commercial requirements for production and traceability data, dietary information and barcodes. GEA’s solutions include integrated labeling solutions, in-line labeling stations for preprinted labels and integrated printers for creating ‘product identification on demand’ labels on the machine.

Easily replaceable dispensing edge

Integrated labeling, marking and coding solutions

Design innovations

Correct marking is essential to meet legal labeling requirements and provide information. The printing techniques including inkjet, thermo-transfer, hot foil and rotary printing systems that can be configured as stand-alone printers or used in combination with a labeler. They not only print on labels, but also directly on film – including on ShrinkPak bottom film and top film.

Twin labeler system for millimeter precision on any surface

The GEA TiroLabel applies labels on a multi-track line with millimeter precision. The unique GEA Inliner cross-web labeling system incorporates a common drive for two dispensing heads, each fitted with a printing system. During thermoforming, the first labeler dispenses individual functional labels, while the second incorporates a programmable thermo-transfer printer for programmable label data. The benefits are greater flexibility for labeling and marking.

Split format operation

The two labelers feed the configuration at full cycle speed, and if one goes down, the other automatically takes over. The remaining labeler covers the full index until the other labeler is back on line. There are no stoppages due to empty reels, and the overall uptime and efficiency are improved.

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The TiroLabel’s stainless steel dispensing edge is designed for quick and cost effective exchanging. Conventional systems use an expensive ceramic coated dispensing sheet which can lead to partial sticking of labels on uneven surfaces due to the ‘straight line’ pressure application (partial contact). TiroLabel’s spring-loaded finger system ensures gentle label positioning on uneven pack surfaces. GEA’s solution features space-saving reels that are turned inward to free up transport aisles. The TiroLabel can be integrated into most thermoformers, on a GEA PowerPak it benefits from harmonized PLC control of thermoformer and labeler. GEA TiroLabel has a fast, motor driven displacing unit for top labeler that ensures constant speed and force during dispensing. This overcomes the drawbacks of a pneumatic displacing unit where the speed and force during dispensing are dependent on air supply consistency.

Printing performance

GEA offers inkjet, thermo-transfer and hotfoil printing systems that can be used either alone or combined with the TiroLabel. Its X-Y traversing unit is designed for easy mechanical integration into packaging machine, while the standardized interface works with established inkjet printing systems. Packs can be printed in-line with consecutive numbers or date series. For more information: GEA Food Solutions Germany GmbH, Im Ruttert, D-35216 Biedenkopf-Wallau, Germany Tel. +49 6461 801 0, Fax +49 6461 801 88 100 E-mail info@gea.com, website www.gea.com

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FachPack 2015 Essentials

Dates 29 September - 1 October 2015 Opening Times 09:00 - 18:00 (Tuesday-Wednesday) 09:00 - 17:00 (Thursday)

Online Exhibitor Platform All exhibitors and their current product information can be found at: www.fachpack.de/exhibitors-products

Venue Exhibition Centre Nuremberg 90471 Nürnberg The exhibition centre is conveniently reached by public transport. If you travel from the airport by underground, you must change trains once. Take the U2 line from the airport in the direction of Nürnberg-Röthenbach, then change at the main rail station to the U1 line to Langwasser Süd. Leave the train at the “Messe” station, which is directly opposite the “Mitte” (central) entrance to NürnbergMesse. • Journey time from the airport: 25 minutes • Journey time from the main rail station: 8 minutes • Fare zone A (EUR 2.60 per journey) For car parking follow the dynamic traffic guidance system, which will avoid all traffic jams and direct you to a vacant parking space (around the Mitte, Süd and Ost entrances).

Ticket Prices 1-day ticket: EUR 40 Permanent ticket: EUR 45 | 14 | Packaging Europe

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Innovative and Popular FachPack is one of the most significant European trade fairs covering all aspects of the packaging theme. And it is extremely popular: In six months – from 29 September to 1 October – the exhibition in Nuremberg will be entering its next round and is currently experiencing a real run on exhibitor places (2013: 1,439 exhibitors). In addition, young, innovative companies from Germany will be provided with the opportunity to present themselves to the visitors at the fair for the first time in a pavilion. Also innovative and well-frequented: the diverse support program.

irector Exhibitions, Heike Slotta, looks ahead with extreme optimism: “This year FachPack was completely booked months in advance. The expected total of 37,000 trade visitors will thus be spoilt for choice.” Around 1500 exhibitors are presenting their products and services from the areas of packaging, technology, finishing and logistics. The focus of this year’s event: the “Marking & labelling” theme, which runs through the visit to the fair like a common thread: the exhibitors, special presentations, forum presentations etc.

Packaging Process Chain Under One Roof The programme of the international specialist trade fair for packaging, technology, processing and logistics presents the packaging process chain compactly under one roof. Visitors and exhibitors alike praise the unique atmosphere, in which they cultivate contacts, initiate new business, make investment decisions and, together, look beyond their own horizons. What will the future bring? What technical trends will be set tomorrow? What will the consumer of the day after tomorrow expect from us?

FachPack Heritage FachPack has excelled for expertise and innovative technology for over 30 years and can look back on a magnificent success story. It started in 1979 with 80 exhibitors at the Nuremberg exhibition venue; around 2000 visitors came to the packaging exhibition at that time, which gained the name FachPack from 1982. 1440 exhibitors and 34,598 visitors were recorded in 2013, and thus FachPack has long since become one of the leading trade fairs in Europe dealing with packaging. Looking back at 2013 whets the appetite for FachPack 2015: • 92 per cent of the exhibitors were able to establish new business relationships. • 95 per cent of the exhibitors were able to reach their most important target groups. • 95 per cent of the exhibitors were satisfied with the organisation and the service. • 96 per cent of the visitors were satisfied with the information and contact opportunities on the stands.

Not only “old-timers” – young, innovative companies take note The personal contact with customers, interested parties, sector experts, but also competitors makes participation at a trade fair such as FachPack a success. Young companies presenting innovative products or services should really seize this opportunity. Under certain terms and conditions, they can receive sponsorship from the Bundesministerium | 18 | Packaging Europe

für Wirtschaft und Energie (Federal Ministry for Economic Affairs and Energy, BMWi) for their trade fair participation. At the last FachPack around 20 companies benefited from this facility. Once again, in 2015, the participation will be supported by up to 7500 Euro in funding or 70 per cent of participation costs met.

Innovative and popular: the diversity of the support program The start to the fair could not be more colourful: the keynote speaker at the opening is Karim Rashid, a “Popstar in the design world”. The packaging designer, who has won a whole series of awards, including the Red Dot Award: Communication Design in 2013, will be focusing attention on the creativity and innovative strength of the sector and generating impulses for the following days of the fair. The diversity of the special themes invites visitors and exhibitors to take a look beyond their own horizons and get inspired through contacts, discussions, lectures and presentations etc. In this context, the PackBox Forum is thus once again presenting a diverse mixture of themes ranging from Smart Labelling through to innovative concepts in machines, logistics, printing and design right up to young, up-and-coming talent and careers. For the first time, within the framework of the central “Marking & labelling” theme, small and medium-sized companies will be presenting themselves in a pavilion organised by the Verband der Hersteller selbstklebender Etiketten (Association of Self-adhesive Label Manufacturers, VskE).

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Marking & Labelling Markings are indispensable: they direct goods flows, supply consumer information, motivate and encourage the consumer to purchase with their individual design and ensure the genuineness and traceability of products.

he focus theme of FachPack 2015 presents a comprehensive overview of all kinds of labels, which aim to provide information (“smart labelling”) or decoration (“nice labelling”). At the fair there will be effective labelling machines, innovative identification, coding and article-surveillance systems, track & trace, various carrier materials, the latest printer and printing processes such as digital printing and 3D printing, auto ID systems, precise marking processes using laser or ink and much more to discover.

Focal point: shows, forum contributions, presentations The supporting program is also devoting itself to the theme of “Marking and Labelling” with many contributions: The “Smart Labelling – A view into the future” special show, organized by the Fraunhofer Institut für Materialfluss und Logistik (IML, Institute for Material flow and Logistics) Dortmund, will be presented in Hall 3A offering the latest results. Best-Practice examples clearly illustrate the trends from research and development in the area of identification technologies. In addition to the optimum packaging, the right marking and identification of goods plays a key role in logistics and opens up new paths for innovative solutions – from standardized track & trace systems up to conducting inventories using drones. On four theme islands the special show is presenting the key economic branches of logistics: production, logistics service-providers, IT and retail. Interested trade visitors can experience the latest technologies and also try them out. Scope for a well-founded extension of specialist know-how, an inspirational exchange, lively discussions or an invigorating coffee in the hustle and bustle | 20 | Packaging Europe

of the fair is provided by the popular Forum PackBox in Hall 4. Here too, the main theme will be examined from various perspectives: serialization in the pharmaceuticals sector, smart labelling and the changed challenges for the logistics sector – implementation here would hardly be possible without intelligent marking solutions. Anyone who would like to obtain more detailed information can take a seat in the PackBox free of charge without having to register and listen in on the lectures. The “Labels & more”Pavilion, which is being staged in Hall 9 in cooperation with the Verband der Hersteller selbstklebender Etiketten und Schmalbahnconverter (Association of Selfadhesive Label and Narrow Web Converter Manufacturers, VskE), is presenting label manufacturers, who create such solutions in daily practical applications for customers from the foodstuffs, beverages and pharmaceuticals industry and the retail trade. Labels are just as diverse as their applications, for that reason the range covers a large spectrum of design, printing processes and finishing. Within the framework of the “Packaging Design” special show in Hall 5, using selected exhibits, bayern design will be devoting itself to exemplary packaging design. “Nice Labelling”, in other words the innovative design of labels, is one of the central factors for successful brand communication and market success. To ensure that the visitors can be quickly and effectively directed to those companies with a specific range covering all aspects of the “Marking and Labelling” theme, at the event an exhibitor track has been specifically created for this purpose. These companies will also be especially highlighted in the exhibitor database and the fair guide.

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Multi-Channel Communication At FachPack the future begins with innovations. The show is expecting trail-blazing, new developments in the packing industry from the exhibitors. Some 37,000 trade visitors will experience innovations across the packaging process chain - and thus in all four FachPack segments: packaging, technology, finishing, logistics.

ith the coffee-to-go in your hand, doing your shopping quickly on your smart phone and collecting your orders on the way home after work – these are extremely realistic scenarios for consumers in the near future. Online retailing is growing at an above-average level, unpacking the ordered goods is the first point of contact with the product. Packaging must deliver more in multi-channel communication than just simply protecting the product and impressing on the shop shelves – it also has to succeed with value-added. This is where marking technology assumes additional functions: it manages the orders and directs them to the correct recipient. In this connection, the structural transformation in the retail trade is posing new challenges for the packaging industry in all areas across the process chain.

Packaging: convenience and individualisation Foodstuff packaging is continuing to be driven by the convenience trend. Stand-up sachets have conquered new product segments and offer real value added. They have been further developed as squeeze bags for baby food in the to-go sector. As a result, fruit pulp, yoghurt specialties and vegetable puree are fed to babies from the practical bag whilst on the move. Also practical: the screw-top serves as an adapter for screw-on feed spoons or dummies which are available from online shops. Bags have even managed to quietly make inroads on to the tinned goods shelves in the supermarkets: sauces and instant soups, which only need to be heated up, are replacing the well-known dry and powder products in the flat, square sachets. An additional trend is the individualization of products: the product range extends from muesli, which the consumer can have mixed in the preferred variation, right up to the creation of personal tea specialties – a bold, audacious concept for automated machine technology. The innumerable variations due to the consumers’ required combinations have to be produced and packed, while the label must also contain the respective individual details and information. This is where innovative solutions in labelling technology are required. | 22 | Packaging Europe

Another important field for labelling and marking solutions: they help to clearly identify products. Brand fakes are particularly a problem for the health and beauty industry, a problem which is being intensified by online shopping. Fakes are becoming increasingly professional and are not only causing considerable damage for the brand manufacturers, but also endangering the health of the consumers. The standardized serialization of pharmaceuticals packaging is placing new requirements on the handling of growing data volumes. All products and logistics information must be registered and stored for each individual pharmaceuticals packaging. Individualization and track & trace systems for efficient, full-coverage product tracking as well as secure product authentication and reliable protection against falsification are based on intelligent software architecture which can be combined with modern machine and printing technology.

Technology: modular machines required The diversity of product variations is posing great challenges for the packaging machine manufacturers. Today flexibility means that machinery and facilities must not only for example fill yoghurts in equally sized tubs, but also completely control various packaging sizes and styles. The machine design is decisive for the efficiency, performance and flexibility of fully automatic packaging systems. The individual components must therefore be optimally coordinated with each other and quickly replaced if required. Tray-sealers are for example designed in such a way that they can process all the tray formats and materials within the product size. The cover film or protective glass are also flexible. Adjustments and product changes can be made increasingly quickly – all possible without using tools thanks to quick-release caps and fasteners. Modular design enables the use of various functional modules in the same machine housing and set-up area. The machines can therefore be put into operation more quickly, more easily upgraded or retrofitted thus also offering scope for future requirements.

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Refinements for the unpacking experience Unpacking or unboxing is becoming a cult trend: on innumerable Youtube channels users in unboxing videos comment on unpacking their ordered goods. In e-commerce the packaging is mostly the first contact with the product. Nevertheless, in online shops we frequently find only a simple listing of the products with small photos. One cosmetics supplier has gone one step further here and is attractively presenting the newly designed packaging in a sales clip: Once the cap is loosened, the sachet unfolds and the cream jar becomes the focus of attention. Cosmetic products are thus also popular in folding boxes with a reflective lid film so that the consumer always has a small cosmetic studio with them when opened. Refinements such as haptic effects and a shiny appearance transform the over-thecounter retail shopping experience into an unpacking experience for online shopping. Packaging is becoming interactive through QR (quick response) codes or augmented reality. Like other product information, these features are being applied using marking technology. Here too, the key word individualization plays a role: in addition to barcodes, QR, logos and character sets, ink jet printers can also print unique codes which are used for tracing and tracking or for promotional coding such as interactive prize competitions. They can be activated using your smart phone or PC.

Logistics: shipping and mailing packaging for satisfied customers With the growing mail-order business generated by the online shops, logistics is also having to take new tasks on board. In the warehouses and distribution centres, orders are being increasingly picked and packaged. Parcel services are responsible for sending the orders to the consumer and are therefore subjected to very different transport problems and stresses than pallet loads and lattice boxes which are distributed to over-the-counter | 24 | Packaging Europe

retail. In the event of damage, return deliveries are pre-programmed. Nowadays packaging is thus designed in such a way as to also enable a secure return. Using a self-adhesive seal, the end-customer can return the goods in the same box without extra expense. Above and beyond that, packaging solutions have been developed for online retailing, which hold products of varying size in place in the box without filling material, and protect against theft through special design. Special sealing mechanisms secure the packages against tampering. Companies specialized in this field often offer advice and consulting services together with logistics support. Automatic, integrable systems have been developed for fulfillment tasks. Once the order details have been entered, they handle the production and application of the shipping label or direct address imprint, invoice printing or the delivery note, along with providing a mailing/shipping bag or box. The operator simply has to place the ordered product along with invoice in the box before it is automatically sealed and transported by conveyor belt.

FachPack: the future of the packaging sector under one roof More detailed information on the new challenges and solutions in all four FachPack segments is available in the Forum PackBox on all three days of the fair in Hall 4. Once again, in its third year, PackBox, with the trio “Inspiration – Innovation – Information”, is presenting the themes and trends which matter to the sector. And the diverse special shows – for example “Smart Labelling – A View into the Future” on the multi-sector theme of labelling and marking technology or the newly created Market Place Process & Materials on the sustainable and efficient use of resources and materials – will also be inviting interested parties to take a look beyond their own horizons.

Stelioplast knows canisters

Stelioplast Kunststoffverarbeitung GmbH is a family run company with 2 production locations in western and southern Germany. Founded in 1970, Stelioplast produces plastic packaging and blow molding canisters from 1L to 35L for the chemical, food and non-food, automotive and agro-chemical industries. Whether standard stackable canisters or custom designs, our team has been impressing our customers with quality, service and know-how for over 40 years. We are innovation leaders in the field of COEX containers and developed this technology together with leading pesticide manufacturers We stay flexible with two production sites, lead in innovation thanks to our in-house mold shop. We maintain a high standard of quality from concept through to delivery with our own fleet of jumbo trucks. Please visit us at the Fachpack trade fair this September. To meet our team, please visit our website www.stelioplast.de

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Headline Events and Press Conferences

Monday 28th September 2015 16:00

Awarding of the German Packaging Award 2015, German Packaging Institute (dvi) NCC Mitte, Level 1, Room München 18:00 Opening Show FachPack 2015 NCC Mitte, Level 1, Room Brüssel

Tuesday 29th September 2015 09:45

Press Tour of the Exhibition for the Daily and Business Press, NürnbergMesse NCC Ost, Level 1, Press Center Ost 12:30 Press Conference Wooden Packaging Materials Industry, Bundesverband Holzpackmittel, Paletten, Exportverpackung (HPE) e.V. NCC Ost, Level 2, Room Prag

Wednesday 30th September 2015 09:30

Mondi Press Breakfast – Get in touch with Mondi’s latest innovations NCC Ost, Level 2, Room Krakau 12:30 International Trade Press Lunch, NürnbergMesse NCC Ost, Level 1, Room Brüssel 18:00 Exhibitors Party, NürnbergMesse NCC West

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Lectures and Forums Tuesday 29th September 2015 11:00 – 12:45 Cyberspace in the packaging machine construction. Flexibility and individualisation in production at high cost pressures are the current challenges, with which packing machine builders are confronted from their customers. Mechatronic engineering, intelligent transport systems within the machine, robotics, simulation and remote maintenance are some of the components of modern, often modular machine construction. Will virtual engineering be arriving soon? 11:00 – 11:15 The cyberspace in the packaging machine construction. Address of welcome. Winfried Batzke-Deutsches Verpackungsinstitut e. V. (dvi). Location: PackBox Forum in hall 4 stand 360

11:45 – 12:15 The cyberspace in the packaging machine construction. Solutions for product-tracing in real-time. Alois Allgaier-MULTIVAC. Location: PackBox Forum in hall 4 stand 360

11:15 – 11:45 The cyberspace in the packaging machine construction. Flexibility and individuality with Multi-Carrier-System. Rainer Feuchter-Optima packaging group GmbH. Location: PackBox Forum in hall 4 stand 360

12:15 – 12:45 The cyberspace in the packaging machine construction. Early mechatronic validation of packaging-machines. Andreas Brandauer-Siemens AG. Location: PackBox Forum in hall 4 stand 360

13:00 – 14:45 Labelling / Coding / Marking – Serialisation in pharma: basics and consequences for the equipment. The podium discussion picks up the focus topic ‘Marking & Labelling’ and lights it up for the pharmaceutical industry. Presenter: Norbert Sauermann. 15:00 – 16:45 Smart design – intelligent und hollistic packaging solutions. Smart materials, creative image campaigns and product innovations inspire new. routes to take. Companies receive an insight based on current brand strategies and practical examples as to how they can create more value and thus competitive advantages – and with the help of design. 15:00 – 15:25 Smart design – intelligent und hollistic packaging solutions. The absurd-affectionate corporate design of Cafe Luitpold. Prof. Holger Felten-rose pistola | Büro für Konzeption und Gestaltung. Location: PackBox Forum in hall 4 stand 360 15:25 – 15:50 Smart design – intelligent und hollistic packaging solutions. Functional packaging for new microwave food markets. Peter Désilets-pacoon AG | strategie + design, München. Location: PackBox Forum in hall 4 stand 360 15:50 – 16:15 Smart design – intelligent und hollistic packaging solutions. Smart materials – smart labelling: an overview of what is available on the market up to now. Aart van Bezooyen-Material Stories, Hamburg. Location: PackBox Forum in hall 4 stand 360 16:15 –16:45 Smart design – intelligent und hollistic packaging solutions. Nice Labelling – packaging as brand ambassador. Designer Marc M. Clormann-Clormann Design – Büro für visuelle Kommunikation. Location: PackBox Forum in hall 4 stand 360 | 28 | Packaging Europe

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Wednesday 30th September 2015 Package printing – dynamic as usual. 11:45 – 13:15 Presenter: Professor Martin Dreher, DFTA Technologiezentrum. 11:45 - 12:00 Package printing – dynamic as usual. Watercolours and plastic foils – how do they get along? Dr. Heiko Warnecke-Follmann GmbH & Co. KG. Location: PackBox Forum in hall 4 stand 360

12:35 - 12:50 Package printing – dynamic as usual. Packaging PrePress - What a job to do! Carsten Hoppmann-Matthews Brand Solutions. Location: PackBox Forum in hall 4 stand 360

12:00 - 12:15 Package printing – dynamic as usual. Fixed Colour Palette Printing - How feasible is that today? David Galton-Asahi Photoproducts. Location: PackBox Forum in hall 4 stand 360

12:50 - 1:15 Package printing – dynamic as usual. How we have cut makeready in Flexo by 50+%. Location: PackBox Forum in hall 4 stand 360

12:15 - 12:35 Package printing – dynamic as usual. Highly processed folding boxes: Economic inline-production in flexographic printing. Rainer Kuhn-PrintCity GmbH & Co. KG // Werner Schwab-Gallus.

13:30 – 15:00 Packaging innovations 2015. With between 200 and 300 submissions annually, the competition for the German Packaging Prize has been the display window for innovative packaging industries in unique ways since 1963. dvi is also selecting the best packaging from all industries and materials in 2015 and is showing examples for current trends like convenience, grafting, e-commerce. or individualisation and is presenting these in the PackBox Forum. Presenter: Winfried Batzke, Director German packaging institute (dvi). 13:30 - 14:00 Packaging innovations 2015. Trends and highlights of the German Packaging Award 2015. Winfried Batzke-Deutsches Verpackungsinstitut e. V. (dvi). Location: PackBox Forum in hall 4 stand 360

14:20 - 14:40 Packaging innovations 2015. Packaging innovations allow new applications. Franz Meyer-Pirlo GmbH & Co. KG. Location: PackBox Forum in hall 4 stand 360

14:00 - 14:20 Packaging innovations 2015. Packaging innovations for more convenience. Thomas Reissig-VerDeSoft GmbH. Location: PackBox Forum in hall 4 stand 360

14:40 - 15:00 Packaging innovations 2015. Packaging innovations for more efficient processes. Location: PackBox Forum in hall 4 stand 360

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Wednesday 30th September 2015

Thursday 1st October

15:15 – 16:45 Innovative logistic solutions. Presenter: Prof. Dr. Rolf Jansen, Head of VVL e.V.

10:00 – 11:30 Achieve more with less: new services and technologies increase production efficiency. Presenter: Thomas Röhl

15:15 - 15:45 Innovative logistic solutions. Intelligent load carriers – standardisation of the auto ID labelling of pallets. Dipl.-Logist. Matthias Grzib-Verein für innovative Verfahren in der Logistik (VVL e.V.). Location: PackBox Forum in hall 4 stand 360 15:45 - 16:15 Innovative logistic solutions. Online food trade – complex logistics require new packaging solutions. Dipl.-Logist. Tim Siebels-Verein für innovative Verfahren in der Logistik (VVL e.V.). Location: PackBox Forum in hall 4 stand 360 16:15 - 16:45 Innovative logistic solutions. Aspects of the packaging design under changed requirements for transport. Prof. Dr. habil. Claus C. Berg-Institut für Logistik und Verkehrsmanagement (ILV). Location: PackBox Forum in hall 4 stand 360

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10:00 - 10:25 Achieve more with less: new services and technologies increase production efficiency. Resource and energy efficiency: New technologies increase the economic performance and reduce resource consumption. Michael Böhmer-Fraunhofer-Institut für Materialfluss und Logistik. Location: PackBox Forum in hall 4 stand 360 10:25 - 10:50 Achieve more with less: new services and technologies increase production efficiency. Industry 4.0 and asset management: Increasing efficiency through the use of modern IT technologies. Dr. Andreas Dankl-Dankl+Partner Consulting. Location: PackBox Forum in hall 4 stand 360 10:50 - 11:30 Achieve more with less: new services and technologies increase production efficiency. Networked production – what must automatisation achieve? Volker Knack-B&R Automation. Location: PackBox Forum in hall 4 stand 360

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Thursday 1st October 11:45 – 13:15 Innovation in materials and technology. Presenter: Sonja Bähr, Director bdvi. 11:45 - 12:15 Innovation in materials and technology. Surprising solutions that are successful in a world of change arise through innovations Location: PackBox Forum in hall 4 stand 360 12:15 - 12:45 Innovation in materials and technology Forgery security through integrated nanotechnology and hologram labels Location: PackBox Forum in hall 4 stand 360 12:45 - 13:15 Innovation in materials and technology. Depicting three-dimensional motifs as prints true to the original. Location: PackBox Forum in hall 4 stand 360

13:30 - 16:00 Competence Meets Future. Under the motto ‘Competence meets future’, everything in this session will revolve specifically around the promotion of new talent and career opportunities in the packaging industry. There will be something here for everyone – be it live presentations in the PackBox Forum, open network meetings or direct dialogue between exhibitors and/or future employers and students. 13:30 - 14:00 Competence meets future. Image of the packaging industry. Winfried Batzke-Deutsches Verpackungsinstitut e. V. (dvi). Location: PackBox Forum in hall 4 stand 360 14:00 - 15:00 Competence meets future. Science Slam (presentations of students). Location: PackBox Forum in hall 4 stand 360 15:00 - 16:00 Competence meets future. Career opportunities in the packaging industry. Collin Weber-Collin Weber Personalberatung GmbH. Location: PackBox Forum in hall 4 stand 360 | 34 | Packaging Europe

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Mondi Presents Alufree BarrierFilm for Food Packaging at Fachpack 2015

When consumers buy packaged food like dried soups or herbs, they expect to store it for a period of time before use. The barrier functions of the packaging are crucial to making this possible. Furthermore, while protecting the packaged goods is important, what about the environmental aspects of the packaging? At Fachpack 2015 in Nürnberg, Mondi Coatings presents its intelligent solution for this dilemma – alufree BarrierFilm.

very packaged good requires certain barriers. Finding solutions for every specific demand is Mondi Coating’s core business. Until recently, the best barriers available were achieved with aluminium foils. Although aluminium provides a good barrier function, Mondi’s technicians have now found an intelligent alternative: the alufree BarrierFilm. Not only is it eco-friendly, it also offers other advantages. Because alufree BarrierFilm contains no metal of any kind, it is now possible to use a metal detector along the supply chain without losing any of the required functions. The BarrierFilm was already awarded with the WoldStart Award, the DuPont Silver Awards and PPI 2014 for “Innovation in Sustainable Packaging”. It offers excellent protection and a long shelf life for food products. In addition, it helps reduce the carbon footprint of the packaging thanks to the removal of aluminium. One customer even reported that thanks to switching to this high-barrier liner for their convenience food packaging, they have been able to reduce the carbon footprint by as much as 25%. “We are both proud and inspired by the recognition that comes with winning not only one but in total three awards with our non-foil high-barrier liner: the PPI Award, the

DuPont Award and the WorldStar Award! It is a true testament to the innovative spirit, persistence and excellence in development that was required to deliver this great packaging breakthrough,” states Jussi Vanhanen, CEO Mondi Fibre Packaging. By introducing a special sealing polymer that helps reduce the sealing temperature and subsequently lowers energy consumption, the sustainable approach has been further enhanced. In addition, the lower sealing temperature leads to higher efficiency on the filling lines. BarrierFilm also resolves another issue that aluminium laminates can cause: as it does not have a memory effect, it is not as sensitive to kink folds. The packaging stays scatheless and safe, emphasising the attractive visual appearance of the product and brand even more. Mondi’s intelligent alufree BarrierFilm is available for a wide array of applications, including dehydrated food stuffs as well as products such as instant coffee that require an outstanding oxygen barrier. Upon demand, Mondi also provides the liner with easy-opening features such as laser perforation and can be processed on high-speed packaging lines. Visit: www.packagingeurope.com/News/64556

Caribbean Feeling at DS Smith How brands can be attention-grabbingly launched on the market on the future is shown by DS Smith in Nuremberg. The display and packaging strategist is presenting a multi-sensory experience world out of corrugated cardboard in hall 5, stand 239, in which visitors can experience the innovations of the company with all their senses in a Caribbean ambience. Light, aroma and sound effects, augmented reality applications, quick response codes, modern shelf ready packaging solutions and the latest digital print technologies – the added value for the customer along the entire supply cycle is always in the spotlight: from the display to the packaging to the efficient manufacturing and logistics processes.

“C

onsumers make up to 70 per cent of their purchase decisions at the shelf in a shop,” says Michael Lamprecht, Sales & Marketing Director Germany & Switzerland at DS Smith l Packaging Division. “Packaging and displays therefore have to inspire the consumers right at first glance at the point of sale and reflect brand values as well as possible,” says the industry expert. The trends of the display and packaging market are shown by the pioneer of innovative brand presentation to an audience of specialists in Nuremberg with new applications and solutions: Effective experience worlds appeal to all of the consumers’ senses, in order to increase incentive to buy and sales. Interactive elements that connect the offline and online world at the Point of Sale create further added value and offer useful information about the product as well as digital entertainment. SalesFront, a packaging system that continuously pushes the products forward on the shelve, ensures the best | 36 | Packaging Europe

shelf space in the competition for consumer favour – and for sales increases of up to 20 per cent. “The exhibition visitors can experience our high innovative power in the area of display and consumer packaging in person at FachPack,” says Lamprecht. Intelligent packaging solutions as well as the latest technology in the area of packaging machines round off the exhibition appearance of the full service packaging supplier. “We supply our customers with integrated and tailored solutions that cover and optimise the entire supply cycle,” underlines Lamprecht. Be it state-of-the-art technology in digital pre-printing or variable laser coding in the area of late stage customisation – with innovative processes and concepts DS Smith reduces the costs and complexity of the packaging processes, minimises risks and at the same time increases sales and efficiency in production and logistics. “This means real added value to our customers,” says Michael Lamprecht. Visit: www.packagingeurope.com/News/64420

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Intelligent Machinery from OPTIMA Machinery with intelligent solutions will be presented by Optima at FachPack, including the OPTIMA Moduline, fitted as a pilot machine line with a multi-carrier system. In this system, conceived and developed jointly with Siemens and Festo, the linear motor driven transport carriages move forward automatically to the different processing stages such as filling, closing and labelling as required. They can be inserted into or removed from the modular system for easy modifications to the process. In this way the line is easily adjusted to different formats, other product types or seasonal requirements.

module for CO2 laser engraving is integrated in the Moduline. As was already demonstrated when German Chancellor Angela Merkel visited the Siemens stand at the Hanover Fair 2015, visitors are able to place their “order” to the Optima machine on an user interface and design their own labels. The first perfume was given the name “Angela’s Dream” and was presented to Angela Merkel during the ceremony. The line shows how today already market products can be customized by Optima machines, just as foreseen by Industry 4.0., in which further machine functions are integrated in the fully automated line processing. In the latest generation of OPTIMA CFL for the production of portion packs, the extendibility of processing modules is brought to perfection. Here simple accessibility is coupled with reduced cleaning and maintenance time. The increased distance between lanes is intended in the first instance for the processing of large-volume portion packs such as capsules, which can be filled with ground coffee, tea or instant products. The version presented at FachPack is fitted with the proven auger filler OPTIMA SD1. The machine has integrated scales and mean value regulation. A press can be coupled as required. The processed capsules are sealed by means of ultrasonic welding. Handling modules, e.g. for inserting plastic filters, are also available. When set up with four lanes, this OPTIMA CFL has an output of 200 capsules/min – at capsule diameter up to 70 mm. With the OPTIMA SD2best auger filler, the company shows a further version of the auger filler family for powders and granular products. For highest filling accuracy, this model has an integrated shut-off weigher. Various flow restriction systems are available for perfect adjustment to the great variety of products. Dosing augers are adjusted to specific products. As an option, the weighing system can be calibrated. The dosing range is quite extensive, from 5 g to 30 kg. | 38 | Packaging Europe

At the FachPack the OPTIMA SD2best is fed with containers by means of a cobot, without the need for format parts. This year, Optima has introduced these cobots in order to handle repetitive and physically intensive tasks. Cobots are special robots intended to interact with humans,alleviating them of physical effort. At FachPack, Optima Consumer provides all the information for further packaging solutions for foodstuffs, cosmetics and chemicals. The company packaging systems process a great variety of products: fluid or viscous, powders and granulates, portion packs or large format – from small portion packs such as mascara, through to oil canisters. Visit: www.packagingeurope.com/news/64327

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Packaging Valley Represented by 13 Companies Under the motto of FachPack “Good Ideas Start Here”, the association “Packaging Valley“ presents itself in Hall 2 with a joint booth of 1,200 m² and a lounge as a meeting place for discussions and networking. Packaging Valley thus creates a relaxed atmosphere for long-term exchanges between FachPack visitors and the member companies.

and around this lounge, thirteen member companies from Packaging Valley, the region around Schwäbisch Hall and Crailsheim, will demonstrate innovative machine systems and the latest technologies. Once again, the diversity of technological skills and competence in the field of packaging systems which is to be found in Packaging Valley is quite clearly demonstrated. The exhibitors include packaging machine manufacturers, components suppliers and service companies. “With our booth concept for Packaging Valley we place great value on displaying the entire processing chain and presenting ourselves as a future-oriented, regionally-linked network in the packaging industry” according to Kurt Engel, CEO of the Packaging Valley Association. For Packaging Valley the FachPack is also an opportunity to present the new joint website and to promote the packaging conference “Packaging Valley Days 2016”. At www.packaging-valley.com/en/find-supplier, visitors will find detailed information about Packaging Valley and its members – an opportunity to find the right supplier thereby providing even more benefits from a visit to FachPack. There are thirteen good reasons to take a break in the Packaging Valley Lounge: 13 companies offer a diverse portfolio of technical systems and solutions for greater efficiency.

Covering various format ranges quickly and easily Visitors can take a closer look at the Clean-Design transport conveyor system developed by HO-MA GmbH which sets new standards in cleanability. It integrates components which enable fast and uncomplicated format changes for practically all sizes. Here too, the company so-matec epple GmbH, manufacturer of cartoning machines, | 40 | Packaging Europe

demonstrates with the interchangeable Stellmax components, products which are flexible and can find use in almost any machine. Newly developed cartoning machines which cover a large range of formats and outputs within the smallest space are presented by Hohenloher-Verpackungs-Systeme GmbH. These are fascinating in their extreme flexibility of applications. The carton erecting machines designed by SVZ Maschinenbau GmbH optimize secondary processing of the latest carton designs for ease of handling by the processing and logistics industries.

Fast further processing through integrated functions Fully automatic filling machines combined with transport systems and labeling machines are demonstrated by STAKO GmbH. These are especially designed for small production lots and make a convincing arguement with their rapid format change facility. At the trade fair the portfolio is extended to include turntables for the pharmaceuticals industry. Separation, detection, glue closing or insertion are all possible in a process presented by POPP Maschinenbau GmbH which is of particular interest to customers in the print and paper branches but which can be transferred to other production and services industries.

High-performance machines for efficient processes Another focus in and around the Packaging Valley Lounge is on high-performance packaging systems for snacks and products that need to be weighed. Here the focus is

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on multi-head weighing devices, as demonstrated by Ishida GmbH with its high-performance machines for the food industry. Also known for its high-precision weighing technology is the manufacturer OCS Checkweighers which demonstrates its extensive range of dynamic control scales for weight verification and X-ray scanners for the detection of foreign bodies. Track & Trace solutions for the pharmaceutical industry round off the spectrum. High production efficiency in the packaging of portion packs or personalized products is achieved by Optima intelligent solutions. Automated and digitalized processes set new standards in the age of Industry 4.0.

Intelligent robotic solutions Also shown here will be a completely automated robotic application for a secondary packaging area. R.WEISS Verpackungstechnik presents their well-known, modular UNIROB Toploading Pickerline. One special feature shown is the Intelligent Shuttle System, which can be easily programmed to transport the cartons to several stations of the Pickerline. BAIER ENGINEERING GmbH offers complete robot automation of palletizing systems for a great variety of packs. Processes are simulated in real time with the Baier Industry 4.0 software tool before the complete line with individual servo-electric grippers and CE approval goes into production.

Upgrading machine engineering with digital solutions for the Industry 4.0 era The company HEITEC AG stands for engineering competence. This services company is also represented at the Packaging Valley Lounge. Here the focus is on virtual illustrations in full scale through which installation time and unplanned downtimes are considerably reduced. Live training is offered by means of 3D glasses.

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As a further manufacturer of robotic automation and software solutions Erhardt + Abt Automatisierungstechnik GmbH is also represented as the latest addition to the Packaging Valley association and part of the HEITEC group of companies.

Other member companies at FachPack: As well as companies in the immediate vicinity of the Packaging Valley Lounge there are also other member companies of Packaging Valley to be visited at the FachPack. In Hall 1 the companies BREITNER Abfüllanlagen, Rudolf Deckert and PCA Roboter- und Verpackungstechnik will present their machines. Visitors should also not miss a visit to the booth of Transnova-RUF Verpackungs- und Palettiertechnik in Hall 3. Visit: www.packagingeurope.com/News/64535

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Mosca Presents Fully Automated Double Strap Dispenser Mosca GmbH from Waldbrunn once again demonstrates technological leadership in the strapping industry at FachPack 2015.

xhibits range from high-quality entry-level machines to the most costefficient, high-end machines. Visitors to Stand 509 in Hall 4A can see Base and Pro versions of the fully automated SoniXs TR-6 strapping machine. Both models offer strapping performance capabilities that make them ideal for highoutput operations where process safety is key. The fully automated double strap dispenser is a new feature. It switches between two strap coils and greatly increases availability. The strapping specialists’ display is supplemented by tried and true classics, including the automated entry-level model RO-M Fusion. “As system suppliers in the strapping segment, we will again seize the opportunity of this year’s FachPack to present our portfolio of strapping machines and consumables,” says CEO Timo Mosca. “We offer everything from multifaceted entry-level solutions, to high-performance machines designed to meet every requirement. We look forward to presenting our products to new and established customers.” Mosca is presenting the fully automated SoniXs TR-6 strapping machine in Base and Pro versions. This high-end, cost-efficient machine can be integrated into any operation that demands high availability and process safety. It is an ideal solution for corrugated cardboard processors, wholesalers, printing companies, logistics, food and pharmaceutical industries. Based on Mosca’s efficient modular system, both models use a maximum number of identical components, including the frame, the energy-saving SoniXs ultrasonic sealing unit, the feeding unit and the strap coil. Because both machines are constructed with a Standard 6 strap path system, they can be easily disassembled without tools. All core components are directly accessible, which means maintenance and cleaning can be quickly carried out by hand. A new feature on both machines is the fully automated strap change. Instead of a single coil, the SoniXs TR-6 Base and Pro models work with two coils as an option. When one coil is empty, the machine automatically picks up the second coil and changes the strap. Production continues uninterrupted and the operator can flexibly change the empty coil without stopping the machine. This prevents expensive downtime and increases machine availability. While the Base model is equipped with simple controls and an intuitive machine interface, the SoniXs TR-6 Pro uses specialised B&R controls and an HMI colour touch panel. Unlike the Base model, the Pro version offers an option to pre-program strapping formulas for fully automated solutions across a wide variety of applications. A detailed display supports the machine’s process reliability. Because it is fully network-compatible, Mosca expert can carry out online maintenance remotely. A Pro machine’s status can be determined at any time with just a few mouse clicks. “Our customers have very different needs when it comes to applications,” explains Mosca. “Not everyone needs a specialised high-end machine, but at the same time, many users are unwilling to forgo top performance and high quality. We close this gap with the Base model. Our customers can choose a cost-efficient SoniXs TR-6 with the same highperformance mechanical system.” Customers who want to install a combination of two identical machines at an angle for cross-strapping will profit from the redesigned angle pusher, which lines up and guides packages between two machines. It now comes with a CE marking from the factory without additional safety devices, making it much more accessible for the operator. Actuators are designed to ensure the net energy is sufficient for the machine’s optimal performance, without posing a danger to the operator. | 44 | Packaging Europe

With its high strapping capacity, super soft strapping and a wide range of options, the compact RO-M Fusion is one of the most reliable entry-level strapping machines. A true classic, Mosca first introduced the RO-M version in the 1970s – and gained a solid position in the high-quality segment of the strapping sector. The RO-M Fusion combines the Standard 3 version of the tried and tested high-end sealing unit with production engineering innovations. Multiple decentralised DC motors have replaced the central drive in the sealing unit. This offers a number of advantages: Key features such as strap feed, return and strap tension can be adjusted to meet specific requirements and can be optimised for specific applications. The direct drive for these functions eliminates the need for wearing parts like toothbelts, clutches or chains. Operators benefit from the machine’s high availability and ease of maintenance. The RO-M Fusion is easy to operate and is suitable for strapping smaller packages and bundles up to 600 millimeters high and 800 millimeters wide. The load is positioned by hand in the strapping area and the strapping process is triggered by a foot pedal. Depending on the size of the product, the machine can do up to 55 straps per minute with a 5mm strap width. Such speeds are required during peak times, when two operators are working simultaneously from the front and rear. The pivoting control panel is a welcome feature for operators. Wholesalers, distribution centres and logistics operations have relied on compact, RO-M series machines for decades. FachPack visitors are invited to discover RO-M user-friendly operation at the Mosca exhibition stand. Visit: www.packagingeurope.com/packaging-elite-news/64471/mosca-presents-fullyautomated-double-strap-dispenser-at-fachpack-2015.html

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BERICAP Presents Closure Innovations BERICAP will be among the exhibitors also on this year’s FachPack trade fair in Nuremberg. The worldwide operating manufacturer of closures BERICAP will present its plastic closures for the markets of automobile, chemistry, pharmacology, agro-chemistry as well as food in hall 6, stand 6-418.

ou need to think innovatively so as to be able to cope with the higher and higher demands on packages and in particular on the sealing breech, which, depending on the field of application, shall not only close and seal the container, but also protect the content against product piracy and at the same time satisfy the high technical demands requested by the government and the authorities. In the years past, BERICAP has worked intensively on the successful development of a DIN closure family for plastic canisters. With the standard sizes DIN 42, DIN 45, DIN 51/55 and DIN 60 BERICAP in the meantime covers more than 80 % of the closure sizes used in the canister field. The entire new DIN closure range is approved for UNhazardous substance in connection with different canister types and/or canister suppliers. In order to warrant product safety and quality, all closures are assembled on fully automatic and process-controlled assembly machines of the latest state of technique. All sizes, also the childproof versions for the sizes DIN 45 and DIN 60, can be custom-

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made and additionally be equipped with a vent diaphragm and/or with an ‘ANTI-GlugSystem’, which provides for steady pouring. The SK 42/21 SFB is a supplement to the product range of BERICAP DIN closures. This closure is equipped with a new-type, slitted strip and is available in two versions. The SK 42/21 SFB Mk has a bore-seal-system and is suitable for light canisters and containers without UN-hazardous good approval. The SK 42/21 SFB MDS is equipped with a foamed PE-seal – for containers with the relevant UN-approval. The SK 42/21 SFB is used mainly for containers in the automotive field, for windscreen cleaners / frost protection, for professional cleaning agents, in the field of health and in the food industry. It is a special advantage that the TE-strip, which remains on the canister after turning off of the cap, cannot e.g. drop into the engine compartment while filling the container of the windscreen washer. Visit: www.packagingeurope.com/News/64517

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Bischof + Klein’s Sustainable Packaging Solutions At the FachPack trade fair, Bischof + Klein is presenting a range of innovative, sustainable packaging solutions for industrial and consumer goods. The newly designed “Twister Plus” wicketed bag for tissue products, for example, requires around seven percent less material. This involves reverse-printed hygiene packaging with a handle and easy opening function. The new design now enables the PE film for the bag to be selected 10 µm thinner. No additional label is required for the handle area. The quality of the printed image is improved thanks to the switch from first printing to reverse printing. Based on an order volume of 10 million units per year, the new wicketed bag enables over 14 tonnes of material – primarily polyethylene, but also lacquer – to be saved.

+K, the manufacturer of flexible plastic and plastic laminate packaging and technical films, has also achieved a quantum leap in terms of material efficiency with its new Value Pack. The large-format PE wicketed bag with handle replaces large cardboard packaging for tissue products. The film has a wall thickness of 60 µm. Cardboard packaging for a filled weight of approx. seven kilogrammes weighs around 600 grammes, whereas a comparable PE wicketed bag only weighs 81 grammes. The transportation costs already reduced as a result of this are further lowered because, for example, the capacity of a Value Pack for paper tissues is around 15 percent higher. Easier handling thanks to the carrying handle offers a further advantage. The SmartFlex® 20 µm stretch hood film enables significant savings. With this super thin securing film, Bischof + Klein intends to conquer the market for securing lightweight, mixed products on pallets. Conventional stretch hood films have a standard thickness of approx. 100 µm and are economically unattractive for securing goods on pallets in certain market segments in comparison with wrapping films. With a significantly reduced wall thickness of 20 µm, SmartFlex® radically shifts the cost effectiveness calculation in the favour of stretch hood technology and enables material savings of up to 39 percent. The fundamentally higher performance of stretch hood film lines in comparison with stretch wrapping lines is further increased by SmartFlex® 20 µm, as the number of reel changes is reduced. In contrast to stretch wrapping technology, loads secured on pallets using hoods are per se protected on all sides and at the top from dust and moisture. The risk of theft is also successfully averted. Tampering with the film hood is immediately noticed. Visit: www.packagingeurope.com/News/64533 | 48 | Packaging Europe

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Clear View for Crystal-Clear Advantages With new, attractive solutions broadening its print portfolio and range of films, Südpack Verpackungen GmbH & Co. KG is better positioned than ever and will be presenting its latest innovations at Stand 240 in Hall 7 at this year’s FachPack.

new digital printing process will enable Südpack customers to quickly personalize their packaging with optimum printing quality and short delivery times. Two new top films for trays guarantee a compelling presentation at the point of sale (POS): Südpack’s newly developed Safe Peel Clear AF with improved anti-fog performance and the extremely durable CanLid Peel with outstanding white coverage. The new Veraplex generation of films provides maximum product protection with minimal film thickness. “From visions to reality” is the Südpack motto at this year’s FachPack trade show. Many of the innovations that Südpack will be showcasing in Nuremberg from 29 September to 1 October are indeed the results of several years of development: “The solutions we will be presenting in Nuremberg enable our customers to tailor their product presentation to individual requirements. The look and feel of a product is often the decisive factor at the point of sale. Our wide range of print and film technologies allows our customers to transform even their most visionary packaging ideas into reality,” says Südpack Managing Partner Johannes Remmele.

Digital printing process opens new market opportunities Just in time for the year’s most important packaging trade show, Südpack presents a new addition to its range of printing processes. Besides the established rotogravure and flexographic printing methods, a digital printing process is now also available. The technology boasts clear color gradients, brilliant colors and razor-sharp outlines. Even small batch quantities can be printed efficiently, opening up new market opportunities. Remmele describes the benefits of the technology: “Our new digital printing process and the ability to print small batches fast and efficiently open up a whole new world of product presentation options for our customers. Companies can now test new sales concepts or launch products on small test markets. Special promotions, seasonal themes or even packaging with personal messages are now possible.” Südpack will be printing films with a thickness of up to 250 µm on the HP Indigo 20000 digital press. A variety of film surfaces can be printed with texts, images or barcodes up to an image size of 736 x 1,100 mm. Simple changeovers of print layouts requiring minimum preparation and lean production processes mean that Südpack can also produce packaging in small-batch quantities. The films are printed with special inks that have been tested by independent institutes and are 100% food-safe.

Top films for trays boast outstanding design and product safety Safe Peel Clear AF top film for trays will be another innovation presented by Südpack at this year’s FachPack exhibition. Its improved anti-fog technology prevents mist from forming on the inside of the cover film to ensure a clear view of the product. “Consumers have high quality standards at the fresh food counter, especially when it comes to meat and fish. They want to see exactly what they are buying,” Remmele explains. “Foggy top films are often interpreted as a sign that a product is no longer fresh. The new Safe Peel enables food manufacturers to stand out at the POS because customers can see the product more clearly.” Safe Peel Clear AF is thin yet stiff. It withstands high mechanical loads and is suited for fully automated processing. The high barrier film lies flat on the sealed PP tray and is easy to open. An improved peel system with a PP sealing layer guarantees a perfect seal, | 50 | Packaging Europe

even if there are product residues on the edges of the tray. The film can be used with all standard tray sealers and seamlessly integrates into existing production lines. Safe Peel Clear AF can be processed at high throughput rates of up to 13.5 units per minute, while significantly reducing the amount of packaging material required. CanLid Peel is another top film for trays developed by Südpack. Its outstanding barrier properties and white top film protecting the product from light guarantee maximum product safety. The film may also be pasteurized for added protection. This extends product shelf life by preventing bacteria formation. Thanks to its easy opening properties, the peel foil also impresses end consumers.

Slim Veraplex film promotes sustainability The new Veraplex generation of films adds to the highlights at Südpack’s exhibition stand. The extremely thin film with maximum product protection represents a revolution in packaging. Its outstanding puncture and tear resistance (upon opening) combined with a high oxygen/aroma barrier make it suitable for a wide range of applications. Veraplex is ideal for products with high mechanical requirements and can be used as bulk packaging in B2B markets and as packaging for end consumers. Owing to its outstanding mechanical properties, Veraplex can be processed on all standard machines at the same packing rate. The film’s thinness leads to individual rolls holding more material, ensuring longer runtimes with fewer roll changes. Visit: www.packagingeurope.com/News/64522

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Noxon affirms itself on the global market as a leader in designing and producing wrapping machines and pallet stabilization with stretch films. The Noxon range comprises self-propelling robots and wrapping machines with rotating table for pallet stabilization, winders with rotating ring for horizontal wrapping of elongated shaped products and manual and automatic sealer machines to close cardboard boxes. All Noxon products are reliable and of the highest quality, and fully comply with the strictest safety regulations and use the latest technological solutions throughout their entire production process. Noxon’s ten-year presence and experience in the packaging sector enables it to offer cutting edge technological solutions and provide high quality service in a timely manner all over the world. These are the reasons why Noxon is considered to be one of the leading companies in the packaging sector in selling wrapping machines and packaging machines for industrial use.

www.noxon.it

PACKAGING & MORE

29.9. - 1.10.2015 | NUREMBERG VISIT US AT STAND 529 IN HALL 3 Packaging Europe | 53 |

Presses,

balers

and more

Founded in 1953, RoitherMaschinenbau GmbH is one of Europe’s leading producers of presses, waste compactors, balers, conveyor belts and reel splitting machines for a number of industry applications. This year, as Packaging Europe discovers, the company will be showcasing several of its leading innovations at FachPack.

oday RoitherMaschinenbau employs around 50 people at its headquarters in Seewalchen and its current CEO, Franz Roither, represents the second generation of the Roither family. Mr Roither’s wife Mathilde also works at the company, as do his children Marlene, Philipp and Lukas so it is still very much a family run business. Its turnover last year was somewhere in the region of €6 million. RoitherMaschinenbau GmbH was founded as a small locksmith’s shop by Franz Roither Senior, the current CEO’s father. The company built its first baling press in 1973, at a time when both the Austrian and European markets as a whole were becoming increasingly aware of the importance of recycling. During this time, its main brand name ‘Austropressen’ was also introduced and initially consisted of only small baling presses for hotels, restaurants and so on. The 1990s saw an important development when RoitherMaschinenbau began a cooperation with a public Austrian recycling company for which it equipped more than 200 waste collection centres. Following this, the company saw more rapid international growth with contracts all over the world, including: balers for every island of the Maldives; projects for can production lines throughout Europe and also in South Africa, Nigeria, Mexico, India and Vietnam; and channel balers for supermarket chains in Europe, Russia and Australia.

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But despite this continuously growing international presence, ever single product is still developed and built entirely the company’s main plant in Seewalchen. Furthermore, it remains flexible enough to offer tailor-made waste disposal solutions when required.

Unique product range Mr Roither is keen to highlight the company’s strengths, which fall into three main categories: “Firstly, we have high quality standards as we only use equipment from respected brands such as Siemens and Bosch. Secondly, there is our wide product range: there is hardly anything we can’t do, and if the product the client wants does not exist our engineers do their best to develop a tailor-made solution. Finally, there is the size and flexibility of our company. We are both big enough to fulfill the highest requirements and small enough to respond to individual requests.” The Austropressen product range covers a large number of baling and compressing machines, including: small baling presses and waste presses for hotel and restaurant clients such as Starbucks and McDonalds; drum crushers and tin presses, also for hotels and restaurants; vertical baling presses for supermarkets such as the Billa (REWE) and Norma stores; horizontal baling presses for packaging produc-

Family members (from left to right): Marlene, Franz, Mathilde, Lukas, Philipp

ers, waste collection points and so on; fully automatic channel baling presses for all kinds of packaging production companies, supermarket chain warehouses (REWE, ROSSMANN) and recycling companies (e.g. Veolia); and can crushers and scrap balers for can production lines for clients such as Rexam, Canpack, Roeslein and Ball. In addition to the above, the company produces other items such as foam balers, reel splitting machines, conveyer belts and special purpose balers.

be cut down quickly. In addition, the material can be reinserted into the production process easily and cost-efficiently.” Indeed, R&D is very important to all aspects from Austropressen – from every single employee to its representatives worldwide. Besides the new equipment to be shown at its booth at FachPack, the company is planning a new series of balers for Spring 2016.

Innovations at FachPack

Global presence and outlook

Constant innovation is one of the pillars behind the growth of the Autopressen brand, as the company will demonstrate at the upcoming FachPack exhibition. Here it will be showcasing its new equipment as well as the new features of its APV vertical balers. Mr Roither explains the importance of this particular event: “We have been taking part in FachPack for many years and have collected a great deal of knowledge about this sector. Therefore we are able to offer many different solutions for the packaging production industry, from balers for cardboard, paper trims, scraps of plastic film or can production to balers for difficult materials such as foam or thermoplastics. With our baling presses the costs of storage and transportation can

In terms of future geographical expansion, the company has been working on many projects in eastern Europe (Romania and Bulgaria) and Iran – most of them focused on waste recycling and waste treatment centres. The number of requests from these countries has been steadily increasing in the past few months. Mr Roither concludes: “We live up to our good reputation, whether in the compression of paper, cardboard, foils, foams, PET bottles, cans or barrels. The wellplanned construction and careful manufacture of our presses takes place entirely in Austria using materials of the highest quality and selected brand components.” Visit: www.austropressen.com

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SOMIC – Partner of well-known companies worldwide for more than 40 years.

SOMIC – The very best end-of-line packaging machines Efficiency out of the modular system: SOMIC offers optimal solutions with its systems engineering.

he variety of products and requirements for end-of-line packaging is always on the increase. After all, each product idea requires an individual cover to create a unique presence at the POS. For this purpose, the customer may also wish to choose between single-part and multi-part packaging. The solution can be found in the SOMIC - modular system. Based on the premise of flexibility and modularisation, five years ago the entirely new machine generation SOMIC 424 was developed, whose concept now forms the basis for all of the company’s machines. A total of 76 standard machines, divided into 4 machine types, are available to the customers. The consistent horizontal and vertical structures used by SOMIC arrange all functional blocks, parallel interfaces and functional units. This allows the autonomous operation of functional units via decentralised control. The uncluttered machine architecture offers impressive simplicity and accessibility. While each machine follows this principle, it also meets the customer’s special requirements, which are covered early on by the systems engineering.

Precise determination of the requirements The customer’s wishes and requirements are at the centre of the planning. Prerequisites, requirements and expectations for the project are developed and formulated. In a first step, the product data are collected and recorded. In the next step it is determined whence and how the product will be delivered, in order to precisely define the interface with the upstream machine. For example, bags may arrive from horizontal or vertical tubular bag machines in a standing or lying position. Various product groups, different box dimensions and service requirements are taken into consideration. Finally, the packaging concept (e.g., wrap-around, tray with a lid) and the employed packaging material are considered. In short, everything that may influence the intended solution is recorded.

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A format list for all products and packages is generated on the basis of the data. This carefully reviewed requirement specification forms the necessary basis for a solution specification.

Developing solutions with the SOMIC modular system The basic requirement for each end-of-line packaging machine is to collect products, to arrange them in groups and to package them in boxes. For each product, all required functional units are combined in a structural plan. This plan documents how the required functions of the basic machine will be implemented with the SOMIC 424 modular system. All SOMIC end-of-line packaging machines are functionally structured and are uniformly based on functional blocks, functional units and functional groups. In the end, all finished functional units are installed in the machine frame and connected to the connector box which is present in each functional unit. The final result is a basic packaging machine that is ultimately individualised and completed with customer-specific functions, tools and programmes.

SOMIC 424 and 232 – two new generations of end-of-line packaging machines The SOMIC principle “Engineered to Perform” also served as the basis for the development of the latest generation of the smaller, yet faster end-of-line packaging machine SOMIC 232 FS. This superordinate principle is clearly apparent in the SOMIC systems engineering, which is based on systematically generated requirement profiles. It is always SOMIC’s goal to offer the most efficient solution for the customer on the basis of the existing modular system, since modularisation, on the one hand, and standardisation, on the other, lead to the highest possible performance and investment security in the customer’s service.

At the FachPack 2015, SOMIC will introduce two machine types that use the advantages of the joint system platform in a consistent and user-specific fashion. The SOMIC 424 DT is designed in particular for larger, single-part or multi-part end-ofline packaging. The SOMIC 232 FS, on the other hand, is designed for the highefficiency production of small folding boxes made from a single blank, using as little space as possible. Due to its versatility and compact design, this latest SOMIC machine type, which has been on the market for 2 years, is especially predestined for use in the pharmaceutical industry, but also for smaller end-of-line-packaging for confectionery and snacks. It thereby also accounts for the general trend toward smaller products and smaller packaging units, while offering a variety of forms and designs.

You can rely on SOMIC!

For more information: SOMIC Verpackungsmaschinen GmbH & Co. KG Am Kroit 7, 83123 Amerang / Germany Tel.: +49 (0)8075 916-0 Fax: +49 (0)8075 916-122 E-Mail: info@somic.de Website: www.somic.de

Mounting of a mechatronical functional unit into the machine frame.

Complete quality control and extensive test runs in the factory ensure the subsequent quick and smooth on-site assembly, a correct and reproducible packaging result and a dependable production. All SOMIC machines can easily be operated via the movable and rotating touch panel, supported by language-independent symbols and images. SOMIC machines are highly flexible and almost always designed for multiple products and packages. Both the products and the groups, and ultimately the selected box models as well, may show significant differences. The deciding factor is the SOMIC machines’ ability to handle these differences in a flexible and dependable manner. This means that after each format change, a subsequent reliable production process is guaranteed. The so-called Quick Change System always fixes each individual format tool in precisely the same position - without readjustment. Performance and investment security from the start. SOMIC – Engineered to Perform.

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AIMING HIGH

Appec Group is the leading producer of vertical packaging machines in the Czech Republic. High performance, quality, reliability, user-friendly control and adroit service support are just some of the reasons for its strong position not only in the domestic market but, increasingly, abroad. Romana Moares reports.

ppec Group a.s. produces and sells packaging and dosing machines for the foodstuffs, chemical, pharmaceutical as well as other sectors. In 2008, the company included production of packaging machines of the renowned company Sellier & Bellot stroje s. r. o., thus incorporating the experience of a 60-year tradition and becoming the leading manufacturer in Europe of dosing and packaging lines for loose products to ready-made bags of 0.5 l up to large volume bags of 25kg. In 2011 the company moved its headquarters as well as its operations to Brno. Its new, larger premises have allowed for dynamic growth in recent years and the establishment of Appec’s own testing station. Two years later (2013) a close partnership was struck with a Brno manufacturer of carton box-folding machines, resulting in a merger of these two businesses. “Today, we are one of the leaders in food packaging in the domestic market,” says Vaclav Vincenc, the company’s managing director. “In the Czech Republic our core sectors are those of bakery production and the production and packaging of snacks and confectionery products. We deliver not only lines for primary product packaging but, in particular, lines for process automation, group lining and subsequent packaging as well as dispatch packaging into cardboard boxes. I believe we are one of the three major machine suppliers in this field of business.”

Wide range “Vertical packaging machines, in a diverse range of sizes, constitute our main production programme. We provide uncomplicated universal and affordable packaging lines, as well as powerful packaging machinery for continuous operation and machines for packaging batches up to 70 litres,” says Mr Vincenc. “Customers can benefit from our wide range of in-house manufactured products. As a complement to Appec products, appliances of other reputable manufacturers are also marketed,” he explains. A wide range of bag shapes and sizes can be created in the group’s vertical packing machines. They offer a complete technological process solution for dosing and packing of loose and fine lump products into bags formed from a roll of packing material. The bags are formed around a tube and filled downwards with a dosed amount of product. The machines, operating in continuous and step-by-step mode, can create bags of up to 70 litres in capacity. Complementing the systems for primary packaging is the portfolio of secondary packaging (group packaging) units for assorted goods to be collated, with film wrapping units. Appec Group also offers automated lines for case and carton packing, including cartoning machines and palletising lines, distributing technologies from leading international manufacturers. The company offers palletising lines for any common

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goods and packages, featuring standard to highest performance. It offers the choice of a conventional system or a robotic system. Other imported products include metal detectors and checkweighers. “The quantity of these products is, however, much smaller than those that we make ourselves. In fact, we offer them only as supplementary products to our own lines,” explains Mr Vincenc.

Shaping the future On the product development front, the company plans a major upgrading of its BSV04 CST continuous packaging machine and is also currently working on a packaging machine for the production of so-called block bags. In addition to this, it is developing its packaging lines for loose products to ready-made bags, acquired in 2008. “We are the only Czech producer of multi-head weighers, achieving great success with our 20 head carrousel weigher for savoury sticks dosing. Our designers did a marvellous job – the weigher is a true high tech product,” says Mr Vincenc. He explains that the weigher will remain an important focus for the product development department, as – despite the influx of cheap products from Asia – demand for special weighers for the dosing of complex and unusual products, such as frozen, sticky and fragile goods, remains high in Europe. “We offer weighers equipped with, for example, tensometric sensors with electronic vibration damping and other special components, and these will also be in demand in the future. We are now considering the development of special weighers for meat product dosing with a special system for goods feeding,” he says.

First class “Starting from transport and handling, through dosing, primary and secondary packaging and up to delivery, we strive to bring our customers high value whilst achieving maximum processing efficiency at minimal cost. Our key competitive advantage is to provide a tailor made solution and meet the customer’s demands to the tiniest detail,” says Mr Vincenc. | 60 | Packaging Europe

He explains that the key task for the near future will be to further strengthen the Appec Group’s position not only in the Czech Republic, but also in western Europe. To this end, the company is working intensively on expanding its sales network in Germany and seeking reliable partners to promote its products in this demanding market. Exports to Asian markets have also been increasing and an imminent challenge is to establish a sales network in North America. “We are not planning to further extend our product offer: quite the contrary in fact,” says Mr Vincenc. “We want to focus on the development of various supplementary devices for our packaging lines, operating in particular in continuous modes. Customers require universal machines with a broad range of uses. We don’t want to enter mass production but wish to continue to meet customers’ demands by means of flexibility and first-class technical solutions.” Visit: www.appecastro.cz

Invisipac™: Next

Generation Hot-Melt While traditional hot-melt systems use large tanks to heat adhesive to a liquid form, Graco’s InvisiPac system is tank-free and its compact melting chamber processes pellets in small batches. Adhesive only spends a short amount of time at high temperatures, so there is significantly less char formation than in traditional tank systems. Operators no longer need to go through the time-consuming process of tank scraping and cleaning as there is simply no tank involved. The end result is enhanced production line efficiency and less down-time, which means significant savings in both time and money for customers.

addition, start-up times on an Invisipac production line are approximately 10 minutes, compared to a 35-minute start-up for traditional hot-melt systems that use a tank to heat adhesives. By using an automatic feeding system, the Invisipac system eliminates thermal shocks, reduces contamination and provides an automated and safe supply of hot-melt to the melting unit. Its integrated vacuum system is used to feed adhesive to an in-line melter. An ultrasonic sensor monitors adhesive in the chamber, and additional adhesive is automatically added based on application demand. The InvisiPac’s efficient heat transfer design provides an equivalent or better adhesive flow than many hot melt tank systems. The result? A continuous flow of adhesive during production that significantly reduces the time adhesive sits at temperature. Less time at high temperature means less char, less maintenance and more uptime: really innovative hot-melt equipment for the packaging industry. Production line operators can also learn to use the system very quickly through its clear graphic display and embedded diagnostics, which also saves Graco customers significant service time. Significantly improved heat-up time is achieved through the product’s intuitive power management system and multi-zone heat controls. These minimize power consumption, whilst maximizing production line performance.

New features Added to these benefits, Graco has launched new, value-adding features to the Invisipac system: the Pattern Control, the GM 100 applicator and the LineSite. The Pattern Control System has a friendly user interface that makes it easy to enter patterns, preview them onscreen and even store them for future use. By pressing a button, the operator can choose to switch from solid to stitched beads at any time.

The GM 100 is the newest applicator for the InvisiPac. With its innovative free-flow manifold design and its integrated module filtering you can eliminate nozzle plugs. LineSite is a data tracking and collection solution for the Invispac. With LineSite, InvisiPac machines can be tracked on the plant floor in real-time from your smart phone, tablet or computer, and the data can be used as a powerful business tool to cut costs.

Case study Syngenta, a French seed producer, was using a Curti packaging line for sealing the ‘top & bottom’ of boxes of treated seeds. Syngenta was experiencing some issues with their standard hot-melt tank delivery system, such as nozzle plugging, the build-up of char, security issues as well as a very long warm-up time. The solution was an InvisiPac HM25 tank-free hot melt delivery system, equipped with four highly efficient Graco heated hoses. Each hose has a quad applicator applying upwards on the bottom and downwards on the top of the box. Extra reporting features are also available which now enables Syngenta to collect information regarding adhesive consumption and unit performance. Immediately after the installation, Syngenta enjoyed the main benefits of a tenminute start up time, no char, nor nozzle plugging and very good application (even for the upwards bottom bead). There was no lost time due to refilling, and data download on hot melt consumption and events was available for analysis. The result is a cleaner area and larger space next to the package line. Syngenta is also now free to work with any hot melt producers, but is also free to choose EVA or metallocene based hot melt. After installation, the production and maintenance managers were very satisfied with their new purchase. Visit: www.gracopackaging.com Packaging Europe | 61 |

The variable adaptors allow the transportation of different types of products and workpieces.

The Ferag headquarter in Hinwil near Zurich, Switzerland,

SkySorter – the new gravity conveying system

Ferag AG of Switzerland has further upgraded the Skyfall system introduced last year with added new and innovative features. Foremost among these is the SkySorter, which made its world debut at LogiMAT 2015 in Stuttgart and will also be shown at Fachpack in Nuremberg at the end of September. Such installations have been designed for e-commerce, warehousing and distribution logistics systems, as well as industrial applications.

ith the SkySorter, the overhead gravity conveying system offers additional options when carrying out tasks such as selective accumulation, order-picking and sorting. For the utilisation of Skyfall technology in goods distribution centres and packaging stations, the increased capacity of 30 kilograms for the conveyed items is an added plus. Thanks to its overhead design and exceptional modularity, the innovative Swiss system can be integrated into virtually any environment – even into existing logistics facilities where space is restricted. The Skyfall system also comes with one crucial advantage: there is always sufficient, unencumbered floor space for workstations and traffic areas. The technology developed by Ferag makes intelligent use of gravity, and moves in free fall sections with no drive power input whatsoever. For products that are transported over longer distances with no gradient, the Swiss engineers have employed the newly developed circulation conveyor. Tight curves, targeted docking and undocking of the carriers via inlet and outlet switches keep distances as short as possible. And with only one drive per 80-metre conveyor section, here, too, energy consumption is extremely low. In spite of the high performance of the installation, the operating and maintenance costs of this highly efficient conveying system stay within very reasonable limits. In addition to e-commerce, warehousing and distribution logistics, Ferag envisages the use of the Skyfall technology in diverse industrial applications. The range extends from simple material flow between two points through linking and decoupling production and assembly steps to integrated processes such as weighing, quality control, labelling and packaging. One of Skyfall’s greatest strengths lies in buffering and intermediate storage. Whether it’s food packets, cans, cartridges, bottles, flacons, items of clothing, or objects that can be placed in pouches, the transported product or workpiece is of secondary importance. That’s because the shuttle adaptors can be individually configured and modified for each application.

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Ferag and SSI Schäfer pulling together For a number of years, Ferag AG of Switzerland has been increasing its focus on areas such as intralogistics and packaging technology. To further expand these activities, the company based in the Zürcher Oberland is now entering a strategic partnership in overhead conveyor technology with SSI Schäfer, the leading warehousing and logistics specialist. The agreement between the two companies relates primarily to the overhead conveyor technology developed by Ferag. SSI Schäfer will be making increasing use of the potential afforded by the innovative Skyfall system in the design and construction of new goods distribution centres.

About Ferag AG Ferag AG, with its headquarters at Hinwil in Switzerland’s Zürcher Oberland, is a specialist in innovative conveyor and processing technology. It is seen as the global market leader in the development, manufacture and marketing of postpress processing systems. At the same time, this traditional, family-owned company is stepping up its activities in the intralogistics and packaging industries. Like its affiliate companies Denipro AG, WRH Marketing AG and PMC Print Media Corporation, Ferag is part of the Walter Reist Holding AG corporate group, which employs a staff of 1000 worldwide. Visit: www.ferag.com

Perfect conveying, accumulating and sorting: Ferag has upgraded the Skyfall system to include the SkySorter and other features.

Myriad packaging alternatives MULTIVAC develops and builds thermoforming packaging machines, vacuum chamber machines, chamber belt machines, labellers, inspection systems and turnkey lines for the food industry, the medical industry, consumer and industrial products worldwide.

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ULTIVAC Sepp Haggenmüller GmbH & Co.KG was founded in southern Germany in 1961 by Sepp Haggenmüller, and is now considered to be one of the most important and innovative manufacturers in the world of packaging machines of all kinds. The product range consists of fully automatic thermoforming packaging machines and tray sealing lines as well as vacuum chamber machines for packaging in pre-produced film pouches. Worldwide, approximately 4600 people work at the MULTIVAC Group, with 1600 at the company’s headquarters in Wolfertschwenden alone. With more than 70 subsidiaries, the group is represented on all continents.

Continuously expanding The company has production facilities in Germany and Austria as well as an extensive sales and service network worldwide. The group’s headquarters in Wolfertschwenden cover more than 63,000 square metres, and undergo continuous expansion. In 2012 the company inaugurated its new Training & Innovation Centre, while today construction work is in progress to finish a new €11.9 million distribution centre. This distribution centre is to provide centralised support for MULTIVAC’s European subsidiaries. At the same time, there will also arise advantages in regard to the material supply for the manufacturing of packaging machines at the facility in Wolfertschwenden. The distribution centre’s inauguration is scheduled for the second quarter of 2016, and should be fully operational in the second half of the same year.

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FachPack 2015 in Nuremberg MULTIVAC will attend the FachPack 2015 trade exhibition in Germany, where the company will present innovative solutions for the packaging, labelling, marking and inspection of food, life science and healthcare products as well as industrial items. FachPack is the international specialist trade fair for packaging technology, processing and logistics taking place at the Exhibition Centre Nuremberg every year – except for every third year when the interpack trade show takes place – this year from 29 September to 1 October 2015. Valeska Haux, senior director corporate marketing, says: “FachPack 2015 is obviously one of the highlights of our exhibition programme for this year. It is an excellent platform to meet with customers, to learn new insights, and of course to show new products. We will be showcasing a couple of new machines we launched this year.”

Vacuum skin packs in small batches Amongst others, MULTIVAC will present a new thermoforming packaging machine, the R 105 MultiFresh™, a compact model designed for the production of vacuum skin packs in small and medium scale batches. Valeska Haux commented: “The demand for vacuum skin packs has remained at a consistently high level for years. Manufacturing these packs requires a special machine that places the upper web around the packaged goods like a second skin,

without any tension. This ensures they retain their natural appearance. The full surface of the upper web is sealed to the lower web, ensuring no liquid can escape from the product. The packaged food is held in place in the pack, allowing it to be presented upright, hanging, or placed flat.” Even though the R 105 MultiFresh™ is an entry-level model, it features the same technical equipment as the large machine models. Thus, the new machine makes it possible for small-scale manufacturers to start using vacuum skin packs. MULTIVAC’s product range also includes an extensive array of skin films for MultiFresh™ applications, for which MULTIVAC has tested and approved materials made by leading film manufacturers.

The next five years

Packaging solutions for Life Science and Healthcare

Visit: www.multivac.com

MULTIVAC supplies many different packaging solutions for food or sterile medical products and industrial applications, most of which are tailor-made to satisfy individual customers’ specific requirements. Valeska Haux concludes: “Our engineers design more and more complete solutions for customers’ packaging process chain. We expect this trend to expand as standards of living increase worldwide and the demand for food safety rises as well.” MULTIVAC expects to benefit from the growing global urbanisation and a surge in demand for product safety, be it in the food sector, the pharmaceutical sector or other industrial sectors.

Two new models from MULTIVAC’s business unit for customers from the medical, cosmetics and pharmaceutical industries will also be showcased at FachPack 2015. The R 081 thermoforming packaging machine is designed for packing products in small batches, and it is suitable for cleanroom applications. This entry-level model can produce vacuum packs and modified atmosphere packs with reduced residual oxygen content. The T 260 traysealer enables medical products to be packed in accordance with GMP guidelines, particularly with regard to packaging quality, process reliability and cleanroom compatibility. The sealing die ensures that there is controlled sealing pressure with high sealing forces and precise temperature distribution, and this gives a consistently high level of packaging quality. The company’s participation in FachPack 2015 is not limited to products; one of the speakers at the PackBox Forum, dedicated as usual to the three i’s of inspiration, innovation, and information, will be Alois Allgaier, division manager for Control Technology. He will be giving a speech on real-time product tracking, and exchanging thoughts with colleagues from the packaging industry.

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European quality from Turkey

Turkish flexible packaging manufacturer Bak Ambalaj offers the strategic benefits of being part of a larger group while delivering fresh, innovative packaging solutions to its customers worldwide. Emma-Jane Batey spoke to General Manager Murat Yildiz to find out more.

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Comexi Group Comexi Group works on a daily basis to build and maintain sustainable long term partnerships with clients in order to support their businesses. Comexi Group, as a leading company specializing in machinery solutions for the flexible packaging conversion industry, and Bak Ambalaj have joined forces to drive Turkish market by meeting the most stringent demands. Bak Ambalaj is planning to increase its production capacity while offering better products to its customers. To reach its goals, Bak Ambalaj puts its trust over the years in more than 10 cutting edge Comexi pieces of printing and finishing machinery.

ak Ambalaj is the leading flexible packaging company in Turkey and has been amongst the major players in Europe since 1973. The company has more than 500 employees and produces laminated flexible packaging as printed or unprinted for various food and non-food sectors across the world for more than 200 customers in over 40 countries, with 80 per cent export mainly to Western European countries. Being located in Izmir/Turkey with four production facilities, a Sales and Technical Service Office in Germany and warehouses in the Netherlands and the UK, Bak Ambalaj can maintain a reliable and fast service for its customers. The Turkish-based company produces a wide variety of solutions for even complex requirements, which General Manager Murat Yildiz told Packaging Europe is a key ingredient in its recipe for success. He said, “We are very flexible, we can always come up with a smart solution to our customers’ packaging needs and we are very proud of our ability to develop functional, attractive packaging that adds shelf appeal and provides prolonged shelf-life that meets and exceeds customer expectations.”

Established in 1973 by Enver Bakioglu, Bak Ambalaj has always been focused on flexible packaging, with its first product the flexo-printed outer packages for pasta. The company’s expertise in food packaging has continued to mark its growth and development, with this being its largest sector and the one with which the name Bak Ambalaj is most associated. Continuous growth and progress followed, with state-ofthe-art facilities and additional sites added to its location in one of Turkey’s largest and most modern industrial zones, Izmir Ataturk Organised Industrial Zone. The 4 different plants and a big warehouse are built to provide sustainability and a good covered Business Contingency Plan. As Turkey’s leading flexible packaging company, Bak Ambalaj is part of the Bakioglu Holding Company, which is operating as a vertically integrated group of companies with productions of BOPP films, PE blown films and rotogravure cylinders. Proud of its high global standards and reputation for excellence, the Holding Company brings true strength and solidity to Bak Ambalaj’s day-to-day and long-term activities. Packaging Europe | 67 |

Always investing Bak Ambalaj’s most recent investments include its increase in production capacity thanks to the installation of a new 10-unit flexo printing machine an 11 unit rotogravure printing machine and new solvent based and solvent free laminations machine. It also started operations in its European Logistics Centre in the Netherlands in 2013, which has played an important role in its continued expansion in Western Europe in particular. In 2014 a subsidiary in Germany has been created. The Technical Service and Commercial team presence in Germany is a new step in the history of the company Bak Ambalaj which aims to be closer to the Market and provide better services. Mr Yildiz explained, “We are very well positioned to serve our customers wherever they are in the world; Turkey is a great gateway to Europe, the Middle East, Central Asia, Africa and many other locations by sea as we are located very close to a major port. We are close to Europe both in terms of location and mentality, and especially quality expectations, while having the distinct cost advantage of being based in Turkey. It’s a very appealing offer for our customers. In order to act as a European producer, our next plan is the establishment of new sales organisations in the different parts of Western Europe” added Mr Yildiz. Offering door-to-door deliveries of flexible packaging worldwide, with customers in Europe and as far apart as North America Bak Ambalaj’s new expansion route will be the emerging markets in all Africa, Eastern Europe and the Middle East. Mr Yildiz noted, “We work with many of the world’s leading brands already as they appreciate our high level of flexibility to adapt any fast pacing environment, cost competitiveness coupled with our high quality guaranteed. We have a very good reputation in the market so the role of our sales team is not so hard – the Bak Ambalaj name is very positive. With our strong and experienced teams we aim to increase our strong foot print in our European Home Markets and grow furtherly in the Emerging Markets.” Regular visits at international trade shows underline the company’s international outlook. Fachpack is one of the most important exhibitions in the packaging field and Bak Ambalaj will be present with its booth in Hall 7-A, Stand 115. “Fachpack is the key point to meet our existing and new customers mainly from Germany and Europe. Germany is one of our biggest markets, where quality matters a lot and we have a proven track record that Bak Ambalaj delivers innovative solutions, high quality service and flexible packaging material with reasonable prices compared to European converters,” said Mr Yildiz.

Expanding flexible portfolio The Bak Ambalaj product portfolio includes a wide range of flexible packaging solutions, with a core focus on the food packaging sector. It includes packaging for snack foods, biscuits and confectionary, bread and fresh food, instant foods, dried foods, pasta, coffee and tea. The company also offers packaging for chemical and hygiene products and other

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products. Working with major global brands such as, Milka, Carte Noir, Nescafe, Lipton and Knorr, the company’s production process includes pre-print, production and application. Mr Yildiz said, “We have many great experts in their field working in our R&D, prepress and graphics departments in order to enable us to continue to offer the very best flexible packaging solutions. We have the very latest facilities in-house, including a laser scribing machine, so that we can design and produce packaging with desirable options such as horizontal line laser scribing for easy-open packages.” Bak Ambalaj is increasingly active in the pet foods, frozen food, health care, hygienic products packaging sector, which represent an important part of its future growth strategy. Mr Yildiz concluded, “We are always keen to stay one step ahead, both of the competition and of our customers’ demands. Our short-term aim is to utilise our extensive production capacity, which we are well on track to do. Our longer-term aim is to increase our footprint in all the major European countries, with a clear focus on our core business of flexible food packaging. We will also continue to expand our pet food packaging activities and will boost our profile in the frozen food packaging sector too. It’s all about increasing our visibility to major brands that will appreciate and benefit from our European mentality and Turkish cost advantage. To further keep our high reputation, and to provide innovative solutions while considering the Total Cost of Ownership of our customers, Bak Ambalaj will continue with investments to increase its 1.2 billion sqm of capacity and its product development capabilities. All these backs up our guiding idea: ‘think flexible!’” Visit: www.bakambalaj.com.tr

Cerutti The long term relationship between Bak Ambalaj and Cerutti Group has been consolidated two years ago with the installation - at Bak-2 production plant, Izmir - of an innovative rotogravure printing machine Cerutti model R984, featuring the most advanced technical solutions and able to produce at very high speed with in-line lamination and in-line water-based cold seal application. The unique solutions adopted on this printing and converting line gave to Bak Ambalaj the possibility to compete among the most important European converters of flexible materials; at the same time, Cerutti has confirmed to be one of the most recognized and well-know manufacturer of printing and converting lines for this industry.

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ALPMA – Quick change, hygienic design More efficient production with consistently high quality: at this year’s FachPack, ALPMA will be showing you how, with the CUT 32 cutting machine. Visit ALPMA in Hall 1, Booth 229, and find out for yourself.

ou will find the seal of efficiency on all ALPMA machines and plants where the two time sinks changeover and cleaning time have been eliminated. These include, for example, our MultiSAN folded packaging plant. It offers maximum flexibility with regard to shape, format and consistency – despite the dimensional tolerances of natural products. The packaging material can be selected as required, too. A modern touch panel ensures simple and state-of-the-art handling.

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The same applies to the CUT 32 cutting machine. Thanks to its cutting-edge measuring technology, sturdy and hygienic design and regulation and control using the very latest servo technology, the CUT 32 delivers highly accurate cutting results. And in combination with the optional DS 32 density scanner, it can also produce fixed-weight Emmental portions. Yields can thus be improved by just under 20 per cent to almost 100 per cent. For more information, contact: fachpack@alpma.de

Cheese is ALPMA’s world. Dairies from all over the world use the technology and knowledge of the Bavarian company, ALPMA Alpenland Maschinenbau GmbH. ALPMA offers solutions to its customers for the preparation of raw milk, whey processing, cheese production as well as cutting and packaging technology for both hard and soft cheeses. ALPMA‘s products range from the mechanisation of partial processes up to large fully automated production lines. Since the founding of ALPMA in 1947, its developments have been practice-oriented solutions based on the needs of the customers. With approx. 700 highly-qualified and motivated employees within the group ALPMA supports its customers in making their cheese production and processing as efficient as possible.

ALPMA Alpenland Maschinenbau GmbH Alpenstrasse 39-43, 83543 Rott am Inn Tel: +49 8039 401-0 +49 8039 401-396 Email: info@alpma.de For more information: www.alpma.com

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Inspection technology visionaries: Optel Vision

Quebec-headquartered serialisation and aggregation solutions specialist Optel Vision is currently undergoing a phase of impressive growth and expansion. Louis Roy, president and founder of the company, tells Packaging Europe’s Tim Sykes about the strengths that are writing new chapters in this success story.

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ounded 25 years ago, Optel Vision has established itself as a leading global player and an innovation-driven engineering company in the serialisation and aggregation markets. To date, more than 250 packaging lines around the world have been successfully equipped with the company’s solutions. This trajectory of success is underpinned, according to president Louis Roy, by “a rigorous commitment to bringing superior value and service to customers. Optel Vision has developed thorough internal procedures and extensive employee training in order to accommodate the increasing demands in Track & Trace solutions.”

Rapid expansion Optel Vision’s substantial growth over recent years has alerted the market to a supplier that has established itself as a trusted leader, both locally and internationally in its field. Yet there is no sense that the company has reached a plateau. Currently counting some 350 employees, Optel Vision expects to employ a staff of around 500 by the end of 2015, as it expands its operations in Brazil and India. These developments build upon major investments in Europe and Canada. Last year Optel Vision established a new EMEA Office in Limerick, Ireland. “This expansion represents our first operation and engineering services outside of North America, as it moves to build up its presence in the European market,” explains Mr Roy. “New roles will be created over five years in engineering, design, assembly, testing, customer support, sales, HR, finance and other administration activities. This European expansion goal is to support our existing customers locally, while harnessing significant growth potential across EMEA.” This presence will be reinforced by the launch of demo centres at European market hotspots: as well as existing centres in Limerick and Brussels, a third, to be located in Germany, is in the pipeline.

After the opening of the Ireland facility last year, Optel Vision announced another expansion with a new 37,000 sq.ft. building in Quebec City. “The construction is already in progress,” reveals Mr Roy. “This new facility will double the manufacturing floor space and offices available in Quebec. This expansion was essential in order to meet demands without compromising our highest standards in terms of quality and timely delivery.”

Innovation culture Since its foundation in 1989, Optel Vision has been characterised by an ethos of consistent investment in R&D. “We have sought to foster a culture of innovation,” remarks Mr Roy. “Our ambition is to create ground-breaking successes by solving complex vision and automation challenges. This is backed up by aggressive R&D investment - exceeding ten million dollars within the last five years. The result is a range of vision inspection tools and serialisation solutions which define new standards.” One celebrated outcome of Optel Vision’s commitment to R&D is the revolutionary, unique inspection technology for tablets or gel capsules TabletProof™ 360°, which provides every single tablet or capsule with a 360 ̊ simultaneous inspection, at speeds of up to 120,000 products per hour. TabletProof™ 360° ensures every single tablet or capsule is inspected while maintaining product integrity and quality control. A precision ejection system allows each defective product to be discarded without interruption. Running at speeds of up to 2000 products per minute, TabletProof™ 360° reduces downtime and rework. This innovative solution uses Optel Vision’s camera and software combined with Aylward’s patented product handling technology. Moreover, it is supplemented with three additional features to enable a complete and precise inspection, namely: top and bottom inspection, unwrap image of the inspected products, and airwash for dusty products.

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In fact, the TabletProof™ 360° is just one of three major new products that have been launched in the past year and a half. Optel Vision’s Flying CartonTracker™, which was launched last year, is a flexible and compact carton serialisation solution with a completely new approach. The solution grips the carton from the top, since the Flying CartonTracker™ unit is inserted over an existing line without having to cut or modify the line layout. This stand-alone ultra-compact unit allows printing and inspection on both sides of the cartons with the ability to reject any single carton on the fly. The system can handle a wide range of carton sizes with speeds of up to 400 cartons per minute. The unit can be either mobile or fixed into position and can be integrated just after a cartoner or at the end of the production line. In addition, the system can be fed automatically or manually by operators. The Flying CartonTracker™ is part of Optel Vision’s TrackSafe™ solutions to address product authentication and traceability requirements in the pharmaceutical industry. Thirdly, launched in May 2015, the CountSafe™ with automated ejection is a system which meets a need in the pharmaceutical industry by reducing the risk of cross-contamination on a bottle filling line, thus reducing the risk of complaints and recalls. This highperformance, cost-effective inspection and rejection system provides electronic counter machines with superior inspection accuracy and efficiency. “Bringing this innovation to the market will be a relief for our customers, who will benefit from 100 per cent automatic ejection of bad products from their production line,” comments Mr Roy. “The inspection of our CountSafe™, combined with the accuracy of the ejector, guarantees 100 per cent rejection of default products, therefore avoiding rework from the operator.”

Optel’s vision As it looks to maintain its global growth, the business has clear sense of identity and purpose. “Our mission is to integrate technologies (such as automated vision and serialised systems), assuring the products safety of our customers and the sustainability of their

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business,” reveals Mr Roy. “Optel Vision is committed to meeting and exceeding the highest quality standards at each step of the business process in order to provide our customers with products that meet their needs.” In addition to professionalism of service and developing ground-breaking technologies, this means working with the best suppliers and partners across the industry. “Of course Optel Vision always collaborates with leading OEMs for packaging line equipment,” confirms Mr Roy. “We draw on extensive experience with many current packaging line equipment manufacturers, including Aylward, Bosch, Domino, Marchesini, Newman, NJM Packaging, IMA, Uhlmann, Videojet, and Weiler.” Meanwhile, Optel Vision is vigorously engaging with the market in the form of trade fair appearances, from major international shows such as Achema and last year’s Interpack, to the forthcoming FachPack show in Nürnberg, where it will be demonstrating the Flying CartonTracker™ in combination with its carton aggregation solution the PackStation™. “Of course we will have a team of experts at the booth to answer any questions related to vision inspection or pharmaceutical serialisation,” says Mr Roy. “Germany is a key territory for Optel Vision to develop and we have all the necessary resources to win a significant market share.” As market leader in North America, Optel Vision also has a consistent presence at the major exhibitions such as Interphex and PackExpo, where this year it will be showcasing a similar serialisation demonstration along with the CountSafe™ and TabletProof™ 360˚. Across all of these markets, Optel Vision’s expectations are bullish. Mr Roy concludes: “With our strong growth plan and our proven management processes, we forecast that we will have business and production sites all over the world in the next few years - and Optel Vision will be the global reference point for serialisation and inspection solutions.” Visit: www.optelvision.com

Retort Pouch

Barrier Lidding

Passion for Packaging Constantia Flexibles is a company with a long tradition in the flexible packaging industry. Elisabeth Skoda spoke to Stefan Grote, the company’s European vice-president for the food division, about what lies behind the company’s success in the food sector in particular. Packaging Europe | 75 |

Stefan Grote

Coffee Capsule Lidding Double Lid

Die Cut 2020; Soup Cubes

onstantia Flexibles has a very proud history centred aroundConstantia Teich, which was founded in Weinburg, around 100 km from Vienna, Austria, in 1912, and also Haendler & Natermann, which was founded in Hann. Münden (North East Germany) in 1825. These two companies are still part of what is now a leading flexible packaging provider in Europe thanks to its consistent and successful growth and acquisition strategy. Over the years, the company grew from a local to a European and now a global supplier of flexible packaging to the food, pharma and beverage industries. The company’s motto, ‘People, Passion, Packaging’ perfectly describes the company as it is today, as Mr Grote is proud to point out. “We have strong, international teams working passionately for the growth and success of our customers, and our motto drives the company forward.”

Returning customers

Global success

With its global leadership position in a number of product lines, Constantia Flexibles offers a wide range of products for the food industry, including cup sealing systems for yoghurts and dairy, wraparound labels for dairy, butter and cheese foils, confectionery packaging, sachets for soups, sauces and ready meals. In addition, Constantia Flexibles also has a strong market position in the area of coffee capsules and lightweight aluminium systems for pet and human foods. “People use Constantia Flexibles products every day, for example when they wake up in the morning they may be using a cereal packs, and then they consume snacks, yoghurts, packaged food products for dinner, feed their pets – Constantia Flexibles offers products for the entire day,” Mr Grote says.

Constantia Flexibles is active in three different business segments: food, pharma and labels. The Food Segment is divided in three regional divisions: Europe, North America and Emerging Markets. “Within Europe, the main production sites for the food sector are in Austria, Germany, Poland and Spain as well as Romania, France and Denmark. Apart from our production facilities, we also have sales offices in most European countries to be close to our customers. In total, we sell to 115 countries,” Mr Grotesays. Constantia Flexibles reported sales of €1.7 billion in 2014. The company headquarters are situated in Vienna, and about 60 per cent of the workforce is located in Europe.

Top Web Lidding

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Toppers

With its strong service culture, Constantia Flexibles wants to offer the best service and quality possible to the marketplace. “We are not just striving to provide the best service to our customers, but also to our stakeholders, investors, journalists and our own people. We are a very customer-focused organisation, and we are proud to offer extraordinary service,” Mr Grote explains. “We have 42 production facilities in 18 countries all over the globe, which provides us with a strong network, and we have long-term partnerships with our big clients. We have been working with many of our clients for decades,” Mr Grote adds.

Varied product range

Toppers

Alufoil Containers

Chewing Gum Innerwrapper

Focus on innovation

Catering for trends

In the food industry, the innovation cycle is very fast, so innovation has to be constantly worked on, as Mr Grote points out. “Innovation is in our DNA, and today we work with our customers on the products of tomorrow. We try to identify with our customers what the challenges are, and how to serve our customers with the packaging that fulfils their needs. R&D and innovation are extremely important to us.” In order to make this possible, Constantia Flexibles has two competence centres, one for aluminium foil and foil laminates, and one for films and film laminates. “Following heavy investment into the film and film laminate competence centre, it will be reopened in 2015,” Mr Grote points out. One example of a recent innovation is ReLap. Due to the combination of different technologies such as lasers, partial laminating, as well as the application of coatings, ReLap has enabled novel composite structures, which prevent contamination of the adhesive surface by the filling material. The result for consumers is fast, easy opening and resealing. Also, this technology requires no modifications to existing packaging machines at our customers. Constantia Flexibles is extremely pleased that ReLap has been nominated for the upcoming German Packaging Award 2015. In addition, DieCut 2020, is an optimal new generation of cup sealing systems with innovative co-extrusion and up to 50% less aluminum. In combination with UV flexo printing it is a solvent-free product.

Mr Grote identifies food safety and Urbanization as among the key industry trends Constantia Flexibles works hard to cater for. Urbanisation is an important factor in the developed markets. “People in urban areas are often living in one person households, which means a trend towards smaller pack sizes, for which flexible packaging is ideally suited.” From a packaging customer point of view, internationalisation is a big trend. “Our customers demand internationalisation. They want to have a global supplier and want to be served internationally. Many of the big food companies are based in Europe and US, but also want to be served in Africa, or Asia. We are currently in the process of acquiring the second largest flexible packaging company in South Africa to extend our global reach in this highly dynamic market, which is important for our customers,” Mr Grote says.

Growth opportunities Mr Grote is convinced that flexible packaging is an extraordinarily strong growth market and that Constantia Flexibles will maintain its excellent track record of steady growth seen in recent years, with extra impulses coming from the emerging markets. “We believe that flexible packaging offers a lot of positive features to manufacturers thanks to its low weight. It also allows machines to run faster and results in minimum n waste, which is an attractive cost proposition.” Visit: www.cflex.com

Sustainability Sustainability is one of Constantia Flexibles’s corporate values and it is embedded in the company’s annual report, where the environmental KPIs (e.g. the annual CO2 consumption) are also published. Sustainability efforts are focused on responsibility toward the environment and future generations, as Mr Grote explains. “We try to avoid all possible environmental risks, we try to use environmentally friendly materials in our products, and we aim at every opportunity to reduce our CO2 emissions and our impact on soil and water. We also implement appropriate measures to maximise utilisation of resources and environmentally friendly technologies.” “We try to optimise our use of materials and try to avoid waste in every aspect of what we do. We believe that future financial success is dependent on sustainable corporate practice. Since the Constantia Flexibles Group was founded, we have been committed to responsible economic, environmental and social policies. Mr Grote adds.

Feinschmecker Pouch

Rolled in Logo

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Leading the way in flexible packaging Bischof + Klein (B+K) is a leading European full-service supplier of flexible plastic and plastic laminate packaging and technical films, and is represented around the world by a strong network of sales offices.

+K GROUP employs a total of around 2400 staff at six production plants in Germany, France, the United Kingdom, Poland and Saudi Arabia. In 2014 the group’s annual turnover was around EUR 500 million. The family-owned company is oriented towards the principle of sustainability. Achieving balance between ecology, economy and the social needs of employees and society as a whole is a significant aspect of all corporate decisions. In 2014 Bischof + Klein was awarded the German Federal Government's CSR prize. The jury's judgement: "Bischof + Klein has been establishing itself as a whole in the CSR sector for a number of years and reveals a high level of innovativeness. The application of stringent environmental standards and the integration of environmental aspects into all areas of the company deserve particular emphasis."

and coating plus for extrusion lamination and coating. Highly developed conversion technology with product-specific facilities for sealed, welded and adhesive designs enable individual production according to customers' wishes. The company manufactures its CleanFlex® clean room packaging corresponding to clean room class 5 according to DIN EN ISO 14644-1 at rest in a separate production facility in Lengerich. Bischof + Klein identifies with its customers' efforts to achieve increased sustainability and regards itself as a partner in a continuous process. In close co-operation with customers, development engineers, application engineers and sales experts achieve progress, e.g. in terms of increased energy efficiency and sparing use of resources. Wall thickness optimisation and support in switching from multi-ply paper packaging or hard packaging to flexible plastic packaging are typical projects.

Innovative flexible solutions

Offering sustainable alternatives

Bischof + Klein's product range encompasses the entire range of flexible packaging: from traditional industrial packaging and consumer packaging to special films for technical applications. Industrial packaging from B+K is used worldwide. Customers include major players within the chemicals, agriculture and horticulture, construction and housing, high-purity products and foodstuffs industries. The product range encompasses open sacks and valve sacks, liners, shrink films, bale wrapping films, flat films, label films, stretch hood films, hazardous material packaging, FFS films and clean room packaging. In the consumer segment, B+K offers highly converted products for well known brand manufacturers in the agriculture and horticulture, construction and housing, hygiene, foodstuffs, pet food and detergents and cleaning materials industries. The product range includes mono films and laminates, U-Pack® product line side gusseted bags, block bottom bags, stand-up pouches, wicketed bags, envelopes, photographic paper packaging, Value-Packs, carrier packs and special pallet covers. Focus in the Technical Films division is placed on the production of surface protection films, technical laminates and films for lamination. The B+K GROUP manufactures its products using state-of-the art systems for mono/ co-extrusion, gravure/flexographic printing, solvent-based/solvent-free lamination

Stand up pouches with individual contours and formats from 50 ml to 10 litres are a sustainable alternative to conventional packaging solutions for foodstuffs. In contrast to hard plastic packaging (bottles or canisters), they consume significantly less material and are also more efficient in terms of transportation, storage and disposal. They are suitable for both foodstuffs and products from the hygiene or detergents and cleaning materials sectors. Bischof + Klein offers plastic peel films for capsule systems as sustainable alternatives to aluminium peel films. The barrier films offer outstanding sealing properties and enable simple punching or cutting out. They can be coated with various lacquers, e.g. matt lacquer. They also offer a significant advantage in comparison with aluminium peel films in terms of their tensile strength. The omission of aluminium also offers clear advantages in other application areas. Barrier films as bag-in-box inliners are ideal for liquid and paste products. Thanks to significantly reduced wall thicknesses, these individually developed laminates help to make sparing use of resources. At the same time, they also meet extreme requirements, e.g. in the case of acidic products or essential oils, and are easier to convert than conventional aluminium packaging solutions. FFS barrier films also score points as regards purity – an aspect of particular importance for milk products and juices.

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Catering for growing hygiene requirements With its two-ply, separable plastic packaging, Bischof + Klein is responding to the industry's increasing requirements on foodstuff packaging purity. This intelligent packaging solution has been developed for products with particular hygiene requirements pertaining to the packaging, such as highly-sensitive foodstuffs (powdered milk or food additives), pharmaceutical precursor products and special chemical products. Protective packaging protects the inner packaging throughout the entire transportation process and guarantees its cleanliness. It can be removed easily and without residues using the longitudinal seam. This system can be used for both FFS films and side gusseted sacks. The inner and outer layers can be individually dyed and printed to achieve effective advertising.

Awards and certifications Bischof + Klein’s success is underlined by the wide variety of certifications and decorations the company receives. Its clean room production facility is certified according to DIN EN ISO 15378 ‘Primary packaging materials for medicinal products’. Both German plants also offer a certified hygiene and quality management system in accordance with DIN EN ISO 15593 and 9001. Material combinations plus raw materials and recipes are approved by the FDA and BGA. B+K’s environmental management system is validated on the basis of the European environmental standard EMAS (Eco-Management and Audit Scheme). Each year, the company publishes a sustainability report in-line with the GRI (Global Reporting Initiative) with integrated environmental statement. In September 2014, Bischof + Klein was awarded the German Federal Government's CSR prize in the category ‘Companies with 500 – 4999 employees’ for its extensive commitment to sustainability.

As a particularly dedicated company, Bischof + Klein received a certificate for its constant commitment to environmental protection in November 2014. B+K's environmental management system was certified on the basis of the European "EMAS" Eco-Management and Audit Scheme for the first time back in 1996. This meant that Bischof + Klein was one of the industry's pioneers. Also in 2014 Bischof + Klein was presented with a ‘best new supplier’ award by American company Avery Dennison (AD). Bischof + Klein won the British Star Pack Award of Excellence 2013 as a partner in a project together with filler OTTO Cosmetic GmbH, British adhesive manufacturer BOSTIK Limited UK and plastic processor Pöppelmann GmbH & Co. KG.

Ongoing investments Bischof + Klein consistently invests in modernising and extending the capacity of its plants, particularly in Germany. Investments of around €27 million are planned in 2015. Of this, €21 million will be spent on modernising the film extrusion facilities and extending the consumer packaging conversion facilities at the two German plants. Construction of a fully-automated, temperature-controlled high-bay warehouse is also underway at B+K Konzell. The company will continue to grow, with Europe remaining Bischof + Klein's most important market, and can still see growth opportunities, especially in Eastern Europe. With its production plants in Europe, Bischof + Klein will continue to remain a leading full-service supplier in Europe in the future. Increasingly, acting on a global footing will also be required. With its strong global sales network, the company is ideally set up to achieve this. Visit: www.bk-international.com

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Dramatic savings Bischof + Klein presents sustainable packaging at the FachPack

odern plastic packaging solutions make sparing use of resources. A recent study by GVM (Gesellschaft für Verpackungsmarktforschung) has proved that the amount of material used today to produce plastic packaging is around one third less than in 1991. Three examples of this are being presented by packaging and film specialist Bischof + Klein at the FachPack trade fair.

SmartFlex® 20 μm The SmartFlex® 20 µm stretch hood film enables significant savings. With this high-performance and super thin film, Bischof + Klein intends to conquer the market for securing lightweight, mixed products on pallets. Conventional stretch hood films have a standard thickness of approx. 100 µm and are therefore economically unattractive for securing goods on pallets in certain market segments. With a significantly reduced wall thickness of 20 µm, SmartFlex® radically shifts the cost effectiveness calculation in the favour of stretch hood films and enables material savings of up to 39 percent in comparison with stretch wrapping films. The fundamentally higher performance of stretch hood film lines in comparison with stretch wrapping lines is further increased by SmartFlex® 20 µm, as the number of reel changes is reduced. Loads can be secured on 2,500 pallets with one reel. In contrast to stretch wrapping technology, loads secured on pallets using hoods are per se protected on all sides and at the top from dust and moisture. The risk of theft is also successfully averted. Tampering with the film hood is immediately noticed.

Value Pack. Bischof + Klein has also achieved a quantum leap in terms of material efficiency with its new Value Pack. The large-format PE wicketed bag with handle is suitable for packaging large quantities of hygiene products such as paper tissues or toilet paper as used in hospitals or industrial enterprises, etc. The film has a wall thickness of 60 µm. Its maximum filled weight is 7.5 kilogrammes. Cardboard packaging for a filled weight of approx. seven kilogrammes weighs around 600 grammes. A comparable PE wicketed bag only weighs 81 grammes. This also equates | 80 | Packaging Europe

to lower transportation costs. This effect is enhanced due, for example, to the fact that the capacity of a Value Pack for paper tissues is around 15 percent higher. Easier handling thanks to the carrying handle offers an additional advantage.

Twister Plus In close co-operation with a customer, the packaging and film specialist developed a new design for wicketed bags for tissue products. The newly designed “Twister Plus” wicketed bag for tissue products necessitates around seven percent less material and requires significantly less effort for manufacturing. This involves reverse-printed hygiene packaging with a handle and easy opening function. The PE film for the “Twister Plus” can now be selected 10 µm thinner, for example. No additional label is required for the handle area. Thanks to the switch from first printing to reverse printing, an entire operation step is omitted. The quality of the printed image is improved at the same time. “For our customers, minimising the use of packaging is an important part of sustainable corporate management. Economy and sparing use of resources - these are our standards!”, explains Andreas Stöber, head of sales for the hygiene sector at Bischof + Klein. “We use our development and sales departments’ know-how and state-of-the-art technology to achieve this.” Based on an order volume of 10 million units per year, the new wicketed bag enables over 14 tonnes of material – primarily polyethylene, but also lacquer – to be saved. Andreas Stöber: “Bischof + Klein is of course also using the information and experience acquired from this project in the further development and production of sustainable packaging solutions.”

New Record Level Bischof + Klein increased its sales by more than seven percent to the new record level of 534 million euros in 2014. This growth rate, which is higher than the industry average, contains no growth through acquisition. In 2014, the B+K-GROUP employed a total of around 2,500 staff, with approx. 1,300 at its headquarters in Lengerich and around. 700 at B+K Konzell in Bavaria.

“Bischof + Klein has invested sustainably and successfully in recent years”, explained managing director Dr. Volker Pfennig. Together with managing director Gerd Sundermann, he recently reported on the successful course of the 2014 financial year to journalists. The family-owned company will maintain its rate of investment, and is again scheduled to spend around 30 million euros on expanding and modernising its European plants in 2015. In addition to infrastructure measures and implementation of the 2020 energy concept, focus will be placed on modernising and expanding production facilities at both of the German plants. In Lengerich, this includes extending the production area in the clean room facility as well as investing in extrusion, printing and conversion capacities. Amongst other projects, a fully-automated high-bay warehouse with space for storing 1,700 pallets has been completed in Konzell. With the extension of the extrusion and printing departments and with the installation of the fourth flexographic printing press respectively, the subsidiary companies in Poland and the United Kingdom are also growing. With its three divisions, Industrial and Consumer Packaging plus Technical Films, Bischof + Klein succeeded in extending its position as one of the leading full-service suppliers in Europe against the backdrop of a European market with relatively low growth rates, high price pressure and increasing competition from Eastern and Southern Europe. For example, Bischof + Klein succeeded in increasing unit sales of U-Pack® side gusseted bags for pet food in Europe and the USA and establishing itself with SmartFlex® stretch hood films in Australia. “One of the highlights of the 2014 financial year was certainly the award of the German Federal Government’s CSR prize”, said managing director Gerd Sundermann. This confirmation of sustainable management at an economic, ecological and social level provides new impetus for further commitment.

The Company The B+K-GROUP is a leading European full-service supplier of flexible plastic and laminate packaging and technical films, and is represented around the world by a strong network of sales offices. B+K employs a total of around 2,500 staff at six production plants in Germany, France, the United Kingdom, Poland and Saudi Arabia. Some 1,300 employees currently work at the headquarters in Lengerich, with approximately 700 workers employed at B+K Konzell in the Bavarian Forest.

Products Bischof + Klein’s product range encompasses the entire range of flexible packaging – from traditional industrial packaging and consumer packaging to special films for technical applications – from 2-gramme portion packaging to flexible liquid liners for 1,200 litres. Industrial packaging from B+K is used world-wide. Its customers include major players within the chemicals, agriculture and horticulture, construction and housing, highpurity products and foodstuffs industries. The product range encompasses open sacks and valve sacks, liners, shrink films, bale wrapping films, flat films, label films, stretch hood films, hazardous material packaging, FFS films and clean room packaging. In the consumer segment, B+K offers highly-converted products for well-known brand manufacturers in the agriculture and horticulture, construction and housing, hygiene, foodstuffs, pet food and detergents and cleaning materials industries. The product range includes mono films and laminates, U-Pack®s, block bottom bags, stand-up pouches, wicketed bags, envelopes, photographic paper packaging, Value-Packs, carrier packs and special pallet covers. Focus in the Technical Films division is placed on the production of surface protection films, technical laminates and films for lamination.

Machinery The B+K-GROUP manufactures its products using state-of-the art systems for mono/coextrusion, gravure/flexographic printing, solvent-based/solvent-free lamination and coating plus for extrusion lamination and coating. Highly-developed conversion technology with product-specific facilities for sealed, welded and adhesive designs enable individual production according to customers’ wishes. B+K Lengerich, at which all processes for manufacturing flexible packaging are bundled under one roof, may well be globally unique. Technicians and development engineers have access to a unique range of production opportunities here. Packaging for high-purity products is manufactured under clean room conditions in a separate production facility. Visit: www.bk-international.com Packaging Europe | 81 |

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Innovative solutions

for transport and storage

As a specialist and pioneer in plastic reusable transport packaging, KTP Kunststoff Palettentechnik GmbH has been a leading container manufacturer since 1988. Elisabeth Skoda spoke to Andreas Wintrich, the company’s managing director, to find out more about its role at the forefront of developing reusable transport packaging.

TP develops, produces and markets foldable, reusable transport containers made of plastic for large-volume and sensitive goods as well as plastic pallets and containers in all common European, US and sea container dimensions for overseas shipping. Mr. Wintrich is proud of the fact that KTP with its 120 employees is still family run.“When KTP was founded by my father, the aim already was to manufacture reusable transport packaging out of secondary raw materials. At the time, this kind of packaging did not exist, so KTP was at the forefront of developments. An innovative press process with open moulds was used to develop a reusable carrier.” The company faced challenging times to convince companies that reusable carriers were the way forward, but with the advent of the new millennium, focus on the supply chain increased, with the automotive industry as a major driver. “In 2000, we gained the interest of Volkswagen. The company transported their goods on single use steel carriers, and their logistics manager was excited about our lower weight options. Previously, a packed item maybe weighed 50 kilograms, but the carrier weighed 250 kg. Our carriers offer a much better balance.” Together with VW, KTP went on to develop a wide product portfolio of containers in different sizes,catering for the trend of moving away from heavy steel containers to load carriers that make more ergonomical sense. Business has grown considerably over the years, as Mr Wintrich is happy to report. “At the beginning, we manufactured 3000 containers a month, today we manufacture almost 3000 containers a day.”

Business with Volkswagen still makes up around 15 per cent to 20 per cent of turnover, but KTP has been keen to spread its wings and widen its customer base. “Apart from other automotive companies, we also work with white good suppliers,” Mr Wintrich adds.

Solution provider KTP does not just manufacture plastic load carriers and pallets, but also offers consulting services. “We see ourselves as a solution provider - our aim is offer the expertise to package parts and send them from A to B over long distances. We gathered valuable experience by working with the automotive industry, not just in the field of containers, but also of interior packaging. We advise our customers on when reusable containers make sense and calculate economic efficiency. KTP gives customers advice, develops solutions, optimises them and does so in a sustainable way,“ Mr Wintrich says.

Innovation KTP keeps developing and moving forward. “We have continuously been growing and developing new containers. We were hit quite hard by the financial crisis in 2008, but we made use of its challenges by increasing efficiency and expanding our portfolio. One of the resulting innovations is our SmartFix® container,” Mr Wintrich points out. The SmartFix® is a returnable plastic transport container with an innovative sandwich folding technology, with components that are tightly connected with Packaging Europe | 87 |

each other. Thanks to this folding technology, a volume reduction by up to 80 per cent can be achieved when the containers are empty. The SmartFix® folding technology guarantees fast setting up and folding, as all components are linked up to each other. Following the financial crisis, KTP was able to increase capacity by 15 to 20 per cent every year, thanks to expanding production and flexibility in supplying the European market. KTP regularly exhibits at trade fairs, showcasing its latest solutions. Major trade fairs coming up include Fachpack in Nuremberg in Germany and Scanpack in Gothenburg in Sweden. “Customers include major OEMs such as BMW, Audi, Fiat, Ford, Peugeot, Porsche and VW as well as Miele and Bosch-Siemens domestic appliances,” Mr Wintrich says.

International reach In order to be closer to customers expanding in the Far East, in 2013 the decision was made to open a distribution and logistics site in China, in Taicang, which is situated around 50km east of Shanghai, in order to be closer to customers who are expanding in the Far East. Taicang already boasts 200 representations of German companies. Together with another German company, KTP rented a storage hall in order to make transport boxes made in Germany directly on site, which serves as a point of contact for Chinese customers. The next step will be the opening of a new production site, as Mr Wintrich explains. “The opening ceremony took place on March 25th with around 120 people. We are watching developments on the Chinese market very closely, and expect it to continue to be positive. Once we have reached a certain volume we will consider whether to increase production and value chain depth.”

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Other interesting markets for KTP include South America. “We deliver to Fiat in Italy, and this automatically leads us to South America, just as we arrived in China via Volkswagen. North and South America are definitely expandable markets, and depending on business volume and market sustainability we will decide whether to open a storage facility with a distribution office there, and whether to start production in a second step,” Mr Wintrich says. He sees great growth potential for KTP, especially in the automotive industry, because of the high volume of products being transported. “There are still many steel load carriers and single use carriers out there that can be replaced by our products. For example, KTP’s Super Quad Box, which is suitable for high-rack warehouses, is not only compatible with wire-mesh boxes, but is the perfect alternative to them. The Super Quad Box can be used in conjunction with already available inner packaging. According to estimates, there are 24 million wiremesh boxes out in circulation in Europe, giving us ample potential for replacement.”

Room for growth Mr Wintrich sees growth potential in various regions in an increasingly globalised world. “As a medium sized company, we pick out the markets with the biggest promise of potential. We see great potential for volume in China, and North/ South America. We also believe in Europe as a market with potential in the substitution business.” He looks towards the future with confidence. “We have many exciting products in the pipeline and are always working on smaller innovations. We will keep working on expanding our product portfolio of solutions around logistics, and are confident that logistics solutions will continue to keep playing a big part in the future,” he concludes. Visit: www.ktp-online.de

COMMITTED

TO KNOWLEDGE Jindal Films, a leader in the production of specialty biaxially oriented polypropylene films (BOPP or OPP), is building on a track record of innovation with an excellent portfolio of first-rate products supported by leading technology and R&D. Vanja Švačko reports on the most important milestones in the company’s growth and its strong international footprint.

he success story started in the 1970s with the launch of the Films Division. In the course of next few decades it grew into a large enterprise, gradually expanding its business from Europe to North America, integrating orientation and coating lines, as well as metallisers. In 2013 the company was acquired by Jindal Poly Films, involving the acquisition of two production sites in the USA (Georgia and Oklahoma) and three in Europe (Netherlands, Belgium and Italy). Jindal Films’ headquarters are in two locations – in Windhof (Luxembourg) and Macedon (NY, USA) – and it supports customers all over the world from its many sales offices. The majority of Jindal Films’ sales are in the greater European region and in North America, but the company also has a strong focus on the Asia Pacific markets.

The company’s management takes its environmental responsibilities very seriously. It implements advanced technologies which enable the development of sustainable flexible packaging and labelling solutions through low weight, low waste and low energy use. The company also improves the sustainability and efficiency of manufacturing facilities with energy efficiency, waste prevention and recycling.

Brand positioning Jindal Films’ portfolio encompasses a wide range of products for the flexible packaging and labelling market segments. Its unique offering includes transparent, white or metallised water based coated OPP that guarantees robust barrier,

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sealing, printability and machine performances typically aimed at simplifying the packaging structures. Last year the company celebrated the 30th anniversary of an important milestone – the successful integration of the OPPalyte brand into the confectionery and bakery industries. The unique cavitation technology enabled the production of a wide range of white opaque films with various densities. The company also offers transparent Bicor films (coated or uncoated, glossy or matt) for use as monoweb or in lamination; Metallyte films (white, coated, ultrahigh barrier) and Label-Lyte films tailored to the specific requirements of the reelfed, cut & stack and pressure sensitive adhesive label markets. The latter one opened a new window of opportunity for Jindal Films, enabling the company to enter the health, beauty and beverages industries.

The ultimate business drive Speaking about the importance of R&D at Jindal Films, market development team manager Nathalie Lesieu emphasises it as the key element in the company’s films strategy. “Over the past couple of years, we have been focused on innovation and introduced several new products to the market. One of them is Bicor 50SUP490, which replaces thicker blown or cast PE or PP sealant films and provides significant improvements in terms of clarity, stiffness, moisture barrier and tear propagation. “The others include Metallyte clear 30MM688 and white 40MM648, which replace laminates for high speed HFFS applications in the biscuit & bakery, confectionery and home and personal care segments. Label-Lyte clear 52LLC210 | 90 | Packaging Europe

and white LLC247 conformable films replace much thicker PE film in no labellook applications.” These ground-breaking products were introduced at Interpack 2014. Moving forward, Jindal Films is committed to new product development and continues to innovate. Mrs Lesieu talks about the next steps for the company: “At IpackIma 2015 in Milano we will introduce Metallyte 15 and 20MM398, which use a new heat sealant technology platform with improved heat seal performance when laminated to thin OPP or PET outer webs. MM398 has a great moisture barrier and greatly improved seal integrity over standard metallised OPP film offerings, providing brand owners with an opportunity to improve the shelf life by reducing pack leak rates in various HFFS segments, such as biscuit & bakery, sweet confectionery and home & personal care. “Metallyte 28 MH 388-ES, a multi-layer, cavitated white, metallised OPP film with an enhanced heat sealable layer which provides very high seal strength, is a new high barrier film that has a great moisture and gas barrier and should be used in lamination with paper, PET or OPP outer webs. It has been designed specifically to replace barrier (e.g. aluminium foil or a metallised film) and sealant webs to simplify packaging structures for flat pouches or sachets. “Together with them we will introduce more products: OPPalyte 30, 35 and 40MH347 combine a very broad seal range (VBSR) with tailored slip properties, offering a robust single web solution on high speed horizontal packaging machines with optimal output, reduced downtime and waste. OPPalyte 20MD347, the thinnest white cavitated BOPP film currently on the market, offers a very high yield white opaque solution for lamination and use on horizontal, vertical and overwrapping packaging machines. Thanks to its high yield, broad seal range and slip controlled feature, 20MD347 is a unique cost-competitive alternative to plain solid white BOPP films with a reduced environmental footprint.”

When asked about the company’s strategy for achieving its growth targets in the near future, executive vice-president of Jindal Films Europe and Asia Pacific Paul Griffith confirmed, “R&D is the fuel to our past and future growth. Jindal Films is committed to new product development and we will continue to put a strong emphasis on this as we seek to find solutions for our customers’ packaging requirements.” Visit: www.jindalfilms.com

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Stretch wrapping

machines from Finland Haloila is one of the world’s leading manufacturers of fully automatic pallet-wrapping machines. Marco Siebel spoke with global sales manager Jyri Lehtio about the company’s upcoming introduction at the FachPack 2015 exhibition in Nuremberg, Germany, and about the latest model within its Octopus stretch wrapping machine series, the new Octopus GP.

aloila’s factories are located in Masku, Finland (producing fully automatic wrapping machines) and Kardjali, Bulgaria (producing semi-automatic wrapping machines). In Germany, the Haloila office is located in Neunkirchen/ Siegen. The company is part of the international Signode Industrial Group which is a leading manufacturer of industrial packaging products. Signode Industrial Group operates in six continents and employs nearly 7000 people. Haloila’s sister companies, Muller LCS and Mima Films, specialise in material technology and the manufacturing of stretch films. The company also provides design, implementation, maintenance, modernisation, spare parts and automated monitoring services for its machines; and wrapping materials and customisable packaging solutions for the pallet transport packaging needs of various companies. It serves customers in the paper, construction, chemical, food and dairy, beverage, logistics and other industries. Haloila was founded in 1972. The first rotary stretch wrapping machines were manufactured in 1976, and in 1983 it introduced the first fully automatic Octopus wrapping machine. Illinois Tool Works Inc. (ITW) purchased Haloila in 1995, and in 2014 it became part of the Signode Industrial Group.

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Global sales manager Jyri Lehtio said: “Since Germany is our biggest export market, together with the other German speaking countries Austria and Switzerland, the FachPack exhibition is the most important one for Haloila. Here we will introduce our new Octopus GP model, which was introduced earlier in 2015 and has been very well received. The new Octopus GP represents innovative out-of-the-box thinking, in a new way that customers have not seen since the introduction of the first ring machine ever made, the Haloila Octopus. It’s too early to estimate a detailed turnover, but based on our historical success and current presence in Germany, our expectations are high. “

Octopus ring technology The world’s first stretch wrapper utilising ring technology – the Octopus – was developed more than 30 years ago by Haloila, in 1983, and it revolutionised the packaging industry. Jyri Lehtio: “The first Octopus machines manufactured for the export markets were shipped to Austria and Sweden. Germany has been the most significant export market over the course of the Octopus machine’s 32-year history. Europe is still a key market for Haloila, but Asia, Africa and the Americas have also become important export markets. The company’s largest growth markets are the BRICS countries.”

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In 2014 Haloila welcomed its newest offspring to the Octopus family of stretch wrapping machines, and showed it to the world in Paris first, followed by Stuttgart and Barcelona. The official launch will be at FachPack in September 2015. Jyri Lehtio continued: “Over 90 per cent of Haloila’s turnover is derived from export sales. We began our quest for domination in the world market in the 1980s and are still on that path. One of our strong selling points is that our employees represent 12 different nationalities and, because it is part of the internationally operating Signode Industrial Group, Haloila’s extensive service network operates on five continents, in more than 60 countries around the world.”

Move into Turkey The Signode Industrial Group is a global supplier of packaging solutions, employing nearly 7000 packaging professionals around the world. Today Haloila itself has local sales & services representatives in 12 countries, with Turkey being the latest country in which it has a dedicated sales person for the Turkish market. Jyri Lehtio added: “Asia, North and South America are getting more and more important. The driving force is not only growth in economic terms: more important to us is the capability to service our global customers locally, regardless of their production location. I see the future very positively; I am excited by the fact that Haloila has become part of the Signode Industrial Group, which offers us great opportunities to cover different packaging needs with a wide range of products and services.”

WrapBOX, LogoWRAP™ and OctoMAX™ Recently Haloila has introduced a new concept in end-of-line pallet wrapping – the WrapBOX. The WrapBOX offers all the benefits of the Octopus ring technology, but is used where automatic turntable wrappers and rotary arm wrappers would typically be used – i.e. low capacity lines, with between 10 and 40 pallets per hour. Jyri Lehtio: “This kind of product has not been seen on markets before. We are continuously bringing new innovations to market. We develop custom-made solutions dedicated for various industrial segments, such as the LogoWRAP™ machines for the construction industry. There are of course also solutions that can be used across industry sectors, such as the OctoMAX™ data acquisition system.” OctoMAX™ is an automated real-time monitoring service for Octopus wrapping machines, which improves their reliability and cost efficiency. Through reporting, it is possible to develop regulating measures to maintain or even improve production and cost efficiency.

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Jyri Lehtio concluded: “The OctoMAX™ data collection and reporting system is a service product that provides valuable information on the usage of Octopus machines. Combined with proactive maintenance and consulting, the data collection and reporting system is an effective tool for improving operational efficiency, monitoring performance and driving down costs. In combination with our new model Octopus GP customers can reap the benefits with the shortest time to reach ROI they can imagine.” Visit: www.haloila.com

Upward spiral Boehl is the global industry leader in vertical stretch-wrap packaging equipment with over 90 years’ experience in designing and manufacturing spiral stretch-wrap packaging machines. Philip Yorke talked to Robert van Veen, the company’s business unit manager, about its latest automated technology and turnkey solutions.

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Boehl was founded in Huckeswagen, Germany in 1925 where it manufactured the world’s first twist wrapping and packaging machines. Since it was founded, H. Boehl has registered many patents and today is the global industry leader in the design and production of high quality spiral wrap and packaging machines for a wide variety of manufacturing industries. The company produces its state-of-the-art machinery and equipment at its production facilities in Hilden, Germany. These are characterised by their high-efficiency, low energy consumption, and short set-up times. Cutting-edge Boehl technology is combined with high quality German engineering to guarantee the most cost-efficient outcomes for its customers.

Setting new standards Throughout its long history, Boehl has pioneered the technology that has moved wrapping forward. The latest examples are no exception and its BSA/BSB machine lines set new standards for packaging long-shaped products by spiral wrapping. Starting with the semi-automatic BSA, up to the modular designed BSB-SX version and the fully automatic BSB-VA model, they cover a wide range of applications for differing customer

requirements. In addition, all automatic machines of the latest series can be delivered to a maximum diameter of 1200mm. Van Veen said, “Our technology is second to none and our customers know they are getting the best possible products to match their needs. They come to us for turnkey solutions and not just for one competency. This sector of demanding engineering services is a speciality of ours at Boehl, where we are a long-term, highly qualified partner for many industrial areas. We support our customers from initial planning all the way through project completion and a full after sales system covering spare parts and various maintenance services for the equipment. Our customers know what they are getting and can rely on our technology and high quality standards. Our main focus is on further expanding our international presence through partnerships in Europe but also overseas. As part of this strategy Boehl setup a strong partnership in the USA through which further expansion is achieved. Our successes in key industries such as furniture, wire, metal service centres and wood show that the planned growth for the years to come is very realistic. Amongst our key customers are some prominent customer brands. “We belong to SIG (Signode Industrial Group) where Boehl is a major brand and this gives us a lot more depth and financial strength than many of our competitors. We also have our own R&D department, which utilises the latest 3D software. As a result of our ground-breaking technology, we can save over 90 per cent of energy with our latest spiral-wrapping systems compared to heat-shrinking systems of competition. Innovation is a major part of our strategy. In this respect it is worth mentioning that for our second product line, banding, we are one of the very first packaging companies to apply bands in direct contact with perishable items such as fruits and meats. Our focus today is now very much centred upon the needs of the end user in this sector.”

Unique spiral wrapping and banding solutions As the industry leader in high quality spiral wrapping and banding machines, Boehl is able to offer unrivalled expertise in its ability to provide optimised, tailor-made solutions. Boehl wrapping machines are used worldwide to package products in a wide variety of industrial applications. These include steel wire, slit coils, pipes & profiles, timber, | 96 | Packaging Europe

furniture, building products and plastic profiles. The function of the vertical wrapping process is to secure and stabilise products and loads. In addition, through its range of banding machines, Boehl provides bespoke solutions for the food manufacturing industry in Germany, such as bakeries, meat producers and fruiterers, as well as other industries like pharmaceuticals, cosmetics and healthcare. All banding machines apply a plastic or paper band around the product for the purpose of product marketing, production information and theft prevention. Boehl’s individual product bands can be printed in-line as an integral part of the production and packaging process and allows for applying a variety of product codings and other information. In this business segment product appearance is of high importance and this is exactly where Boehl provides support. Together with their customers new bands are designed and finally tested to assure a professional product appearance combined with efficient operation. Boehl provides their customers with a variety of wrapping films and bands. “We have been working closely together with suppliers of films and bands for many years who often assist us on developing the right products for our customers.

Environmentally friendly systems Boehl believes that businesses like consumers, must act responsibly to help make the world a safer, cleaner and more environmentally friendly place. This means carefully evaluating how its products are used, manufactured and disposed of, and utilising those methods and products to preserve resources, energy and the environment. Just a few metres of Boel plastic wrapping is able to replace bulky containers, cartons, bags, stuffing, styrofoam and other packaging materials. The company routinely re-designs its own packaging systems to use the least amount of packaging material for each shipment. A fine example of this approach is a wrapping system where a combination of wrapping film and cardboard are used to secure high value components such as touch screens or auxiliary car heating systems. The TVP wrapper automatically secures the product to a cardboard tray which is placed in a card board box. This solution serves a steady growing market where companies are looking for the optimum in protecting their products combined with low packaging cost. With this approach Boehl is making their contribution towards a cleaner environtment. For further details of Boehl’s unique wrapping and banding systems visit: www.boehl-einwickeln.de and www.boehl-banderolieren.de

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Truly environmentally sustainable Not many companies can claim to offer truly sustainable products. SCA Sustainable Packaging can, as Johan Malker, product manager Sustainable Packaging, and Mattias Wikström, sales and marketing vice-president Sustainable Packaging, explain to Barbara Rossi.

CA Sustainable Packaging is part of the Stockholm-headquartered SCA Group, a leading global hygiene and forest product player. Specifically, it is part of SCA Forest Products, which is one of the SCA business units. SCA Sustainable Packaging was launched one and a half years ago and is a result of the combined experience of SCA Packaging and SCA’s publication paper operations. The product area´s core offer consists of a range of new packaging paper for lightweight packaging applications under the two main product families Solo Print and Puro Performance. While Puro Performance has been offered by SCA since the very beginning, Solo Print was launched in November 2014. Mr Malker explains, “Solo Print is a one-side coated paper. It was specifically developed for flexible packaging applications and is well suited for wrapping paper, banners and for laminating with PE/PP for flow packs. Solo Print offers unique opacity and very good printability.

“Puro Performance is an uncoated paper and an alternative to MG/MF papers where high opacity and good print are desirable characteristics. Typical applications are lightweight bags, wrapping paper and banners. It is also used in lightweight board.” R&D is very important to the company’s success and SCA is equipped with an extensive R&D centre, where it is continuously upgrading and developing its products. Some product news will be announced later this year.

Largest private forest owner in Europe Mr Wikström says, “We are Europe’s largest private forest owner with 2.6 million hectares of forest land, located in northern Sweden. Our paper mill, SCA Ortviken, where the Sustainable Packaging range is produced, is also based here. All our products are entirely made from fresh fibres from this area. They are BFR certified for use in food applications, as well as featuring the FSC and PEFC certification.

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“This set-up allows us to control the entire value chain, from the tree nursery to the finished paper at SCA Ortviken. We grow and plant 100 million seedlings (for every tree harvested, we put three new ones in its place) every year. The forest growth exceeds fellings by a good margin and forests with high nature qualities are altogether set aside from harvesting in order to preserve biodiversity. A sustainable forest management and mill operation is an integral part of SCA. Environmental sustainability has become a bit of a buzzword and is claimed by many companies. However, there aren’t many players out there who can claim to be fully sustainable. Thanks to our forest, location and vertical organisation, we can. Sustainability is at the heart of what we do. Furthermore, the SCA Ortviken paper mill, where sustainable packaging is produced, has a 900,000-tonne paper production capacity. This,

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alongside the efficiency of our mill operation and the effective use of our forest, makes us a very competitive and sustainable lightweight packaging paper supplier,” adds Mr Malker. SCA Sustainable Packaging supplies its lightweight packaging paper to converters in the flexible packaging segment. Geographically, its main market is Europe as a whole, although it also serves customers in other continents, such as Asia. In the near future the geographical focus will remain on Europe. The company is going to exhibit its product range, Solo Print and Puro Performance, at FachPack 2015 (Hall 7A/7A - 636). Visit: www.sca.com

Boxing clever Recycling company Purus Plastics GmbH offers a unique take on high quality plastic industrial and display pallets. Emma-Jane Batey spoke to marketing director Thorsten Zillman to learn how its environmentally aware solutions are appreciated by an ever-growing audience.

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ounded in Germany in 1994, Purus Plastics GmbH is dedicated to conserving a raw material that is much in demand. Its core business is to process used plastic into new products for new purposes, taking production waste from the plastics processing industry and used packaging from both commercial sources and domestic collection points. The company’s strict quality management system enables it to ensure that all its products and services are of the highest European standards, allowing for the Purus Plastics name to represent the very best in recycled plastic pallets. Marketing director Thorsten Zillman spoke to Packaging Europe to explain more about the Purus Plastics philosophy. He said, “Purus is all about quality, not quantity. All our products bear the ‘Made in Germany’ stamp; because we use high quality plastic granulate, we are proud to offer our customers environmentally-aware and affordable premium products like our plastic pallets.”

Green solutions Focused on developing and providing green solutions, the Purus plastic granulate products utilise the company’s many years of experience and technical know-how. Mr Zillman continued, “We pour all our knowledge into our processes and products on a daily basis. We have the most incredible ultra-modern, in-house production facilities that have recently been extended, which means that we are future-ready when it comes to recycled plastic pallet production.”

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The Purus portfolio is certainly in tune with both today’s and tomorrow’s demands for ecologically-responsible transportation across industry sectors. Mr Zillman said, “With today’s modern logistics landscape it is imperative that every aspect is optimised down to the very last detail, which of course places enormous demands on all the packaging materials used. Cargo must be as light as possible whilst remaining totally stable, resistant to dirt, oils, greases and acidic liquid – all while being easy to handle and affordable. Purus is able to meet that demand with our range of recycled plastic pallets.” Purus Plastics offers a pallet range in standard sizes from small 600x400mm lightweight display pallets up to large heavy-duty pallets for bulk handling applications of 1200x1000mm and various multi-trip pallets. It also develops a large number of custom solutions such as its pool pallets, which are often used in retail applications. The timeline of Purus Plastics highlights how its product portfolio has developed perfectly in tune with its customers’ changing needs – and often well in advance of market trends. Its carefully curated list is well matched to a broad range of industry sectors and transportation demands.

Strong and famous In 1995 Purus Plastics launched its now-famous ECORASTER injection moulded ground reinforcer. Known as a good all-rounder, the product is billed as ‘your top choice when it comes to the ground reinforcement of car parks, paths, green areas and outdoor riding arenas’. Available in a range of specialisms, such as the super-elastic grid, the universal grid and the indestructible grid, the ECORASTER and its range of accessories have a

number of benefits. Mr Zillman explained, “ECORASTER truly comes into its own where other systems are reaching their limits. It’s economical and environmentally sustainable, it allows for quick and effective installation, it has a safety interlocking safety system and is extremely strong. Furthermore, it has very low transport and handling costs as well as providing surface reinforcement without sealing. No wonder it’s our best-selling product!” Purus Plastics has invested in a series of expansions since its foundation in order to ensure that it maintains its market-leading and indeed market-defining position. Its recycling plant and its injection moulding plant have seen new state-of-the-art machines installed as well as further capacity. In 2011, the company saw sales of its ECORASTER reach 10,000,000m2.

Investing in growth In the past few years, Purus Plastics has seen the greatest single investment in its history, with €8.5million spent in 2011 to increase its recycling capacity in order to start the production of automotive parts, further expanding its portfolio. Mr Zillman added, “In

2013 we also completed the expansion of our shape injection moulding facility. We are totally equipped for new challenges and as such we are always on the look-out for new technology that will complement and enhance our existing offer. Our eco-friendly sites utilise biogas and solar energy too.” With Purus Plastics’ main geographical markets currently in central Europe, the company’s ambitious expansion plans also include territories further afield. Already present in over 29 countries worldwide, it aims to further penetrate the US and Middle East in the coming years. Mr Zillman concluded, “We already have a fixed five-year plan for new products and investments that also includes us working with new partners and customers across the US and Middle East as well as our traditionally strong markets throughout Europe. Our goal is to be one of the top manufacturers of pallets and boxes within the next ten years and we are well on our way to achieving this – in an environmentallysustainable manner of course!” Visit: www.purus-plastics.de

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A perfect fit Carré Karton BV, located in ‘s-Gravendeel, the Netherlands, was established in 1996 with the core focus of developing and introducing square fibre drums to the market. As the daughter company of ENR (Eerste Nederlandse Rondkartonnagefabriek) founded in 1930, which is a producer of round paper cores, round drums and reels, Carré Karton was a natural evolution for the company to introduce a different solution to a sector in which it already held over 70 years of experience. Libby White spoke with Rob Prins, European marketing manager, to find out about the success and benefits of the square fibre drum, and the company’s plans for further expansion.

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a rather unique solution, Mr Prins explains the difficulties of promoting the clear benefits of the square fibre drum to the marketplace. “If a company has been using the generic round drum for a long time (which have been present on the market since the 1930s), then it can be difficult to stand up and encourage switching to a square drum. People can be afraid of change, especially within one of our focus sectors, the pharmaceutical industry which is highly regulated. But the moment a company changes from round to square drums, they never look back.”

Market presence Carré Karton’s main focus is the pharmaceuticals industry, especially for APIs (active pharmaceutical ingredients). Mr Prins explains why their fibre drums are in demand for this sector: “As an example, the active pharmaceutical ingredients are filled into the drums in Ireland and then shipped globally where they can then be blistered by the local markets, conforming to local regulations.” The company also has a large number of customers in the agro-chemicals industry such as for the transportation of herbicides, pesticides and dangerous products. Carré Karton has achieved the highest UN approval for the transportation of dangerous goods, and holds esteemed customers such as Bayer which relies on Carré Karton’s square drums to transport its goods.

To expand its healthy customer base, Carré Karton has been present on the crucial exhibition circuit, and is a regular exhibitor at both Interpack, Dusseldorf and Fachpack, Nuremberg. 2015 will see the company for the first time at Scanpack held in Sweden. Mr Prins explains the reasoning behind this new move, “We will be attending as one of our competitors has closed their Swedish facility and transferred their production of round fibre drums to Denmark. There is currently no company producing round fibre drums in Sweden. We see this as a clear opportunity to promote the square fibre drum to this market, which we have received a number of enquiries from in the past.” Carré Karton will be showcasing its square fibre drums as well as discussing its latest developments. It has recently received a new UN marking on the square drum which allows it to make the walls thinner, giving cost and environmental savings to customers. Mr Prins adds, “In addition to this, we have also received a new UN certificate which ensures the customer is free to use any closure to seal the drums. Beforehand, a tape of 50 mm minimum wide was required to seal the cover to the drum body. Our larger customers have automatic machines for this process; however, this affected our smaller customers who needed more manual labour with the use of tape dispensers. This is revolutionary for us as it will now make the process of changing from round to square drums easier.”

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Logistical advantages Owing to their shape and design, square fibre drums give a long list of logistical advantages, as Mr Prins explains: “We solve space problems such as for companies that have a lack of room in their warehouses. Also for aspects such as internal transport, more square drums can fit on one pallet than round drums which can make a big difference overall.” Square fibre drums are also a safe solution. “On a pallet, round fibre drums only touch or connect at one or two points, whereas with square drums they are completely connected to one another. This makes it much more stable when they are stacked in a warehouse and increases safety on the pallet.” Round fibre drums are commonly used worldwide, however Mr Prins points out the advantages of swapping to square: “We were receiving a lot of enquiries from our customers asking us to address the loss of space between round fibre drums during transportation.” “Recently we helped a chemicals company based in Amsterdam to change from round to square fibre drums. Now, on a CP9 pallet, they can increase from five round drums to nine square drums.” After filling the drums in Amsterdam, these are loaded in containers and shipped to Brazil. The company calculated they can reduce their annual shipment by 60 containers as the amount of products in the containers is increased by 80 per cent on the same pallet capacity.

Environmental advantages The square fibre drums are made out of 100 per cent mono-material Kraftliner. In comparison, the conventional round fibre drum consists of different materials such as paper, plastic, metal and hardboard, which are hard to separate from each other and make it hard to recycle. The Carré Karton drum, however, can be recycled as a high-quality scrap.

Mr Prins is keen to point out that the Kraftliner comes directly from replanted trees, rather than from recycled paper. “This means that the fibres are long and when it comes to recycling. The paper industry loves this raw material which is of big value to them.” Another environmental advantage can be found in the transportation of the square drums, which have a much lower carbon footprint than the round fibre drum.

Investing in the future Carré Karton is growing from strength to strength, as shown by its latest investments. Last year, the company invested in a brand new production line at its facility in ‘sGravendeel for the manufacture of its square fibre drums, whilst also updating a second production line. Mr Prins comments, “Our old production lines are now being used by our partner company based in India. They can produce square fibre drums for our customers who have a presence on the Indian market, saving on shipping costs.” Carré Karton’s main regional markets are Germany, Ireland, the UK, France, Belgium, the Netherlands and Norway. In addition, it is present on both the Indian and Chinese markets. “We have the huge advantage of our location in the Netherlands as we are situated very close to the Rotterdam harbour, meaning we have brilliant transportation links for shipping our products,” Mr Prins says. He concludes, “We are looking towards continuous future growth. It is not always easy for customers to change to square immediately even if they see the huge savings, logistical and environmental potential this will bring. But we have a lot of interested companies who are figuring out this beneficial transition at the moment, and we look forward to meeting potential new customers at the upcoming Scanpack.” For more information, visit www.carrekarton.nl

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Case by case

know-how

Germany-based Gregor Hofbauer GmbH manufactures innovative, high quality industrial cases, transport and packaging solutions. Elisabeth Skoda spoke to the company’s sales director Rupert Englmaier to find out more about its product range and upcoming appearance at the Fachpack trade show.

The company serves a wide range of customers, from small-scale enterprises to large brands, and also supports its distribution partners as a components partner and supplier in the most important markets in Europe and beyond. “We have two production sites – one in Planegg, just outside Munich, and another one in Türkheim, 70km away from Munich, with a total of around 75 employees. Our products are mainly sold into Germany and Europe, but also overseas. We are proud of our dynamic team that works hard to provide solutions for German and international customers,” Mr Englmaier says.

Varied solutions

a family run company based in Munich, Hofbauer has had a long tradition in the manufacture of hardshell cases, starting in 1902 with cases made from wood and leather, and moving on to plastic 40 years ago. Today the company is proud to be one of the oldest plastic case manufacturers. Hofbauer’s unique proposition is the manufacture of plastic cases made both with injection moulding and extrusion blow moulding, and it is happy to be the only German manufacturer of extrusion blow moulded – double walled cases. | 108 | Packaging Europe

The company’s product offering comprises a wide range of standardised packaging solutions in the area of cases in different sizes and designs. Apart from providing a wide range of technical cases for varied industries, core markets include electronics, measuring equipment, medical devices as well as transport and logistics. Thanks to its flexible production, Hofbauer is able to provide a very small number of cases as well as high volume batches of tens of thousands of cases. “We have 16 different designs in at least eight different standard colours, more than 500 different sizes and out of these standardised containers we make an individual container for every customer. We offer good value standard containers with completely individualised foam inlays. In addition, individual printing of cases is possible,” Mr Englmaier explains. “We offer screen printing as standard, and also digital printing of case surfaces and plastics in photo quality.”

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Thanks to its expertise, Hofbauer is able to create individualised packaging solutions for its customers. “We offer our customers complete individual solutions. If a customer has parts he wants to package he can come to us, and we look after the entire packaging concept, the choice of case, size, quality, requirements and use, and of course we look after the interior and also print the case with a logo or grafics, depending on the customer’s wishes. We are able to fulfil even highly technical requirements for packaging,” Mr Englmaier adds.

Fachpack innovations Hofbauer will be exhibiting its case solutions at the upcoming Fachpack exhibition in Nuremberg in September 2015, showcasing new additions to its range of outdoor cases, the Explorer range. All Explorer cases are made to perform even in the most severe conditions, and are watertight, airtight, sand- and dust-proof, corrosion-proof, crush-proof and shock-proof and thereby virtually indestructible according the IP67 norm. A wide range of accessories allows for customisation of the interiors according to individual requirements. Another innovation showcased is the system-box, a transport and storage box for any circumstance. It is offered in over 400 standard sizes in eight colours, is stackable for optimum space utilisation in transport and storage, is extremely shock-proof and resistant to harsh temperatures and has a low empty weight. It is available in several versions, for example with wheels, handles, fastening, labelling or metal reinforcements. “The system-box is the ideal packaging system for demanding technical parts,” Mr Englmaier says.

Focus on double walled cases “Our focus in general is on double walled cases with a formable core and a customised interior wall as a stable, robust alternative to foam packaging, for example for medical or technical devices. This is one of our key USPs.”

Close to the customer As a German independent family run business, Hofbauer is not dependent on investors and has a high manufacturing competence and technical expertise. “All our products are made in house, and therefore are made in Germany. Our employees are highly skilled and therefore can advise and consult our customers very well.” | 110 | Packaging Europe

Hofbauer’s main market is situated in Germany, with an export share of about 30 per cent. A majority of export goes to neighbouring countries, but also overseas. “We recently entered a partnership with a Japanese trader, as we want to generally increase our export business and provide our solutions to international markets as well.” Mr Englmaier sees good potential for the company in the future. “We are well equipped thanks to our excellence in high quality technical packaging that we are well known for with our customers. We see big potential in the OEM business, as we are also able to develop and produce completely new cases for big companies and plan to focus our developments in that direction.” For more information: Gregor Hofbauer GmbH Behringstr.6, 82152 Planegg www.hofbauer.de

Global player in box lining solutions The family-owned manufacturing company Pattyn Packing Lines is proud of its unrivalled responsiveness and its growing portfolio that is perfectly in tune with its worldwide customers’ needs. Today the company exports to more than 65 countries worldwide. Food and non-food processing companies worldwide use Pattyn equipment daily to pack their bulk products automatically and efficiently into lined containers. Emma-Jane Batey spoke to CEO Stan Pattyn to learn more.

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stablished in Bruges in 1952 by Jean Pattyn, Pattyn Packing Lines has continued to grow and innovate ever since. Now managed by Stan Pattyn (the third generation of the Pattyn family to take over the firm) alongside his highly committed team, the company is as bright and active as ever. Today, the company employs over 200 people across its three sites (Belgium, France and the US) and is a reliable partner for over 800 customers. Pattyn Packing Lines operates throughout the world via carefully selected exclusive business partners. Right from the start, Pattyn Packing Lines has been focused on providing high quality and high reliability bulk lining (bag in box) solutions for its customers, with the first product developed being a fully automatic industrial weighing for confectionery. Its first fully automatic bag inserter followed in 1976, paving the way for its core business of box lining systems. CEO Stan Pattyn told Packaging Europe, “Ever since then we have continued to develop ever more forward-thinking box lining solutions. Today, over 90 per cent of our turnover comes from customers in the food processing industry.” Pattyn’s customers include both medium- and large-size companies as well as large groups with a global presence. Mr Pattyn continued, “The bulk packaging machines are used in many different industries, such as: nuts & dried fruits, frozen foods, edible oils & fats, tobacco, caps and food packaging – it’s a wide variety but the expertise required is similar. That’s why we use the strapline ‘Responsive Box Lining’ as it is that which is our USP.” “We are totally dedicated to being highly responsive to the market demands and across all aspects of our business, from the initial query to the final machine delivery and after-sales.”

Family passion for innovation & technology This responsiveness promise, together with the passion for innovation & technology, is a clear reflection of the Pattyn family’s dedication to maintaining a market leading position in an ever-changing field.

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Mr Pattyn added, “Our ultimate goal is to enhance our customers’ packaging processes and to reduce their running costs. We have a unique expertise and over 35 years of know-how in the packaging and weigh filling of bulk products into lined containers and as such provide a valuable contribution to our customers in optimising their packaging process.” In order to achieve this cross-company responsiveness, Pattyn Packing Lines is continually investing in the development of new technologies and has acquired something of a reputation as a trendsetter. Its R&D team is continuously working to improve its standard machines and to develop new packaging concepts, with all developments driven by the current and future needs of its customers. Mr Pattyn noted, “We do not falter from developing and delivering cost-effective packaging machines and complete lines from case erecting to case closing at the minimum running cost and maximum efficacy. Our customers benefit from having just one dedicated supplier taking full responsibility for their complete packing line, and with just one pivotal point of contact at Pattyn who is responsible for managing the project. It’s a personalised, local service that is perfectly in tune with the customer and their actual day to day requirements – both for today and for tomorrow.” Mr Pattyn explained how the company’s product portfolio is based in two key areas; solutions to pack bulk products into 5–30 kg boxes and a unique range of XL machines to pack tobacco, preforms and vegetables into pallet boxes up to one tonne. “For both areas Pattyn offers fully automated and complete lines, consisting of a case erector, polybag inserter, weigh filler, bag sealer and case closer.” All the company’s machines are designed, developed and assembled at its premises in Bruges. Constant innovation enables the company to stay ahead of its competitors and it has won several rewards in recognition of this, including: the Europain Innovation prize and trophy for Automation; and an IWT Award for the development of three bag-in-box machines.

Showing off In order to continue to reach new customers and to highlight its latest offer to existing customers, Pattyn Packing Lines is attending a number of upcoming international trade shows. At the European ScanPack and FachPack, it will be showing its more compact bag inserter which provides excellent automation at the lower end of capacity, and for the US market it will be showing both the compact bag inserter and the unique XL bag inserter for pallet containers at California’s Pack Expo. Growth is practically assured for Pattyn Packing Lines. Having already doubled its turnover in the past five years, the company expects to see around 20 per cent growth year on year for the coming three years. Its status as a family-owned company will ensure its continuity, long-term relationships and reliable service offering. Mr Pattyn concluded,

“We have identified several exciting market opportunities for us both in terms of geographical growth and new markets.” “We see eastern Europe and the Middle East as important target markets. In terms of sectors, the part-baked bread sector is seeing exceptional growth in Europe especially and we know that our products are ideally suited to this application.” High commitment and hard work payoff. Pattyn Packing Lines has recently been nominated for the Export Lion 2015. The “Export Lion” is the annual prize awarded by Flanders Investment & Trade to Flemish companies that have been most successful in terms of export and innovation during the previous year. Also Pattyn North America is doing very well. The North American site received the Future 50 award, given to the 50 fastest growing companies in the Greater Milwaukee area. Visit: www.pattyn.com

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Sonoco and Weidenhammer. An Uncanny Combination. 175 years of experience, 21,000 employees, 340 locations, two companies, one mission; to use rigid paper packaging to develop uncanny solutions for customers around the world. In late 2014, Weidenhammer Packaging, headquartered in Hockenheim, Germany joined forces with Sonoco Products Company, a $5 Billion global packaging company based in Hartsville, SC, USA to form the world leader in rigid paper containers, or as some call them, composite cans. As Europe’s leading provider of composite cans, along with composite drums and rigid plastic containers, Weidenhammer, with approximately 1,100 employees and 13 production facilities throughout Europe and South America, helped to expand Sonoco’s geographic and technological footprint. | 114 | Packaging Europe

ommenting on the acquisition, M. Jack Sanders, Sonoco CEO, said, “Combining Weidenhammer’s state-of-the-art production and technological capability places Sonoco in a leading position to provide its global consumer product customers with unparalleled packaging expertise throughout North America and Europe, and creates a strong presence in the emerging markets of Southeast Asia, China, Eastern Europe and South America.” Already a strong global player in rigid paper packaging, Sonoco saw exceptional value in the intellectual capital, engineering and production capabilities of Weidenhammer. By bringing the two companies together, they are able to offer customers a literal “end-toend” solution when it comes to rigid paper packaging because they are able to produce every element involved in making a high performing composite can. Additionally, Weidenhammer helps broaden the Sonoco packaging portfolio in the area of technologically advanced plastic packaging. The acquisition not only expands the global footprint of the Sonoco, but it also introduces a further evolution of the composite can itself. The primary new technologies that

will be offered around the world include shaped or non-round can production capability, recessed membranes and paper bottoms. The application of unique, non-round technology allows for the production of shapes ranging from oval to square to rectangles. The new shaped composite cans really stand out on the shelf and capture consumer attention at the point of sale. With the addition of Weidenhammer’s capabilities in barrier injection molding, specifically barrier in-mold labeling, the combined company is able to offer another high-performance packaging format that can disrupt the retail shelf. And with a retail market more challenging than ever, products have to stand out from the crowd. Over the past 29 years, the average supermarket has gone from carrying 9,000 products to nearly 47,000 products. Additionally, the average consumer is exposed to over 1,000 advertising messages each day. Well-designed packaging is a brand manager’s greatest tool to engage the overwhelmed consumer. As we all know packaging should be much more than just a container for a product.

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It must also: • Attract attention on crowded shelves • Deliver a positive brand experience to encourage repeat purchases • Protect the integrity of the product • And ideally, it should be cost efficient, lightweight and eco-friendly The composite can delivers exceptional branding, even post-purchase. One of the great advantages of the composite can is resealability. In “at-home” tests, consumers disliked having to transfer food to another container after opening. Composite cans have an easyto-reseal plastic lid, which means customers don’t have to transfer the food to a different container. The majority of millennials and consumers aged 55 and older agree that the most important benefit of the composite can is the ease of opening and reclosing the container. As a companion option to the composite can, the barrier IML (in-mold label) package combines robust product protection, with trendsetting shelf-appeal through full-body graphics. Like the composite can, it offers a cost effective alternative to metal and glass, and provides superior moisture protection when compared to traditional multilayer plastic packaging. The IML package also delivers a high barrier in a monolayer structure. Durable and lightweight, it is also compatible with retort, hot-fill or gas-flush filling systems. And to top it all off, it comes in a wide variety of shapes including nesting options for efficient transport. As more and more households are becoming food-waste conscious, it is extremely important they don’t feel like they wasted money on a product that went stale overnight.

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An easy-to-seal container like the composite can helps maintain the freshness they want without the hassle of having to use a separate closure, like a chip clip. To match the growing “on the go” consumer trend, the barrier IML package is ideal because of its light weight and easy open features. Sonoco continues to experiment to see how far they can take the composite can. This includes developing cans that are able to withstand pressure – for soft drinks, beer and aerosols. And they are looking at new markets such as warm fill for syrups and fruit fillings. The same holds true for the barrier IML package with provides an exceptional option for a number of different retail products. With the rigid paper container and the barrier IML package, Sonoco is able to offer customers two extremely attractive and versatile packaging formats. These two packaging platforms allow Sonoco to serve a wide range of markets including, processed foods, moisture-sensitive powdered beverages, tobacco, confectionery, personal care, pet food, pharmaceuticals, baby food, and home and garden products. By coming together, Sonoco and Weidenhammer are building a products and services portfolio that delivers a 360° Customized Solutions™ approach tailored to the unique needs of each customer. When combined with a unique i6 Innovation Process™, deep material science expertise and the capabilities to offer end-to-end packaging services, customers’ can have access to a partner that is focused on providing innovative packaging solutions that enhance their business and their brand. And that is an uncanny combination. Visit: www.sonoco.com

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Global growth in hot melt adhesives One of the first players on the scene with metallocene polyolefin based hot melt technology, Paramelt BV has not been standing still when it comes to the development of its Excelta portfolio of products. At this year’s Fachpack, Paramelt will be presenting a number of exciting new additions to its metallocene line coming from its new state-of-the-art production facility in the Netherlands.

a mid-sized global player, Paramelt prides itself on its experience and responsiveness when it comes to listening to the voice of the customer. “As well as continuously improving the performance of our standard product line, we’ve also been concentrating on bringing forward innovative solutions to address unmet market needs at the limits of current capabilities,” informs Neill Dutton, global business manager packaging coatings & adhesives at Paramelt. As a result of this process Paramelt are currently launching 3 exciting new grades to complement their existing range of packaging hot melts. | 118 | Packaging Europe

Excelta 804 Plus: high-speed heat resistant hot melt From North Africa to Iberia, Southern China to California, fresh produce growers are frequently challenged in achieving demanding strength requirements from their packaging trays whilst operating at high speeds under harsh ambient conditions. Excelta 804 Plus has been developed to address these challenging operating requirements, offering fast and reliable setting under the most demanding conditions and a thermal resistance of up to 70°C. This combination of features makes Excelta 804 Plus equally beneficial for hot filling applications and for packages which are required to resist elevated temperatures through the supply chain or in use.

Neill Dutton, global business manager packaging coatings & adhesives

Excelta LM 2: metallocene performance at lower temperatures

Paramelt: expanding around the globe

With safety and economy in mind, the industry is increasingly driven towards lower application temperatures for hot melt bonding. “The challenge here is to maintain a credible working range for the bonded package,” says Dutton. “Whilst it is simple enough to modify thermal and rheological characteristics to meet these lower application temperatures, this can come at a price.” With its new low melt product, Excelta LM 2, Paramelt has managed to achieve an efficient balance in performance, offering a service temperature range from -30°C to +45°C whilst still allowing for a reduction in hot melt application temperature as low as 100–120°C.

With these new product innovations and other similar developments, Paramelt has been growing strongly in recent years. On a global level, it has recently introduced hot melt production capacity for both conventional EVA as well as metallocene hot melts at its facilities in Muskegon (MI) and Cleveland (OH). A purpose built, high efficiency hot melt plant at its Heerhugowaard (NL) site has recently come on stream, effectively doubling its hot melt capacity in Europe. Along with the completion of a new food-safe, green field site in Suzhou, China Paramelt is expanding across the globe. “It all goes to show: the customer does know best,” says Dutton. “By coupling close partnership with local support and targeted development it’s possible to provide a truly differentiated service to the market place. When this commitment is backed by investment from the company in terms of production capacity the sky really is the limit in the years ahead.”

Excelta 604: even greater savings from polyolefin technology The benefits of metallocene-based adhesives are now well appreciated, including their excellent colour, low odour and superior thermal stability which brings reduced downtime and lower maintenance costs. Thanks to their better flow properties combined with a significantly lower product density, efficient bonding can be achieved with a substantially lower applied weight per bond (in some cases up to 50 per cent less). Until now, however, the cost/benefit calculation has not always been as black and white as the market would like. “Due to the special characteristics of the metallocene polymers available until now, there has only been a limited palette of compatible raw materials available for the formulator. At Paramelt we’ve been working in partnership with our suppliers to broaden this formulation space and allow us to change the game in terms of our cost structure,” explains Dutton, introducing Paramelt’s new cost effective general purpose metallocene grade Excelta 604.

Visit: www.paramelt.com

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Pioneer in image

processing and

direct engraving

With a history stretching back more than 60 years, HELL Gravure Systems is a leading manufacturer of prepress engraving systems, specialising in packaging gravure, publication gravure and flexographic printing. The company is set to showcase its latest innovations at FachPack 2015, as Packaging Europe discovers.

he name Rudolf Hell (1901–2002) is synonymous with German engineering. He is one of the 20th century’s stand-out inventors and entrepreneurs. The well-known font designer Hermann Zapf once called him ‘the Edison of the graphics industry’. Hell’s current corporate slogan ‘Based on Innovation’ is therefore extremely apt. In 1947 in Kiel, Rudolf Hell founded the company which, following a number of mergers and takeovers, continues to this day as Hell Gravure Systems GmbH & Co. KG. The emphasis was initially on printing form manufacture for gravure printing, which dominated the field of mass-circulation magazine printing at that time. Rudolf Hell was able to develop electromechanical engraving technology in which a vibrating stylus tool cuts the recessed print elements into the surface of the rotating cylinder – thereby completely eliminating the intermediate step of the copying film. The market launch took place in 1962. There have been further developments since, and the HelioKlischograph engraving machines are still an important part of the Hell portfolio. In 1985, the feasibility of electron beam engraving was demonstrated, but the fibre laser ultimately became the established scribing source. This resulted in the 2005 introduction of the Cellaxy – the system for direct laser engraving of metal cylinders. | 120 | Packaging Europe

From 2000 onward, Hell also applied its know-how in digital printing form imaging to the filmless imaging of photopolymer printing plates and sleeves for flexographic printing. Laser imaging of photopolymer printing forms was first achieved in the form of the HelioFlex imagesetter. In technological terms, this was simply an intermediate step for Hell on the way to more sophisticated, efficient, and precise direct laser engraving for flexographic printing. With all its expertise in direct engraving and printing form manufacture, Hell launched the first PremiumSetter as early as 2006. This device’s high-performance fibre laser engraves directly into elastomer printing plates and sleeves. The maintenance-free optical head and the ultrafine, variable spot size are the key highlights of PremiumFlexo technology, which enables three-dimensional shaping of the printing elements.

Flexographic printing Flexographic printing is a direct letterpress printing method. In other words, the printing elements are raised as on a stamp and transfer the ink directly onto the printing/packaging material. The printing form materials are flexible polymers or elastomers (rubber).

There is no end to the variety of printable materials – from plastic films with all kinds of functional properties to metallised surfaces, paper, card and corrugated board. And the postpress options are no less diverse – folding cartons, displays, supporting structures, pouches, bags, cups with a cover film, labels, and shrink/stretch films to name only a few. Printing plates very similar to flexographic plates are also used in dry offset printing, but this is an indirect letterpress printing method. It got its name from traditional offset printing because, like this form of printing, it transfers the print image onto the printing material via a blanket. Unlike normal offset printing, however, in which the various ink colours are applied one by one to the paper, the dry offset method first ‘collects’ all the inks on the blanket and then transfers the entire motif with all the colors to plastic tubes, cups and containers or aluminum cans.

High-quality applications Hell PremiumFlexo is the key to taking the quality of flexographic printing to the next level. Hell is systematically pressing ahead with developments to achieve highquality, cost-efficient solutions with razor-sharp laser engraving of elastomer forms. The halo effect and cloudy printouts that used to be associated with flexographic printing are now a thing of the past. The quality of the halftone images and screened vignettes is outstanding, and the fineness of the positive and negative (reverse) types and line elements is exceptional. As a result, established technologies are losing more ground than ever before. What’s more, the excellent ink transfer properties of elastomer forms come into their own in solid areas, resulting in higher ink densities, brilliant images, and high-contrast graphics. Flexographic printing is therefore making ever-greater inroads into the premium segment. Discerning manufacturers of branded goods are increasingly forming the target group. Flexographic printing scores particularly highly in the food segment with its functional film properties. Oil-repellent, frost-resistant, and breathable films are just a few examples. Furthermore, product manufacturers can now attract even greater attention at the point of sale and establish an enhanced brand-oriented image with customers. Directly engraved elastomer plates also offer new possibilities when it comes to producing corrugated board cartons – in both postprint (direct printing) and preprint (preprinting the laminating layer) applications. In corrugated board printing, this enables flexographic printing to compete with folding carton sheetfed offset printing in terms of costs and quality. Top-quality preprinting has now become possible for the first time. Flexographic preprints on the laminating layer with engraved elastomer forms can no longer be distinguished from offset or gravure printing without a magnifying glass. Thanks to PremiumFlexo, a level of edge definition and reproduction of contrast/ details that was previously thought impossible in flexographic printing now also enables completely reliable bar and QR codes to be printed and hidden images to be implemented in the screen. With the move into the premium segment, greater demands are being placed on the packaging in terms of protection against counterfeiting. In addition to traditional flexographic printing on packaging materials, PremiumFlexo is also hugely beneficial in other applications, because elastomer optimizations are not restricted to ink type, but also include Shore hardness, a flexible printing form structure, and a robust, dimensionally stable metal reverse side. This means outstanding elastomer properties such as resistance to swelling, a long mechanical service life, and impressive quality can be combined with requirements for specific tasks and materials. In dry offset, the quality of the vignettes and highlights especially, which remain printable down to extremely low tonal value ranges, far exceeds the possibilities of conventional printing form materials and imaging technologies. In particular, more sophisticated designs with more vignettes are possible, which offers manufacturers of branded goods new opportunities.

Direct is better Until modern-day direct engraving of elastomers was available, there were no genuine alternatives to the photopolymer plate that had been established for decades in flexographic printing. The polymer is enriched with a photoinitiator, which reacts to UV radiation and triggers a curing reaction at the imaged locations. This creates the printing elements. The covered areas, on the other hand, remain chemically inactive, do not form a solid structure, and are washed out as uncured polymer residues during subsequent process steps. They form the nonprinting recesses in the letterpress form. In this way, a three-dimensional plate relief can be produced with two-dimensional masks. The areas that subsequently do the printing undergo selective UV imaging through a motif mask. In the analogue era with conventional photopolymer plates and sleeves, this was a negative film that served as an original film. When the digital workflow was introduced, this film was replaced by a thin, black masking layer. Black absorbs the heat generated by an infrared laser on the LAMS (laser ablation mask system) layer, which exposes the printing areas and makes them accessible to the UV radiation. As in the case of analogue imaging, however, this digital imaging does not enable customisation of a screen dot’s profile edges by means of printing technology. For this very reason, the “secret’ behind the big leap in quality achieved by razor-sharp direct engraving of the elastomer lies in defined control of the fine laser beams. A further drawback of photopolymer forms is that this production principle requires a large number of process steps – laser imaging, multiple UV imaging, washing out, and drying. UV radiation creates harmful ozone in the oxygen present in the air, which needs to be removed in a time-consuming extraction process. And in addition to the washout line taking up space, the washout solution also contains chemicals and generates waste that is difficult to separate and requires special disposal. Direct engraving with PremiumFlexo, on the other hand, is an environmentally friendly two-stage process that saves space, time and money compared with the six-stage photopolymer process. The elastomer has already completed its chemical reaction when it is introduced into the printing form manufacturing process, which saves users any relief curing and washout work. There are also benefits in the print. Elastomer printing forms deliver higher stability for users. Thanks to the three-dimensional relief – undercut, first step, shoulder profile, and relief depth – and the digitally controlled laser intensity, the ultrafine, high-power laser beam can create the relief down to the full depth in a single step. This means that, even with small relief depths, isolated and negative screen dots are no longer a problem. As a result, detailed and intricate motifs, finely screened images and vignettes, brilliant colours, and high contrasts/tonal value ranges can be achieved in the print. This alone can win new and, above all, demanding customers. Yet another argument in favour of laser engraving is that printers using sleeves – seamless, continuous printing forms that no longer need to be mounted – do not have to wait for weeks for the blank sleeves to be delivered. Elastomer sleeves arrive in just a few days – a big competitive advantage in a market where high deadline flexibility is a must. All these indisputable advantages in form manufacture and printing make PremiumFlexo equally attractive to repro service providers and printing businesses. In addition, direct laser engraving is so simple to use and so time- and cost-efficient that printers can enjoy the process and printing benefits directly in-house. Visit: www.hell-premiumflexo.com

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KBA-Metronic

at FachPack

At FachPack 2015, which takes place in Nuremberg Messe, 29 September – 1 October, KBA-Metronic will be exhibiting both in Hall 3, Booth 141, and the theme park ‘Packaging in medical technology and pharmaceuticals’ in Hall 9, Booth P1.

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Ready for the Smart Factory For German coding expert KBA-Metronic the focus of this year’s appearance at the FachPack is the topic ‘Industry 4.0’. With cross linked coding systems in various printing technologies, its customers are fit for the Smart Factory and the increased demands on the design and quality of the marking. ‘Industry 4.0’ is the slogan on everyone’s lips. Even at this year’s FachPack. The complete networking of devices of all kinds, in particular of machines and plants in production, is the foundation of Industry 4.0. Networkable coding technology is an important element of Industry 4.0, because without clear, readable marking, neither automatic detection of products in packaging lines nor Track & Trace in logistics and trade will work. KBA-Metronic has many years of experience with the interlinking of coding and marking devices. “We started to equip our coding systems with the appropriate interfaces early,” explains Oliver Volland, CEO of KBA-Metronic. “This applies for inline coding solutions as well as for offline coding equipment.” With integration into intranet order planning, production planning and marketing can have access to the coding systems, based in production lines. The order planning department adapts on the PC to the respective coding job of layout templates created by designers. Marketing is able to create Codes for competitions and promotions quickly. Last but not least, the error rate in centralised management is lower than with manual input in production. Errors by telephone transmission of codes to the operators on the production floor are eliminated. With the integration of camera and scanner systems for verification a higher cross-linked-level is achieved.

“Because of the modularity of our equipment and the compatible software, we can offer customised coding solutions,” Oliver Volland makes clear. “Thanks to having our own in-house development department, we are very flexible. The trend is towards more flexible and integratable marking devices, faster print speed, and better print image with more design options for marking and seamless integration with the Smart Factory of the Future. In all of these requirements, we are already well positioned.”

About KBA-Metronic Founded in 1972, KBA-Metronic GmbH is a medium-sized company with approximately 260 employees and has been a wholly owned subsidiary of Koenig and Bauer AG since 2004. KBA-Metronic specialises in the development, design, production and marketing of printing, coding and marking technology. As a total coding solutions provider, KBA-Metronic is at the forefront of the very latest market developments and totally in touch with customer needs. KBA-Metronic coding systems can be found in many industrial application fields all over the world. Global leaders in all industries have successfully implemented ink jet, laser, thermal ink jet, hot stamp, thermal transfer printer and offline coding systems from KBA-Metronic. Visit: www.kba-metronic.com

Attractive marking Packaging is crucial to the sales success of a product. With a wide variety of product offerings it seems that small details also influence the purchasing decisions of consumers. This applies to all product categories - in addition to food and care products, mainly products from the entertainment and communications area and other lifestyle products. A well designed product must be reflected in high-quality packaging and a flawless coding imprint. “The claim of the manufacturer on the packaging design and therefore to the design of the marking imprints obviously increases. Coding is mandatory, but the freestyle option is a marking that is harmoniously integrated into the design, “says Sandra Wagner, sales director of KBA-Metronic.

She continues: “Through our wide range of coding technology in connection with the modular PC software code-M, we can offer a suitable solution for nearly every coding task. For high-resolution prints placing high demands on the design of betaJET we offer our thermal inkjet (TIJ). When it comes to permanent marking, our laser from the series laserSYSTEM is the optimal choice. Along with the continuous inkjet (CIJ), the alphaJET series, thermal transfer printers (TTF) of ttPRINT series and the hpdSYSTEM, our hot foil coding systems, we cover all the additional requirements for coding equipment.” In the future the market will continue to fan out. Individual solutions such as those offered by KBA-Metronic, will be trump cards.

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Labelling and coding systems The German companies Bluhm Systeme GmbH and Weber Marking Systems (Bluhm Weber Group) develop and produce labelling and coding systems for industrial marking. Volker Bluhm, member of the board of directors of Bluhm Systeme GmbH talked to Marco Siebel about the companies participation in this year’s FachPack exhibition.

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luhm Systeme is, together with its sister company Weber Marking Systems, part of the Bluhm Weber Group, headquartered in Rheinbreitbach, Germany. The Bluhm Weber Group employs over 450 people, generating a turnover of over €100 million. Volker Bluhm, member of the board of directors: “Our customers span all industries – after all, marking or labelling products and packaging is essential in every sector.”

FachPack Bluhm Weber will be presenting numerous innovations. First is the high-performance labeller Legi-Air 6000, whose servo motor-driven dispensing applicator made of carbon fibre means it can continuously label boxes of various heights with speed and precision as they move along. Volker Bluhm: “Our design and development department is constantly developing new device variants and completely new marking systems. And it is not just EU regulations that give rise to development ideas, the interesting requirements of our customers also provide a constant source of inspiration.” Also new is the label printing dispenser Legi-Air 4050 CWS with corner-wrap applicator. This device can place different length labels in different aspect ratios around corners precisely and cleanly, without having to change tools. The new labeller Alpha Print plus labels collapsible boxes accurately and quickly. Depending on the requirement, it applies pre-printed labels or prints variable data such as batch numbers onto the labels using the integrated printing module before applying them to the product. Volker Bluhm: “Alongside Interpack, FachPack is one of the most important trade fairs for us because its theme fits very well with our product range. The local character of the Packaging Europe | 125 |

fair, coupled with our strong presence in the German-speaking business world, are also driving factors behind our attendance. FachPack is traditionally the trade fair for new products and heralds the start of a strong final quarter.” The company will also present the new Epson ColorWorks C7500. This colour label printer with integrated paper cutter prints brilliant colour labels in various formats. In combination with a Geset 141 labelling system or an Alpha Wipe-On label dispenser, additional individual solutions are possible. For example, winemakers can label their wine bottles and their outer packaging individually. One highlight for the end customer is that they can upload a photograph of the ‘recipient’ or their host, which is also printed on the label. Volker Bluhm: “With our Markoprint products, development is advancing very quickly as usual. Besides print heads from Hewlett Packard, Funai and Trident, the marking system Markoprint X1Jet is now also available with a print head from manufacturer XAAR – known for its brilliant printing results. Another newcomer to the market is the non-stop printing feature that allows the cartridge to be changed during operation. In contrast, Shutter Printheads from Markoprint have a shutter that prevents the ink from drying out when the printer is not in use.”

Investments

Marking & labelling

BluhmWeber is growing at various levels on an international scale. It expects to develop and expand its presence in the Asian market, where growth is possible through organic expansion. In other target markets, acquisitions are better suited to drive growth. Volker Bluhm concludes: “We believe that we can achieve a sales increase of up to 60 per cent within the next five years in the DACH region. As part of this, we will expand our corresponding service and sales network, and further tighten our partnerships with selected solid suppliers. At the same time, we will turn to other markets such as eastern Europe, India and Asia, where we will be seeking to work with interesting suppliers as well.” Visit: www.bluhmsysteme.com and www.bluhmwebergroup.com

FachPack’s main theme for this year, marking & labelling, fits perfectly with the company’s range of products. Bluhm Weber develop and market labelling and identification technology and offers tailored system solutions for industrial marking applications. With the systems, products and packaging can be marked throughout the entire supply chain. Volker Bluhm: “Traditional applications can be seen in production and logistics; without information being printed directly or provided by a label, it would be impossible to distribute and deliver products and goods. Marking is also essential in order to trace products.” | 126 | Packaging Europe

The BluhmWeber Group has production and sales facilities across the world. In Europe the company produces in Germany, the Netherlands, Austria, France, Great Britain, Ireland and Bulgaria. In addition to its facilities in Rheinbreitbach, it has seven branches in Europe alone, including four with production capacity. There is also a wider distribution network with 56 business partners in total spread around the globe. Volker Bluhm: “In 2013/2014, we significantly expanded our office and warehouse space in Austria from 700m2 to 1250m2. The investment amounted to €1.5 million. We also plan to expand our market presence in Switzerland.”

“We believe that we can achieve a sales increase of up to 60 per cent within the next five years in the DACH region. As part of this, we will expand our corresponding service and sales network, and further tighten our partnerships with selected solid suppliers.” Future growth and developments

A cut above Established in 1931 as a paper bags producer, A. Hatzopoulos S.A. entered the flexible packaging market in 1981, and flourished into the Greek market leader of this sector within the short stretch of a decade. The family owned business which is based in Thessaloniki, the second largest city in northern Greece, still holds its leading position today. Mr Sotiris Papageorgiou, exports manager, spoke with Libby White about the company’s plans for further expansion into Western Europe and its clear focus on product development.

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convey the continuous success of the company, Mr Sotiris Papageorgiou talks through the major developments of the company within the last 7 years. He begins by sharing a significant breakthrough in the corporate history of Hatzopoulos, when the first of its export activities were realised in 1992. On the back of this progress, in 1997 the company invested in new production facilities, by building a second plant, also located in Thessaloniki. “Within the coming years we launched packaging solutions in the market such as X-laser cut perforated films, films printed with unique codes (the X-code), and the development of laminates for retort and aseptic applications,” he comments. In the company’s more recent history, he shares that, “In 2008, we expanded our capacity with a new plant of 20 000 m², an investment of about 25 million euros. A year later in 2009, we introduced green production systems which were installed in both of our plants. In 2014 we invested in a fully automated cylinder engraving line in order to produce our own cylinders for rotogravure and few months later we installed a brand new ten colour rotogravure, Rotomec 4003 MP press and also launched our range of stand-up pouches.”

Exports expansion With a team comprising of 269 employees operating on a pan European level in over 25 countries, a streamlined and well organised network offers unparalleled customer service: “Our exports account for 70 per cent of total sales and we operate in sales offices in Germany, the UK, France, and the Netherlands. Our main target is to establish long lasting bonds with our clients, to whom we deliver packaging solutions by either meeting or exceeding each specific expectation,” stresses Mr Papageorgiou. To build on its strong position, Hatzopoulos has plans to increase its presence in Germany, one of the largest flexible markets in Europe. “We are strategically targeting

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Germany as we see great potential in the coming years in this market. This year, we will be exhibiting at the FachPack trade fair in Nuremberg, showcasing all of our product range and the latest packaging solutions that we have developed,” Mr Papageorgiou explains. “We will be located in hall nine, stand 215. Our main objective is to increase our awareness on the German market and to expand our current customer portfolio.” 2015 has also seen the opening of new offices in Stuttgart for Hatzopoulos, to further expand its operations. A dedicated, highly trained team of professionals will now be able to offer immediate attention to new and existing customers in Germany. The recent expansion has provided Hatzopoulos with further exposure across Germany for its range of flexible packaging services as the company looks to build upon its established presence in the German market.

Commitment to progress Hatzopoulos accomplished a turnover of 57 million euros in 2014. “Our growth rate this year is above the European industry growth rate at 17 per cent, and we expect to achieve a turnover of around 65 million euros in 2015,” Mr Papageorgiou is proud to share. He pins this success on the company’s team of employees, which he believes is its most important asset. The company also follows an active Corporate Social Responsibility plan and participates in the SEDEX programme, and has been a participant in the United Nations Global Compact since 2010. Due to its commitments, Hatzopoulos has been bestowed numerous times with the Greek Merit Award for its distinguished social responsibility and environmental policy. Adopting a consultative approach, the company strives to provide clients with integrated customer solutions, making use of its technological expertise alongside its strong

customer service. Exemplifying its quality management, Hatzopoulos is ISO 9001:2008 accredited and certified with BRC/IoP and has implemented concrete eco-policies according to ISO 14001:2004 for the protection of the eco-system. At the same time and testament to its credibility, it is an approved supplier of many of the major European retailers.

Wide product range Hatzopoulos’ portfolio is spread across six wide ranging product categories. First and foremost, the largest category is for food packaging including: laminates for salty snacks, confectionary, baked goods and cookies; high barrier films for dry nuts, dehydrated foods and beverages, ready meals and spices; laminates for pet food, frozen food, coffee and beverages, dairy and meat products; and stick packs for a wide range of applications. For the non-food packaging segment, Hatzopoulos offers laminates for cosmetics and personal hygiene, pharmaceuticals, household goods and detergents. Decorative packaging comes in the forms of sleeves, labels and both sided printing laminates. Promotional packaging is achieved through the company’s specially designed unique X-codes, and thermo-sealing promotional stripes, whilst Mr Papageorgiou also reveals a solution recently introduced to the market, the playpack promotional packaging solution which enhances the pack and engages the customer through an attractive scratch experience. Innovations include resealable lids and resealable cold seal applications, and lasercut technology, which provides easy-to-tear capabilities for a wide range of packaging types across different market segments. Mr Papageorgiou puts forward retortable packaging as one of the most important categories of the company’s portfolio. These multi-layer laminates are suitable for aseptic processing within retort or autoclave units. Different types of packs can be formed from stand up pouches, to pillow packs, lidding films, and stick packs. This packaging can be used in numerous segments and is applicable to ready meals, seafood, baby food etc. To remain competitive on the market and ahead of the competition, Hatzopoulos invests more than one per cent of its annual sales into research and development and new

product development. Mr Papageorgiou points out, “This is above the industry average, considering the size of our company. Our R&D department focuses on developing new packaging solutions, making improvements on existing packaging, and on marketing applications, consumer safety and convenience.” An exciting packaging development project being led by Hatzopoulos entitled the BioActiveLayer project has the explicit aim of developing a novel paper-based, bio-degradable, multi-layer structure by increasing paper-moisture barriers (through introduction of blends of waxes and resins) to supercede current solutions for Modified Atmosphere Packaging and provide a cost-effective and fully recyclable film for the dried food industry.

Future potential “The greatest potential areas for growth in our opinion, is in high barrier laminates (3ply & 4ply) mainly for the coffee and beverage markets, retortable disposable products for ready meals, and lidding films,” Mr Papageorgiou is quick to highlight. High barrier laminates (either alu-containing or alu-free) represent 40 per cent of its product portfolio, whilst multi-layer high barrier films (mainly for lidding) make up 18 per cent, of the company’s business. The company’s biggest markets at the moment are Belgium, Austria, France, UK and the Netherlands which together account for more than 60 per cent of its export activity. Mr Papageorgiou observes, “We are a company that is very oriented towards the Western European markets, this is where we see the biggest growth potential in the coming years. And of course the reason that we are exhibiting at FachPack is because we want to expand further into the German market.” He concludes, “Our targets are simple and clear. The major target is to continue with a turnover growth rate of above 10 per cent for the coming years and to do this profitably in order to support our growth and future investment plans. To do so, the main efforts will be focused into the German, UK and French markets.” For more information, visit www.hatzopoulos.gr

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With more than 146,000 employees, the DENSO CORPORATION is one of the largest Japanese corporate groups. As one of the world’s largest data manufacturers of mobile data devices, DENSO follows one mission: Driven by Quality – maximum quality in mobile data capturing. Decision-makers in the fields of retail, logistics and production rely on DENSO for their business requirements and in implementing the Internet of Things.

Security meets Innovation:

Secure QR Code designed by DENSO

ENSO WAVE, one of DENSO’s main subsidiaries, is a worldwide leading manufacturer in the field of mobile data capturing and the inventor of the QR code. The company’s terminals and scanners stand for maximum quality in technology, performance and functionality.

Forgery resistant QR Code IT security has become more and more important in today’s economy. For this reason a lot of companies are expected to spend more money on IT security in the future. To protect the mobile data capturing business, DENSO has developed the Secure QR Code (SQRC®) which is forgery resistant. A study by the “National Initiative Information and Internet Security” (NIFIS) from 2014 shows that almost half of the participating German companies are expected to spend a lot more money on IT security in the future. Regarding mobile data capturing, the risk of forging a QR Code has increased as almost everyone is able to generate a QR Code today with the help of any popular freeware application. How can a company be sure that a QR Code used i.e. on a voucher, is printed by the company and not copied by third parties? DENSO WAVE, the inventor of the QR Code, has developed a secure solution to meet this challenge: the Secure QR Code. Security meets innovation – SQRC® combines the unique advantages of the QR Code with the element of security. It looks just the same as any typical QR code printed on advertising billboards, but it is resistant against forgery. With the Secure QR Code, it is possible to identify the two-dimensional Code that is shown on the smart phone with a special reader as the one that in fact solely belongs to the original company who printed it. By using the Secure QR Code, sensitive data content can be encrypted and hidden from third parties. If a SQRC® code is printed on a discount coupon, as a payment code, or as a travel ticket and then is copied or manipulated illegally, only the public data will be readable from any “free” QR code software. The hidden or sensitive data can only be decrypted with the corresponding scanner (e.g. DENSO’s QK30) that has the same | 130 | Packaging Europe

decoding encryption as programmed by the original owner of the QR Code. The Secure QR Code by DENSO thus meets all the requirements of IT security in today’s economy. DENSO is a member of the Toyota Group and is exclusively represented in Europe by the DENSO Auto-ID Business Unit of TT Network Integration Europe GmbH. Find out more at www.denso-autoid-eu.com

High-tech coding and marking equipment

With its roots in Japan and active in a wide range of industries all over the world, Hitachi offers state of the art coding and marking equipment. Elisabeth Skoda spoke to Joseph Gregory, the general manager of Hitachi Europe GmbH, to find out more about the latest innovations the company will present at the Fachpack trade fair in Nuremberg.

itachi was founded in Japan in 1910, and over the years has grown to become a global industrial conglomerate consisting of over 900 different companies worldwide with more than 300,000 employees overall. “In the 2014 fiscal year, Hitachi reported a revenue of $ 80 billion,” Mr Gregory says. The Hitachi group is involved in a wide range of industries and markets including IT, construction machinery, chemicals, metals, equipment for factory automation, and a huge number of other products, which are developed and sold worldwide.

Coding and marking expertise Hitachi’s coding and marking section has enjoyed great success. As a globally operating company, it works in most high-technology sectors, and has provided continuous innovation in coding and marking for 40 years. The company offers individual solutions for a wide range of applications and industries including food, beverage, wire and cable, construction, pharmaceuticals, cosmetics and automotive. The product offering includes high quality robust printers based on the continuous inkjet (CIJ) principle and lasers for industrial coding applications, , offering up to date technology for highest reliability, precise coding. Applications range from stand-alone date printing on food products to complex procedures, in which printers can be integrated in a system of machines via a network. “We started to develop continuous inkjet technology in the 1970s, and today are one of the global leaders in this field,” Mr Gregory points out. With its strong continuous inkjet background and over 40 years of experience in the field, the company has now expanded its coding portfolio by offering an innovative laser coding product and vision system.

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“We take pride in providing the absolute highest quality for all of our products. We believe we have products that our customers can trust. We have a global network of Hitachi companies or partners, and we can support our customers in almost every corner of the world.” FachPack innovations Hitachi works hard to innovate, and will showcase a range of its products at this year’s FachPack trade fair in Nuremberg. “One of the most recent innovations we are premiering at FachPack is a new laser product, which will be released into the market this year, the LM laser series. This will be a market leading technology which encompasses many of the requirements for modern coding applications. We have aimed to create a robust product, which can be used in extremely harsh environments. It features an air blow system to keep the lens area clean, which we believe is a world first. We have created a very small, compact, all in one system.” Another product highlight at FachPack will be the UX inkjet printer, designed for ease of use and maintenance combined with improved environmental credentials. “With the UX series, we have introduced a new fluid consumption reduction system for the clean and easy use of inks and make-up. This printer will also be world leading in terms of total cost of ownership, through the significant reduction in makeup consumption, and an innovative cartridge bottle system which allows for the use of every last drop of ink and make-up. Its ergonomical print head makes it ideal for printing on milk and juice cartons. The cabinet is IP65 rated for dusty environments,” Mr Gregory explains. At Fachpack the company will not just present its coding and marking range, but also factory automation products, including control and drive systems. Hitachi considers the trade fair an ideal opportunity to reach out to new customers and also forge relationships with existing customers. “We want to show to the market that Hitachi is expanding its coding line up and that our products have high levels of integration capabilities to meet the growing demands of interoperability of coding technologies,” Mr Gregory says.

Customer focus Hitachi is proud to be a reliable partner for its international customers. The company has a very long history, and it is built on very strong principles, with the customer as an essential focus. Packaging Europe | 133 |

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Premium

wood packaging In the two years since Quadpack acquired Technotraf, the extensive investments and strategic development that ensued has garnered excellent results. Emma-Jane Batey spoke to commercial director Jaume Ordeig to find out more.

ounded in the UK in 2003 and now a globally-active market leader in the field of high quality packaging for the skin care, cosmetics and beauty industry, Quadpack Group is an independent packaging organisation. Present in 10 countries worldwide and operating sourcing operations in Asia and Europe, the company also has its own test laboratories and a dedicated logistics centre in Barcelona. Quadpack’s concept-to-completion offer for prestigious beauty packaging is its USP. Specialising in total packaging development for skin care, cosmetics and perfumery brands, the company portfolio includes airless packs, glass and plastic jars, bottles, tubes and pumps, caps and dispensers. Its airless range from leading manufacturer Yonwoo has been particularly well-received by the premium beauty brands across Europe, thanks to myriad benefits including formula protection from external contamination, the ability to dispense both low and high viscosity formulas and less waste, with over 95 per cent of the product being dispensed. Quadpack has also performed strongly in the glass bottles range with leading perfumery brands, with 30ml, 50ml and 100ml options of all manner of standard and bespoke designs.

A beautiful match In March 2013 Quadpack acquired manufacturer Technotraf Wood Packaging to create its new Manufacturing Division. This strategic move has added beautiful bespoke caps and components from sustainably-sourced wood to the Quadpack offer. Packaging Europe spoke to commercial director Jaume Ordeig to gain an insight into how this development has boosted the presence of both parties. Mr Ordeig said, “Wood packaging is truly beautiful – naturally beautiful – so to partner with a leading premium-brand beauty packaging company is a perfect match for us. In the two years since Technotraf Wood Packaging became a part of the Quadpack Group, we have made considerable developments, made structural changes, invested heavily and put in place all manner of positive changes. Extensive renovations were carried out in the factory, we’ve added new automated machinery and our production workflow has been upgraded.” These progressive moves have already resulted in a steady increase in orders, with 2014 figures posting a 20 per cent more than anticipated growth. Mr Ordeig added, “Technotraf products are becoming increasingly sought after by the leading global

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beauty brands thanks to our focused sales drive, our successful international marketing campaign and of course our unique, beautiful wood packaging.” Established in Torello, Spain in 1983, Technotraf Wood Packaging manufactures wooden components for beauty packaging. Sourcing all its raw materials sustainably from managed forests, Technotraf is certified by the PEFC. Its bespoke products are the perfect complement to high-end beauty, fragrance and skin care ranges. Mr Ordeig was keen to highlight how the company essentially created the wood packaging for the beauty industry, following a period of strategic reassessment. He said, “We are the market leader in premium wood packaging and have been for some time. A few years ago we decided to start looking for new markets and we thought that the high end perfume and cosmetics sectors would be a good fit for our products and expertise. So essentially we created our own market as there was nothing available before in wood for these types of products.” This year’s WorldStar Packaging Awards, the most prestigious international packaging award, has already recognised the world-class quality of Technotraf ’s work. The wooden fragrance pack created for Armand Basi’s Wild Forest received an award in the Health & Beauty category. This packaging places a glass bottle within a wooden container crafted from a single, solid block of ash complemented by a matching ash cap. This bespoke design was highly successful in setting the product apart from its competitors.

Commercial and creative

promote the balance between wood as a commercially feasible product and one which would work in a qualitative environment. We achieved this through a total conversion of our activities including investing in new machinery, changing some production processes and a change in our company culture. Really it was a total transformation so that we were prepared for the cosmetics and perfumery markets. Of course, our dedication to wood stayed the same, but the type of packaging and the type of market was a real turnaround.” Following the success of this transformation, Technotraf is now in a period of consolidation. Mr Ordeig continued, “I’m proud to say that we convinced the market of the beautiful potential of wood as a premium packaging material, particularly due to our creating some truly outstanding projects for leading cosmetic and perfumery brand owners. Now our aim is to make this material even more accessible, to connect with more people in the industry to share the value-added benefits of adding wood to premium beauty brands. Just last month I was in London visiting a number of design agencies, highlighting the possibilities of wood as a packaging material. It’s very much a material of the future; when sourced from ethically and sustainably managed forests, wood is an endlessly renewable packaging material.” It is understandable that the Quadpack and Technotraf teams are feeling optimistic. Mr Ordeig concluded, “We’re keeping ahead of the market and of our competitors. We’re continually adding innovative ideas to our portfolio and promoting the use of wood as a packaging material for brands that value premium presentation of their products.”

Mr Ordeig continued to explain how this market needed convincing of the benefits and possibilities of wood as a suitable packaging material. He said, “We had to carefully

Visit: www.quadpack.com

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New Ultrasonic Top Seal Module TSM 35: the Fast Way Towards Series Production If packaging producers specify ultrasonics as their sealing technology, the manufacturers of packaging machines are now able to integrate the appropriate technology faster and better, thanks to the slim design and the standardised interfaces of the new top seal module TSM35 by Herrmann Ultraschall. Opening widths of 50 to 100 mm between the anvil and the sealing tool, i.e. the sonotrode, cater for both rotary tables and longitudinal processing designs, also in the form of multi-track lines.

Top seal module TSM35-40-50

he new module can be integrated into packaging machines in various ways thanks to its different types of mechanical interfaces. Mounting can optionally be performed by one of the two side surfaces or by the topside of the top seal module. The drive interface may be positioned either on the left or on the right. This provides key advantages, particularly for multi-track machines. Flexible arrangement of interfaces for different machine concepts

and analysing the major measuring variables. More than twenty different measured values are recorded and processed 10,000 times per second. The integrated HDM ProcessControl makes sure that critical conditions in the seal are safely and gaplessly detected. The system identifies and indicates: • Creases in the top area • Big chunks in the seal area • Incorrect positioning in the weld station • Lack of pouches • Double configuration This feedback allows for consistent assessment of the process. Based on that information, faulty bags and pouches can be safely identified and rejected and thus process safety is significantly increased.

Micha Augenstein of the Herrmann Ultraschall product management team answers our questions Is the module suitable for integration in all conventional SUP machines?

Micha Augenstein

“During development, our focus was on creating a product that comprises tried and tested standard components and at the same time provides maximum flexibility. Thanks to the modular structure we use eight standard variants to cater for most varied machine designs. Moreover, the six available fieldbus connections allow for fast and comfortable integration into the overall machine control.” The transfer of movement and force build-up are now integrated in the top seal module, while the drive for the closing movement will still be provided by the machine builder. Robust, precise guiding rails ensure the required parallel travel of weld tools. Separation of the drive movement from build-up of force using pre-loaded pneumatic cylinders allows for operation of the module even at high cycle rates. The weld force does not have to be built up after contact. Instead, the weld process can start directly upon contact of the weld tools. In connection with the optionally available proportional valve, the device provides a high degree of flexibility for setting the weld force, particularly upon format change. Ultrasonics is particularly reliable and suitable for large production volumes, with liquid, pasty, chunky, and fibred products, such as pet food or convenience food and with thermally sensitive products, such as cheese, salad, chocolate, and pharmaceuticals. The major benefits over the widely used heat contact process are the hermetic weld seals, despite seal area contamination, and the fast cycle times.

HDM ProcessControl - detecting critical conditions during sealing The digital ultrasonic generator allows for directed build-up of the oscillation amplitude and provides valuable data for quality surveillance thanks to its permanent measuring | 138 | Packaging Europe

What are other highlights does the TSM35 offer? “The travel function and generation of force have been separated. The pneumatic cylinder is operated in pre-loaded condition, i.e. the set process force is permanently applied. This ensures that we achieve best sealing results even at high machine speeds. Our thoroughly tried and tested HDM ProcessControl, which reliably detects faults in the seal area, completes the package.”

What about the drive? “The actual drive operation of the module is performed by the packaging machine and can be realised through the main drive shaft or a separate servomotor. This ensures additional flexibility for individual adjustment to the respective machine conditions. In general, this option provides higher speeds and better output than the purely pneumatic drives.” Visit us on our website www.herrmannultraschall.com or visit us on our booth 506 in hall 4a at FachPack tradeshow, 29.09. – 01.10.2015, Nuremberg, or on our booth H72 at PPMA show 29.09.2015 – 01.10.2015, NEC Birmingham.

Weighty success Family owned in the 5th generation, Germany-based Bizerba has been providing its customers with a unique solutions portfolio of both hardware and software around its core business of weighing since 1866. Products and solutions on offer include slicing, processing, weighing, cashing, checking, commissioning and labelling. Elisabeth Skoda spoke to Dieter Conzelmann, the company’s director of industry solutions, and to Richard Schick, director industry solutions market organization Germany to find out more about what makes the company so successful.

ith its headquarters in Balingen in Germany, Bizerba is active all over the globe and has enjoyed a particularly successful recent few years, expanding its international presence. “In 2014, Bizerba established new subsidiaries in South Africa and Ukraine and was able to secure a leading market position in Switzerland through the acquisition of BuschWerke AG. In March 2015, Bizerba took over the French company Luceo, a technology leader in the field of optical inspection solutions,” Mr Conzelmann explains. He is proud to point out a special achievement - in the last financial year, Bizerba exceeded the sales mark of 500 million euros for the first time in its history. “In 2014, the company with its 3300 employees generated sales of 503.8 million euros - an increase of 8.1 percent compared to the previous year. The growth is attributable to a positive development in all key sales regions as well as the consolidation of a company acquired in Switzerland. Almost all regions were able to contribute to the record sales: as

in recent years, the regions North America and Europe excluding Germany posted disproportionately strong results with an increase of 8.6 percent and 11.7 percent, respectively. Germany also posted a significant increase in sales by 4.4 percent and continues to be the largest single market, followed by the US. Overall, the share of international sales increased to 67.3 percent. All product segments, including retail scales, slicers and industry solutions as well as labels and other services, recorded encouragingly strong sales growth.”

Quality solutions at Fachpack Bizerba will present a range of solutions for the packaging industry, including both hardware and software applications as well as high-quality consumables (labels), services and label management including new financing concepts at the upcoming Fachpack trade fair in Nuremberg.

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Industrial Automation is a key topic, focusing on solutions for product and process security in the logistics and packaging industry, as is the implementation of the latest product labelling and software tools to improve quality, equipment availability and performance. “Trade visitors from all sectors, both the food and the non-food industry, attend the trade show and this is an ideal opportunity for Bizerba to reach new and existing customers in this wide range of sectors and to convince them of our capabilities,” Mr Schick explains. He lists Bizerba’s products and solutions on show: “We will be showcasing an automatic labelling system, checkweighers with integrated product inspection, and high-quality label applications especially for the packaging industry, which can be used in all sectors.” Mr Schick is keen to point out what will be new on show at Fachpack –vision product inspection to check seal strength, Bizerba industry terminals (iS10 to iS50 through to Industry PC iS65/70) for process optimisation, software solutions based on the pioneering BRAIN2 (Bizerba Rapid Application Industry Network), and business models such as Life Cycle concepts and integrated service also in combination with labels.

USPs Unlike any other manufacturer, Bizerba offers a complete and seamless range of solutions in the field of weighing, monitoring and labelling technology, with added inspection systems, logistics components and individual software solutions and services. The range also includes high-quality labels and an individual label management system. Customerspecific solutions are an important component in all areas. Mr Conzelmann gives a few examples: Bizerba Leasing (BLG) offers appropriate, ground-breaking financing services – a competent partner for a seamless customer solu-

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tion. In the area of Industry 4.0, Bizerba offers specific solutions and applications, such as OEE (overall equipment effectiveness), a software module for determining availability, performance and quality, giving the customer an important control element for monitoring and continuous optimisation. Bizerba has more specific solutions and applications in the area of Industry 4.0, both in the food industry and the non-food industry, such as LCC (Life Cycle Cost), a term licence model, tailored according to duration of use and predictable values over a defined period; equipment hire concept, which enables the customer to pay a monthly amount and in return receive the latest technology, up-to-date software and complete services with defined response times. New machine to machine models mean greater availability and lower costs.

Bizerba for packaging Mr Conzelmann gives some examples of how Bizerba’s solutions can be of use to the packaging industry, and highlights the importance of catering for the demands of the Industry 4.0 concept. “By inserting rolls of coded labels, so-called Plug -In®-Labels, we are now able to verify whether the inserted label also matches the order and then automatically configure the machine at the same time. This reduces the set-up time and enables increased process security. With the advance in networking, network-compatible, modular and individually expandable equipment is becoming increasingly important.” Flexible labelling techniques to keep all options open in terms of customised labels are also key. “As well as universally networked machines, controlling intelligent factories depends more than ever on the appropriate software. For example, with BRAIN2 we offer cloudbased software for the manufacturing industry. Our customers are able to use this to

store their machine back-ups and status messages in the cloud for the first time – making things much easier in terms of data security, error analysis and the commissioning of new devices,” Mr Schick explains. He points out the importance of the topic of “Industry 4.0” especially in the areas of industry and high quality labels. Mr Conzelmann predicts that Industry 4.0 solutions will gain even more importance and that people’s food shopping behaviour will change quite radically in the future. “Today, people are rushing around supermarkets, taking items off the shelf, but I predict that in 30 years supermarkets in their current shape will have disappeared. Supermarkets will come to the home, and their business model will change, similarly to what is happening already today with big online retailers such as Amazon, who know a lot about their customers and use this knowledge for promotion.” This development is driven by generation Y, who prefer a more individual shopping experience. This has an impact on the machines in the food industry, on business models, on customer relationship. Production has to be more flexible. Bizerba is working on machines that allow to handle these requests in the future in order to be able to provide for this ever-growing trend. “All machines we produce for marking and labelling are able to handle very small batches or even a single pack,” Mr Conzelmann says.

solutions. In the general food industry sector, including baked good and confectionary, growth is planned particularly for checkweighers and inspection systems/software, especially in terms of automation and quality assurance solutions,” Mr Schick says. For the non-food industry, another important component, Bizerba provides solutions for process automation and process security in the logistics sector, as well as the manufacturing sector (metal, electric, automotive, chemistry). Internationally, Bizerba is planning for above average growth especially in new countries such as South America and South Africa, in addition to markets in Europe and further expansion in North America. Bizerba will open up new markets and further optimise and expand quality assurance with combined sales/services/facilities/labels solutions for process optimisation. “As the market shares in Germany are already very high, a proportionally much higher increase is expected in the rest of Europe, North and South America and South Africa in particular. The export share is currently already over 65 percent and even with growth in Germany it will increase further.” 2014 was a particularly successful year, and Mr Conzelmann is confident that the company is well set up to continue on in this vein. Visit: www.bizerba.com

Investments Bizerba continuously invests to stay at the top of its game, and uses targeted acquisitions as a means to grow and develop its expertise. “In addition to Busch-Werke AG in Switzerland last year, we recently acquired Luceo France to further develop expertise in the field of inspection systems, primarily in camera technology (solution for sealcontrol). We also recently established a Bizerba sales and service organisation in SFA, expanded our logistics division at the main facility in Balingen in order to implement new logistics requirements to take place in 2015, and acquired a new label production facility in Austria,” Mr Conzelmann points out.

Main markets In Germany, Bizerba has a large market share in the food industry sector, in particular ‘fresh food’. “We intend to continue to grow there, primarily with labels and software

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Innovation in labelling systems As a leading developer of barcode and RFID label designers and label management systems, NiceLabel is a rapidly growing, globally-active specialist. Emma-Jane Batey spoke to marketing director Ken Moir to learn how this is being achieved.

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ounded in 1993, NiceLabel has grown to become one of the world’s leading developers of barcode and RFID labelling solutions for SMEs and global businesses. Developing and supplying solutions that reduce the complexity of labelling, NiceLabel helps companies of all sizes implement process improvements, meet regulatory standards and ultimately achieve greater levels of productivity and agility. Marketing director Ken Moir spoke to Packaging Europe to explain how NiceLabel’s solutions add value to its customers. Mr. Moir said, “Our solutions provide a myriad of advantages to our customers, including increased operational and supply chain efficiency as well as brand consistency and protection. Our next generation platform is the most trusted label technology available as it delivers unrivalled productivity for label design, label lifecycle management, automated label printing and cloud-hosted web printing. Many of the world’s largest organisations rely on NiceLabel solutions to consolidate labelling, collaborate with their business partners and use their supply chain to provide a real strategic advantage.” NiceLabel is also the world’s leading developer of Microsoft Windows drivers for thermal, ink-jet and direct marking printer technologies, which allow organisations to standardise all of their marking technologies with a single label management system. Mr. Moir added, “We are a Microsoft Gold Certified Partner, Oracle Gold Partner and SAP Partner. The three largest and many other printer manufacturers ship NiceLabel-based software with their printers.”

Next generation solutions for print productivity For its barcode and RFID solutions, NiceLabel has worked consistently to develop customer-focused innovative products. Mr. Moir explained, “Until relatively recently, customers had to choose between simple label design packages and expensive proprietary first-generation labelling systems. Our innovative label technology platform has been carefully designed to reduce the complexity of the label management process. The platform is modular, consistent and standards-based, with modules designed to be configured without coding.” The aim of NiceLabel’s label technology platform is to minimise the number of label templates, making the whole labelling process smarter, faster and more efficient. Mr. Moir continued, “Thanks to our design philosophy we are able to deliver printing productivity solutions that provide rapid ROI regardless of whether the customer is a small, medium or large business. We can adapt to organizations with specific requirements as well as regulated businesses such as pharmaceutical. Our unique platform design also enables us to offer cost-effective solutions to specific vertical markets such as textile, garment, chemical, medical device, food and other industries.” To support NiceLabel’s aim of reducing label templates, it has introduced a label catalogue feature. This allows designers to search all existing templates based on label attributes and preview labels in their web browser, which avoids label duplications. All label templates are stored in a central database that allows role-based access. Mr. Moir explained that the NiceLabel solution separates design and printing Packaging Europe | 143 |

Ken Moir, NiceLabel Marketing Director

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operations: “In order to prevent mislabelling, we recommend that print operators, typically working in a warehouse or production environment, should not be able to modify the label design. We aim to de-skill the label printing operation as much as possible. Print operators should not change label design, but have access to a simple interface. This is achieved using printing forms. Using forms reduces the risk of errors and the time required for training. Combining forms with touch screens can also eliminate the need for a mouse and keyboard. Using forms with graphical icons can additionally allow non-native language speakers to operate with fewer errors and less training.” The platform allows the whole system to be managed – the process, the people and IT. Integration with other systems ensures a single source of truth and streamlines the printing process, eliminating duplication and mislabelling. If companies address all these aspects, they can increase productivity, be more agile and lower both the direct and indirect costs of labelling.

Meet NiceLabel at FachPack NiceLabel will be actively participating in the upcoming FachPack trade exhibition. Here, the company will present its next generation barcode labelling solutions, showing how its offering can create value through improved print productivity. Mr. Moir added, “Our team will explain how enterprises can decrease operational costs and increase agility by using an all-in-one centralised label management, printing and integration platform.” He continued by saying, “We will also show how VARs can differentiate their business and create real end-user value with NiceLabel’s label management systems, which allow them to secure their customers’ business and be more profitable. Label

management systems address all areas of labeling like design, printing, integration and management to drive productivity gains while leveraging new technologies like touch screens, mobile devices, the Cloud and the Internet of Things that are driving industry change. By combining label management systems with these new technologies, resellers can create new business models to differentiate, increase margin and create significant end user value.” A global business with its HQ in Slovenia, NiceLabel has sales and support offices in Germany, Singapore, China and the USA as well as a development team located in Slovenia. In order to continue its impressive global footprint and enhance its capabilities, the company acquired the US-based NiceWare International LLC in 2013 and it is continually investing globally to increase its market presence, with a focus on Asia. Currently sold in 27 language editions in over 100 countries worldwide, NiceLabel solutions are used by over 500,000 companies. The actual number of NiceLabel technology users – including the users of free versions and industrial printer drivers – accounts for several millions. The company is confident that its achievements will continue as it expands into new markets and presents innovative solutions to its present markets. Mr. Moir concluded, “There are so many opportunities for us to grow even further. We see the market shifting from simple barcode label design to print productivity, minimising risk and improving the management of the entire label lifecycle. NiceLabel is uniquely positioned to deliver these solutions and we plan to continue to add even more value to our customers in the future.” Visit: www.nicelabel.com Packaging Europe | 145 |

An Explosion in

Flexible Packaging

NITRO-CHEM S.A., a long established explosives manufacturer based in Bydgoszcz, Poland, moved into the polymer film market in 2009 and has quickly emerged as one of the region’s leading innovators. Commercial and marketing manager Arleta Babska and Krzysztof Uziałło – General Manager of Plastic Film Department tell Packaging Europe’s Tim Sykes about the company’s ambitions.

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ince its first investment in plastic films facility in 2009, in a move to diversify production operations, NITRO-CHEM has intensively developing its TRINIFLEX® brand. In the ensuing years a series of new offerings were introduced to the market: cast PP films in 2011; cast PET films in 2012; and ultrathin (12-micron) cast unoriented PP films in 2013. Last year saw the introduction of ultrathin (20-micron) cast PET films of very high formability and cast PLA films, as well as BRC-IOP certification. “As you may expect from the heritage of our core business in the defence industry, we place the highest importance on innovation, perfect quality and full customer satisfaction,” observed Mr Uziałło. “These principles have been inculcated into the Plastic Films Department. Initially, our activities focused mainly on the Polish, and later on the European markets. Today we can proudly state that our films are supplied to many regions all over the world.” In addition NITRO-CHEM’s manufacturing facility in Bydgoszcz, the business has a daughter company NITRO-CHEM Americas llc. It is commercially active throughout western and central Europe (via official sales agents in the United Kingdom and Germany) and eastern Europe (where it is also represented by an official agent in Russia). NITRO-CHEM is commercially active in the US, Australia and South Korea, with global customers accessible thanks to an efficient logistics and customer service network.

TRINIFLEX®: building a brand Asked to characterise NITRO-CHEM’s brand proposition, Ms Babska offers three traits: “innovativeness, professional approach and continuous development”. She elaborates: “Due to these three factors we have established long-term and mutually-satisfying relationships with many customers. We consequently build our recognition in flexible packaging industries under the brand name TRINIFLEX®, which works for our films family as: TRINIFLEX® cPP, TRINIFLEX® cPET and TRINIFLEX® cPLA films. Furthermore, we are flexible in our approach and ready to face new challenges. This means we often undertake projects that other producers cannot or do not want to execute.”

The offering thus comprises a full spectrum of cast films. The range differs from other manufacturers because NITRO-CHEM specialises in the production of films using polymers that normally have not been used for cast film production, such as PLA, or PET, PP films of special thickness. “Polypropylene cast films are commonly manufactured and used all over the world, and we also produce such films,” says Ms Babska. “To meet the requirements of our customers, we have developed a whole range of TRINIFLEX® cPP products that can be used for standard applications (sealing, lamination, printing), as well as for more advanced ones, such as anti-fog, peel, tinted films, and ultra-thin films of 12–18 microns. Another branch of our products are cPET and cPLA films. We are indisputably the pioneer in the production of these materials in Europe. Polylactide films (20-150 micron) are compostable films of varying softness for packaging applications used directly or laminated with other materials. Our cPET film (thickness range 20-150mic) has a wide scope of application in various specialist laminates: films of Very High Formability for plastic, steel, paper, cardboard lamination, coextruded films also with G-A-G and other co-polyester combinations.” Standing behind this product range is a fleet of modern machinery lines and a highlyqualified team of experts in plastic processing. With this combination of technology and human commitment, NITRO-CHEM has a manufacturing capacity of around 4500 tonnes of film per annum.

Innovations on show at FachPack “R&D is the key to our success,” states Mr. Uziałło. “Launching our products onto the market, from the very beginning we have focused on innovativeness. We do not rest on our laurels but continuously look to improve our products, develop new formulations and test the most modern raw materials available in the market, in order to offer innovative solutions to our customers. We strive to always be one step ahead. This means we are not afraid of development. Thanks to our efforts, the TRINIFLEX® family is continuously expanding.”

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A recent success for the R&D department has been the launch of a new cPET G film, while the range of ultra-thin PP films are proving a great success on the marketplace. Meanwhile, the technological team is currently conducting work on cPP films with flame-retardant properties. NITRO-CHEM’s commitment to innovation can also be understood within the framework of the market’s demand for sustainability and socially responsible production. “Sustainability plays a more and more important role in our business decisions,” reveals Mr. Uziałło. “Starting from investment in more eco-friendly products, going through introduction of some unique materials which could give the customers to produce mono material packaging instead of using laminated multi-material structures, ending on introduction of family of compostable films.” The TRINIFLEX® brand will be proudly exhibiting its range at the forthcoming FachPack 2015 fair in Nuremberg, 29 September – 1 October. “Our booth will be focusing on our specialised range, not commodity films,” explains Ms Babska. “We expect our participation at FachPack will boost our brand recognition. Our visitors will learn that we are focused on innovative films which give them opportunities to introduce added-value

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products. Last year’s Interpack Fair proved a huge success for NITRO-CHEM and we hope this time in Germany our products will similarly be recognised and attract customers from all over the world. We’d like to invite customers reading this article to come and visit our stand!” Those FachPack visitors who do make their way to the TRINIFLEX® stand will encounter a company with a big vision in the flexible and rigid packaging markets. Ms Babska concludes: “The first of our objectives has already been achieved: the TRINIFLEX® brand is gaining increasing recognition and acceptance all over the world. Now our main objective is to strengthen cooperation with our current customers, as well as continuous development of existing products and expansion of production volumes. In particular, with regard to special film solutions, after the initial, period of introduction to the market, we intend in incoming years to increase our production capacity by installing state-of-the-art production lines.” The TRINIFLEX® exhibit at FackPack 2015 can found at Hall 9, Stand 615. Visit: www.triniflex.com.pl

Fast-moving static technology Simco-Ion is a world leader in the development and manufacture of anti-static products and static bonding systems. Philip Yorke spoke to Erwin van ‘t Hul , the company’s marketing director about its unique IQ Easy system and latest technological breakthroughs.

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imco-Ion Europe is a member of the worldwide ITW Group, which has operated in Europe since 1946 and started with the introduction of plastics in the textile industry. Today the company offers a comprehensive range of products that control static electricity in the packaging, converting, plastics and printing industries. The company’s products are sold through an extensive network of highly qualified agents worldwide. Simco-Ion operates four modern production facilities - in Lochem in the Netherlands, Hatfield in the USA, Kobe, Japan and in Shenzhen, China.

Diverse packaging applications It is well known that static charges can cause problems in many areas of packaging processes and Simco-Ion’s diverse range of products can eliminate these problems in a broad variety of packaging applications. These include printing, bottling, labelling, thermoforming overwrapping, trim collection and form-fill and seal operations. However, static electricity can also be useful for temporarily bonding materials, for example in stacking, folding and labelling and in many cases static bonding can be

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used as an alternative to glue. Today more and more products are produced with the aid of a static charge. For example, instead of printing directly onto a package or placing a sticky label onto the product, the print is achieved with a pre-printed plastic label. This label is then positioned in the injection mould and kept in place by a static charge. This way the label can be moulded together with the product shape and be delivered as a finished product. Static bonding is also capable of keeping together large and heavy objects. For example, stacks of brochures or flooring laminate can be held together with a static charge to keep them from shifting during transportation. This demonstrates the enormous force that can be generated by an electrostatic charge.

Unique IQ Easy Platform Simco-Ion’s IQ Easy System is the first product on the market that enables the control of up to 30 anti-static devices into a network via the IQ Easy manager. This unique concept makes it possible to fully control all the process parameters and allow devices to interact with each other to optimise efficiency and cost-effectiveness.

van ‘t Hul said, “We see our main growth coming from our new IQ Easy platform. Technology is changing our business sector at a very rapid pace and our unique IQ Easy platform allows further innovations to be created by converting the whole product range to 24DC supply voltage and making our products communicate with our new IQ Easy System. In the past all components were driven by their own power source and controls but with our new system all functions can be connected and data-logged as one. In addition, with 24DC power supply it is possible to develop much smaller, lightweight components. We will be demonstrating the unique benefits of our Easy IQ System at the FachPack trade show at the end of September this year. van ‘t Hul added, “We serve a broad range of markets, in fact wherever static electricity plays a part. In packaging it starts with the extrusion of film, all the way to using film to produce packaged items. The same applies to all other packaged materials, such as those produced by blow-moulding, injection moulding and vacuum forming etc. Today packaging markets are still growing due to growing economies and an expanding population. Simco-Ion focuses on these markets with new products that enable our customers to improve their process with regard to increasing speed, reliability, quality and cost-savings. “As the clear market leader we are committed to maintaining our technological lead and unrivalled after sales service. What also differentiates us from our competitors apart from our unique IQ Easy Platform, is that we have by far the biggest global coverage with local reps and agents strategically located throughout the world”.

production problems ranging from electrical shocks to operators and the attraction of air born contaminants to the surface of the material, to hazardous situations where a spark from a static discharge occurs where volatile vapours are present, which can lead to a fire. ATEX approved static elimination equipment is required in these circumstances to neutralise static charges and prevent the risk of fire. In yet another area, digital printing on demand (POD) has become widely adopted and digital technology offers high flexibility for personalised, security and financial documents. This requires substrates with a high degree of cleanliness. Simco-Ion has designed a complete ‘Plug and Run’ system for narrow web cleaning where contamination is removed, print quality enhanced and misprints prevented. For further details of Simco-Ion’s latest innovative static control systems and services visit: www.simco-ion.co.uk

Optimal solutions Whatever the process, Simco-Ion can provide the optimal solution. When it comes to labelling machines, static electricity may cause poor label feeding on high speed labelling machines, as well as on plastic bottles where static can result in poor label placement and bad positioning. These problems cause slower production speeds and higher rejection rates. Simco-Ion’s strategically placed ionisers will eliminate static charges and allow for optimum process productivity. In addition, in the coating and laminating operations, where insulating, non-conductive materials are processed at very high speeds, static charges may cause a myriad of

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Lighting up Northern Europe’s Packaging Industry Scanpack, which takes place this year in Gothenburg, Sweden, on 20-23 October, is the largest exhibition of its kind in Scandinavia and northern Europe, with something for everyone in the packaging value chain, from designers and manufacturers to subcontractors and buyers. More than 500 exhibitors, an extensive seminar programme and events that will provide interest, information, business opportunities and glimpses of the future of packaging.

canpack is a fair covering the complete packaging supply chain, from packaging machinery to finished packaging and raw materials. It attracts buyers, production managers, designers, marketing managers, and senior decision makers from a range of end-use markets and related industries. Moreover, this year’s event is set to feature greater interest from outside the Nordic region, with an increase in exhibitors from around the world, including companies from Japan, Taiwan and Turkey. “Our long-term efforts to market Scanpack at the major international exhibitions has produced results,” says Scanpack’s Pernilla Sandberg. Scanpack has a solid reputation as northern Europe’s biggest packaging exhibition – a reputation that has spread far beyond Europe’s shores. “Japan has a major packaging industry that is far advanced technologically. They’ve now turned their attention to Europe and regard Scandinavia as an excellent gateway to the European market,” explains Pernilla Sandberg. “The exhibition’s continuing internationalisation is a very positive development. At the same time, Swedish and Scandinavian

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exhibitors face greater challenges as international competition for market share in Sweden and Europe grows. What’s more, packaging industries from Italy, Germany, Poland and the Baltic states will all exhibit at Scanpack 2015, as well as our Nordic neighbours.”

Save Food Parallel with the exhibition Scanpack will be hosting an array of stimulating lectures and seminars addressing some of the most pertinent questions facing the packaging industry today. Occupying a major part of the programme, Save Food, a combined exhibition and conference, will receive its Scandinavian premiere. The initiative comes from Interpack in Düsseldorf, the world’s largest packaging exhibition, in collaboration with UNFAO and UNEP. Anna-Lena Friberg, Exhibition Manager for Scanpack, welcomes the Save Food initiative. “We’re extremely pleased to be able to include this kind of sustainability issue in our agenda. Something that is, in the highest degree, about

the survival of humanity. It’s an issue that affects everyone, both locally and globally,” she says. A key talk will be delivered by Robert van Otterdijk, Agro-Industry Officer, Global Initiative on Food Loss and Waste Reduction at FAO, on 20 October, giving a broad picture of the problem with a special focus on the role of packaging. Food losses are defined as ‘the decrease in quantity or quality of food’ and are the agricultural or fisheries products intended for human consumption that are ultimately not eaten by people or that have incurred a reduction in quality reflected in their nutritional value, economic value or food safety. An important part of food loss is ‘food waste’, which refers to the discarding or alternative (non-food) use of food that was fit for human consumption – by choice or after the food has been left to spoil or expire as a result of negligence. Studies commissioned by FAO estimated yearly global food loss and waste by quantity at roughly 30 per cent of cereals, 40 - 50 per cent of root crops, fruits and vegetables, 20 per cent of oilseeds, meat and dairy products, and 35 per cent of fish.The value of food lost or wasted annually at the global level is estimated at US$ 1 trillion.

Recognising the linkage between food loss and waste and food packaging, the Save Food Initiative was launched at interpack in 2011. Since that time the Programme has grown steadily and has been incorporated in FAO’s strategic framework as the “Global Initiative on Food Loss and Waste Reduction”. It is an integrated programme, updated and redesigned for 5 years in 2015, with a budget of nearly 100 million dollar. It has to be noted however that the programme is an Initiative of FAO, Messe Düsseldorf and many other partners, like Scanpack, who have subscribed as members, and that the funding is expected to come from these partners. The main partners from the UN side are UNEP, IFAD and WFP.

An inspiring events programme Other lectures and seminars taking place Scanpack 2015 include: Packaging Environmental Sustainability at Nestlé (Lars Lundquist, Sustainability and Novel Packaging, Nestlé). This presentation will describe the Nestlé approach to packaging environmental sustainability and the importance of considering packaging in the context of the product system of which it is a part.

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“The Psychology of Colour” - the global importance of colour (Fabio Ven-

Using packaging to delight the customer: a retailer perspective (Paul Earnshaw, head

turotti, sales director, Pantone). Venturotti asserts that communicating a brand

of packaging for Tesco). Paul asks why packaging is so important for our customers, ex-

through the right colour immediately renders a company’s message and value

plores the means of demonstrating the potential of value-added packaging, and discusses

more effective.

strategic challenges.

Win the battle of the Shopper - an intensive course in Shopper Marketing (Martin

Packaging Innovation as a Strategy (Oliver Campbell, Dell, Director – Worldwide

Moström, partner and strategic adviser in shopping marketing at Retail House). An in-

Procurement & Packaging Engineering). As Director of Packaging at Dell Oliver’s global

tensive course of 30 minutes in Shopper Marketing - a rapidly growing discipline within

organisation focuses on packaging design, strategic sourcing, technology commercialisa-

consumer marketing.

tion, logistics, and fulfilment.

The Story of the Entrepreneur and the Company (Karl Fallgren, ifoodbag). Karl is the

The law on food waste: from Courbevoie to the Assembly (Arash Derambarsh, elected

innovater of the new, exciting paperbag, which could hold grocery products cold for up

official in the city of Courbevoie, France). Arash Derambarsh is the French politician

to 24 hours. A really food saving innovation.

who recently managed to pass a law requiring or incentivising supermarkets to give –

How can Purchasing be a real source of Value Creation (Gordon Crichton) How do

night after night – all their unsold food to the association of their choice.

you create value in a different way of working with suppliers and how can you capture

The Power of Consumers to Stop Wasting Food (Selina Juul). It’s time for a revolution

innovation and get products faster to market? That is important questions that Gordon

against food waste: We are 7 billion people on this planet, of which 925 million are starv-

Crichton will discuss in his presentation.

ing. Yet we annually waste 1.3 billion tons of food - or enough to feed 3 billion people.

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Jonathan Bloom, journalist, discusses the topic of food waste. Wasted food is a global phenomenon with harmful ethical, environmental and economic consequences. Yet, few

individuals or organisations recognise the magnitude of the problem or those significant treble impacts. In his talk, Bloom will detail the major causes of food waste in the developed world, the staggering effects, and how we as individuals and a food industry can minimise the footprint of food waste. And don’t worry--the packaging industry can also be part of the solution! The Role of Packaging in reducing food waste and ensuring resource efficient food consumption globally (Stefan Glimm, Executive Director, EAFA and FPE) Today more than 30 per cent of all food produced globally is not consumed. Aside from being “lost calories” the unnecessary production and consumption of wasted/lost food globally a significant contribution to global warming. The Future Doesn’t Just Happen (Steve Edge, founder and creative director of Edge Design). Having been diagnosed with dyslexia at a young age, Steve Edge relied on art and design to express himself. A bag of glitter, some magic markers and a pair of plastic scissors have been the foundation of his creativity ever since.

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3D printing and packaging: The future is now? This session explores the marked effect 3D printing will have on how we order, design, and manufacture products. They will have a major Impact not just on products, but on our society, and how we live and do business.

Who would you like to meet at Scanpack? Aside from the exhibits and seminars, Scanpack emphasises the fact that it is a trade fair centred on doing business. “Meetings are key,” proclaim the organisers. “Scanpack is the leading trade fair of its kind in northern Europe. But what does that mean for you specifically, as a visitor? You will obviously get to know all the latest developments. All the key players, from designers via industry subcontractors to manufacturers, exhibit there. You can also hear experts in various fields talk about their ideas, work and views on the future. “But a central aspect of the fair is the meetings with other people, visitors and exhibitors, and the contacts you make there: with colleagues in your sector, current and prospective customers, experts, consultants and suppliers. The benefits and enjoyment of Scanpack are created by all its participants, irrespective of whether they exhibit at or visit the fair.” Visit: www.scanpack.se

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Protective packaging perfection Storopack UK is part of the Storopack Group of Germany, which is a leading European manufacturer and distributor of protective packaging products. Philip Yorke spoke to Mark Mardel, the company’s UK National business manager about its focus on expanding its presence in the Nordic markets and beyond.

he Storopack group of companies is represented with over 60 locations in 17 countries and is seeing strong growth in Europe, North America, South America, South East Asia and India. In 2014 the group achieved consolidated sales of more than €350 million. In Europe Storopack recorded revenues of more than €250 million and the group currently employs more than 2300 people worldwide. Storopack continues to expand its presence in the emerging markets with new offices opened in Pune, India and in Bangkok, Thailand. The acquisition of the manufacturing arm of FP International UK Ltd in 2014 increased Storopack’s production capacity for its protective packaging product lines in the UK. The Storopack group has also invested in new production process optimisation systems and is further expanding its services for a temperature controlled transport system with its unique range of pre-qualified system solutions. One of the recent milestones for the Storopack Group has been the acquisition of its long-term partner: Alternative1999 Srl in January 2015. This Italian company has been a partner of Storopack’s since it was founded in 1999 and currently has sales of around €6 million.

Flexibility across the board When it comes to flexible packaging, Storopack offers a menu of ‘flexible’ options when it comes to both standard and customised made-to-measure solutions. Storopack produces high quality protective and transport packaging from EPS and EPP for a variety of industries including electronics, optics, sanitary, automotive and many others. Protective packaging made from expanded foams is stable and stackable; furthermore, mouldings made from EPS and EPP provide excellent shock absorption characteristics. Storopack works in close partnership with its customers to develop solutions specifically tailored to meet their individual needs. Mardel said, “Storopack has a long and interesting history dating back to 1874 when it was founded as a leather tannery in Germany. The company soon expanded to focus on the manufacture of packaging products and in 1973 entered the market with its own range of flexible packaging products. By 1977 Storopack was a major player in Europe and had moved into some key overseas markets as well, such as North and South America, Asia and Africa. In 1987 it was pioneering bio-degradable packaging and in 1995 launched its now well-known Baker range of packaging products.

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“Today we are still innovating and expanding into new markets and are operational in 60 locations and in 17 countries worldwide. Currently the Storopack Group has a turnover of more than €350 million and employs more than 2300 people worldwide. “You ask me what is our flagship product and I would say that our most visible and important flagship product is our ‘Working Comfort’ work ethic, which is principally about looking at workflow, the economics of production and process optimisation. This is a key discipline for us and helps to constantly improve the productivity of our customer’s protective packaging process . This year at Scanpack we will be showcasing our integrated solutions, advanced packaging processes and our bespoke solutions, which are designed to meet our customers’ specific requirements. We offer process optimisation as a major driver for increased efficiency and profitability for our customers. Mardel added, “We are also focused on increasing our presence in Scandinavia, which reports directly to our UK office. In another strategic move, we have recently acquired the manufacturing operation from a leading UK packaging company: FP (Flo-Pak), which provides us with a 2nd major production facility in Brackley , England.” “Here the UK remains a strong market for us and we are seeing double digit growth year-on-year. We also see a major growth opportunity in the form of the E-Commerce market, where the reduction in processing time can have a major impact on efficiency and cost reduction.” , adds Mardel.

Acquisition and innovation driving sales In a another strategic move, Storopack acquired its long-term partner, Alternative 1999 SRL of Italy in January this year. Storopack acquired 100 per cent of the shares in the company which was founded in 1999 and has been Storopack’s Italian partner ever since for the sales of PAPERplus paper padding and AIRplus air cushions. This step has given Storopack its own subsidiary in the Italian market, thereby improving accessibility to local customers for protective packaging products. In tandem with this expansion, Storopack continues to deliver a range of innovative products to the protective packaging market. The company recently extended its range of | 160 | Packaging Europe

AIRplus air cushions with three new types of film. All three film types are designed to replace conventional, pre-inflated bubble-wrap. As a unique, on-demand system, AIRplus significantly reduces storage and handling costs and the AIRplus machine system can be set up directly at the packaging station. For further details of Storopack’s latest innovative products and customer services visit: www.storopack.com

consumer trends in packaging UK-based Tyler Packaging is a specialist supplier of flexible packaging to a range of industries. Adam Kay, the company’s sales and technical director, discusses the company’s operations, including its innovations in single-use packaging and its continued growth in the European market.

t seems that everywhere you turn a ‘need it now’ culture is developing. It’s no different with packaging. With the everyday pace of life becoming more and more frantic, people are increasingly opting to eat on the go, which means packaging needs are changing accordingly with an added emphasis on ‘direct to mouth’ requirements. It’s not just the fast pace of life that’s affecting consumer trends either. With more and more of us opting to live alone or as couples rather than in the traditional family unit, the family pack is becoming less and less of a necessity. Now, people are increasingly turning to single serve options. As a consequence packaging providers have to adapt their outlook if they’re to keep the consumer happy. Looking around supermarkets, it’s evident that packagers are already investing in this consumer trend. Observers might decry this growing development as a cause of unnecessary additional packaging in a world where we should be more environmentally focused. After all, it would seem fairly straightforward to assume that packaging a smaller portion rather than packaging in bulk would require more packaging materials to do so. However, that isn’t necessarily the case, nor is it necessarily detrimental to the environment. The type of packaging used is hugely important. Flexible packaging weighs significantly less, which means its effect on the environment is greatly reduced. When combined with innovative design, the amount of packaging required can also be streamlined to require as little as possible.

reduced in dimension to produce single packs, with little adverse impact on excess packaging.” When it comes to sustainability targets, the clear and obvious benefit of single serve packaging is the reduction it affords in food waste, as it preserves food for longer. Single people can buy food specifically for one meal rather than leaving leftovers, which means a second portion, packaged individually, will be as fresh tomorrow, or even next week, as it is today. According to WRAP, a sustainability charity, UK households waste 7 million tonnes of edible food and drink every year. Single serve packaging will help to greatly reduce that figure as food stays fresher for longer, meaning there’s less requirement to bin the leftovers. Work-life balance is becoming an increasing struggle, making convenience all the more important, which consumers are willing to pay extra for. This opportunity is making it an increasingly popular area for businesses to explore. With food often being delivered direct to desk now, ‘on the go’ packaging is certainly here to say, with more and more businesses adding it to their portfolio. Convenience combined with better preservation is a powerful partnership, which consumers are only set to embrace as time goes on. Single serve packaging is not only here to stay, it’s a growing market and one that shows all the signs of continuing to do so.

Focused on innovation

Expanding European focus

Adam Kay says: “Innovation is something that we pride ourselves on at Tyler and something that is key to meeting sustainability targets. Much of the packaging formats that we currently use, such as our flat base pouches, can easily be

In recent months, Tyler Packaging has been expanding its European focus with the implementation of multilingual websites and the appointment of a European sales manager. Packaging Europe | 161 |

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The new multilingual websites target a broad spectrum of languages, and are now available in German, French, Spanish, Swedish and Russian. The sites have been comprehensively translated, acting independently of each other with their own dedicated domain names .de, .ru, .fr and .es being used as appropriate to the country. According to Adam Kay: “With the increasingly integrated packaging community within the eurozone and indeed the wider international community, it’s important for us to be able to reach as many prospective customers as possible. By creating dedicated websites that are properly translated, we hope to appeal to a much broader market and offer a sufficiently high standard of service.” The English language website has been comprehensively translated – as opposed to using an onsite translation tool – meaning the standard of the language is much higher, with the aim of appealing to key decision makers in positions of influence. “Despite current Eurozone fears, we’re experiencing the effects of an ever increasing flexible packaging market that continues to flourish. We receive interest from a diverse international market, which means we need to be in a position to communicate to a high standard with a multilingual audience. Poorly translated websites can often be detrimental, so we want to ensure that we’re taking the optimum approach.” The Tyler Packaging team has also been expanding with a global audience in mind, thanks to the appointment of Frederic Dionisi, a fluent English, French and German speaker, in the role of European sales manager. The firm is looking to recruit more technical salespeople for Europe as it continues to build its team. Adam Kay says: “Our high level of customer service sees us provide the best experience possible for our clients. Good communication is essential and if we can speak in a customer’s language then it gives us that extra edge.” He concludes: “The multilingual websites are just another example of our growing ambition and intent. The flexible packaging market is expanding at a terrific rate and we aim to emulate that growth through our own endeavours.” Visit: www.tylerpackaging.co.uk

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29 Sept - 2 Oct • Brussels

LABELEXPO europe 20 15 www.labelexpo-europe.com

Labelexpo Europe 2015 Strengthens Focus on Package Printing Package printing will be a core subject at Labelexpo Europe as the show prepares to return to Brussels this autumn. Set to be the biggest ever edition in its 35 year history, Labelexpo Europe 2015’s show floor and feature areas will firmly put the spotlight on the lucrative commercial opportunities package print production offers.

aking place at Brussels Expo in Belgium from 29 September to 2 October, the show is aimed at trade professionals including label and package printers, brand owners and designers. Visitors to the show will be able to see and source the latest label and package printing solutions from over 600 exhibitors. Leading industry suppliers will be there in force with exhibitor highlights including Soma Engineering showing a working press for the first time. Soma will display its mid web Optima CI press platform to present a completely new concept in flexographic printing presses to the label and package printing industry. More commonly perceived as a wide web press manufacturer, Soma has developed the Optima as a mid-web CI press optimized to run label stock paper and film packaging materials, and to bridge the gap between narrow and wide web printing for products such as shrink sleeves, retort | 164 | Packaging Europe

stand-up pouches and sachets, in-mould and wraparound labels, as well as paper sacks, cups and plates. Soma’s Optima will be running live job demonstrations throughout the show. The press being displayed will be equipped with eight printing stations and will feature fast web changeover, intelligent impression adjustment to reduce start-up waste and Soma’s new, award-winning print cartridge system for spot colours, which offers printers a means of significantly reducing ink costs on printing jobs where expensive colours, special effect and metallic ink formulations are required. In addition, the award winning REVO team – consisting of Nuova Gidue, Flint Group, Apex International, AVT, DuPont, Esko, UPM Raflatac and packaging converter Adare Group – will bring new technology to Labelexpo Europe demonstrating how low migra-

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29 Sept - 2 Oct • Brussels

LABELEXPO europe 20 15 www.labelexpo-europe.com

tion UV flexo inks can be used to convert flexible packaging. Currently, most food-grade flexible packaging is printed with either solvent or water-based flexo inks or with solvent gravure. UV has been considered problematic because the photo-initiators can migrate if not fully cured. The REVO team claims to have developed a technology to guarantee that every meter of film within a roll has been fully cured, and that brand colours are consistently matched by a seven-colour process ink set. Covering an unprecedented eight halls, Labelexpo Europe will also host an array of educational feature areas. The Packprint Workshop will give practical insight into how printers can diversify and grow their business with press demonstrations by Xeikon using its 3500 for digital folding cartons and Nilpeter showing its FA* flexo press for flexible packaging capabilities. The Smart Packaging Lab will focus on opportunities in intelligent and active packaging, while the inaugural Packaging Design Studio will give show-goers a chance to network with some of the industry’s leading creative designers. HP Indigo and partners will present their package printing solutions with the return of the Print Your Future feature area. Visitors will be able to see a wide range of applications, including flexible packaging, shrink sleeves and labels alongside new advanced colour management tools and inks. Both the HP Indigo 20000 and WS6800 Digital Presses will be on display. Lisa Milburn, managing director of the Labelexpo Global Series explains: “Package printing is now central to the label printing community and Labelexpo experience. With 53 per cent of our total exhibitors showing products for flexible packaging and 32 per cent featuring products for folding cartons, Labelexpo Europe offers all printers the most extensive showcase of package printing solutions available. Nowhere else will print industry professionals find such a comprehensive range of suppliers and technologies which will help gear up their business, improve profitability and add value for their customers.” An early bird discount rate is available until 18 September with entry to the show costing €55. Registration and further information: www.labelexpo-europe.com | 166 | Packaging Europe

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29 Sept - 2 Oct • Brussels

LABELEXPO europe 20 15 www.labelexpo-europe.com

BST Eltromat Presents Innovations AN

abundant trade fair programme with numerous product introductions and live labelling, product labelling and print technology demonstrations await visitors to FachPack. As one of the world market leaders for quality assurance and production optimisation, BST eltromat International GmbH sees LABELEXPO as an occasion to present their current new developments and further developments to a wider audience. With the focus on the areas of 100% inspection, workflow, web monitoring and colour measurement and web guide regulation, BST eltromat presents innovative production solutions, which contribute to improvements in production efficiency. With regards to web guide regulation, things have changed quite a lot at BST eltromat. Apart from the established product portfolio, the trade fair visitors can get to know further developed solutions for web guide regulation live, promises Ingo Ellerbrock, Product Manager, with a view to the future in label printing: “The trend in label printing is increasingly going in the direction of standardized, extendable compact solutions. At LABELEXPO we present our cost saving entry level solution for web guide regulation with EcoGuide amongst others. Furthermore, we are combining a Wide Array Sensor from our subsidiary AccuWeb Inc. USA with our tried and tested controller ekr 500 digital for the first time. These Wide Array Sensors have large measurement areas to electronically compensate for changes in the web width, and therefore make mechanical adjustments and/or manual alignments of the sensors superfluous.” Apart from the further developments in web guide regulation, the tried and tested BST eltromat systems CompactGuide and SmartGuide, the digital sensor CLS Pro 600 and the current ekr controller generation will also be presented. The trade fair visitors can also look forward to highly interesting further development, where Inline Spectral colour measurement is right at the top of the agenda. Of course BST eltromat is showing its innovative solution for the measurement of absolute colour values with the iPQ-Spectral. In addition however, a further process sequence will also be introduced, which was developed in cooperation with coe, a renowned company in the pre-print stage with headquarters in Bremen and Stuttgart. “What is brand new is that we have transferred the fitting of the colour measurement system from the machine into the

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pre-print stage,” reveals Dr. Christopher Kauczor, Product Manager, in the run up to the trade fair. “Therefore, data and colour values could be determined even in the pre-print stage, which is significantly more economic. This leads to an optimisation of processes which pays off.“ At the same time, the development partner coe will also present the joint solution at its trade fair stand at LABELEXPO. Dirk Volkening, Product Manager, about a new feature of the iPQ-Center: “iPQCheck, the module of the iPQ-Center for the 100% print image inspection, now has new, self developed high performance LED lighting. This means that the module is excellently suited for printing flexible packaging, for all opaque (lightproof) and reflective materials, but of course also for normal paper. We are pleased to be able to introduce these further developments to a larger audience at LABELEXPO, and look forward to the reaction.“ “We are not short on innovations,” Volkening assures us. This also includes the Shark 4000 Lex. The flexible, adjustable 100% inspection system for use on rewinders and narrow web printing machines will support the iPQ-Workflow from now on. “Of course, all data will still be recorded e.g. on the customer server and can be viewed on any PC,” says Volkening. “But due to the fact that the focus is on the important data when evaluating the minutes, the rewinder only stops at the process relevant points. In this way, the production can be run at maximum speed.” This means a significant process improvement says Volkening on the innovations for the Shark 4000 Lex. A further trade fair focus of BST eltromat is the most economic model for video web monitoring, the PowerScope 4000. The operation of the system primarily conceived for label printing and other narrow web applications, is now even more user friendly. “We have taken on an established operating element from our ‘large’ solutions, and added a joystick to the PowerScope 4000. This makes the operating concept of the rotatable and removable keyboard and touch screen even more flexible, and the handling even more intuitive,” reports Dr Christopher Kauczor and adds: “But that is not all. Not by a long shot. In future, the PowerScope 4000 will have the optional possibility of recording a freely configurable order history.” Visit: www.packagingeurope.com/News/64566

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29 Sept - 2 Oct • Brussels

LABELEXPO europe 20 15 www.labelexpo-europe.com

Gallus Showcasing Performance & Efficiency

allus DCS 340 is the first ever modular digital converting system from Gallus – an inkjet printing module integrated into a Gallus machine platform combines the latest digital printing technology with the benefits of conventional printing and further processing technology. This new machine system – developed as a joint venture between Heidelberg and Fujifilm, the leader in inkjet technology – sets new standards in label printing in terms of quality, short-run production efficiency and scope for customisation. A native resolution of 1200 dpi delivers print quality that is unmatched in UV inkjet printing today. By combining the strengths of digital printing with an inline finishing process that has been specially optimised for digital printing, the Gallus DCS 340 gives users the chance to varnish, embellish and further process labels inline – from the roll to the finished die-cut label in a single production operation. For over ten years now, the Gallus RCS machine system has been setting the benchmark in terms of print quality, productivity and flexibility in narrow-web label printing. The success of the Gallus RCS is based on its unique combination of modular design, outstanding process flexibility and high level of automation. Thanks to maximum, end-to-end automation, the Gallus RCS’s extremely short job changeover times and minimum paper waste deliver optimum operational cost-efficiency. For the first time since its market launch, the Gallus RCS is being completely revamped. The machine system is being equipped with a state-of-the-art control platform so as to be ready for future market requirements and advances in technology. This control platform promises printers potential synergies in terms of providing a standardised technology platform for a range of machine systems. Additionally the Gallus RCS 430 convinces with a powerful new UV-drying solution for varnishing. Since its launch, the Gallus ECS 340 has been the top-selling label printing machine with short web path. Over 250 machines worldwide provide daily support to Gallus customers in the label printing sector, helping them to increase productivity and cut

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costs. Installing the new high-performance matrix stripper gives the Gallus ECS 340 an additional feature that further boosts this machine’s productivity and cost-efficiency. The new, innovative functions represent a masterpiece of mechatronics by Gallus development engineers. Additionally the machine system Gallus ECS 340 convinces with a new UV flexographic printing unit with even better performance. The main feature of the new A-Line is its exceptional robustness, which is particularly advantageous when handling screen printing plates both inside and outside the press. The Gallus Screeny A-Line is therefore ideal for maximising the number of times plates can be re-used. This higher re-utilisation rate is also the quickest way to significantly cut costs per screen-printed label. Excellent print results, optimum image resolution, a wide range of possible applications, a perfect ink flow and straightforward final checking of the imaged screen printing plate are further factors that have been taken into account during the development of the Gallus Screeny A-Line. All this makes it the best and most cutting-edge screen printing plate that Gallus currently supplies to the market+

Gallus Original Parts and Consumables present the new self-adhesive Twinlock-Sleeve The special Twinlock surface texture makes it possible to install printing plates time and time again without any need for double-sided adhesive tape. Dirt can be removed from the sleeve with a simple cleaning technique to reactivate its self-adhesive properties. The permanently self-adhesive polymer is connected to a high-quality polyurethane foam that is compressible and maintains this property over the long term. This compressibility ensures that ghosting does not occur with Twinlock. The almost perfect roundness of the sleeve, combined with the quick “recovery” of the polyurethane foam, makes for exceptionally high print speeds. Visit: www.packagingeurope.com/News/64282

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29 Sept - 2 Oct • Brussels

LABELEXPO europe 20 15 www.labelexpo-europe.com

OMET Covering Labelling Needs N

ew iFlex with laser pre-register, XFlex X6 with Flexo+Offset combination, JetPlus digital inkjet printing and UV LED Flexo curing. This is OMET’s plan for the upcoming Labelexpo Europe at stand Stand 6C49-C53. Queen of the show will be the new iFlex 370mm label press, whose simple operation and great ergonomics of use have arisen great interest among converters all over the world since its debut last May. With iFlex, label printing has changed forever as it is by far the ‘best in class’ among entry-level presses. iFlex is supported by tools designed to reach the best performance in terms of quality, rapidity of changeover, waste savings and manoeuvrability by the operator. Specifically, we refer to innovative pre-register and register devices that contribute to speed up the machine set-ups and job changeovers. Among these, iLight, laser-based system supporting the printer to reach the best register in the shortest time and iVision, control system using video-cameras placed on each print unit for immediate register correction before the job reaches the end of the line. The iFlex converting section is a work of art as far as technology and simplicity in use are concerned: the Quick Change Die Cutting (QCDC) is a trolley with two separate parking spots that simplify the replacement of the die cylinder, while Rock’n’Roll is by far the most performing matrix waste rewinding system on the market. XFlex X6 Offset, introduced 2 years ago in Brussels, has scored an incredible success in sales, rapidly becoming the standard in Flexo+Offset label and packaging combination printing. The XFlex X6 Flexo+Offset press represents the ideal bridge between label

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printing and packaging printing as it mixes the highest Offset quality, researched by brand owners worldwide, with Flexo flexibility and completeness. This press is the best solution for converters handling runs of flexible packaging, shrink sleeves, IML labels and special tailor-made applications. The XFlex X6 Offset 430mm (17’’) on show at Labelexpo will introduce, too, the Quick Change Die Cutting converting station as a booster of changeover speed and time saver. If one’s desire is to be ready for the Future of print, XFlex X6 Digital, the third printing machine on show, is the right press. XFlex X6 Digital 430mm (17’’) with 4-color digital inkjet unit JetPlus is the perfect choice when variable data, short runs or sampling are involved. Through XFlex X6 Digital you can print any digital file with no need of pre-press and with the guarantee of high quality results. The combination with Flexo and a full array of in-line finishing and converting options widens the printing possibilities to levels never seen before. Another news awaits customers visiting OMET stand. Flexo printing on XFlex X6 Digital will introduce a great innovation: UV LED curing, which will bring enormous advantages in terms of energy consumption and overall performance. OMET Staff looks forward to meeting all the customers, supporting partners and media on stand and invites all label and packaging potential clients to stop by and ‘touch by hand’ OMET’s full range of solutions for label and packaging printing. With OMET, the Future of the Label and Packaging business is revealed. Anything is possible through OMET innovation, let us guide you in your Future! Visit: www.packagingeurope.com/news/64433

Revolutionary Hybrid Printing Technology from Edale

igh specification printing and converting specialist Edale will be exhibiting its much‐anticipated Graphium‐Hybrid in Brussels this month. Graphium is a fully integrated solution that combines workflow, digital and flexographic print with automated finishing, delivering a highly productive solution for the manufacture of short, medium and long run labels, packaging and cartons. Edale’s partnership alongside FFEI led to the creation of the Graphium Hybrid, a printer that provides the efficiencies of digital printing technology alongside the more traditional, robust flexo printing and finishing. This allows customers to choose a significantly wider range of solutions for their printing requirements. As the packaging and labelling market demands more time and waste efficiencies, Edale have manufactured a machine that allows printers the opportunity to invest wisely in new technologies that support the current market trend and are flexible enough to maximise future commercial growth.

“Edale has been involved in the design and development of web transport technology for single pass inkjet since 2002 and can observe the commercial potential that Graphium holds for the future of the packaging industry,” says James Boughton, managing director. “Developing the web transport, hybrid print and finishing technologies for Graphium over the last 2 years with FFEI has resulted in significant productivity advances.” The Graphium engine is robust, reliable and delivers exceptional print quality on a wide range of substrates and is exactly what is required to be part of an industrial print and finishing solution. ”Edale will be exhibiting the Graphium Hybrid at this year’s LabelExpo across all four days” says Bernhard Grob, Edale export sales director, “demonstrating a wide range of processes and samples, Edale’s experienced team of technicians and designers will be on hand to discuss this innovative machine in more depth.” Visit: www.packagingeurope.com/News/64630

Packaging Europe | 173 |

29 Sept - 2 Oct • Brussels

LABELEXPO europe 20 15 www.labelexpo-europe.com

Goss Reveals New Capabilities G

oss International will be presenting its latest offset technology developments and opportunities for converters at 7-D18. First-hand information about Alwan’s Color Expertise Technology, a recent addition to the Goss Sunday Vpak press series, will be a highlight for visitors to the Goss stand. This latest suite of software is now commercially available following months of rigorous testing at Goss’s Packaging Technology Centre in New Hampshire, USA. Alwan’s technology suite features an extended colour gamut, which adds two or three inks to conventional process inks, enabling exact brand colour reproduction without the need for spot inks. Facilitating a substantial reduction in the costs usually associated with ink changeovers, the update is expected to bring customers a 30 to 50 % cost reduction compared to the use of spot inks through a combination of eliminating ink changeovers and reduced ink inventories. “We are extremely committed to pushing the boundaries in printing and packaging, and consistently delivering best-in-class products,” said David Muncaster, director of EMEA business development for packaging at Goss International. “We are delighted to have partnered with Alwan, who share our passion for innovative print solutions. Our Vpak range already combines cost-effective hybrid solutions with superior print quality and the addition of Alwan’s extended colour gamut further strengthens our offering in the labels and packaging market. We are confident that our combined expertise will enable not only reduced time and material waste but will also allow us to continue delivering market-leading quality, flexibility and control.”

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The extended color gamut is just one feature on the four-part technology suite from Alwan which is now available on the full Goss product range. The suite also includes colour management and quality control software which helps to increase print quality and consistency; reduce cost and ultimately maximise productivity across the production cycle. Goss have also made a number of highly anticipated changes to its Vpak presses in order to further reduce waste and optimise the printing process for flexible packaging customers in particular. According to Goss, the partnership and technology updates reflect the company’s commitment to driving ongoing development across their portfolio, and follow a number of recent ‘kaizen’ events held specifically to improve equipment design and streamline processes. “With the growing trend towards shorter run lengths, printers and converters are increasingly having to find solutions to balance customer expectations and profitability,” continues Muncaster. “Our most recent ‘kaizen’ event focused on job changeover process which is now increasingly critical in order to make customers’ working lives easier and more profitable. We are extremely excited to share our latest developments at Labelexpo this year, and demonstrate how our people, products and partners are together delivering the flexibility, high quality and cost effectiveness that is so essential in today’s packaging market.” Visit: www.packagingeurope.com/Packaging-Europe-News/64708

Next day delivery thermal transfer ribbons T

hermal Transfer Solutions Ltd (TTS) is Europe’s leading thermal transfer ribbon converter dedicated to helping trade only partners increase sales of thermal transfer ribbons. The majority of its trade partners are manufacturers of labels and selling thermal transfer ribbons helps these companies add value, increase sales and help protect their label business. TTS has grown quickly in the UK market by offering a premium range of products with very competitive prices delivered on a next day basis. To help expand its sales into the Benelux area TTS has recently appointed two new business development managers to support its growing network of partners in the Benelux. Jordy Brouwer has many years of experience and is based from Amsterdam. Pierre van Aerssen also has many years of experience and is based from Brussels. TTS will now be stocking an extensive range of thermal transfer ribbons from their new Amsterdam facility for next day delivery throughout the Benelux.

TPS signs partnership agreement with leading Italian Print & Apply giant Meanwhile, sister company Thermal Printer Support Ltd (TPS), the UK’s leading trade only supplier of thermal transfer printer on-site support and ad-hoc services has added the ARCA range of print & apply and label applicator’s to its range of products that they can support. TPS will be able to support manufacturers who have existing ARCA systems with on-site support, spares and engineering support as well as supporting them through new projects starting with the consulting & planning stage right through to the installation and on-going support. TPS recently appointed a new business development manager Tony King who brings with him a wealth of knowledge in offering innovative solutions for companies who wish to automate or update their existing production lines with new high speed, precision label applicator’s and print & apply solutions. Visit: www.thermaltransfersolutions.com and www.thermalprintersupport.com

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29 Sept - 2 Oct • Brussels

LABELEXPO europe 20 15 www.labelexpo-europe.com

Smart Packaging Lab Active and intelligent packaging technology is continuously evolving; its rapid development propelled by the growing pressures of modern society and brand owner’s demands. With these necessities fuelling continued innovation for smart applications across the label and packaging sector, Labelexpo Europe 2015 will focus on some of the latest various systems as part of the inaugural Smart Packaging Lab.

ackaging Europe caught up with some of the feature area’s exhibitors to find out what’s driving this surge and what lies ahead in the future for consumers and brand owners alike.

What have been the key drivers for you developing and offering this kind of smart packaging? Reinhard Zimmermann of Systec says “RFID is beginning to roll out in all major industries world-wide. The food industry is utilising RFID for monitoring of food freshness from point of origin to end consumer. The medical industry has jumped on board with RFID to help monitor patients and keep track of medications and medical instruments.” For Avery Dennison, which is showcasing a range of different technologies, Judy Abelman explains “Our development of RFID solutions is primarily to provide our customers with increased levels of inventory accuracy and visibility that cannot be achieved with current solutions. The company’s TT Sensor Plus is designed to help solve a number of problems in the supply chain with regard to temperature monitoring - from reducing food waste, identifying where/when temperature excursions

happen to providing accurate temperature data for pharmaceuticals. DirectLink is about consumer engagement it gives the brand the ability to directly connect to the consumer through their smartphone using an NFC feature.”

Smart packaging is still going through a huge period of development and take-up. What are the main barriers you face in rolling this kind of application out to your customers? Abelman tells us that “Based on the experience of early RFID adopters, every retailer can benefit from the right RFID solution optimised for their operation. The hurdle that our customers face is trying to determine if their organisation is ready for RFID and then evaluating which solution is right for them. From a consumer engagement perspective one barrier is consumer awareness of NFC. Many consumers don’t know their phone even has NFC capability.” Zimmermann points out that “Equipment cost is always a factor. However, I believe one of the greatest barriers is helping companies understand that this technology is the wave of the future. RFID technology and other forms of smart and active packaging are here to stay and will only continue to grow.”

What are the main benefits smart and active packaging offer different users – brand owner, retailer and consumer? Abelman believes that “Consumer engagement from a brand’s packaging will benefit all three. Brands can more closely engage the consumer resulting in sales lift and building loyalty, consumers benefit by receiving incentives and more prod-

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their decisions and want to be assured that they are making the best purchase decision no matter what the industry. It’s our job to help our clients deliver this satisfaction.” Abelman emphasises the importance of consumer engagement “Smart packaging gives brands the ability to directly connect to a consumer from their product. A brand can deliver virtually any kind of digital media right from their product on the shelf. A brand can deliver incentives, tutorials, cross promotions and they can connect that consumer to their social media page. All this without having to purchase signage or shelf space from the retailer. Smart packaging has the ability to give the brand more control on ways to reach their end consumer.” Ignacio López-Baillo of Taghleef Industries backs up the other’s views “Smart packaging is already playing and will continue to play a very important role in influencing consumer’s purchasing behaviour and its loyalty to a brand. It will help increase the interaction between the consumer and the brand, build up trust on the brand and therefore consolidate stronger ties between the consumer and the brand.” uct information and retailers benefit from sales lift as well. Other benefits can be realised from smart packaging as well, anti-counterfeit features can be included in the package and correcting supply chain issues by providing accurate data on the temperature the product is exposed to throughout the supply chain just to name two. For retailers, the increased inventory accuracy and visibility that RFID allows, helps them have the desired goods in store when the customer wants them. The more items a retailer can sell for full price, the fewer the markdowns and the higher the profit margins.” Zimmermann echoes Abelman in the value smart packaging can add: “Brand owners are able to track and collect data of their products like never before. They can then analyse this data and use it to create their next big product or to tweak an existing product. Smart and active packaging helps brand owners better understand their customers, clients and themselves.” “Retailers benefit from RFID in similar ways as brand owners. However, retailers may want to receive and analyse different types of data. Do you need to order more of one product versus another? There is no longer a need to spend countless amounts of money on labour to have your employees hand count items; not to mention the elimination of human error. With RFID technology, inventory is done for you and in real time. RFID technology can help eliminate theft. If you can keep theft down, you can keep your prices down and your customers happy. Zimmermann sums up “Consumers can benefit from RFID through cost savings! Just as the retailer example, if a store is decreasing the amount of items that are loss due to theft every year, the retailer will not have to raise their prices to cover the lost inventory which ultimately keeps the prices low for the end consumer. Another benefit to the consumer is brand awareness and being confident to make informed decisions. How would you like to go to the grocery store and have the ability to pick up a litre of milk and be able to see the freshness or quality of that product in its current state displayed on an electric patch? This technology is already rolling out into grocery stores across the globe.”

Lastly, where do you think the future of smart packaging lies? The exhibitors were unanimous in the increasingly important role smart packaging will play going forward as Zimmermann reasoned “Smart packaging is here to stay. It is already impacting all of our major industries; food, retail, automotive, manufacturing, etc. We are only going to see this trend continue to grow and it will soon become the norm.”

How much do you think smart packaging technologies can impact a consumer’s purchasing behaviour and brand loyalty and how do you think the retail sector will evolve as a result? Zimmermann comments “Once more and more grocery stores start displaying this type of technology on their food products that consumers are going to grow accustomed to it. Think about it – Are you going to go to the grocery store that shows the level of freshness on your food or go to the grocery store where you grab something off the shelf and hope that it’s still good? Consumers are becoming more conscious of Packaging Europe | 177 |

Originate, emboss and laminate ITW Foils is a global leader in the manufacture of technically superior foils, films and laminates for a number of markets including packaging and labels. Libby White spoke with Mr Gary Jones, sales director, about the company’s exciting recent developments and its plans for the Labelexpo Europe 2015 exhibition.

TW Foils is part of a company that has operated for more than a century, Illinois Tool Works, which has a global footprint and presence in over 50 countries worldwide. Consisting of seven segments and 90 divisions, ITW is supported by over 50,000 employees worldwide, with a total revenue of 15 billion US dollars in 2014. The company has grown significantly through a 30-year period of acquisitions of profitable, well-run and innovative companies. Today, ITW focuses on innovating and organic growth. The ITW Foils division was acquired by ITW in 1991 and consisted of one manufacturing site in the US and one in the UK. In 1998, a further acquisition added holographic capabilities, and a final acquisition was made in 1999 of a state-of-the-art facility based in South Korea. Today it has over 500 employees in total.

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Mr Jones expresses the unusual characteristics of ITW Foils in the industry, “We are one of the few companies who can on a global basis offer foils, films, and lamination alongside tooling capabilities.”

Making brands shine “Our customers are printers and converters, and we also work with the brand owners such as Proctor & Gamble, Diageo and Unilever, providing bespoke designs and solutions for them. Our portfolio also caters to the greetings card market with renowned customers such as American Greetings, and Hallmark. Publishing is our third main market in which we cater for paperback books, and dustcovers for hardback books. The packaging and labels markets are our main focus,” Mr Jones explains.

ITW Foils has three main product groups. Firstly, it offers hot stamping foils with both metallic and pigment foils. They are specifically designed to meet all the challenges of substrates, design and production. Whether used off-line or with rotary stamping equipment, its foils produce a crisp, durable impression and provide the highest quality finished product with a superior level of shine and brilliance. Secondly on offer are cold foils. Mr Jones comments, “This is an extremely large and fast growing segment within the industry which has seen significant growth within the last seven years, whilst also eroding into the hot foil segment. As we will continue to advance the cold foils, and alongside the developments in technology and machinery from the equipment manufacturers for the printer, it has become a competitive, cost effective, and efficient solution to compete in the marketplace.” The third focus is the manufacture of high volume, wide web laminations, custom holographic design, origination services, and high volume wide web film embossing. For a more environmentally friendly solution, ITW Foils also offers Ecoshine™ transfer metallised substrates where holographic patterns are applied to papers and paperboards without the use of plastic film carriers for packaging that can be easily recycled using conventional methods. In addition, ITW Foils offers UV casting films which uses a revolutionary inline decorative process to create rich, high gloss holographic effects on a variety of substrates in both sheet fed and web environments.

High end solutions ITW Foils strives to be at the forefront of new product development. At this year’s Labelexpo Europe exhibition, the company will be showcasing its latest solutions and of note a new solution that will be introduced predominantly to the European market. Designed to cater for specific needs, the new GSP hot stamp foil has great adhesion characteristics at low temperatures, is designed for a very high working speed, and has excellent opacity. Furthermore, at Labelexpo, the stand will be focused around ITW Foils’ dedication to innovation and its ability to provide bespoke and custom designs for brand owners. “We

will be showcasing our holographics range, as well as our cold foil innovations. Cold foil has seen significant growth already in the US and this is now really starting to take off in Europe as well, and Labelexpo is the perfect platform for us to share our products,” Mr Jones comments. For holographics, Mr Jones points out that typical colours used tend to be gold or silver. “We focus on developing customer backed innovations, and in terms of holographics we are receiving requests from the brand owners for more muted colours. To address this, we have developed what we call ‘white holographics’, which are becoming increasing popular. A number of beverage brands are already starting to use our white holographic solutions.” Another demand from the brand owners has been directly addressed by ITW Foils. Seamless holography is the new standard of excellence within the packaging industry. With ITW Foils’ advanced capabilities, the troublesome seam in holographic film can be eliminated to create apparently perfect holographic surfaces. “Our customers can be safe in the knowledge that all of their products will be seam free. To build a brand and keep integrity, they can now achieve a high end finish without imperfections,” Mr Jones is proud to say.

State of the art facilities The headquarters for ITW Foils are located in the US in Newburyport, Massachusetts. Here, the state-of-the-art facilities have the capabilities to produce cold and hot foils and films, as well as holographic embossing, and it houses the holographic origination laboratory. Mr Jones comments, “There is so much shelf competition today that packaging is one of the critical sales and marketing vehicles that allows brands to differentiate and stand out. Our holographic lab gives us the ability to develop custom and bespoke designs for brand owners.” The second main state-of-the-art manufacturing facility is located in South Korea. Together, these two facilities can provide ITW Foils’ products on a global scale. Packaging Europe | 179 |

A lamination facility is located in Montreal, Canada, and a facility in Bloomfield, Connecticut focuses on producing environmentally friendly transfer films. Manufacturing for cold foil and converting warehousing is also located in Connecticut. Florida is home to the Ikela facility, where production of tooling is based, such as brass tooling for flat hot stamping and narrow web brass cylinders. The company’s European headquarters are located in Holland, supported by further warehousing facilities in Spain and Italy.

Expanding markets ITW Foils has made a number of investments and improvements recently to cater for current and future expansion. Mr Jones says, “As we continue with the success of our cold foils, we have added capacity to cater for growing demand. For our seamless solutions, we have continued to upgrade our seamless technology and modify our existing equipment.” The core focus of ITW Foils is to expand its current product range for the packaging and labelling markets; however Mr Jones highlights that it also looks towards adjacent markets for expansion: “A significant segment we are excited about developing into is shrink sleeves, which is obviously a growing segment within the industry. New bottle designs require shrink film and foil to shrink greater than 40 per cent. Historically there have been limitations around holography, as when you try to shrink a metallised film to that extend it cracks and distorts.” ITW Foils has been working on overcoming those limitations and working alongside its customers to produce shrink sleeves with metallised or holographic images, without resulting in cracking or distortion. Flexible packaging is another potential market for expansion. Mr Jones shares, “We have customers with multilayer flexible packaging asking for a holographic layer. We are currently working on the ability to add a holographic metallised layer to give multilayer packaging added shelf appeal.” | 180 | Packaging Europe

Core strategies Mr Jones points out that during the recession, there was less demand for holography as customers were cutting back on their own investments. However now the global economy is growing again, brands are naturally investing more and he sees a rise in demand for their solutions. He shares, “We are well positioned in North America and see significant growth in the European market. We have a strong base in Asia and are looking at South America as a potential market for growth, where we will be focusing our efforts on expanding our current base over the next several years.” ITW Foils, in sync with the ITW group, has three main focuses to garner success. Firstly, it follows the 80:20 philosophy whereby 80 per cent of the results are achieved from 20 per cent of the activities of the company. The second focus is to produce customer backed innovation, as Mr Jones explains: “We work closely with our customers – the printers, converters, and brand owners – to ensure we develop solutions to address the needs of the market.” The third strategy is decentralisation. Although a large company, ITW allows its divisions to make their own decisions without any red tape. Mr Jones says, “This means we understand our marketplace better and can develop solutions more quickly.” He leaves us with his view on where he believes future growth will come from, “The cold foils segment will continue to grow over the next five years as advancements are made on both the product development and equipment development side of the industry.” For more information, visit www.itwfoils.eu

DynaMelt SR - The Packaging Flagship

Application excellence Global hot melt adhesive solutions company ITW Dynatec is growing across its market segments, with innovations, investments and expansions all in place for 2015 and beyond. Packaging Europe spoke to sales director Stephan Schultheis to learn more. Emma-Jane Batey reports.

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Dyna MicroBead applicator - High speed fast intermittent for packaging application

Cross CoatTM - Flexible width - highest accuracy

CrossCoatTM The European Headquarter in Mettmann, Germany

Streak-free non-contact coating

ounded in 1992 from the merger of two US and one European companies, ITW Dynatec is a globally-active hot melt adhesives solutions company with four key market segments. Active in disposable hygiene products, coating and laminating, product assembly and packaging, ITW Dynatec’s broad range of solutions all draw on its extensive capabilities in the adhesive machinery sector. Sales director Stephan Schultheis spoke to Packaging Europe about how the company has grown and developed in its more than 20 year history. He said, “From the beginning we have been a global company, with major offices in the US, Europe and Japan. At that time, our parent company recognised the growth potential of the adhesive market and made strategic investments in order to secure a leading role. Since then, ITW Dynatec has acquired companies in France and Germany and we are now successful across Europe, the Americas and Asia, especially China.” With four core market segments, ITW Dynatec has clearly identified its position. The largest segment is disposable hygiene products, such as nappies, incontinence products and medical wound care. Mr Schultheis continued, “This segment accounts for nearly one third of our sales and is our strongest growing area. Here, we cooperate with major manufacturers of hygiene products as well as manufacturers of their machines who | 182 | Packaging Europe

Stephan Schultheis, sales director

integrate our systems into their production lines. We are seeing especially strong growth in this segment in Asia, thanks to its rising birth rates, and in Europe, the US and Japan due to the ageing society in these countries.”

Strong position ITW Dynatec’s second biggest segment is its coating and laminating activities, which focuses on the production of self-adhesive film labels, packaging films and technical textiles such as those used for label stock. Mr Schultheis added, “In 2011 we strengthened our position in the coating and laminating segment by acquiring Inatec GmbH. Inatec was particularly strong with regards to reel to reel processing technologies but was primarily focused on its domestic German market. Since we acquired the company we have been able to utilise the processing technologies capabilities while integrating this into our global footprint.” The company’s third segment is product assembly, which sees – among others - it offer solutions to the automotive industry including bonding solutions for the assembly of car headlights. ITW Dynatec’s packaging activities represent its fourth largest segment and here it offers packaging films and self-adhesive films as well as carton closing and tray bonding

DynaMelt D series . Multiple pumps, flexible melt rates

Apex Application heads - High speed intermittent application

capabilities. Mr Schultheis explained, “Generally our range of solutions for the packaging and labelling sectors includes systems for standard, reactive or UV curable adhesives that meet our customers’ most challenging demands. We provide a range of different adhesive materials in this field suited to various application technologies and solutions, such as our DrumUnloader, adhesive units or pumping stations.” Mr Schultheis is clear that continued innovation is at the core of ITW Dynatec’s ongoing success, particularly within the packaging sector. He said, “We know that the success of a perfect adhesive application stands and falls with the application head technology. We have proved to our customers that we are able to provide extremely innovative solutions. An example of this is our ITW Dynatec Vector Surge Technology which has won awards at both IDEA in Miami and the INDEX in Geneva. Its core advantages are that it can lay down adhesives in one path both in line and cross machine direction, which means it can deposit rectangles with a blank centre at high speed. Coming from the nonwoven business, this technology allows special label designs to be produced with a combination of intermittent and continuous application using just one application head.”

placed, with its growing market share and constant innovation putting it strongly in the market-leading position. Mr Schultheis concluded, “We are always investing in our future success. We are expanding our production facility in France in order to ensure that our module business is as strong as possible; an application module is one of the most important elements in the production process and the quality, speed, durability and reliability of the modules we provide are key to the sophisticated applications in the various markets in which we operate. Customers know they can trust ITW Dynatec. We see a lot of growth potential across our active markets and we are excited to be presenting at a number of international trade fairs in the future coming months.” Visit: www.itwdynatec.com

Winning innovation Another award-nominated innovation from ITW Dynatec is its TwinCoat technology, which was rewarded at the last LabelExpo in Chicago. This patented technology can run two adhesives at the same time and, depending on the customers’ specific requirement, can be run on top of each other or in a stripe design next to each other. The two different adhesives can have different characteristics such as coat weights, colours or qualities, making it an extremely flexible technology. With its main locations in Hendersonville,USA; Cherisy, France; Tokyo,Japan and Sushou,China, as well as an assembly and test facility in Mettmann, Germany, ITW Dynatec has a solid global footprint and the ability to meet its customers’ needs wherever they are in the world. The company’s ambitious plans for continued success are well-

TwinCoat TM - Winning Innovation

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Bringing Japanese

inspection quality to Europe Futec was founded in Japan 30 years ago as a pioneer in inspection systems and has become a market leader in a wide range of industries. The company has been present on the European market for 20 years, and recently opened a hub in Germany so more customers can benefit from the high quality of products made in Japan. Elisabeth Skoda spoke to Peter Wintjens, one of the company’s sales managers, to find out more about recent innovations and its upcoming appearance at Labelexpo.

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a market leader in Asia, Futec currently sells around 400 pieces of 100 per cent inspection systems a year. Applications include optical flaw inspection systems for surface inspection and printed web inspection. “Inspection systems are a lot more widely used in Asia than they are in Europe. In Japan, there is commonly a separate inspection system for each product step from raw materials and films to printing and rewinding. Europe is lagging behind in this development, but we see potential for a similar development towards more inspection in Europe,” Mr Wintjens says. Futec has been present on the European market for 20 years. In order to improve both sales presence and service levels in Europe, Futec Europe GmbH was founded in Duisburg in Germany at the end of 2014. “We already have sales/service offices in Italy and the UK and many sales partners selling Futec equipment in Europe. There will be further growth in manpower in Germany, where the European headquarters will also be situated,” Mr Wintjens explains. Also, the agent network across Europe will be developed further.

Product portfolio Futec’s inspection system business is divided in two divisions – surface inspection and print inspection. Surface inspection focuses on films, paper, metal and nonwovens, and print inspection covers gravure, offset, digital, label and flexo. Futec’s printed web inspection systems, encompassed in the EasyMax range, are intended to inspect a wide range of printed materials, such as flexible packaging film, cigarette cartons and pharmaceutical packaging continuously printed by gravure, flexo or offset printing machines. An innovation in the field of surface inspection Mr Wintjens is keen to talk about is the MaxEye.FilmST, a quality control system for films. “There is a growing market for film extruders, and this product, an entry model with a good price/performance ratio,

addresses this demand. The MaxEye.Film range features the next generation of quality control systems for today’s market and encompasses flexibility, ease of operation and modern technology.” This is especially true for high end applications in the electronic industry (photovoltaic, capacitors, touch screens and so on).

Labelexpo premiere At the upcoming Labelexpo trade fair, Futec will showcase the newest version of EasyMax.Label. Some other newly developed products are FCU (full capture unit) and IQM (Integrated Quality Management) for all systems. The FCU system allows the user to store all raw data from the inspection system and to re-run the data in order to optimise parameter settings or to compare the performance of different inspection systems. IQM is a higher-level control tool, used to manage inspection systems at different production steps, locations etc.

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Futec’s appearance at Labelexpo is a premiere, and apart from recent innovations the company will also showcase accessories for a range of products. “It is the first time we are attending Labelexpo, to see what the competitive situation is in Europe and what is happening in the industry. Label print is one of the growing market segments. Futec wants to grow in Europe, so exhibitions like Labelexpo, Scanpack and Drupa are of great importance,” Mr Wintjens says.

Reliable partner Futec combines Japanese high quality standards and European service levels with short reaction times in order to offer the best possible product for its customers. “We develop and produce all our components in-house, which allows us to provide stable, accurate products. We want to further reduce our reaction time to make us an even more reliable partner to our customers. Of course everybody expects high quality, but serviceability after the product is sold is an even bigger distinguishing factor. Our 30 years of experience is a good argument for our customers to buy our systems,” Mr Wintjens is proud to point out. Mr Wintjens explains that Futec’s systems are robust and work consistently well. “PCs can be unreliable and slow, but with Futec, this is not a problem, as the signal processing unit for the inspection system is hardware based. Microsoft Windows is just used to present the results and so our customers never have to worry about a blue screen ever again. Other systems are software based, which gives them a less stable package. Futec is able to make systems very reliable.”

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At its new sales office in Germany, Futec hired eight people in a short period of time in order to increase the brand presence. “We expect to grow significantly in the next two years, investing in new products. We have several new products in the pipeline, and our investment in R&D is continuously high.” France, Spain Portugal, UK/Ireland, BeNelux and Scandinavia are covered with the company’s agents. In the remaining parts of Europe it is currently working on its sales network.

Potential Mr Wintjens identifies the main market in Europe as the flexo print segment. “We see big potential in this area and are well equipped for it with our product range. Futec is already one of the market leaders in Asia. Our new focus of expansion is Europe. With our European offices, we want to make sure that our European customers get access to our technology and are provided with a reliable and good service. With our new German office, we made strong progress in this direction.” He sees a very positive future for the company especially in the flexo market. “We expect growth rates in the region of over 10 per cent in Europe. Customer satisfaction is what really brings growth in the long term. If our customers are 100 per cent happy with us, they will come back to us time and again.” Visit: www.futec-global.com

RESEARCH IN THEIR BLOOD IGT Testing Systems, one of the global leaders in the production of printability testers for paper, ink and printing industries, is returning to Labelexpo Europe 2015 in Brussels with some new high-tech products. Mr Wilco de Groot, managing director of IGT, talked Vanja Švačko through the journey that has made the company what it is today.

ounded in 1939 in the Netherlands as a national research Institute for Graphic Techniques TNO, IGT has kept research at the core of its business for eight decades. The company started by studying various aspects of ink and printing technologies, developing some provisional tools for TNO using what were, at the time, very basic facilities. Over time the Institute has become an outstanding global player, resulting in cooperation with similar organisations and availability of instruments for all. As the national institutes were not allowed to have any commercial interest, research remained their primary business. However, the sales of test equipment significantly increased turnover, which inevitably influenced what happened next. “In 1982 the Institute was closed down and the process of privatisation began,” explained Mr De Groot. “The independent life of IGT, working not only for research but for industry as well, started when many national institutes in the Netherlands were closed. Commercial activities such as selling equipment became the focus of the newly privatised business. “However, for IGT research has always been the basis of its existence. We continued working on past projects, hoping for some possible spin-offs in the future. This gradually grew into third-party research and troubleshooting. Once we moved from TNO, we started running new laboratories with different functionalities and we are still doing the same work.”

Changing product philosophy In the 1990s IGT changed its product philosophy, turning from complicated multipurpose instruments for the research institutes and departments at large-sized companies towards a two-tier range of instruments. Exploiting the findings from the complex products, the company has developed a number of smaller, single-purpose instruments mainly for quality control in paper mills, ink manufacturing and the printing industry. Today IGT’s portfolio is directly related to printability and tack measurement, including printability testers, which produce strips in offset, flexo and rotogravure. These are suitable for measuring colour and testing the quality of inks, paper, plastic and many other substrates. The company also runs training and offers education on the printability on all kind of materials, consultancy, troubleshooting and laboratory testing. Services also include a print shop certification for ISO 12647 and ink certification according to different parts of ISO 2846. Mr De Groot told us, “Although sales of the instruments create the most revenue, we cannot sell them without providing proper test methods. Most of our instruments are sold based on preliminary research by our trouble-shooters in direct contact with clients on their premises. Once we develop test methods for them, they buy the instruments related to specific methods. It means that we actually sell the test method to the customers who then buy the instruments with it.”

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The company has affiliates in the USA, Singapore and Japan, and is currently opening a new office and a completely new laboratory. Its representatives are located in 40 countries, but in terms of sales IGT is active in more than 100 countries.

Eye-opening exhibitions In 2011 IGT took over the company Testprint, whose outstanding design team helped IGT to redesign several instruments, introduced at DRUPA in 2012. “The exhibition was an eye opener as well as a confirmation for us,” added Mr De Groot. “We have learned that demands on the market were high, so over the past three years we have been developing a number of small devices and redesigning existing ones and this was the right choice.” “We strive to make a compatible range of instruments for research and QC. The larger, more expensive, multi-purpose instruments can be used in R&D and to develop the QC test procedures. In the QC departments the materials can be tested with the same settings and materials on single purpose, lower cost machines. Also most printing processes can be simulated on one multipurpose instrument. All new instruments have almost identical displays and operational interface so that handling can be easily learned by anyone who already knows how to operate one instrument.” This year was exceptional for the number of innovations developed by IGT’s expert team. They include Amsterdam 6 (a general purpose printability tester with 6 print-

ing stations), a Laray-type viscometer with integrated temperature sensor and viscosity calculation software, completely renewed software for Lintview tester, Cloudoscope and a sizing tester for paper coating. IGT regularly introduces new instruments at Labelexpo. “This year we will formally introduce our F1 Flexographic tester,” said Mr De Groot. “This device has been fully renewed with a complete PC functionality inside for control and storage of data and settings for each test. It has a number of pre-programmed test methods and the possibility to add customised or complete new test methods. The settings can also be exported, for example, to an Excel file for later analysis or can be printed on a label printer to mark the printed strips before filing. Another device, initially intended for the Asian market, will be introduced to the European customers: Simply Gravure, a very low cost gravure ink proof printer with limited functions for the small print shops.” The company is actively pursuing the options for printability testing for digital printing in the widest context. “Our strategy for the future with respect to modern instruments is to link them to our own relevant devices and to allow the connection of third party instruments so the results and the settings are available in an integrated database, saving the user time, errors and effort to do their own analysis.” Visit: www.igt.nl

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Emax Label Solutions - the

labeling solution

engineers from the Netherlands Emax Label Solutions offers labelling solutions the garment, mattress, carpet, automotive, and food & non-food packaging industries. Packaging Europe spoke with Managing Director Mark de Beurs.

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ark talks about the company’s upcoming participation in the world largest labelling exhibition Labelexpo in Brussels, and the company’s desire to establish itself as a globally recognised provider of labelling solutions, in particular for tricky and challenging labelling needs. Mark de Beurs says: “Part of our future growth will come from the growing demand for smaller print runs - more variable data and personalised labels. Digital printing in combination with demand for special requirements on the adhesives will be a growing market where we will be able to gain market share.” The history of Emax Label Solutions goes back to 1975, when the company Multistiq was founded, of which Emax is a spin-off. Multistiq develops and sells a wide range of substrates, varying from textiles to paper and films, for the label industry. These substrates are coated with heat-seal, hot melt or acrylic self-adhesives, or top coatings which improve non-fray- and/or printing properties. Mark de Beurs adds: “When we founded Emax Label Solutions in 2011, we widened our customer base significantly by expanding our product portfolio to garment, mattress, and carpet labels.” Emax Label Solutions is a joint venture with the Spanish company Chiasa, with a production facility approximately 45 minutes north of Barcelona, and another production facility in the Netherlands, at approximately one hour drive

from Amsterdam, and one and a half hour drive from the major German cities Essen, Duisburg, Dortmund and Düsseldorf. The joint venture employs around 200 people. “The synergy of know-how, our efficient production procedures and the proficient sales and distribution channels are the perfect combination for our labelling activities in the garment, mattress and carpet industries. The materials that we offer are available for both digital and traditional printing. Both production facilities have potential to grow and are located close to important logistic lines, both for Europe and export worldwide,” Mark de Beurs points out.

Labelexpo Europe in Brussels Labelexpo Europe is the world’s largest event for the label and package printing industry that takes place every year, in Brussels. Printing and converting professionals as well as label designers learn about global label trends and technologies, and can meet with the world’s leading industry experts. Mark de Beurs: “Labelexpo Europe is one of the largest events for our company. Since the exhibition is a showcase of latest trends we expect that we can attract new customers that are dealing with complex labelling applications and need to find intelligent solutions that Emax can offer.”

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The company intends to show quite a number of new products especially designed for industries. Emax has started to leave its footprints, most notably in the automotive, construction, and chemical industries and has just signed a 3-year contract with a major European tyre manufacturer. Mark de Beurs explains: “We have developed a range of new materials with strong adhesives for high speed inkjet printing. This includes textiles, synthetic paper, films, paper, and non-woven. We also have extended our range of tyre labels, and have started selling label materials for the concrete, steel, and chemical industries, adhering to the BS 5609 standard, in combination with high speed inkjet materials.”

New products While the company has traditionally been well-known the world over in the garment, mattress, and carpet industries, it has steadily been working on developing labelling materials for the banding industry in the food and beverage market. “As for the food and beverage markets, I don’t see us supplying label solutions for the straight-forward labelling of food packaging, but I think we are the right partner when it comes down to the more complex labelling demands, that are quite often also the more interesting ones to work on. At the Labelexpo we will probably attend at least the workshops on digital printing, since we believe this will be a fast growing market segment, and the one on label, folding carton and flexible packaging solutions - ‘print your future’,” Mark de Beurs adds.

Investments Emax Label Solutions recently inaugurated its new 15.000 m2 production facility in Goor, the Netherlands, and expanded its production facility in Sallent, near Barcelona, by 5.000 m2.

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Mark de Beurs: “The expansion of both of our production facilities has improved efficiency and delivery times. In the Netherlands we also invested in a new stenterframe for our textile products and a hotmelt coating line, while in Spain a new slitter/rewinder has been installed.”

New market orientations The textile industry has traditionally been the company’s playground; it has supplied customers from New Zealand to the US & Canada, mainly due to the excellent quality of the company’s products, its flexibility and ability to customize products. “We now want to expand our experience to the industrial markets, where we believe our knowledge of strong adhesives, in combination with reliability, flexibility and inventiveness will create chances for us and our customers alike,” Mark de Beurs adds.

Shared sales offices Emax Label Solutions has its own Turkish sales office in Istanbul, while the company has service access to local customers the world over through the sales offices of its joint venture, based in the UK, Italy, Brazil, Mexico, Bangladesh, Vietnam, Hong Kong, and the US. Mark de Beurs concludes: “For the near future we will focus more on organic growth and partnerships than on acquisitions, although you never know when a perfect fit comes along. For the next five years this should allow us to have an average growth of between five and ten percent per year, which we can easily produce after our latest investments.” Visit: www.graphid.nl

High-tech die-cutting

on a low budget Just in time for Labelexpo Europe, Berhalter is introducing a new die-cutting tool concept for in-mould labels (IML) for the global market. The company will be exhibiting the latest Berhalter die-cutting machine generation in combination with the new LABEL-light™ tool, which offers different advantages such as lower tool costs and short lead times.

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he Berhalter LABEL-light™ punching tool is a patented tool concept combining the advantages of the flat-bed die-cutting, such as unique printto-die registration and perfect handling properties, with the advantages of affordable tooling. The cost for a LABEL-light™ punching tool is up to 70 per cent lower compared to a traditional punching tool, even allowing for a label contour correction of +/- 0.5mm. Furthermore, there is no need to re-grind a LABEL-light™ tool – the cutting components can be easily exchanged by the operators in order to resume production immediately. This punching tool has been designed especially for the cost efficient production of small to medium sized IML label volumes. The machine model to be displayed at our booth E41, hall 5 during Label Expo Europe is the Berhalter B 500 high-performance die-cutting machine equipped for IML production. The machine features eight synchronised but separately and individually controlled servo drives. The B 500 sets new standards in high-precision print-to-die registration. The foil tension is fully automatically monitored and regulated. This means that exactly the same die-cutting conditions are maintained throughout the die-cutting process, irrespective of how well the reel is wound. The result is precise dimensional accuracy of the in-mould label, which is crucial for the seamless functioning of the feed and injection-moulding systems, as well as for the aesthetic appearance of the end product.

Unique advantages As materials become ever more complex and more sensitive, and quality demands grow stricter, a perfect interplay between die-cutting machines and die-cutting tools is more important than ever before. Reducing cost also means

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using thinner in-mould labelling films. Berhalter aims to be the leading company worldwide in the die-cutting and processing of IML labels as thin as 40µ or even less. Other important aspects include the stack accuracy of labels as well as the static charge on plastic films. Berhalter die-cutting machines are characterised by their non-contact die-cutting process, which is ideal for the avoidance of static charges. Additional anti-static devices are included in the die-cutting process in order to guarantee the greatest possible process security. Additional operations, such as the finishing of a surface texture, the insertion of a micro-perforation (for applications in the deep-drawn/blow-moulding area), precut holes (for injection nozzles) or die-cut holes for technical functions (centreing aids, windows) are very easy to achieve on Berhalter die-cutting systems.

Using the Berhalter die-cutting system, it is possible to realise any marketing solution without having to impose restrictions in terms of the choice and design of the packaging. For Berhalter, in-mould labelling is not a temporary fashion, but the result of continuous development reaching back almost 25 years. Berhalter is known worldwide for its flexible, efficient and innovative die-cutting solutions. 55 years of experience and continuous quality development has allowed it to grow into a dynamic company in the packaging materials industry. Its systems are tuned precisely to the production needs of its customers. Furthermore, the Berhalter flexible modular construction system allows for individual adjustments to existing or new production concepts at any time. Visit: www.berhalter.ch

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Vpak print technology is ideal for reproducing very fine line detail and subtle vignettes.

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For flexible packaging, the Vpak print quality benefits include finer line screens and fast, easy colour adjustment

The Goss Sunday Vpak design merges the proven operability and productivity traits of the renowned Sunday presses with a size-change capability that is easy, reliable and cost-effective

New web solutions Goss International is a leading global manufacturer of printing presses for packaging, newspaper and commercial applications. Philip Yorke spoke to David Muncaster, the company’s director of business development for packaging, about its growing influence in the web offset sector and latest award-winning Vpak range.

ddressing the trend towards more product SKUs and shorter run lengths, Goss has been able to illustrate how flexible configurations featuring its latest Sunday Vpak press technology are able to deliver a compelling argument for high quality packaging applications. The company’s latest web offset solutions can turn marginal short run jobs into sustainable, profitable ones with the advantage of plate and imaging costs that are a fraction of those associated with Flexo or Gravure processes. In addition, web offset allows converters to offer their customers later artwork deadlines. There are other Goss press production capabilities that reinforce this argument, including premium print quality, greater colour control and the benefit of a standardised, repeatable web offset process, with the ability to handle a wide range of substrates including films as low as nine microns, to heavy board stocks and at high speeds. The company’s clear commitment to the packaging and label sector was underscored recently with the launch of its state-of-the-art Packaging Technology Center at the company’s headquarters. The new facility featured a Sunday Vpak 500 press with seven web offset units, as well as EB and UV curing and flexo coating. The unique technology center provides demonstrations, testing and educational programmes for its clients and prospective customers. Goss’s latest Vpak 500 and Vpak 3000 web offset press models for folding carton, flexible packaging, pre-print and label applications are available in web widths from 520mm to 1905mm with print speeds of up to 457 metres (1500 ft) per minute. Key features include quick-change sleeve adaptor technology for cost-effective running that provides efficient, cost-effective size changes and advanced offset inking, tension and control systems.

Integrated solutions Last year Goss joined forces with Alwan Color Expertise to maximise the Vpak benefits for the packaging market, establishing a new benchmark for colour quality. The company agreed a strategic alliance that will ensure repeatable colour accuracy for all Goss Vpak press users across a wide variety of applications including labels, carton and board, and flexible packaging. Muncaster said, “We are continuing to build the Goss brand in the packaging sector through innovation and superior performance. Our expertise covers a very broad range of packaging applications. When it comes to established processes such as flexo and gravure, web offset has become an increasingly practical and economical alternative, especially in the area of small to medium print runs. We are working hard to challenge traditional thinking and promote the many advantages of web offset in the packaging sector. A big Goss advantage is that whilst we are relatively new to the packaging market, historically we have specialised in web offset technology for the commercial and newspaper markets. Our unique and unrivalled offset expertise has now been put to work in the packaging industry, providing converters with the opportunity to enjoy the same industry-leading levels of quality, productivity and service enjoyed by our huge global install base of newspaper and commercial printing systems for decades.” He added, “We are also very ‘sustainability conscious’ and throughout our product range we actively strive to optimise efficiency. The offset process is inherently eco-friendly as it does do not rely on solvent-based processes, thus eliminating the risk of emitting harmful CFCs into the atmosphere. The outstanding benefits of web offset printing cannot be ignored as they offer high print quality, high productivity, fast make-readies and Packaging Europe | 197 |

low image costs. The ability to produce printing plates in-house within minutes rather than in hours or days provides converters with shorter lead times and the ability to be more responsive to market needs whilst providing a more cost-effective service. “Our recent collaboration with Alwan Color is a further example of how we can maximise efficiency and offer improved print quality and colour consistency for our packaging sector customers.”

Award winning innovation

Today the company is clearly differentiated by its unrivalled printing process knowledge and engineering expertise. Goss International is headquartered in Durham, New Hampshire, USA and operates major manufacturing sites in North America, Asia and Europe as well as being supported by an extensive global sales and service network. For further details of Goss International’s latest innovative products and services visit: www.gossinternational.com

The latest InterTech Technology Award was once again presented to Goss International for innovation in the packaging sector. Whilst extending its significant track record for technological achievements, the latest distinction marks the company’s first major award for innovation in the packaging sector. Key differentiators of the Vpak presses acknowledged through the award include the application of Goss patented gapless blankets to the Vpak platform, along with the development of quick-change plate and blanket sleeves and a new, purpose-designed ink train. This has created the widest and most productive web offset packaging press option currently available with an infinitely variable repeat range.

About Goss Goss International develops and manufactures presses and finishing systems that offer the most highly automated and efficient web offset presses in the world. Founded by brothers Fred and Sam Goss, who established the original Goss Printing Press Company in Chicago in 1885, their vision and passion for innovation lives on and continues to deliver many of the most important breakthroughs in web printing and finishing technology in recent memory. | 198 | Packaging Europe

Goss Sunday Vpak press models are available in narrow and wide web widths from 520 mm to 1905 mm for flexible packaging, pre-print, label and folding carton applications.

Transfer to more TTS is Europe’s largest independently owned converter and supplier of thermal transfer ribbons with a capacity of more than 100 million square metres. Philip Yorke talked to Jason Asser, the company’s Managing Director about its unique range of products and services and its move into new markets.

TS is much more than a converter and supplier of thermal transfer ribbons (TTR), its meteoric growth since it was founded in 2006 is testimony to its success and its ability to offer customers far more than any of its competitors. The company recognised from the outset that it is crucial to offer long-term stability in terms of supply, service, pricing and reliable sales strategies. However overriding these principles is its unique ability to combine them with unrivalled thermal printer service and support in the form of its sister company Thermal Printer Support Ltd (TPS). No other company is able to match this value-added formula, and it’s a package that has proved invaluable to its growing customer base. TTS’s exceptional and consistent growth has been achieved in part by following a strategy of working exclusively with the trade channel only. Thus TTS is committed to providing printer manufacturers, distributors, dealers, systems integrators and resellers with the optimal range of competitively priced thermal transfer ribbons and services.

Exclusive formulations TTS specialises in converting an extensive range of ribbons sourced in jumbo roll format from a number of the world’s foremost TTR coating companies. TTS also offers an exclusive range of formulations that they have developed which are contract coated using the latest high-quality Japanese coating machines, ink mixing technology and utilising the latest environmental solvent recovery systems. TTS’s unique manufacturing operations use the latest state-of-the-art slitting machines and production methods allowing the company to offer products of the optimal quality at highly competitive prices. The company stocks Europe’s most extensive range of over 400 ribbon sizes and 38 product grades. The majority of these items are available for same-day shipping with a maximum of five days for tailor-made items. This huge range of ribbons from stock and fast delivery times, helps TTS’s partners to minimise their investment in stock inventories. Packaging Europe | 199 |

TTS also develops value-added strategies that enhance the efficiency and profitability of its partners. The company is also committed to maintaining the highest product quality and quality control systems. Thermal Transfer Solutions Ltd. is fully certified to ISO 9001, ISO 14001 and OHSAS 18001. Asser said, “We have two main business units and they compliment each other to combine and offer services that are not available under one roof anywhere else in the world. These are TTS: Thermal Transfer Solutions and TPS: Thermal Printer Support. We are therefore the production and distribution hub as well as being the ‘one-stop-shop’ printer supply and service centre.” Asser added, “No other company provides the technical service back up support that we do for such a wide variety of thermal transfer printers. Over 90 per cent of all thermal transfer ribbons that we manufacture are custom branded on behalf of our partners. We offer fast turnaround and are also able to provide over 200 ribbon sizes for next day delivery if ordered before 3.00pm. Consequently, if a company runs out of thermal transfer ribbons for its best-before dates or bar codes, then they can rely on us and our partners for the swiftest replacement of their stock.”

New Benelux facility As Europe’s leading thermal transfer ribbon converter dedicated to helping trade only partners increase their sales of thermal transfer ribbons, TTS has enhanced its European presence by the appointment of two new business development managers to support its growing network of partners in the Benelux. Both Jordy Brouwer, based in Amsterdam, and Pierre van Aerssen, based in Brussels, have many years experinence of working within the TTR and label industries. TTS is now stocking an extensive range of thermal transfer ribbons at their new facility in Amsterdam for next-day delivery throughout the Benelux. “This strategic move will enable us to offer the same high levels of service in the Benelux, as we offer our customers in the UK.” commented Asser.

Increasing customer support Thermal Printer Support (TPS) is the UK’s leading ‘trade-only’ supplier of mobile, desktop and industrial thermal transfer printers. This is in addition to offering in-line thermal transfer coders, label applicators, print and supply systems and associated software. With its extensive network of UK engineers the company provides a complete range of thermal printer service and support, including installations, on-site annual maintenance contracts, and ad-hoc repair and return-to-base services for all brands of thermal printers, print and apply systems, label applicators and in-line coding printers. In addition, TPS is now stocking and selling many of the world’s leading brands of thermal transfer printers including Godex, Sato, TSC, Printonix, Carl Valentin, Toshiba and many more.

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TPS appointed as the GODEX master distribution partner for the UK TPS has been appointed as the UK master distribution partner and repair service provider for the high performance Godex range of thermal transfer printers. Godex first started making barcode printers 20 years ago as an OEM supplier to major brand printer companies worldwide. After years of working with these companies Godex have developed a company infrastructure and a culture that produces optimal product development performance for the customer. And being located in Taipei Taiwan ensures that the highest technology and the lowest costs are included in every product Godex manufactures. TPS will also be the service provider for the range of very competitively priced ‘GOCARE’ warranty upgrade packages.

New partnership agreement with ARCA In another new development, TPS has signed a partnership agreement with the leading Italian ‘Print & Apply’ giant – ARCA. Through its partnership with ARCA, TPS is now also able to offer its network of label resellers and their customers a complete range of label applicator systems and print and apply solutions. These services start

at the consulting and planning stage right through to the installation and on-going support programmes. TPS will also be able to support manufacturers who have existing ARCA systems with on-site support, spares and engineering support, as well as supporting them through new projects through it’s network of partners. It is worth noting that TPS also recently appointed, Tony King, as its new channel support manager, who brings with him a wealth of knowledge in offering innovative solutions for companies who wish to automate or update their existing production lines with the latest, high-speed, precision label applicators and print & apply solutions.

Carl Valentin innovation at TPS TPS has added another leading manufacturer of thermal transfer printer systems to its portfolio recently; the renowned German manufacturer, Carl Valentin. This agreement allows TPS to add in-line coding printers and dual colour printers to it’s portfolio of products. For further details of TTS and TPS’ unique products and services visit: www.thermaltransfersoloutions.com and www.thermalprintersupport.com

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Ensuring optimum

performance for printers

Since its foundation in 1989, France-based Recyl has been providing flexo, gravure and offset printers with a range of different cleaning products to improve printing quality, from anilox roll cleaning to parts and plates cleaning. Elisabeth Skoda spoke to the company’s deputy directors Anthony Petrier & Arunkumar Venkataraman and marketing assistant Christine Sondaz to find out more about the worldwide success of its product range and its appearance at the upcoming Labelexpo exhibition in Brussels.

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ecyl has 26 years of experience in the market and achieves an annual turnover of around 3.5 million Euros. Mr. Petrier explains how printers’ needs for continuous print quality led to the foundation of the company: “When the laser engraved anilox method was invented and commercialised in the mid 1980s, printers found that anilox worked very well when they first started out, but that once it had been in operation for a while, the cells started to get clogged and ink transfer suffered. Pierre Chevreux, Recyl’s founder, worked with an international team to solve the problem, and came up with the formula that ended up as the product we today refer to as Recyl’Cobra.” The Recyl’Cobra range is ideal for declogging ceramic rolls, whatever the ink type or varnish, to ensure good ink transfer in the long term. Thanks to Recyl’s international outreach, with over 100 distributors and resellers, its products are available virtually everywhere in the world. “We are a small company with just 17 employees in a small town near Geneva, but we are able to ensure that we support our customers worldwide and that they receive a good return on investment,” Mr. Venkataraman points out.

Product range Apart from Recyl’Cobra, the company’s comprehensive product range includes another maintenance product for Anilox, the Clean range. A daily cleaning range called Quick Wash, for parts and plates, completes the portfolio. “Our competitors tend to only offer one all-purpose chemical, whereas we offer a wide range of products – after all, there are thousands of different ink types in the flexographic, gravure, offset and coating markets, which are the main segments we serve. Having been in the industry for over 26 years, we offer solutions for daily or weekly cleaning as well as for maintenance every three months,” says Mr. Petrier. “Our daily cleaning products are available in a range of different packs, such as a 30 litre can or a 100 litre container. We try to optimise transport for our customers and offer them concentrated products wherever possible,” Mr. Venkataraman adds. In addition to its cleaning solutions, Recyl offers machines for cleaning automation and a range of accessories integrated into a printer’s workflow, doctor blades, brushes, and optical instruments, adding even more value to printers.

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“We are essentially a chemical company, and we go one step further than our competition – we offer machines, chemicals and accessories to provide our customers with everything they need under one roof,” Mr. Venkataraman says.

Innovations at Labelexpo Recyl is prototyping a whole new range of products and will offer test samples to clients from selected geographic zones and segments during the event. Mr. Venkataraman describes the innovation process: “We work on a product for several months, we come up with different formulae, after that we try to test different inks in the labs, followed by several rounds of testing with our sales team and our customers. We do a lot of prototyping with chemical products as there is such a wide range of applications. In this way, we setup a long-term partnership with clients and take it up as a challenge to resolve precise cleaning issues with which, a certain client or even at times, a segment of the industry struggles.” Also at Labelexpo, Recyl will be showcasing a narrow web prototype model machine for anilox cleaning. “It offers focus and simplicity. We have bettered the machines in our range all the time and loaded them with functionality, but now we have come up with a simple, one size fits all solution in order to marry product and machine together,” Ms Sondaz says. Lastly, an improved version of Magic’Protect will also be unveiled, a product which reduces the amount of cleaning product needed. “This product is to be used on ink trays which, if stained with certain inks are a nightmare to clean. It creates a dry invisible film that’s insoluble in the ink and can be simply peeled/scraped off after print. This is a change of routine in the maintenance industry – to keep things spotless rather than cleaning up the mess,” Ms Sondaz adds.

Customer service A lot of documentation goes into Recyl’s chemicals, which makes life easier for customers. “Whether it is new transport or usage regulations or dangerous goods regulations, we offer local support throughout our entire network of distributors. We have a global outreach despite being situated in a small town in France, offering cleaning products, accessories and automation solutions all from under one roof,” Mr. Venkataraman explains. | 206 | Packaging Europe

Recently Recyl invested in and expanded its headquarters and production facility in Ville-la-Grand in France, creating a new R&D laboratory and increased storage areas, in order to cater for increased market demands, especially in the growing flexo industry. “We are also looking to expand our R&D team in order to be even more innovative in the future and look after our customers’ needs even better,” Mr. Venkataraman adds.

Future prospects Mr. Venkataraman is keen to point out the company’s plans to boost its global business even further in the future. “We supply to countries from Japan to Chile, and from Canada to Fiji. Through our global network of over a hundred distributors and resellers, we offer great local support. We are currently in early discussions about setting up a distribution hub in Asia in order to serve our customers even better by cutting down turnaround time.” Recyl will continue to expand organically. “Our market penetration is already quite high, but has expansion potential, especially in North or South America. There is a huge market out there waiting for us,” Mr. Petrier says. “We will continue to prototype new chemicals and focus on offering a complete solution to a problem at hand. Our focus in the future will be to build on our strengths and eliminate our weaknesses,” Mr. Petrier concludes. Visit: www.recyl.com

The Future of Print Consumerism, an increase in global populations, the effects of the internet and e-commerce – all of these developments are impacting our world, changing forecasts for the future and having a huge impact on the evolution and survival of print. Consumers are reaching out to purchase the latest products in consumables, pharmaceuticals and decoration. The drive for goods with desirability, branding and quality is impacting the industrial, packaging and print industries. Meanwhile, the upsurge in interest in 3D printing, printed electronics, RFID, coding and mobile applications is taking the concept of communication into a new space. Looking ahead to drupe 2016, veteran print journalist Gareth Ward offers his view on the future of print. According to Gareth we need to embrace the trends and all the developments affecting our world. We also need to face the challenges and use our creativity. The future of print is here today – we can touch and grasp it with both hands…

he successful printer of the future will deliver customers a full service offering that extends well beyond printing and finishing. The exact mix of digital communications, value added print, data manipulation and logistics will depend on the customer base and how the printer positions himself, or perhaps how he forms partnerships with others with expertise in these areas. But what is going to make print a successful communications medium in the next decade is already clear: print has to be relevant. This was not necessary when print was the prime channel for advertising, information, communication with government and so on. Much of this mundane printing has transferred to digital and will never come back, but print is not shrinking. It is evolving into something smarter, more versatile and above all more relevant to those who receive it. If a printer is not part of this development, the only option is to sell print services as cheaply as possible and this is no way to build for the future nor to create enduring partnerships with customers. Unfortunately there are many printers that lead with price and face the same inevitable fate as the wooly mammoth: extinction.

IT drives print relevance Tomorrow’s printer must become as comfortable with IT as he is with offset litho. That can stretch from operating a website to harvest jobs, to creating automated workflows that minimise touch points where errors can be introduced, using management systems - MIS to record and present up to the minute details of how a company is performing through to data handling to create personalised communications for customers to talk to their customers in the most relevant way. If that means using social media alongside print, the new print house has to deliver. The problem here is that printers continue to prefer to invest in a new printing press rather than in IT. It is as if the press is tangible and understandable. If it runs at 18,000sph (and machines at drupa 2016 are likely to hit 20,000sph) this is 20-30% faster than their current machine, so must make sense. But few give due thought to how jobs are to be processed either before reaching the press, or once printed. Across the globe, print runs are falling and time allotted is shrinking. A faster press magnifies the problem of handling Packaging Europe | 207 |

Claus Bolza-Schünemann,

Sabine Geldermann,

Alon Bar Shany, Vice President and

Gareth Ward,

CEO of KBA

Director of drupa 2016.

General Manager of HP Indigo

Print journalist

more jobs in less time without introducing errors. In addition, too few consider training for their staff to be an investment rather than an imposition. The first drupa ‘Global Insights Report’ published in October 2014 highlighted this: “Only 23% of the drupa expert panel report an increase in IT spend in the last five years, and virtually all decision makers stated a lack of IT specialists. This is a major challenge for printers,” says Sabine Geldermann, Director of drupa 2016. IT knowledge is key for automation at the process level. Those supplying software to the industry take it as read that JDF compliance is essential. Workflows have to become more sophisticated. Producing an eight page section on standard paper is simple, but tomorrow’s customers will want something far more than this. They will want their printed products to stand out, to have the impact to cut through the thousands of marketing messages that are received each day. drupa President and CEO of KBA Claus Bolza-Schünemann predicts: “In some years from now there will be fewer printing companies but they will be larger and more industrial with a broad service range. In the commercial sector printers will turn into marketing service providers for print and online services.” “The connection between print, online and mobile activities will grow stronger.” says Claus Bolza-Schünemann. The transition is in its infancy. A well known commentator on advertising and the internet pointed out last year that consumers spend vast amounts of time with their smartphones, but these only take a small proportion of the overall marketing spend, whereas the fast shrinking newspaper sector receives a disproportionate amount of advertising spend. One must shrink its share while the other one grows – unless the newspaper becomes more relevant to its reader. This means hyper local sections, printed digitally with targeted advertising.

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Revalidating print in a digital world The same can be noticed in magazines where the mass circulation titles that used to be printed gravure are losing circulation while magazines that focus on the special interests of readers remain healthier. There will be fluctuations across national boundaries and as fashions change, but the magazines that focus on this sort of reader will not be displaced by digital delivery of content because reading a magazine is so much more than the information presented. A decade ago it was predicted that with the growth of the internet, video on demand and the ability to interact with websites, fashion magazines must disappear because websites can show clothes being worn, have links to prices and instant ordering. But fashion magazines are stronger than ever because possession of Vogue makes a statement about the women carrying it. Online fashion websites like ASOS and Pret-a-porter have launched printed magazines because of this phenomenon. The doomsayers who predicted the same fate for catalogues have also been thwarted by human nature. We like to browse a catalogue or holiday brochure. They spark our imagination in a way that digital fails to do. And retailers that either exist only online or else which dropped their print catalogues are returning to print to remind customers to visit their websites to complete a purchase. If online shopping is going to grow, (though it remains only a relatively small share of consumer spending even in the industrialised countries) more and more print is going to be needed. But it is not going to be the same sort of print as of old. Why send someone who always takes a vacation in Mexico details of holidays in Canada for example? Instead the holiday company, with the help of the printer, can tailor a brochure that features the best hotels and resorts in Mexico. It will be a smaller publication with a shorter production run, but production standards can be higher in terms of print, paper and personalisation.

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The printer must be ready to deliver this to his customers. It means investment in technology that can cope with shorter print runs. It means the ability to print on uncoated papers which are popular because of their tactile qualities, and this can be addressed through the new UV technologies that are spreading through the industry. It means being able to enhance the printed product using varnish, foils, raised print effects, die cutting and other processes that enhance the value of the printed product and make it more exciting and engaging to the consumer. This can involve the inclusion of printed electronic circuitry to turn a printed page in a book or magazine into a loudspeaker to tell a story, the dashboard of a car which comes alive when various buttons and switches are activated, a printed label which can light up when a sensor detects movement. Embedded codes within the printed page are scannable by smartphones to unlock digital information for the consumer, perhaps an offer to be redeemed in a certain store or restaurant, while providing the company making the offer with information about who has scanned the code, where and when. The printed poster or advertisement acquires a measurable value because it proved to be relevant to that consumer at that time.

Marketing innovation The sorts of high quality print and finishing effects that sell the premium bottles of spirits are finding their way to other types of packaging, especially as the movement for artisan produced goods gathers pace. While overall volumes are small, the value of the printed pack is that much more important. And the printer can have far more influence on the quality than the company working for global brands with extensive product marketing teams forcing printers to toe the line. However, even these global companies must become more flexible in order to match society’s craving for innovation and novelty. It means that printed packaging becomes a major marketing tool, consider the impact that Share a Coke has had for example. The printer must be able to help cut the time to market for new products, either through automated workflows or perhaps by also taking on prototype creation using 3D printing technology. | 210 | Packaging Europe

Jiffy Launches Superlite® Foam Lined Mailer

Jiffy Packaging has expanded their portfolio with the introduction of a new mailer to add to their already respected mailer range. The Jiffy Superlite® is a foam lined, fully laminated, non-abrasive, light-weight mailer. The high quality mailers are also compact allowing 100% extra per box, meaning reduced handling, storage and distribution costs. As one would expect from the Jiffy brand, performance is not compromised with the new Superlite® mailer performing equally in drop tests to Jiffy’s wellknown Airkraft® mailer. Fiona MacDougall, Sales and Marketing Director, Jiffy Packaging comments, “It is always exciting to bring a new product to market and that is certainly the case with the Superlite® foam lined mailer. It’s a market differentiator and will offer our distribution partners a competitive advantage which will benefit their businesses.” “The product exemplifies the Jiffy brand with high performance values owing to its fully laminated foam lining, a strong eco message and clean aesthetics.” Superlite® is available in introductory sizes 1, 3, 5 and 7 (popular oversized A sizes). This ensures that a wide range of goods can be catered for. The launch of Superlite® follows the announcement of Jiffy’s multi-million pound investment in a new foam extruder. Extruding at an impressive 2.5m wide, with in-line lamination, winding and slitting capabilities, this new technology will enhance Jiffy’s position in the protective packaging foam market, in the UK. In closing, Fiona said, “As a business we are committed to innovation and working with our customers to develop new products. The Superlite is a great example of our forward thinking and desire to keep pushing the boundaries.” Jiffy Packaging is a leading manufacturer of polyethylene foam and bubble film products for a wide variety of end-applications in various market segments including protective packaging, automotive, building and construction. For more information visit our website www.jiffy.co.uk or contact us on 01606 867 200.

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There is room too for using the new inkjet technologies by printing directly to the bottle or package itself, what is called direct to shape printing. The printing system becomes part of the bottling or packing line and rather than printing and delivering labels, the print company’s task becomes managing this new technology and establishing a new workflow. It is going to require a whole new approach to marketing what a printer is and can do, and this is very much unknown territory for many print service providers. The exceptions are the online printers that have grown rapidly in recent years, sweeping away swathes of small print businesses as they have done so. But even these rarely lead on price; they are selling convenience and ease of access and that is down to constant marketing and sponsorship to raise brand awareness.

Increasing the value Printers should focus on benefits such as personal service, same day printing, wide choice of substrates, design, fulfilment and so on. Even this requires marketing skills that need to be developed. The answer will be different depending on the printing company says Claus Bolza-Schünemann: “Every printing house knows its customers and its strengths best. Therefore, it is of little help to simply copy the recipe for success of others. If every company offered the same this would automatically lead to overabundance in the market with the familiar consequences.” “Large trade fairs, such as drupa, offer good chances to find out more about new technologies and future-focused business models and the appropriate path for a company.” says Claus Bolza-Schünemann. | 212 | Packaging Europe

Alon Bar-Shany, Vice President and General Manager of HP Indigo, agrees: “There is pressure to commoditise, options for lower quality and lower pricing, but that would spell disaster for the industry. The opportunity is for less pages but higher value ones.” “Printers need first to acknowledge change and then embrace it. The industry needs to evangelise the inherent beauty and effectiveness of print in a digital world.” says Alon Bar-Shany. Printing will remain at the heart of it, but printers must become like project managers, shepherding the different aspects of the communication chain to achieve the result that the customers want, reaching a measurable return on investment. The focus on reducing overheads in the end to end supply chain has already transformed how books are printed and distributed; digital printing is starting to eat into packaging for the same reason. It is not the cost of producing an individual carton or label that is important, it is the overall cost of wasted materials and time in the supply chain that is important. Printers need to expand their thinking beyond the creation of the box. For those companies that can do this, that become engaged with their customers and work together to find solutions that embrace print at some level, the future is bright. “Print can still create emotions and print lasts, preserving moments and memories,” says Alon Bar-Shany. Print is no longer the dumb sheet of paper that is recycled in moments. The smart printers are discovering this. Value now is a function not of scarcity but of relevance.

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Inkjet – State of the Art or Sci-fi Fantasy? The great inkjet future has sometimes seemed like the destination of a never-ending journey. As we look ahead to the macro trends manifested in next year’s drupa 2016 exhibition, digital print guru and author of Smithers Pira’s ‘The Future of Inkjet Printing to 2019’ Sean Smyth takes stock of the progress the industry has made and where we are heading.

arents know this refrain well – “Are we there yet?” – just as they know the answer – “In a little while.” I spend my working life with printing technology and have heard this for many years. In the case of inkjet, this is a recurring theme. And while we are not there yet, we are getting much closer.

Approaching the destination Some print providers have arrived. A great example is REAL Digital International based in South London. In 2004, the company was founded based on the belief that transactional and direct mail production could be improved using a flexible inkjet solution. They invested heavily in secure premises and powerful workflow with finishing systems to cut, fold, collate and insert almost anything. They invented 650mm wide high quality colour duplex | 214 | Packaging Europe

web inkjet printing by mounting a pair of single pass inkjet presses on a flexible transport system. Further REAL Digital International developed new paper coatings to reach acceptable quality for leading brands, printing personalised carriers, mailers and magazines. The business proved out the belief, winning multiple awards – including the PrintWeek Company of the Year – while inventing new business models as the marketplace matured. They identified inkjet’s potential and went for it, making good money in the process. REAL Digital’s journey continues by upgrading to a pair of Screen Jet520 duplex lines in 2014, but is not stopping there. They continue to monitor the technology to see what the future holds. David Laybourne, REAL Digital International Managing Director, comments, “Inkjet technology provided the flexibility enabling us to deliver solutions that address latent customer demand and to drive new demand in areas where we have seen further opportu-

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nities. The technology continues to evolve, and inks are more flexible with increased colour gamut, reducing the need for special substrates whilst increasing productivity.” “As the ink manufacturers accept more viable pricing models, the proportion of the marketplace that inkjet solutions are able to address will only increase,” David Laybourne, REAL Digital International Managing Director.

benefits in regards of individualisation and customer targeted content without additional cost related to special inkjet treated papers. This offers commercial printers the opportunity to combine a broad range of applications on one digital press with productivity and quality equivalent to offset,” Peter Wolff, Director of Commercial Pritning Group Canon EMEA.

Viable ink costs are key

Books leading the way

Laybourne’s opinion about viable ink pricing models is informative. Ink cost makes medium to long runs with high ink coverage uneconomic in inkjet, as compared to analogue print. Suppliers want to maximise profit and this disconnect is holding back adoption of inkjet in commercial print, publishing and packaging applications. Printers using analogue presses think the ink is too expensive. There are several supply models for equipment, service and consumables (mostly ink, but cleaning fluids and replacement heads must be considered). High value recurring consumable revenue is attractive to suppliers, but print service providers are not used to this. They buy a litho press and negotiate for plates, inks and support from the established supply base – although some press manufacturers are competing there. Costly ink is turning some potential customers away from inkjet.

It is important to note that the costing of inkjet production is different from that of analogue print. It has lower prepress and set-up cost, but ink – and until recently, paper – is more expensive, often much more expensive. This means long run, high ink coverage inkjet

Substrates also important Another historical barrier to wider adoption of inkjet, especially for commercial printing applications, was the need to use specially treated papers and the inability to effectively print on glossy coated stocks. The latest generation of production inkjet presses is rapidly eroding those barriers. According to Peter Wolff, Director of Commercial Printing Group Canon EMEA: “With the latest system introductions of the ImageStream, the reachable range of applications extends even further, due to the printability of offset coated material for matte, silk and glossy applications. With these new capabilities, additional applications like magazine printing, catalogue printing and others are now doable on inkjet with all the Packaging Europe | 215 |

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is not cost effective, so there is little appetite for printers to change. In book production, however, there are advantages in combining inkjet with in-line finishing, delivering finished blocks ready for cover application and final trimming. This is particularly true for monochrome books. Publishers and book printers have gone beyond just comparing print costs to considering the total cost of manufacturing, since inkjet can deliver folded, collated and glued blocks for a simple cover application and final trim for books in any format or pagination with minimal waste. The flexibility of inkjet allows book production to be re-engineered with overall cost and service advantages, enabling book publishers to reduce their stocks and their publishing risk. Colour books are quickly following the mono lead. For other products, the benefits of changing manufacturing processes to inkjet are not so clear yet. Well-established analogue methods are meticulously honed to minimise cost while delivering high quality. This will change as more companies install inkjet equipment, learn the capabilities and exploit new opportunities. New inkjet equipment will provide higher return on investment for many print products.

Production inkjet: a growth opportunity In 2015, there are many inkjet early adopters and profitable users. Ricoh is at the forefront of quality with the high speed Pro VC60000 press launched in 2014. It has several early adopters, including HansaPrint in Finland, a €70m turnover firm specialising in retail and publishing. Jukka Saariluoma, HansaPrint Business Unit Director, says, “Prior to experiencing the Ricoh Pro VC60000, I did not believe that there would be a major shift from offset printing to inkjet. But the new press has changed my mind.” “Our clients are very excited by the new level in quality and the increased flexibility offered and are moving significant amounts of their work from offset to inkjet,” Jukka Saariluoma, HansaPrint Business Unit Director. | 216 | Packaging Europe

The print world is certainly changing. All the key analyst organisations predict very high growth continuing for inkjet print volumes and values. Smithers Pira forecasts that the value of inkjet printing output for graphics and packaging more than trebles over 10 years, from €23 billion in 2010 to more than €70 billion in 2020 (in current values), with CAGR forecast of 12.7% between 2015 to 2020. HP alone reports that its customers have produced more than 100 billion inkjet pages since its first installation of a production inkjet press in 2009, a clear indicator of overall market trends, with other inkjet press manufaturers reporting rapidly growing volumes as well.

Beyond traditional print The applications for inkjet are many. There is coding & marking, addressing, security numbering & coding, photo-printing, wide-format (sheet, roll-fed and hybrid), flatbed imprinting systems, narrow web, tube & irregular shapes, high speed wide web and sheetfed, to name a few. Outside of traditional printing and graphics, inkjet has revolutionised ceramic tile printing and it is growing very strongly in textiles and other industrial decoration applications – from pens and memory sticks to architectural glass and laminated decor. “Inkjet has become the preferred decoration process for ceramics and other decorative materials,” Jon Harper Smith, Fujifilm Speciality Ink Systems Business Development Manager. Thus, inkjet offers opportunities for expansion into related areas that may not normally be considered by traditional print providers. Paul Adriaensen, Agfa Graphics PR Manager, comments, “Not too long ago, inkjet was praised as an alternative to conventional systems for its ability to offer single-off sheets, short runs and personalised prints. In the meanwhile, the technology is challenged to offer higher speeds and higher volumes to replace some of the conventional systems.”

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“But the technology is also introduced in new areas never related to the printing industry before. This creates interesting dynamics in the industry,” Paul Adriaensen, Agfa Graphics PR Manager. Mimaki and other manufacturers are bringing innovative digital inkjet solutions on the market delivering higher speed and productivity to meet demands of the booming textile market. From a technical perspective, inkjet has a major advantage over all other print processes because it is the only non-contact, high quality, high performance process. The advances are primarily in new and better control of print heads, better inks and a much wider selection of readily available and more affordable inkjet treated papers. New applications are developing almost daily. For example, Canon has installed lines in Nigeria to print election ballot papers.

Think ink Ink manufacturers spend lots of money on developing new inks that perform well in the heads and provide excellent print quality. Such research is not cheap. But the result is that ink properties have improved, with higher density levels that result in more offset-like quality with lower coverage. There are also now more substrates that perform well with inkjet, aided by colour management improvements. There are many routes to market for inkjet inks. Some equipment manufacturers formulate and manufacture their inks; others sell ink that is made under license by ink specialists. In low-end wide-format inkjet, there are independent third-party ink suppliers competing with the OEM. That is probably the healthiest part of the market for end users, with thousands of machines sold each year consuming millions of litres of inks. This is not the case for high performance systems, where the equipment supplier typically provides the ink tailored to optimise performance within the overall system. There are indications, however, that this is changing. Collins Inkjet is an independent inkjet ink manufacturer who sells a range of inkjet inks, innovating in many applications including new electron beam curing. It makes water-based inks for many of the high speed single pass presses. It remains to be seen how effective this company and others will be in establishing itself as a third-party ink provider, in competition – or partnership – with OEMs. | 218 | Packaging Europe

Chris Rogers is Vice President of Sales & Marketing at Collins. He is optimistic, saying, “Low consumables costs promote growth and easier adoption.” “When customers see competitive pricing for the more efficient inkjet technology, it is easier to switch, and they are more willing to change,” Chris Rogers, Collins Vice President Sales & Marketing. “Our business model is a traditional ink company; our manufacturing scale allows us to price inks at lower profit margins. This long-term strategy has proven successful over 25 years and it seems that OEMs are now starting to agree. They realise the easiest way to grow market share is to price their consumables fairly and we can help them with that.”

Inkjet: driving new market opportunities Inkjet has been around for some time. Today a huge amount of money is being spent developing printheads, inks, substrates, control software, transport, drying and turnkey print systems. While these investments have forced changes on the world of print, it is nothing compared to what we expect to occur over the next few years. The inkjet markets today are largely new. As productivity grows, inkjet is becoming greedy, with suppliers now turning toward siphoning volume from analogue print markets for additional growth and offering directly competing solutions. The productivity, quality and economics are pushing inkjet firmly against sheetfed litho and narrow web flexo, and it has larger format flexo and web offset in its sights. While a few inkjet suppliers may be guilty of hyperbole (sorry, they are very guilty of it in some instances!), it is good to see users and customers voting with their feet and their wallets. That being said, we will continue to see enhancements to productivity and boosts to the cost performance of inkjet. Some totally new formats and systems are coming to market. At least a couple of these will be on show at drupa, in new formats and markets. What is also new is that these will be firmly aimed at the heartland of offset and flexo printing. Choice of printing methods changes because of one or more reasons: to reduce cost, to improve quality, to achieve greater levels of service, or to do new things. Inkjet allows printers to do all four – and no doubt there will be other new reasons going forward. Flexibility. Agility. Power.

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See the future of inkjet at drupa 2016 In addition to graphics and packaging, inkjet is making rapid progress in textile printing, ceramics and industrial/architectural decoration. Then there is the new arena of 3D printing, where inkjet is an important enabler. These have the potential of opening huge new opportunities for companies that are smart enough and brave enough to explore the potential and exploit new markets. In technology terms, inkjet is state of the art. In business terms, inkjet is being used to re-engineer supply chains, making money. That certainly is not fiction. Go to drupa to find out what inkjet can do for your business.

Executive summary Production inkjet is already driving change in the printing industry, both by enabling new applications and by capturing volumes previously produced with analogue technologies such as offset and flexography. This expert article by Sean Smyth provides insight into the state of the inkjet business, where it is enabling new opportunities now and into the future, and what we might expect to see when the printing community converges on Düsseldorf for drupa 2016. This includes advances in both technology and pricing models, with ink and substrates being front and center in the future success of the production inkjet model. Viable pricing for ink, the broader availability of inkjet substrates, and the ability of nextgeneration production inkjet systems to use standard offset litho media will be key factors in driving additional volume from offset litho and flexography to production inkjet presses and in further enabling the printing community to discover new inkjet-based applications and revenue streams. The article shares insights from printing companies who are already innovating with production inkjet, successfully moving volume to digital from conventional printing technologies as a result. It also identifies the many applications for inkjet beyond traditonal print, including coding and marking, addressing, security numbering & coding, photo-printing, wide-format (sheet, roll-fed and hybrid), flatbed imprinting systems, narrow web, tube & irregular shapes, high speed wide web and sheetfed. Inkjet has also revolutionised ceramic tile printing, and it is growing very strongly in textiles and other industrial decoration applications – from pens and memory sticks to architectural glass and laminated decor. | 220 | Packaging Europe

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Empack Brussels, your appointment with the packaging industry in Belgium

mpack Brussels, the annual packaging event in Belgium, this year takes place for the 14th time, at Brussels Expo. Empack is the meeting place for the packaging community, more specifically companies active in a variety of packaging materials and machinery, control systems, and labelling. This two-day event allows exhibitors to showcase their innovations and benefit from face-to-face interaction with several thousands of visitors.

• Modified Atmosphere Packaging: What gases extend the shelf-life and freshness of your food products? • 3D printing in pharma • Smart Intelligent packaging and active packaging • More sustainable e-commerce and the consequences for your packaging • Good Manufacturing Practices: How reliable is your production system?

Food & Pharma

Empack has also invited packaging experts and international guests:

The 2015 edition focuses on 2 major themes: the pharmaceutical and the food industry. Many Empack exhibitors and visitors are simultaneously active in these two sectors. To enhance interaction and dynamics, Empack Brussels features two demonstration areas: • The Food Pack Terrace is an interactive winter market where exhibitors can serve various packaged food samples and beverages. The visitor is in for a sensory experience: as he walks through the winter market, he can discover, unpack and savour packaged food samples and beverages. To add to the dynamics, the booths of the participating exhibitors will be indicated on the floor plan. • In the Pharma Clean Room exhibitors can put innovative pharmaceutical packaging solutions on a pedestal - literally. To protect the medical packaging and highlight the sterile aspect, the pack will be presented in a glass bell jar.

• Rowland Heming: The Six Secrets of Packaging Designs! • Innolabel: what are the innovative advantages of the patented FreshCode smart barcode label?

Seminar programme Empack organises each year an interesting and varied programme with room for hot topics and burning issues. As in previous editions, partners of the seminar are the Belgian federations Pack4Food & Packaging People, and the Belgian Packaging Institute. The Universities of Hasselt, Leuven and Antwerp will also address specific topical issues.

Topics include the following: • Packaging and transport: How to deal with this efficiently? • Opti barrier: What is the optimal barrier between packaging and product?

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Packaging Innovations: the event for design and inspiring packaging! After four successful editions in Amsterdam, Brussels will for the first time be hosting Packaging Innovations on 25 & 26 November 2015. This unique networking event is centred around keynote speakers and enthusiastic exhibitors. The exclusive catering and inspiring setting complete the experience. Packaging Innovations is the exclusive networking event where professionals will be inspired as they learn about the latest trends and developments in the area of creative and inspirational packaging and design. More info? Info-empack@easyfairs.be • www.empack.be • www.packaging-innovations.be LinkedIn empack Benelux • Twitter @empackBenelux • #empack

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Diary FachPack Date: 29 September - 1 October Visit: www.fachpack.de

Venue: Nürnberg, Germany

Labelexpo Europe Date: 29 September - 2 October Visit: www.labelexpo-europe.com

Venue: Brussels, Belgium

PPMA Show Date: 29 September - 1 October Visit: www.ppmashow.co.uk

Venue: Birmingham, UK

Scanpack Date: 20 - 23 October Visit: www.scanpack.se

Venue: Göteborg, Sweden

Smithers Pira Packaging Forum Date: 2 - 3 November Visit: www.pack-forum.com

Venue: London, UK

Plastic Caps & Closures Date: 4 - 5 November Venue: Nice, France Visit: www.plasticscapsandclosures.com

Manufacturing & Engineering Giants Gather for PPMA Show AS

growth in the UK’s manufacturing sector continues to accelerate, with manufacturers reporting a rise in sales and indicating plans for expansion, industry professionals are gearing up to visit the PPMA Show 2015, the UK’s premier, freeto-attend complete production line event for processing and packaging machinery – set to be the largest of its kind in recent years. Results from the Manufacturing Advisory Service (MAS) Annual Barometer revealed that over 95 percent of manufacturers expect to maintain or increase their investment on machinery, premises and new technology, demonstrating a commitment to continuous improvement and making the PPMA show the ideal place for processing and packaging professionals to discover the latest technologies and product launches from across the UK’s manufacturing industries. Returning to the NEC, Birmingham, the show will run over three days (29th September – 1st October) and will be opened by Lord Digby Jones, former director General of the CBI and Trade and Investment Minister. With exhibitor space up by more than 20 percent compared to preparations for the 2014 show, this time last year, the event is quickly becoming the processing and packaging show that must be not be missed.

Robotic and Industrial Vision zone showcases potential for automation New features to the 2015 exhibition include a Robotics and Industrial Vision zone which will showcase the latest inventive and quirky uses of robotic technology including robots that can dance, pour drinks and even play snooker. Highlighting just how robotics and automation has come since the first industrial robotic arms were integrated into production lines, Rich Walker, Managing Director for the Shadow Robot company will demonstrate the ‘Moley robotic kitchen’ – capable of cooking chef quality meals using a normal kitchen. Walker will also speak as part of this year’s seminar line-up to reveal what robotics could hold for the future of food manufacturing.

10th European Bioplastics Conference

Justin King to take centre stage at seminar theatre

Date: 5 - 6 November Venue: Berlin, Germany Visit: www.european-bioplastics.org/conference

A leading figure in the FMCG and Grocery retailing sectors, Justin King CBE is set to headline this year’s PPMA Show seminar theatre. Taking to the stage, Justin will discuss the future for multiple retailers, how the growing market shares of discount retailers will affect the supply chain and how the continued emergence of supermarket convenience outlets is shaping the market. Also confirmed for the 2015 exhibition; Keith Thornhill, Business Manager for Food & Beverage at Siemens will present the case for technology and data analytics for the

Plastics Recycling Show Europe Date: 25 - 26 November Visit: www.prseventeurope.com

Venue: Brussels, Belgium

drupa Date: 31 May - 10 June 2016 Visit: www.drupa.com

Venue: Düsseldorf, Germany

K Show Date: 19 - 26 October 2016 Visit: www.k-online.de

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Venue: Düsseldorf, Germany

EVENTS

digital factory of the future; Rhys Herbert, Senior Economist at Lloyds Banking Group will explore what’s in store for the manufacturing sector and Mike Crosby, Finance Director for Burts Potato Chips will examine how sales targets and profitability have soared thanks to continued factory investment and new technology.

Manufacturing skills gap under the spotlight The topic of the current manufacturing skills gap will be addressed in more detail at this year’s seminar theatre following the launch of the PPMA BEST initiative, a new charitable trust aimed at recruiting more young people in the industry. The new division will highlight and promote the benefits of apprenticeships throughout the industry, highlighting how the skills shortage can be resolved through improved engagement between the industry and the UK’s academia. Addressing the ingredients for success and highlighting the opportunities for an engineering future in food and drink, Sam Kelly, Electrical Engineering Apprentice for PepsiCo and Hannah Whall, Graduate Project Engineer for Nestle will provide an up-to-date insight into the opportunity in engineering in the largest industry in the UK. Representing two of the routes open to young people, including apprenticeships and graduate schemes, Sam and Hannah will share their personal stories as their build a career in the UK’s food and drink manufacturing industries. In an effort to further encourage young engineers into the sector, the PPMA Show will also welcome the return of the Ones to Watch Awards which recognises the contributions of processing and packaging professionals under the age of 35. Sponsored by Festo, the awards are chosen by a select group of industry specialists from the PPMA Group Industry

awards judging panel, with colleagues being urged to nominate outstanding candidates to the PPMA Show press office.

Demonstrating the future trends in manufacturing Attendees at the NEC in September can also find out more about the latest trends and innovations taking the industry by storm. With the productivity puzzle still proving an issue for four fifths of the UK’s smaller manufacturers, visitors can visit stand E90 where Festo, the innovation leader in pneumatic and electric drive technology will be showcasing a number of its exciting new developments, concepts and solutions for the food and beverage sector. Visitors to the stand will be able to discuss how they can increase productivity in different ways by considering efficiency, simplicity, security as well as accessing Festo’s key competencies. Finally, the team at Lloyds Bank Commercial Banking (stand F40) will once again have a dedicated stand at the show where its team of specialists will be offering advice ranging from day-to-day banking requirements to funding for expansion to exporting. Lloyds return as headline sponsors highlights the company’s confidence in UK manufacturing and in particular, Small to Medium Enterprises (SMEs). The team, made up of 13 dedicated sector teams, have the autonomy to make local lending decisions up to £1m – on a case-bycase basis. They will once again have a dedicated stand at the show, the team will also be taking to the show floor to discuss banking opportunities with exhibitors and visits alike, following its 2014 commitment to provide lending facilities to the manufacturing sector of £1bn per annum every year until 2017. To register your attendance at the show please visit: http://bit.ly/PPMA2015. For more information on the PPMA Show 2015, please visit www.ppmashow.co.uk.

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Sneak Preview: Highlights of the 10th European Bioplastics Conference 2015 T

he European Bioplastics Conference will be celebrating its 10th anniversary this year and has put forward an exciting two-day agenda to celebrate the achievements of Europe’s bioplastics industry over the past decade.

Focus: new policy frameworks, market developments, and new products & materials The European Bioplastics Conference has been witness to and a driving force behind the outstanding developments in one of the most innovative and exciting sectors of the European bioeconomy over the past decade. Today it is the leading business and networking event for the bioplastics industry in Europe. The 10th edition of the conference will take place on 5/6 November 2015 in Berlin with more than 350 delegates, speakers, and exhibitors expected to attend. The preliminary programme is now available online. “The agenda of the 10th edition of our conference is starting to take shape, and we are excited to present you with a programme that will live up to the industry’s expectations to celebrate this exciting milestone”, says Hasso von Pogrell, Managing Director of European Bioplastics. The agenda will cover a wide range of areas including the current EU policy landscape, the latest technological innovations in materials and conversion of bioplastics, advances in standardisation and labelling, biobased feedstock, end-of-life solutions, as well as the end-user and brand perspective. Some of the highlights this year include:

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Kevin Vyse, Primary Foods Packaging Technologist and Innovation Lead at Marks & Spencer will outline the UK retailer’s ‘Plan A 2020’, a self-imposed sustainability programme consisting of 100 commitments to reducing the social and environmental footprint of M&S and becoming the world’s most sustainable retailer, and the role of bioplastics in achieving this ambitious goal. The morning session of the first day is dedicated to the European policy landscape and in particular the revised Circular Economy Package (CEP) and its ramifications for the bioplastics industry. After first-hand insights from senior representatives of the European institutions, Joachim Quoden, Managing Director of the Extended Producer Responsibility Alliance (EXPRA), will dissect the CEP with regards to producer responsibility when it comes to product design and waste management for (bio-)plastic packaging. The Open-Bio project investigates how markets can be opened for biobased products through standardisation, labelling, and procurement. Antonis Mistriotis, Senior Researcher at the Dept. of Natural Resources at Agricultural University of Athens and Lara Dammer, Dissemination Officer and Work Package Lead on labelling at OpenBio will present their results on labelling opportunities for bioplastics, especially with regards to extending the EU Ecolabel to biobased categories. We will also hear the latest updates on the progress of the project’s research into marine biodegradability, which no doubt will be of huge interest.

EVENTS

Another highlight will be the presentation of the 2015 bioplastics market data update, conducted by nova-Institute and IfBB on behalf of European Bioplastics. Followed by an extensive session on the ‘Latest Advances in Materials, Products, and Processes’ featuring a host of frontline R&D and marketization players, including the likes of BASF SE, Perstorp, Corbion, BioAmber, Innovia Films, Cargill, NatureWorks, and Floreon, presenting their latest advances in their fields. And in keeping with a well-received tradition, the Bioplastics Magazine will announce the winner of the 10th Annual Global Bioplastics Award.

Festive fringe programme to celebrate the 10th anniversary The programme of the 10th European Bioplastics Conference will be complemented by a number of networking opportunities and festive fringe events, such as the

Conference Anniversary Lottery, friendly sponsored by Braskem, as well as a Gala Dinner on 5th November, sponsored by Belgian certifier Vinçotte co-locating their OK Compost logo’s 20th anniversary celebrations with the conference, to which all attendees are cordially invited. If you would like to participate or present your organisation in the exhibition alongside the conference you can secure your places via the online registration. European Bioplastics offers an exclusive 15% discount for readers of Packaging Europe when registering online with the discount code 2015EUBPCONFPE. Simply go to www.conference.european-bioplastics.org or contact conference@european-bioplastics.org

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Fakuma 2015: More International than Ever W

ith a fully occupied exhibition centre in Friedrichshafen on Lake Constance, the 24th edition of Fakuma is headed for record-breaking exhibitor figures, as well as expecting roughly 46,000 expert visitors from over 100 countries. The Fakuma international trade fair for plastics processing thus firms up its reputation as Europe’s number one industry event for injection moulding, extrusion and thermoforming technologies.

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With its user-oriented focus on plastics processing, Fakuma has acquired a special status, because similarly positioned trade fairs have a more plastics-polytechnical orientation and thus a different emphasis. Manufacturers and distributors from 35 industrialised nations will present a sparkling array of new technologies and processes at this year’s Fakuma, as well as applications from which the industry sector will already be able to

EVENTS

profit in October 2015. Time is money, and short time-to-market promises an advantage and thus more business success, for which reason the manufacturers and distributors will present a host of world’s firsts and innovative processes at Fakuma 2015. Within this context, additive and generative 3D processes have of course taken on an exceptional role, even though precisely this segment and its associated processes, such as STL and laser sintering, have been part of Fakuma’s exhibition portfolio for more than 20 years, whereas they were used in the past above all for prototyping and the production of samples. Based on rapidly expanding material diversity and material characteristics which are customised for specific functions, the spread of 3D processes might well be greatly accelerated and more than just round out offerings for manufacturing processes involving plastic processing. The extent to which the Fakuma international trade fair for plastics processing has established its omnipresence within the industry sector is illustrated by further increases in the number of foreign manufacturers and distributors from more than 35 industrialised nations. As has traditionally been the case, Germany is represented by the largest number of exhibitors (925 companies) followed by Italy (102), Switzerland (97), Austria (63), France (43), China (41), Portugal (27), the Netherlands (25), the Czech Republic (20) and Turkey (17), so the Europe still plays the leading role. At any rate, manufacturers and distributors from all over the world view Fakuma as the most suitable business platform for presenting their companies to expert visitors in the highly demanding German and European markets. Beyond the exhibition, the East foyer will once again accommodate the popular and coveted exhibitor forum, for which numerous experts have already registered to deliver presentations and talks.

Furthermore, a special show will be held in the West foyer which has been conceptualised as a “Thermoforming Island” and will provide information in a compact format concerning thermoforming technology in all of its aspects. The goal of this collective booth is to provide potential users with in-depth insights into the thermoforming process, especially in light of the fact that modern thermoforming is now approaching accuracy levels which were only recently deemed impossible. Another exhibition segment worthy of special attention is additive and generative manufacturing, which is represented at Fakuma in tool and mould making as well as in parts manufacturing itself. Due to the fact that tool and mould making are essential Fakuma constituents, the presentation of so-called complementary manufacturing processes, by means of which the production of highly complex shapes and the integration of cooling channels close to the contour are made possible through the application of metal powder and the use of machining, is an absolute must. At the same time, new and alternative materials are offering undreamt-of substitution options in the production of samples as well as series parts with the 3D printing process, which in many cases is capable or more than just supplementing injection moulding, thermoforming and extrusion processes. The Fakuma international trade fair is the world’s only technical event to provide a complete overview of all technologies and processes which are currently relevant for industrial plastics processing. Fakuma 2015 takes place at the Friedrichshafen Exhibition Centre on Lake Constance, where Germany, Austria and Switzerland meet on13 -17 October. Opening hours: Tuesday to Friday from 09:00 to 17:00; Saturday from 09:00 to 15:00. Visit: www.fakuma-messe.de

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Bio-PET bottle provided by Spectra Packaging

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Green-PE tube provided by L’Occitane en Provence

Green-PE garbage bags provided by Papyrus

Devoted to Nature For more than 20 years, FKuR has committed itself to nature and its uniqueness. The company was founded in 1992 under the name FKuR GmbH as a research and development institute dedicated to plastics and recycling with a focus on resource preservation and efficient resource utilization. Libby White spoke with Patrick Zimmermann, global marketing director, to find out more about this progressive and innovative company.

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rom the very beginning we have followed our commitment and slogan: ‘Plastics – made by nature’,” Mr Zimmermann begins. In 2003, the company was reorganised as FKuR Kunststoff GmbH and to this day has remained true to its values as a privately owned family business. The objective of FKuR is to develop, produce and sell bio-based and / or biodegradable plastic solutions globally. Mr Zimmermann comments, “Our strategic development partnership with the Fraunhofer Institute also guarantees this focus. Today, FKuR is one of the leading bioplastic companies in Europe with nearly 50 employees. We have a global market presence with 16 agents on five continents, a US subsidiary and an annual turnover in the mid eight digit figure in euros.” The core market for FKuR is currently Europe. Due to the diversification of its portfolio, the company does not concentrate on a specific region or market. “Of course, there are markets like Italy or France, with an increased demand for compostable solutions, whereas Scandinavia seems to prefer biobased solutions,” Mr Zimmermann points out.

“Therefore, we do not differentiate by country, but rather we have to analyse the respective markets with regard to the products needed for a certain market segment and understand the existing method of disposal to determine which bioplastic meets the requirement of the brand or the end consumer best.”

Product range FKuR offers a variety of products for the flexible packaging market. For solutions which need a biodegradable or even a compostable film, it can offer various grades from its Bio-Flex® series. This series includes grades which are certified as compostable according to EN 13432 with a wide range of properties. Films made from Bio-Flex® have characteristics comparable to LDPE or HDPE, depending on the type. Bio-Flex® grades for the production of cast films and heat resistant thermoforming parts are available as well. If compostability is not a concern, Mr Zimmermann says there are still solutions using bio-based raw materials: “Our Terralene® compounds have been used successfully in the production of stand-up pouches along with paperboard coatings. Packaging Europe | 231 |

from sugarcane based ethanol. Therefore, each ton of Green PE produced captures more than two tons of CO₂, thus, helping to reduce harmful greenhouse gas emissions. Green PE performs similar to conventional polyethylene in the recycling stream and is, therefore, 100 per cent recyclable. As a further development, with the brand name Terralene®, FKuR increases the range of applications for Green PE by offering tailor made compounds based on Braskem’s bio-based polyethylene. Terralene® and Green PE have the same properties and process ability as conventional polyethylene and, thus, have the ability to be a drop in replacement as they can be processed on existing production lines.

Continuous developments In addition, Green PE can offer a variety of opportunities for packaging applications where a high amount of renewable resource content is preferred.” FKuR also offers Globio®, a partially bio-based PET that has been successfully used for bottles and films in packaging. Globio® is a ‘drop-in’ solution and is able to replace conventional PET in a wide variety of applications. It can also be recycled at up to 100 per cent in the existing PET recycling streams.

Green PE portfolio “With growing legislature and corporations focusing on sustainability, it was apparent that there is a need to find replacements for fossil based polyethylene,” asserts Mr Zimmermann. He continues, “If compostability is not a concern for a customer or a brand we are able to provide solutions using bio-based raw materials. The Green PE portfolio includes LLDPE, LDPE and HDPE grades.” These can be used for several applications including blown film, injection moulding or extrusion blow moulding. The main difference between Green PE and conventional polyethylene is that the ethylene used for Green PE is not produced using crude oil, but instead is derived

FKuR’s latest developments concerning biodegradable plastics include its own Bio-Flex® brand. Mr Zimmermann comments, “With Bio-Flex® we have a variety of ongoing developments and are continuously launching new blends. For example, we have a PLA blend for injection moulding with short cycle times, as well as heat resistant blends that can withstand temperatures (Vicat A) of up to 140°C.” In addition, with its bio-based Terralene® brand FKuR has now developed a partly bio-based PP compound. This compound enables the production of PP parts with a bio-based content of 35 per cent. Along with expanding its biodegradable and bio-based plastics product range, FKuR has also broadened its bio-based plastics portfolio with a suitable distribution business. In addition to distributing Braskem’s Green PE, FKuR also sells Globio®, a partially bio-based PET and Vestamid® Terra, a bio-based PA from Evonik. Mr Zimmermann leaves us with news of FKuR’s latest development, which opens the door for future innovative solutions: “Most recently, we have entered into a development cooperation with Corbion Purac for their PLLA. With this variety, FKuR is able to offer bio-based and biodegradable resins for a multitude of applications.” For more information, visit www.fkur.com

Bio-Flex® for agricultural films

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Bio Logical High performance biobased products specialist Corbion Purac is active across the packaging industry thanks to its ability to convert lactic acid into PLA thermoplastic resin. Packaging Europe spoke to Corbion’s Marketing Director Bioplastics François de Bie to learn more. Emma-Jane Batey reports.

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uropean biotechnology company Corbion Purac is the global market leader in lactic acid, lactic acid derivatives and lactides, and a leading company in functional blends containing enzymes, emulsifiers, minerals and vitamins, Corbion is proud to deliver high performance biobased products made using renewable resources. Thanks to continual innovation and investment and an in-depth understanding of the plastics and packaging industries, Corbion Purac is able to offer lactides and PLA resins for general purpose and high performance bioplastics. Marketing Director Bioplastics François de Bie told Packaging Europe, “We are also developing biobased FDCA for high performance PEF (Polyethylene Furanoate) resin. This is very interesting because PEF can, for example, be used for bottle and film applications thanks to its excellent barrier properties. Furthermore, through our Succinity joint venture with BASF, we are now producing and selling biobased succinic acid for PBS.”

The science bit The range of lactides and resins for the global bioplastics market sees Corbion Purac convert lactic acid into lactide monomers which are then polymerized into PLA thermoplastic resin. This PLA resin is then supplied to compounders and converters who then produce everything from packaging products to automotive components. Mr de Bie continued, “PLA is increasingly becoming the material of choice for more demanding applications in the automotive, electronics and textile industries. PLA is a biobased plastic with a low carbon footprint that is currently already used in the packaging and food serviceware industries. Now, thanks to our latest developments in lactide technology, PLA that is based on our high quality lactides delivers even better heat resistance.” With the Corbion Purac PLA proven to withstand temperatures of between 100 – 140 degrees Celsius, the company can assure its customers and users – primarily brand

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owners and manufacturers – that biobased PLA can be a replacement material for polystyrene, polypropylene and acrylonitrile butadiene styrene in more demanding applications. Mr de Bie added, “Corbion is a true partner to our customers; a reliable partner. We offer our customers high performance PLA bioplastics, as we are the innovator in the industry that has commercialised high heat technology.” As industry innovator, Corbion Purac’s ongoing investment and development is clearly evident in its latest launch – its new range of PLA neat resins which will be unveiled at Fakuma in Germany this October. This solutions-based brand will be tailored to enabling optimal processing for its converting customers, with specially-developed grades for injection moulding, fibre spinning, extrusion and thermoforming.

Packaging partner In terms of applications and potential applications for PLA, Mr de Bie notes that PLA is well-suited to the packaging industry. He explained, “PLA is a great material of choice for any packaging items where compostability or biodegradability is of importance. But it is also ideal for tougher, more challenging packaging applications where PLA can be a biobased replacement for PS or PP, offering a significantly reduced carbon footprint. Bioplastics can already be found in the packaging and food serviceware markets, such as single-use cups at festivals, yoghurt pots in the supermarket, biobased films around | 236 | Packaging Europe

fresh fruits and vegetables and shopping bags. We’ve also more recently seen a huge new market in single-serve coffee capsules for use in Nespresso-type machines which is made possible thanks to our high heat technology.” In order to support its customers, Corbion Purac operates a global service network with extensive expertise in key conversion processes utilised in combination with profound application knowhow. This means that the company can effectively match application requirements from markets like automotive, appliances, packaging, wovens and 3D printing. With ambitious plans for continued development, Corbion Purac’s future looks set to be as bright as its achievements so far. Currently in the pre-engineering stage of the construction of a new PLA polymerisation plant, the company is ready for its predicted growth. Mr de Bie concluded, “As our global capacity increases it will allow for even more parties to make the switch from oil-based to biobased plastics for their packaging applications. More and more brand owners, retailers and converters are using bioplastics within their packaging portfolio. We are also seeing increasing activity amongst European governments and local authorities as they take a more active role in promoting the sustainability benefits of bioplastics to their constituencies.” Visit: www.corbion.com

When Packaging Becomes Art Can the packaging of a product become a work of art? According to one of the most prestigious museums in Italy the answer is yes – writes Luca Desiata, professor of Corporate Art at LUISS Business School and curator of the ‘Corporate Art’ exhibition at Galleria Nazionale d’Arte Moderna in Rome in the latest of his series of articles on the intersection of packaging design and art.

he National Gallery of Modern and Contemporary Art (GNAM) in Rome is hosting the first ever ‘Corporate Art’ exhibit until 11 October in an effort to enhance and inspire relations between the business and the worlds. The exhibit, organised in collaboration with the art crowdsourcing website pptArt and the LUISS University Creative Business Center, aims to restore the traditional cooperation between the two fields by displaying the recent rediscovery of art’s potential in marketing, corporate social responsibility and business communication.

Nespolo’s artwork and the packaging it inspired

Willow’s artwork and the packaging it inspired

Among the artworks on display, there are several examples of packaging design created by artists. The exhibit opens with one of Willow’s paintings. Willow is an Italian neo-pop artist whose lively and amusing style has been adopted by several companies for their packaging designs. In 2011 Borsalino, the quality-hats manufacturer, commissioned Willow a series of handpainted hats. In 2012 Mottart invited the artist to create the packaging for Panettone d’Autore, one of the main desserts on the Italian Christmas tables. Finally, in 2013 Willow’s art lands in the schools with his series of Comix diaries (Special Edition 2013/2014/2015 for Edizioni Panini). | 238 | Packaging Europe

The Gianduiotto chocolate, Caffarel’s flagship product, has been on the market for over 150 years. An important anniversary that the company has decided to celebrate with an exclusive design, where Caffarel’s tradition meets the contemporary style of Ugo Nespolo, a painter and sculptor from Turin. The wrapping of Caffarel’s Gianduiotto is created in Limited Edition: unique, original, colorful and humorous.

Labels are another interesting field of application for artists.

The internationally renowned Brazilian-American neopop artist Romero Britto participates to the Corporate Art exhib it with three of his works commissioned by Absolut Vodka for their 1989 advertising campaigns. The three digital prints are characterized by vibrant colors and bold patterns as a visual language of hope and happiness, reflecting the artist’s optimistic faith in the world around him.

Design Opinion

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Design Opinion

Going back to the beginning of the 20th century, two historical advertisements were contributed by the Historical Archive of Martini & Rossi from their rich Casa Martini’s gallery at the corporate headquarters of Pessione near Turin). Leonetto Cappiello and Giuseppe Riccobaldi were among the most sought-after artists in the Italian advertising world of the 20s and 30s. The two posters were used for the labels of a limited edition of bottles in 2003. As a celebration of the Italian style, a hand-painted Vespa scooter realized by the artist Nespolo for the exhibition “Vespa and the Cinema” stands at the center of the main hall. Though not an example of packaging, it can definitely inspire some creative ideas on how art can be integrated into product design processes. So, if you are looking for some inspiration for your next packaging design, you just need to get a flight to Rome to visit the Corporate Art exhibition at the Galleria Nazionale d’Arte Moderna between now and 11 October.

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Equipment Closures

Caps & Closures: Uncapping the Trends By Kevin Heap, Packaging Expert, Sumitomo (SHI) Demag

lobal demand for caps and closures is continuing to rise, with market volume estimated to reach 2,312 billion by 2018, up from 1,826 billion in 2012. Screw caps for canisters and bottles, in addition to plastic caps for cups, containers and pouches is driving this growth, with advancements in tamper-evident closures also pushing demand. Beverages remain the dominant market, with lightweight packaging a strong trend among suppliers that are striving to satisfy both environmental and cost concerns. Demands on injection moulding machines in the packaging industry continue to increase. In recent years, cycle times have got shorter, performance has increased, and higher cavity numbers are demanded. At Sumitomo (SHI) Demag we are seeing increasing demand for applications with cycle times of between 2-3 seconds. There is also bigger demand for machines with higher clamping force. Manufacturers in this sector are often contracted to produce millions of caps and closures, so to be cost effective, investment in high performance plant equipment is fundamental. When it comes to packaging applications, Sumitomo (SHI) Demag’s Systec SP and the El- Exis SP machinery ranges are selected. The name gives it away – SP stands for ‘Speed Performance’. Another important factor is energy efficiency. All-electric systems are fast becoming the system of choice for UK moulders. One of the most notable reasons is the figures stack up. Electric mould machines consume up to 75 per cent less energy than conventional equipment and the speed in which moulders are seeing a return on investment (ROI) has dropped from eight years to three. Guala Closures UK is one of our many caps and closures customers that opted for all-electric IntElect machines. Since installation their Kirkintilloch plant has increased the output of its customised bottle cap closures by 12 per cent, delivered a 40 per cent reduction in scrap waste and boosted its overall equipment efficiency (OEE) rating by 5 per cent. Plastic is by far the preferred material nowadays for these daily use components, replacing traditional materials like aluminum, tinplate, glass or cork. Aside from the cost advantages, the lower weight and versatility of plastic applications can further enhance product quality and security, and offer manufacturers better graphic capabilities. Polypropylene continues to be the leading caps and closure resin but there Kevin Heap, Sumitomo (SHI) Demag Packaging Expert Packaging Europe | 241 |

Closures

With material still being the largest cost element of a closure, thin walling and weight reduction has been the theme for the last few years

are expectations that the material may be replaced with HDPE which has economic and sustainability advantages. The use of bioplastics is also poised to play a greater role in packaging going forward. Technically speaking, a moulder doesn’t need to invest in new processing equipment to run bioplastics through it, although they do need to carefully consider how the material will perform as an end product and factor in the melt stability.

Fit for the future Injection moulding has surpassed compression moulding, predominantly due to the widespread adoption of multi-cavity moulds. The process entails thermoplastic and thermosetting polymer granules being fed into a heated barrel where they are melted and mixed under pressure by a rotating screw until there is a homogeneous melt which is injected into a mould cavity where the shape is configurated to the cavity and is replicated exactly. The mould is then cooled and opened, ejecting the finished cap/closure. Given that the average European discards 159kg of packaging material each year, sustainability is an ongoing concern with a strong commercial incentive to do more with less. The challenge for manufacturers of caps and closures is they are balancing a wide range of variables, including cost and functional requirements, as well as responding to demographic and lifestyle changes and environmental impact. However, with material still being the largest cost element of a closure, thin walling and weight reduction has been a focus area for innovation at Sumitomo (SHI) Demag. From a machinery manufacturer point of view, thinner wall sections bring changes in processing requirements. Among them, higher pressures and speeds, faster cooling times, and modifications to part-ejection and gating arrangements. These process changes have in turn prompted new considerations in mould, machinery, and part design. For cap manufactures that that may have been reticent about switching to all-electric, Sumitomo (SHI) Demag recently solved one of the production bottlenecks. It’s an

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especially beneficial development for the caps and closures market. Our new ejector technology stops components bouncing around and ricocheting into opposite cavities when they come off the mould, giving manufacturers the cycling speed, precision and repeatability of a hydraulic system often favoured in mass-production environments. With packaging formats constantly changing, it makes economic sense to build a complete moulding system that anticipates future applications. Many of today’s manufacturers are looking towards full turnkey solutions, with robotic capabilities integrated. Speed, yield, repeatability, reliability, multi-tasking and long-term cost saving are all reasons why end users might opt for a robotic solution. Our customers, particularly in the caps and closures market, increasingly ask for complete IM packages, which once set up require little modifications or engineering intervention.

The adoption of IntElect injection moulding technology has reduced energy consumption and boosted output for the Guala plant in Kirkintilloch by over 12 per cent

Traditional Label Printers

Moving into Packaging There has been much talk about the opportunities label printers could embrace by moving into the packaging printing sector, not to mention the synergies that could be adopted, writes Jules Lejeune, managing director of FINAT.

here adoption rates among European self-adhesive label converters remain highest is in the sleeve sector. 40 per cent of surveyed companies are already active in sleeve printing, while another 20 per cent are seriously looking to embrace this technology as part of their portfolio. About one fifth of label converters surveyed indicated that they have already entered, or are considering entering the European stand-up pouch market, which in itself is forecast to grow at 5.5-6.5 per cent per annum over the next five years. About one quarter have successfully penetrated other segments of the flexible packaging market, with another 15 per cent indicating they are very interested in this. Furthermore, almost one out of three surveyed converters are already active, or seriously interested, in the printing of in-mold labels, a market that is projected to grow an estimated two to three per cent annually over the next five years in Europe. Finally, the number of label printers that have successfully penetrated the folding carton market is small. In fact, less than 10 per cent of surveyed FINAT converter members are active in this sector and 73 per cent of polled companies indicated they are not currently active and are not interested in entering the folding carton market. That is according to the latest findings of our FINAT RADAR report on the European Narrow Web Market. They are based on a backdrop of overall good health in the European label market. In fact, in the first quarter of 2015, European demand for self-adhesive label materials increased by 7.1 per cent compared to the previous year. Over the past five quarters, year-on-year growth in the label industry averaged 5.8 per cent for paper roll materials and 8.3 per cent for filmic label material. In 2014, demand for self-adhesive

label materials in 30 European countries reached 6.4 billion square meters (roll and sheet materials together). This was an increase of 5.7 per cent compared to the previous year (in 2013, year on year growth was 3.4 per cent). In one year, European label printers added some 320 million square meters of self-adhesive label business to their market in 2013. In 2014, the volume of European label demand was 50 per cent higher than in 2002 and more than 100 per cent above the estimate for 1996. It is in the high-end, filmic roll label applications as a vehicle for product decoration and identification (‘PDID’) applications, where there has been rapid emergence. Since 1996, annual consumption of these materials quadrupled (with a duplication taking place over the past decade), and in 2014 filmic rolls represented about 25 per cent of total selfadhesive materials consumed in Europe. Another fundamental driver of self-adhesive label materials growth has been the growth in Eastern Europe. In 2014, Eastern European label demand increased by 8.7 per cent over 2013, ahead of Southern Europe (6.3 per cent), UK and Ireland (5.6 per cent), Northern Europe (5.2 per cent) and Central Europe at the end of the line with a modest 2.6 per cent growth rate. By market it is the Food & Household Chemicals that saw significant growth in 2014 - both registering 5.3 per cent. Beverage followed in the third place with 4.9 per cent of growth. Office products, consumer durables and Pharma accounted for the bottom three. With 60 per cent of installations, flexo remains the ‘work horse’ of the industry, but digital is growing rapidly. Some key findings were: • Planned investment in new digital technology is evenly divided between inkjet (54 per cent) & toner based (46 per cent) • More than 30 per cent of converters are planning investment in at least one press or other equipment • More than 50 per cent of respondents that have planned digital press investment are looking at inkjet solutions The report found that the global labeling sector continues to see a steady decline in average run sizes. We asked respondents to break down run sizes per end-use vertical for both their conventional jobs, in addition to their digital jobs (for companies that have digital presses). Conventional remained the clear leader in in the food and beverage sectors. It is also interesting to note that digital run sizes for 8 out of 11 sectors fall within a range of 250 – 750 linear meters per job. Digital production represented almost 11 per cent of total aggregated sales revenues of all participants, but digital sales revenues averaged almost 18 per cent for the entire respondent group that indicated they have digital presses. Out of all the printed packaging sectors, the flexible packaging industry has been more impacted by run size contractions than any other. European brand owners in the food industry are reporting job sizes have gone from millions of units to hundreds of thousands of units over the past five years and continue to go down. As flexible packaging run sizes decrease, opportunities open up for label converters with narrow web presses. So while there is the opportunity to move into packaging, some disciplines remain more attractive than others, with barriers ranging from margins to machinery investment. It is clear that flexible packaging offers the most synergies and that coupled with the growth in end uses such as sleeves and pouches indicate clear possibilities as long as companies bear in mind that their production capabilities need to remain as flexible as the product. Packaging Europe | 243 |

Italian leaders in tape

Fabo is a family-run Italian company with a long history in the production of adhesive tapes for packaging. Laura Travierso reports on the development of the company, its know-how and its respect for the environment.

Maurizio Fagni, owner and chairman

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TAPE - PORTRAIT

abo was born over 40 years ago in Tuscany with the launch of the selected production of gummed paper. In the years since the company has grown into a specialised producer of no-noise acrylic and hot melt products. “We have been present on the European and international markets with customised, functional and reliable tapes for more than 40 years,” said Mr Maurizio Fagni, owner and chairman of Fabo. The company is also an active member of Afera, the European Association for the Self Adhesive Tapes industry, a central organisation for the production and trading of tapes. Fabo offers a wide range of tapes, manufactured according to customer specifications when it comes to combining size, backing and adhesive, label, cores and packaging as well. “Dedication and reliability – those are the main ingredients of production at Fabo that have always guided our decisions. Fabo’s packaging, protection and reinforced tapes are

efficient, reliable and high-performing products. Today as well as tomorrow, we are ready to face new challenges in order to keep pace with evolving technology,” says Mr Fagni. Markets change in time and the model that had worked out in the past was not likely to prove as successful in the future. Therefore, the company has always made significant headway thanks to its internal Research and Development department. Constantly engaged in product innovation and research of new applications, the area develops prototypes and conducts tests and quality reports in its laboratory. The Company also carry out other activities such as checking of the product conformity on incoming raw materials; the quality control of semi-finished and finished products; the issuance of analysis and compliance certificates always under the constant verification of monitoring and measuring devices.

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State-of-the-art production

Thinking worldwide

Fabo’s product range is designed to respond to all manual or automatic application requirements with high-performance products. This guarantees the customisation of tapes based on specific technical or printing features. Thanks to multiple slitting lines, they can create tapes of any format and size according to the customer’s needs. Used in the paper packaging, converting, laminating, labelling and hygiene markets, it is clear that Fabo’s water-based adhesives serve a diverse range of markets. It specialises in the production of self-adhesive tape with hot melt and water-based technologies. The coating process with water based technologies uses cold-applied acrylic adhesives that do not contain aqueous emulsion solvents.

Thanks to a total integration between man, machine and the corporate information system, the company can ensure complete production control. In this way is easy to manage the stock and control the production phase starting from the maximisation of efficiency in business processes up to the minimisation of errors. “Our strategic plan is focused on growing exports which already account for more than half of our manufactured products. Indeed, our well-established position on foreign markets makes us an international company with customers in over 80 countries worldwide,” Mr Fagni noted. “Our business relationship with our customers is directly managed through our extensive sales network. Europe is our main market and we have a dedicated foreign office that looks after the business in a professional and transparent way.”

High-quality print The company’s latest product, the Tape Portrait offers a new and original way to use the tape as a communication tool, turning it into a ‘printed portrait’ with photographic quality. The internal graphic department supports the customer in the development of the project right the way from design to production. Fabo also offers standard printing services on-top e under surface ‘sandwich’ with both eight- and four-colour flexographic print.

Focused on sustainability

The Security Tape line

Branding and awareness

Fabo’s Security Tape line exposes any attempt at tampering by leaving visible traces on the surfaces. The use of this tape guarantees absolute protection for both senders and recipients. The anti-tampering packaging tape is ideal for envelopes and carton boxes. It is effective in many industrial applications to protect and safeguard sealed packages.

Fabo often sponsored and managed events and initiatives in Tuscany and outside, being always present in the territory with its steady attention to activities as sport and culture.

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Even though Fabo processes polypropylene and oil derivate materials, the company is fully engaged with environmental compliance issues. All production departments are equipped with energy-efficient systems as well as automatic safety and control devices. They follow a strict policy of rational usage of resources thanks to the complete recycling of process waste and the reduction of harmful emissions.

Visit: www.fabotape.com

Alveolar in Bubble guard® board for automotive packaging

Bubble guard® board sample

Bringing in the new

Innovation, flexibility and customised solutions are at the heart of Imballaggi Prottettivi’s success, as MD Alessandro Aledi explained when he talked to Barbara Rossi.

mballaggi Protettivi was established in the Lodi area of northern Italy (near Milan) in 1995. Each of the three founding partners, who still lead the company today, have had significant experience in flexible plastic products, especially air bubble polyethylene. They were respectively a commercial, technical and plant expert and, armed with the will to create new products and solutions, were particularly interested in moving from air bubble polyethylene to air bubble polypropylene. Today the company belongs to the B-Pack holding, which is specialised in manufacturing barrier films and other materials for the food and pharmaceutical sectors. Today the company’s range of customised products is divided into two main categories: flexible and rigid (board) and serves four main market segments, namely automotive interiors, general packaging, automotive packaging and graphic applications. Around 70 per cent of turnover is generated by board products (15 per cent of which is accounted for by Bubble Guard® matt® for graphic applications) whilst the flexible range accounts for the remainder (30 per cent). The main products within the flexible range are Bubble Guard® Flex and Ondubol®, whilst their board counterparts are Bubble Guard® Board and Ondubol®. Bubble Guard® Flex is an alveolar coextruded PP film, while Bubble Guard® Board is an alveolar coextruded PP sheet. Ondubol® is a corrugated coextruded PP. The board products are used for applications in all four of the previously mentioned market segments, while their flexible counterparts are mainly used for general

packaging of various final products, as well as for components for the steel, metal, wire and tube industries. Both flexible and board products are used in the construction sector (Bubble Guard Board is for ceilings or formworks, whilst Bubble Guard® Thermo Flex and Ondubol® Thermo Flex are niche products for thermal insulation).

Dedicated to innovation Imballaggi Protettivi is continuously working on the development of new applications. What truly distinguishes its innovative and patented products from those of its competitors is that they are laminated in line, without using glues. The many benefits of this technology include higher quality, competitive prices and greater production speed. The company, which has a wide network of commercial partners and distributors, re-invests at least 10 per cent of its turnover each year, as stated in its 2013– 2015 business plan. When asked about recently introduced products, Mr Aledi said, “In January this year we invested one million euros in the implementation of this vertical production line, including a new production facility, machinery and an HP digital printing system. The implementation of a 100 per cent vertical production system brings several benefits in terms of cost reduction and high quality. Another very significant investment was made in 2013, when we purchased a new production system for Bubble Guard® Board, which has an annual output of 6000 tonnes.” Packaging Europe | 247 |

Thermoforming part in Bubble guard compact®

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Bubble Guard® Board scheme

Ondubol®

In terms of the automotive interiors segment Imballaggi Protettivi sells its products to Tier1 suppliers, but deals directly with most of the major car manufacturers (FCA group, Nissan, BMW, Renault and PSA Peugeot Citroën, amongst others) to establish the required product specifications. One very important factor bearing on product specifications is lightness, which is important for fuel saving purposes. For graphic applications it mainly supplies distributors, as it does for the construction sector. Final industrial clients are supplied for general and automotive packaging, as well as for the steel, metal, wire and tube segment.

The company is also committed to environmental protection and on average its products contain 30 per cent recycled materials, something which clients appreciate and might be part of their requirements. Imballaggi Protettivi belongs to several associations and special projects, including: namely ATA (Associazione Tecnica dell’Automobile); ANFIA (Associazione Nazionale Filiera dell’Industria Automobilistica); and MaTech, a ‘Galileo Science and Technology Park’ project, which provides consultancy services for the research and application of new materials and new technology aimed at product innovation. It also collaborates with Materioteca© a world of plastic sensory in Milan. “We participated in IPACKIMA, in Milan, in May of this year and are going to be at FachPack in Nuremberg, Germany, from 29 September to 1 October. You will be able to find us at Stand 106, Hall 9.” Visit: www.imballaggiprotettivi.it

Continued success “In the past three years we have experienced a 20 per cent annual growth in turnover. Our 2014 turnover was €13,500,000 and for this year we have a confirmed €17,000,000 turnover, achieved thanks to our 44 members of staff. In terms of market segments, our two main client sectors are automotive packaging and graphics applications.” Geographically, 40 per cent of turnover comes from the Italian market and the rest (60 per cent) from exports. 80 per cent of the export turnover is generated in Europe, 20 per cent in Israel, South and North America and Africa. The main European markets are the UK, Germany and Poland, with the UK being particularly important for graphic applications, but most EU countries and Turkey are served. “We operate and grow in all countries where automotive production is on the increase and luckily enough this seems to be happening in Italy as well. The target of our 2016 business plan is to increase our turnover to 20/21 million euros within three years and our staff to 55 people. We aim to grow within the boundaries of the four previously stated main application fields. Then we plan to consolidate, as we want to remain a small/medium company, because we want to retain our market speed and flexibility and keep our absolute focus on innovation. For us continuously achieving something new is a must.” R&D is at the very heart of this UNI EN ISO 9001:2008 certified company. This does not only take place in the laboratory, but also at marketing level, through trade fairs and developing an understanding of clients’ needs. “Our innovation processes are not just in terms of improving our products, which we obviously do, but also unfold at another level. We strive to understand what clients need and find fulfilling solutions. In fact, our products are all customised. All the staff members who deal with customers are involved in our continuous research and development processes, exactly for the reason previously explained. “Our partners, who supplies us with our production systems, are also extremely important for our success. The fact that they provide us with cutting-edge technological equipment allows us to be very innovative and serve our customers in the best possible way.”

Bubble guard® Board with non woven laminated no glue

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The value alternative in aseptic carton packaging LamiPak.eu is part of the LamiCan Group, a Finnish packaging company with manufacturing offices in China where the LamiPak product range is manufactured and commercial offices for the European market in Finland. LamiPak is the only alternative aseptic liquid packaging supplier that produces their material on their own board, thereby providing cost advantages and control over the quality in the entire production chain. Marketing director Henry Alzamora and Head of Marketing & Sales Marco Verkaik discussed the reasons why they expect European beverage manufacturers to make the switch to their products.

amiCan Finland produces the award winning beverage container named LamiCan, the paperboard-based cans. The company is based in Finland, and is the only company in the world that produces paperboard based cans in-house, LamiCan Finland is the pioneer and creator of this quirky paperboard can. The company also manufactures the machinery and the packaging material at their own facilities; it also has its own maintenance service team for the LamiCan packaging machine. LamiCans can be filled with a wide range of beverages, except carbonated ones. They can be filled aseptically and have a 12-month shelf life without refrigeration. Henry Alzamora: “The paperboard can is currently shaking the premium drink sector. A major selling point is that it has the lowest carbon footprint when compared with PET and aluminum packages. The use of 50 per cent renewable raw materials in the LamiCans generate significantly fewer greenhouse gas emissions during production than during the energy intensive production cycle of the traditional aluminum cans.”

Cost savings plus eco-friendliness Customers today are paying more attention to the product’s performance from an environmental perspective. With LamiCans customers get an eco-friendly bundled package in a handsome package deal. LamiCan is produced with PEFC certified board. Established in Finland in 2007, Lamican’s roots go back to the early 1990s, when its predecessor Walkican was founded. An ongoing focus on innovation and more products diversification has continued to pay dividends in packaging success. | 250 | Packaging Europe

Henry Alzamora: “Although some people say that the beverage packaging market is a conservative one, you can clearly see that there is a strong demand for innovation, for new ideas and beverage concepts in a hyper competitive market looking forward to differentiating. We offer an innovative product based on an environmentally sound concept – renewable paperboard. For those future customers that are considering taking the plunge with this innovative packaging concept, we offer low cost co-packing services in Europe, this means the beverage companies do not have to invest in costly equipments or new filling lines. Low cost trials in LamiCans means a low risk way to do market research and slowly penetrate your market niche. We have two co-packers in Europe, one is named nordickoivu.com located in Finland and the other one is orskovfoods.com located in Denmark. Send us email at marketing@LamiCan.com if you are interested in our co-packing approach in LamiCans, the paperboard can.”

LamiPak LamiPak produces aseptic cartons for the dairy and juice packaging industry. LamiPaks are fully compatible with standard roll-fed filling lines. Henry Alzamora: “ Since our launch in Europe, we are steadily growing out customer base by offering a cost competitive alternative for dairy and juice packers. Our contracts are flexible with commercial terms, and have no complicated price structure. We want to be very straightforward and clear with our customers.” Lamipak has production facilities in China and commercial offices in LamiCan Finland. Delivery times are generally seven weeks, which is a lot when packers are

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looking for promotional packaging, but is perfectly alright for 75 per cent of the market, where packaging size and design requirements are stable. Marco Verkaik: “We offer our customers the option to have their LamiPaks transported by train, which cuts delivery time by two weeks. There is a weekly container train service between China and Germany, passing through Russia.” LamiPak has its own supply of paper to produce LamiPak. The pulp comes from sustainably managed forests, and when asked whether this concerned only part of the carton production, Marco replied that in order to obtain and keep the PEFC certificate, 100 per cent of production had to be sourced from PEFC forests. The PEFC is the largest certification framework in terms of forest area, covering about two-thirds of the globally certified forest area. Its head offices are in Geneva, Switzerland. Marco Verkaik: “In the Middle East we are the largest alternative supplier. In Europe we are steadily growing our customer base, so we will need some time before we have convinced decision makers on a fairly conservative market. But I think we’ll get there – you don’t need to be an Einstein to see the simple benefits of switching to lower cost, same quality products.”

New developments! LamiPak offers 200ml, 250ml and 1000ml cartons, both in base and slim format, and a 65ml ice lolly packet. It recently introduced a 125ml slim carton, together with a 1000ml slim carton with pre-laminated hole (PLH) for a screw-cap. Marco Verkaik: “So far our product range has followed the demands from the European market. We are very pleased with the launch of our 1000ml PLH cartons, which is a carton in slim format with pre-laminated hole for a screw-cap on top. We can also provide the screw-caps.” Marco Verkaik adds: “Margins are small in the beverage packaging industry. Packers that want to improve their margins will have to look at both sides: their selling position as well as their buying position. With us they can improve their buying position, and increase their margins. It’s what they need.” Henry Alzamora: “The current beverage brick-shaped packaging market is a conservative market. Where we have succeeded in convincing customers to come to us is where companies wanted to cut back on costs while keeping the possibility to interchange cartons from different suppliers, between production batches. Our cartons are European standard size, which means packers can intermittently use | 252 | Packaging Europe

our packs with those they still have or had in stock. There is no need to reconfigure machines. It seems obvious, but often the most obvious of arguments are the best arguments to convince customers.”

Awards LamiCan, the paperboard can has been awarded with different awards for the last two years, the technology has been recognized in international events and tradeshows both outside and inside Europe. LamiCan, the paperboard can has been catalogued by most of the packaging magazines and experts in the industry as a revolutionary package. The attention has been so huge that we have in plans to open new co-packing facilities around Europe in order to provide the innovation push that most of the European beverage companies are striving for nowadays. Visit: www.lamican.com

At the forefront of carton design With the winning combination of a strong background and a drive and ambition for growth; anticipated turnover from Belfast-based printing business Delta Print Ltd is expected to be over €70 million in 2016. Libby White spoke with company chairman Terry Cross to find out more about the successful investments and expansions that have been driving it forward since its humble beginnings.

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elta Print Ltd was founded 35 years ago by current chairman, Terry Cross, as a small commercial printing business in North Belfast. In the late 1980s, the company focused on folding carton packaging, invested in converting capability. Settling on the present site in 1995, the now named Delta Packaging Ltd operates a 20,000m2 facility encompassing flexo and litho printing and converting lines and is a major supplier to the branded food service and frozen, chilled and ambient retail food sector.

Advanced capabilities Delta has invested in exciting expansion plans to its facilities and also in pushing new innovations into the forefront of the industry. Its production capabilities in Belfast have recently been expanded to include a new 55,000 square foot facility housing one of Europe’s most advanced carton manufacturing environments. Mr Cross comments, “Delta’s new plant offers 10-colour HD flexo reel-to-reel printing with bespoke, variable, downstream coating and drying units for the in-line application of functional barriers and specialist finishes. Complementing the press are off-line sheeting, large format platen die-cutting and off-line rotary die-cutting options. This new plant has the capacity to convert an extra 300 million square metres of substrate per annum.” 2015 will see the establishment of a new manufacturing facility in Poland, giving Delta a strong base for geographical expansion. “Through the relationship with EPS Poland, Delta can expand its geographical reach throughout central and eastern Europe,” Mr Cross explains. “The facilities in Gliwice will also offer both flexo and litho printing op-

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tions with a full range of converting capability designed to enhance Delta’s penetration of the European Food Service business and also to facilitate further growth with existing general carton packaging customers.”

Strengthening skills Delta has recently invested in P4CK ltd, leading to an exciting synergy of skill sets between the two companies. “P4CK is a young, talented product design company which brings patented designs for portable, direct- and indirect- contact pack concepts to market. Delta brings procurement, manufacturing and logistics strengths to the association as well as its extensive customer and contact base. In addition to putting weight and scale behind the marketing of existing designs, the companies are working on specific customer-driven design briefs and new industry-focused pack concepts to bring to market,” Mr Cross tells us. On a wider basis, P4CK’s pure design and invention credentials will enhance Delta’s innovation capabilities and broaden the product ranges available from both Belfast and potentially through EPS in Poland. An example of the innovative designs born from this collaboration is the BevBax™, a robust packaging solution that can carry a combination of snack food and beverages. The flat-pack design pops open easily and can feature high impact branding with up to six colours. The BevBax™ can be configured to suit a number of different applications: Multiple beverage sizes and snack types, from popcorn to fast food, to drinks, and branded and unbranded applications.

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DELTA PACKAGING CHOOSE KOMORI-CHAMBON AS THEIR IDEAL PARTNER Presentation of the company:

Komori-Chambon is specialised in the design and manufacture of web offset and gravure presses and rotary die-cutters. It was founded in 1989 through the merger of Machines Chambon: a French company established in 1887, pioneers of in-line printing, cutting and delivery systems for packaging, and the Komori Group, established in Japan in 1923, world leader manufacturing high-quality offset presses. Liquid, tobacco packaging and general folding carton are the company’s main markets.

Delta and Komori

Delta Packaging, well-known for delivering high-volume packaging, with the quality, accuracy and stability demanded by the large brand owners, have now more than doubled their production capacity in Belfast by investing in an extremely productive Komori-Chambon new line. Neal McCone, director of Delta Packaging Ltd., Belfast, explains: “We spent a lot of time to examine all the possibilities, benchmarking everything available globally. In the end we chose Komori-Chambon as our ideal partner for the offline rotary die cutting. We are delighted to have made this choice - the Komori-Chambon solution is the best fit for our growth aspirations, meeting the high productivity, low waste and demanding engineering expectations. We now have an incredibly productive line, designed for delivering the demands of large brand owners.” “The new Komori-Chambon rotary die-cutter installed in Belfast enables us to have important technical capabilities, and the very stable profile, accuracy and super-high volumes sought by the large brands” Neal McCone tells us, adding that “the customers have to be big enough to get their production made on the new line”. With its new manufacturing capability in Poland, Delta will therefore have two rotary die-cutting units amongst their equipment to service their customers in Europe.

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KBA-FLEXOTECNICA S.p.A. Sets Top Performance in the Folding carton After a number of successful installations in the North American market KBA-FLEXOTECNICA is proud to announce to have successfully delivered and put into production a unique flexographic printing press of the prestigious series EVOXG fully sleeved and gearless featuring highly innovative technical systems and specially engineered for HIGH PERFORMANCES up to 600 m/min (1969 fpm) on paper and board up to 450 gsm with water based inks in Northern Ireland to Delta Print & Packaging. Delta Packaging print for Blue Chip companies such as McDonalds, Kellogg’s, Nokia and Jacobs to name just a few. Primarily the press has been purchased to run medium and large fry scoops and burger boxes for all of Europe in vast quantities together with fast food products the press will be printing a large variety of cartons for the breakfast cereal marketplace, biscuits, phone boxes and a variety of food cartons. The high grade press from KBA-Flexotecnica will be run reel to reel to feed a reel to rotary die cutting line and a reel to sheeter which in turn will feed two sheet fed flat-bed die cutters. The press has been future proofed with a 10 unit CI with large repeats, 1500mm (59”) web width and two independent in-line flexo units with large capacity, multi zone drying capacity to cope with future developments of anti-grease coating applications with large lay down capability which ensure optimum converting efficiency. Both of these in-line units have the facility to print on the front side and backside of the substrate in tight register to the CI section for patterned varnish and anti-grease coatings. Developed to achieve top performances in terms of quality, productivity and operational efficiency, this machine incorporates several unique features such as the fully Automatic Impression System AIF, automatic register control between the print run on CI and the patterned front and reverse varnish or coatings, automatic wash-up system SPEEDY CLEAN with integrated new generation ultrasound viscosity controls, in-line spectral colour measurement system which together with high performance 100% video inspection offer standardized consistent print quality and significant reduction of in setup time and material waste minimizing the need for human intervention at press stops. The printing press will be completed at the end user’s plant in Belfast with the installation of automatic shaft-less winders from Monomatic capable of handling reel diameter up to 1,800mm for automatic butt splice at maximum line speed featuring the ability to easily handle long run jobs with high speed capability. To achieve cost effective and reliable performance KBA –Flexotecnica relies on comprehensive innovative design engineering, precision machining and advanced electronics to offer with their presses ease of operation, high quality execution, technical sophistication and proven performance. Further details and info: Ms Maria Costantino, Sales & Maketing Manager, maria.costantino@kba-flexotecnica.com or visit www.kba-flexotecnica.com

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Colm Bradley, Managing Director, Delta Packaging and Senator Stanley Rosenberg, MA Senate take a tour of the Delta Packaging headquarters.

Another innovative design is the Flexicarry™, a one-, two-, three-, or four-pint beer carrier whereby one size fits all pint cups. Flexicarry™ is the only flexible multi-cup carrier in the world which can conveniently and safely carry and share up to four drinks without spilling. Supplied flat, this international patented design is manufactured in the UK from fully recyclable low slip PP. It can be branded on both sides with up to 4 colour litho printing. On testing at stadia events, the Flexicarry™ has been shown to increase speed-of-service at beer concessions by up to 50 per cent versus existing cardboard carriers. The product also benefits from being extremely light, reducing packaging waste and storage space by over 75 per cent compared to competitors. The Flexicarry™ has passed stringent health and safety tests, and unlike other carriers, is not a trip hazard or a potential projectile.

Customer relations From ice cream to consumer electronics, Delta produces packaging for some of the world’s largest brands, and offers supply and logistics support across Europe whilst protecting the global brands. In particular, Delta manufactures a broad range of branded retail packaging for customers across the dairy, cereals, prepared meals, biscuits, confectionery, added value meat and ice cream sectors. Delta has significant, long-standing client relationships, with the first key packaging client acquired 25 years ago. Terry Cross is quick to point out, “Customer retention has been achieved through a flexible attitude to service, production and development needs, underpinned by a commitment to reinvesting profits into renewing production assets.” Offering both rotary flexo and sheet-fed litho capabilities and being early adopters of productivity driven technologies has allowed the Company to maintain a competitive edge throughout the UK, Ireland and western Europe. A constant focus on cost reduction and seeking optimum scale supports the investment plans.

Future growth Geographical expansion is important for the business. Terry Cross explains, “Driving market share in branded foodservice packaging is a key facet of our growth strategy. However, building a flexible production footprint that allows the business to target a ‘best fit’ product mix across central Europe is important. The team is seeking opportunities that play to the company’s innovation, production and service strengths within the food, household goods, foodservice, healthcare and consumer products sectors.” A commitment to R&D and process improvement has resulted in a leadership position in the application of functional barriers for direct food contact and other areas. This remains a key strategic direction for the company in light of the many emerging migration issues driving European legislation. Delta will focus on maintaining the growth profile established for the Belfast site in line with qualifying supply from EPS in Poland by Summer 2015 and ramping up volume production there in the months ahead. Terry Cross concludes, “We expect 2016 and 2017 to offer double-digit growth on the way to targeted turnover of €120 million by 2020.” For more information, visit www.deltapack.com or contact Neal McCone, Sales Director of Delta Packaging on +44 (0)7785 327252

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Elitron: Your Automatic Packaging Partner The Italian company Elitron started out as the dream of a man who revolutionised the leather cutting industry with automated systems, both locally and all around the world. Laura Travierso reports. | 260 | Packaging Europe

litron’s worldwide success is the result of a winning formula: innovation and creativity, which have evolved side-by-side over the years. A wide range of software solutions and state-of-the-art production systems allow the company to address today’s market needs in multiple sectors: visual communication and packaging, general industry, leather and upholstery. Elitron is a leading player in computerised design and CNC automatic cutting systems. “We are able to offer a complete range of sector dedicated products specially designed for the packaging, graphics, general industry and leather sectors,” said sales and marketing director Daniele Gallucci. “Our goal is to help our partners perform their job quickly and efficiently, thus maximising their profit.” The new generation of Elitron cutting systems and software design packages also offers high quality solutions for a wider range of sectors, including aerospace, marine, automotive and a greater range of technical materials. At the heart of Elitron is a young, highly qualified team which works closely with the entire Gallucci family to offer an exclusively Made in Italy product, combining expert know-how, artisan tradition and the very latest technologies.

Originally Giuseppe Gallucci, founder and CEO of Elitron, wanted to automate and revolutionise the leather cutting industry in the Marche Region, where the company is still based. This region traditionally has a high concentration of footwear production and today Elitron has three factories there with 100 people working on a wide range of products and software. “We believe in human capital,” said Mr. Gallucci “ 95 per cent of Elitron’s new products start from a simple idea. The internal technical office is full of drafts and codes, suggestions and dreams with a single purpose: bringing them to life”.

The intelligent feeding system Heleva, the result of Elitron’s RFA (Researching Full Automation) activity, is an automatic feeding system that picks up, aligns and loads sheets or panels onto large format digital plotters. Heleva automatically feeds any printer, for a non-stop production cycle. This intelligent sheet feeder is able to communicate and interface with the printer for maximum flexibility. Heleva comes in two formats, depending upon the size of the

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media used and can load multi-sheets simultaneously. Moreover, in order to further automate the process, there is a motorised roller system which can transport pallets of different material in order to change media without interrupting the printing cycle.

Innovative solutions Kombo TAV is one of Elitron’s SuperPlotters which has two independent cutting heads. Fully automated, Loading – Cutting/Creasing – Unloading, it is the ideal solution for packaging, POS Displays and boxes. This flexible operating system accelerates production times and reduces costs whilst offering maximum versatility for both short and medium run production. With maximum flexibility over 24/7 and high performance, the Kombo TAV guarantees the complete automation of the production process, without operator intervention. The Kombo TAV comes with innovative systems patented by Elitron: the Seeker System for automatic recognition of images and reference points, and Airo Panel, a unique system for automatically unloading materials using a powerful suction panel. Kombo SD+ is an automatic cutting and finishing plotter dedicated to responding to the new requirements of the digital printing, cardboard, and signage industries. Kombo SD+ is equipped with the patented Seeker System that automatically recognises the printed images. This dual camera system reads the sheets and recognises printed images, detecting the position of the reference point and automatically loading the cutting files. The powerful, high-resolution video-projection

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system is perfect for rapid prototyping. It clearly projects the shapes to be cut onto the sheets and with a simple click the operator is able to nest the shapes, in order to optimise materials. The unparalleled cutting speeds of up to 102 mt/min accelerate production times, increasing productivity with minimum operator intervention. Visit: www.elitron.com

Sustainable Emotion, Iggesund’s Underlying Advantage Can anything really be new at an integrated pulp and paperboard mill, where the leading position in Europe has been held for over forty years? First, let’s take a look at the facts about this business.

nvercote from Iggesund has enhanced the messages and functionality of packaging for leading brands for many decades. Iconic perfume boutiques along the Champs Elysees in Paris would not be the same without the mood established by elegantly printed and converted paperboard. Duty free shops at international airports rely even more on the impact of packaging for luxury goods, also including chocolate and spirits. Even pharmaceutical packages and a myriad of other products convey image. “Emotion rules in luxury retail. When a consumer connects with a product – a brand, sales happen, and satisfaction follows, especially when the product itself delivers a promise,” says Jessica Tommila, Iggesund’s Marketing Communications Manager. “What’s new in our business is the growing expectation of a sustainability commitment, including environmental as well as corporate and social responsibility. Many consumers will support brands, based upon evidence of actions taken for a better planet.” In this new context, Iggesund is an even better fit for branders, because ‘emotional sustainability’ goes from their forest nurseries to finished packages and graphical applications, as well as recycling and making use of all waste streams as value streams.

Industry in a natural wonderland “At Iggesund, the daily life of running a pulp and paperboard mill balances well with the joy of living in a natural wonderland. Around here we think long term, and we live long term, always with the next generations in mind,” says Anna Mårtensson, Environmental Manager at the Iggesund Mill. “As families, we cross country ski, jog and take walks, and hunt in the forests. We place a high value on the various ways that trees enhance our lives. We take full responsibility for our handling of the forest, including constant dialogue with customers about raw material reduction to full

custody of every aspect of our products. With hundreds of customers from around the world coming to see our forests and our mill it adds up to a lot of visibility for our actions.”

Anna’s desk Every modernisation project crosses Mårtensson’s desk, because continuous improvement for environmental practices are incorporated into every design. A recent retrofit of the chlorine dioxide facility improved safety and productivity. An ongoing effort to minimise the impact of effluent from the mill aims to reduce undesirable or toxic substances to immeasurable levels. 5th generation Mårtensson reluctantly settled down to live and work in her hometown. “I traveled the world for five years, teaching kids in Cambodia, milking cows in Israel, chopping fish in Norway and stuffing croutons into lunch packages in Scotland for Marks and Spencer. Actually, all of my life experiences prepared me well for my current job. We make products that touch lives in many obvious ways. What’s not obvious is whether coated paperboard meets high sustainability levels or not.”

Efficiency and environment “Every time we have a win for safety, efficiency and the environment, we are genuinely excited and motivated to find the next step ahead.” And there are the big investments too, such as the 2009 purchase of a €25 million chemical treatment plant to improve water quality. “In 2012 we had the highest production in the mill’s history and also the lowest emissions to water in our history,” Mårtensson says. The new treatment plant has reduced phosphorus by nearly 80 per cent, which is an important step in combating the growth of aquatic plant life (eutrophication) in the nearby Baltic Sea. “We are world-class when it comes to the quality of effluent water. We borrow water from the Packaging Europe | 263 |

Iggesund River. First we clean it to use it in production and then we clean it in three additional steps. The last step is equivalent to how drinking water is processed, so the water is of a very high quality when it is returned to the sea.”

Making energy a priority In June 2012, a bio-driven recovery boiler replaced two old boilers at the mill at a cost of €260 million. Only a year later, sulphur emissions were down 84 per cent. Particles have been reduced by nearly 90 per cent and nitrogen emissions have decreased by 10 per cent. Most of all, Iggesund is 100 per cent thermal energy selfsufficient and more than 90 per cent for electricity needs. Iggesund even delivers energy for the local community’s district heating. The new boiler has a strong environmental capability, incinerating weak, sulphurcontaining gases to further reduce sulphur emissions to air. The investment is a key factor in being able to run the operation without using fossil fuels or purchased electricity over the long term – in 2014 the mill was operating on 98 per cent bio energy.

What about a price premium for Iggesund products? Arvid Sundblad, Iggesund’s head of Sales and Marketing, comments: “When an end user or carton maker chooses Invercote, they do so knowing that they pay a premium.” Sundblad is quick to point out that paying more for Iggesund board is often a wise economic decision. “Converters tell us that they have less waste with

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Invercote, and often they run their machines faster. Some choose our lighter weight grades and achieve equal results for their customers. Invercote’s technical support, and understanding of how to optimise production runs as well as creative appearance on the shelf, wins us a lot of repeat business.” Sundblad says that Iggesund’s business is becoming global, and reaching into markets and end use segments where the company has not been very active in the past. He believes that packaging growth will continue to be strong in Asia over the next decade. “We have learned that converters in Asia are being strongly challenged by international as well as local brand owners. They want the most out of every carton. So we are educating them about functionality, and planting sustainability ideas for their customers to harvest.” Back to the ‘what’s new at Iggesund’ question “What’s new at Iggesund is something small, and sometimes very big, every day,” says Mårtensson. “Often very small is what I like the best, because with my work, no measurable content of unwanted substances is always good.” Concludes Tommila, “We tend to get very excited about sustainability progress all along the value chain. That’s why ‘emotional sustainability’ well describes our approach to business, and our way of satisfying customers and end users.” Visit: www.iggesund.com

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Fast, flexible and reliable printing With its headquarters in Plymouth, Minnesota, USA, Primera Technology, Inc. is a leading developer and manufacturer of speciality printing equipment including colour label printers, label applicators, laser marking systems, label presses and digital finishing systems. Elisabeth Skoda spoke to Andreas Hoffmann, managing director of Primera Europe GmbH, about exciting developments in the field of label printing and to find out more about what lies behind the company’s success.

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rimera boasts over 40 years of experience in building specialised printers and has sold well over 1.5 million printers to the industry. “Part of this high number is thanks to our plastic card printing business which we sold in 1998, and which today operates under the name of HID Global. We gained a wealth of experience over the years, and we are busy working on developing new technologies every day,” Mr Hoffmann says. Primera is divided in three separate business units: Primera Disc Publishing, Primera Label, and Primera Healthcare. “Primera Disc Publishing provides printing equipment for CDs, DVDs, Blue Ray and other media. We started out with standalone printers, and this grew to robotic systems and complete production systems which can burn and print quantities of discs in one step,” Mr Hoffmann explains.

State-of-the-art technology Primera Label has seen impressive growth in the past few years. One milestone was the LX800, which was launched in 2006 as the first wide format desktop label printer on the market providing a printing width of 216mm. And the innovations just kept on coming, as Mr Hoffmann points out. “Our smaller inkjet printer, the LX400e offering high resolution inkjet technology, was launched at the end of 2007, followed 2008 by the AP label applicator series. Primera’s AP-series label applicators are the perfect semi-automatic labelling solution for cylindrical containers as well as many tapered containers, including bottles, cans, jars and tubes,” he adds.

In 2009, the CX1200e printer was introduced, allowing simple and easy production of labels in house, which is ideal for individualisation and smaller print runs, together with the FX1200e finisher, which was launched in 2010. “With CX and FX we are able to offer a complete production machine, where prints of any size and shape can be printed and laminated,” Mr Hoffmann is proud to point out. Since 2011, Primera has a third area of expertise – Primera Healthcare, offering speciality printers for labs and pharma industry, including Signature Cassette Printer, Signature Slide printer, and label and wristband printers.

A steady stream of labelling innovations Mr Hoffmann highlights the new LX2000e label printer and AP550e flat surface label applicator as the most recent innovations, which incorporate the essence of customer wishes. “LX2000e is our fastest pigment inkjet label printer, offering good value for the industry thanks to large, separate ink cartridges and print speeds of up to six inches per second. Our customers want low cost per label and speed. We addressed these issues with LX2000 and made clear improvements thanks to a new HP technology. Another key customer request was for long lasting labels, for labels used outside, to prevent them from fading and making them waterproof. New pigmented inks provide this extra level of durability. Labels printed on the LX2000e are ideal for outdoor use. What also sets the LX2000e apart is its connectivity. It can be connected not just via USB, but also via Ethernet and W-Lan, and also supports several devices in one room. As is always the case with our products, it is low maintenance and can be operated by anybody.”

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The AP550e Flat Label Applicator was also created following customer wishes, asking for printing on a wider range of packs. “The AP360e and AP362e enabled us to label bottles and round containers, but labelling packs such as crisps packets, tins, and oddly shaped boxes was still a challenge. With the AP550e it is possible to precisely apply product and identification labels onto a wide range of flat surfaces such as rectangular or tapered bottles, boxes, packages, bags, pouches, lids and tins. Labels are applied straight without wrinkles or folds in exactly the location desired. To operate, the container is put in the mechanism, and the arm is pulled to the container, when the label is automatically applied,” Mr Hoffmann explains. Primera also recently introduced the Primera Trio, the world’s smallest and lightest allin-one printer. It also has a built-in scanner and makes photocopies for working people who are “on the go.” “It weighs just one kilogram and allows the user to scan and print post cards, photos, A4 documents. It is easy to use and extremely portable,” Mr Hoffmann says. “There is still a lot to do in the area of labels. What is important especially in the area of label print is that we are at home with all technologies, be it ink, thermo transfer, and laser technology, and our new devices will also feature this technology.”

A wide reach Primera’s main production is situated in the USA, in Plymouth/Minneapolis, Minnesota where all of its devices are developed and prototypes are built. There is an additional factory located in sunny and warm Montego Bay, Jamaica, BWI. A small part of the work, such as final packaging, localisation, modifications and accessories also takes place in Germany. In addition, the FX400e, a small foil imprinter is manufactured in Germany. The main markets in Europe include Germany, the UK, France, Italy and Spain, followed by Scandinavia. “There is a growing demand in eastern European countries, but the challenge is that customers still want to save money, and often prefer to buy cheaper machines providing less functionality,” Mr Hoffmann points out. “Personalisation, which is a major trend for example in the UK and Germany, has not progressed as much in some countries for cost reasons.” Trade fairs are important for Primera as a forum to show off its latest innovations. Important upcoming events include Labelexpo in Brussels, followed by Speciality & Fine Food Fair 2015 in London, Anuga in Cologne, and Empack in Madrid. Partner trade fairs include Scanpack, Fachpack and Empack in Portugal and Brussels.

“We try to pick out big fairs focusing on labelling and packaging, and also small specialised fairs for certain product segments such as cosmetics, beverages or food. After all, a wide range of products do need labels,” Mr Hoffmann points out.

Room for growth Mr Hoffmann sees the biggest growth potential for Primera in the labelling market. “This market is unlimited, as there are so many applications, be it promotional materials, marking or packaging. The possibilities are endless. We have been innovating and developing ideas, but we are still at the beginning, and are busy with research. Printing technologies will be expanded in the future, that maybe will enable us to print directly on advertising materials, pens or even food. There are plenty of ideas floating around.” Primera serves a wide range of industries, but the main markets at the moment are drinks, food and cosmetics. “Industrial applications are catching up. Packaging for screens, screw boxes etc. is gaining popularity as the product has to be labelled from the outside. With our new LX2000e we address the industry directly. Another growing branch is the printing of shipping labels. I’m predicting that the mix in industry will grow even further,” Mr Hoffmann says. Mr. Hoffmann sees a strong trend towards more individualised products. “Big brands like Coca Cola are following this trend with individual name labels. This new trend creates a need for more and more flexible printers, which we are well equipped for.” Primera’s printers cater for advanced industry demands. “Global developments are working in our favour with demands for higher security and traceability of production processes, which allows for strong growth. The same is true for the food industry, where barcodes show what is in a product, who manufactured it and where it comes from are key factors pushing the market forward. We are in an ideal position to cater for these demands, so we are looking forward to exciting times,” Mr Hoffmann concludes. Andreas Hoffmann, Visit: http://primeralabel.eu managing director of Primera Europe

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We can handle it The US company PakTech has been delivering innovative handle solutions for beverage and foodstuff containers to American customers for nearly 25 years. Now it is setting its sights on the European craft brewing market.

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rom its plant in Eugene, Oregon, USA, PakTech ships more than 300 million plastic multipack handles each year to many of the world’s best-known processors of beverages and food as well as to producers of household and consumer goods. The vast selection of handle styles it is able to offer can be used to bundle many different kinds of containers with a variety of sizes, volumes and neck diameters. In fact, the company’s range of innovative standard and custom designs provide handle solutions for almost any kind of package. The PakTech brand was established in 1991 when Jim Borg designed and created the first TwinPak handle to join two gallons for an up and coming retailer called Costco. “Timing is everything,” says Andrew Powell, marketing associate at PakTech. “We had a simple and effective handle design, and club store suppliers needed a new solution for ‘bulk’ packaging of bottles. Then, after a few years of providing handles, our customers were asking how to apply our handles faster and more economically. So that brought us to our next milestone – our investment in automated handle application equipment. We now have over 150 applicators in operation in plants across the US. Subsequent important milestones included purchasing a new facility for applicator design and build in the early 2000s and switching material to Post-Consumer Recycled HDPE just a few years ago. We are committed to constant innovation and improvement. “As a privately-owned family business, we pride ourselves on being a valued supplier to food and beverage processors in the S and beyond as well as being a valued member of our community here in Eugene, Oregon. Our customers are constantly pleased about our high-quality products and services and our staff takes pride in providing these in an efficient and friendly manner.”

Compete capability Today PakTech’s services encompass the whole range of handle solutions, from custom design and prototyping to high volume manufacturing and the supply of high volume application equipment. The company’s in-house engineers produce part designs that can be sent direct to the tool room, where prototype moulds for plastic handles are built within days. The result is an extremely quick turnaround for its customers as well as maximum flexibility in updating and improving plastic handle designs. In its manufacturing plant PakTech employs some 15 state-of-the-art injection moulding presses as well as robots with end-of-arm tooling. The constant development of new technology enables the company to deliver maximum flexibility and reduced costs to its customers, including multiple stock colour options and UPC label applications. Finally PakTech’s handle application systems offer processors cost-effective in-line equipment that runs with minimum downtime and maintenance. These range from machines for applying handles manually through semi-automatic machines that can apply handles at a rate of up to 15 cycles per minute to fully automated application systems that apply multi-pack handles in either intermittent or continuous motion modes. PackTech has been supplying innovative solutions for handle application systems to many major brands for more than 15 years and it continues to grow and develop its product lines and its capacity.

The solution of choice “PakTech’s brand speaks to quality,” explains Andrew Powell. “The smooth features of the injection-moulded handles and the designs allow consumers to easily grab, carry and release multiple products. Our handles add value to a product on the shelf.

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“And because we have been in the industry for over 24 years, and because our handles are seen on all major brands and in so many retail settings, those seeking a multi-pack solution know that all they need to do is to call PakTech. Often, even a retailer will tell a new product entry to ‘call PakTech’. When they do, they will be provided with prompt and reliable service, and we’ll get their project ‘handled with excellence’. We have strong partnerships and have been servicing many companies for over 15 years. It’s our culture to provide amazing products and service, and our customers agree.” Although PakTech offers customers more than 100 different handle styles, the greater part of its sales are of no more than a dozen or so styles. A big seller is the UniPak handle for single gallons, which simply makes it easy for customers to grab and pour a gallon bottle. TwinPaks for 48, 64 and 96oz juice products are also popular models; TwinPaks and 3Paks are popular for ketchups and other sauces. In addition, an increasingly important product line is the Can Carrier handles (QuadPak and 6Pak) for 12 oz. craft brew and ciders.

New markets Innovation is a key driver of growth for PakTech; it is what enables it to continually improve current offers, as well as to find new markets to explore for both handles and applicators. Andrew Powell outlines some of new opportunities the company is currently pursuing: “For handles, we see a growing interest in the pill and vitamin market as well as in canned food. Both of these newly designed handles had unique design requirements, such as easier removal for pill bottles. By using proven design features as well as meeting the unique requirement of the project, we can provide a new winning packaging option. For applicators, we listened to craft brewers who needed a ‘medium’ speed machine. | 272 | Packaging Europe

There are just over 100 CCA120 machines in the market, which are low-cost machines applying up to 120 cans per minute. We also offered a CCA600 machine, which runs at 600 cans per minute. Then many brewery operators and customers told us they needed something faster – but not that fast. So in mid-2014 we finalised a CCA280 machine and have now sold four models to those needing this kind of mid-range machine. In the packaging business, as so many others, it’s ‘Innovate or die’!”

European opportunities In fact the remarkable growth in the craft brew and cider industry has been an important driver of growth for PakTech. And now it’s not only the US market it is focusing on; European craft brewers want PakTech can carriers too. The company has already established a distribution fulfilment in the UK to serve European craft brew and cider houses so that customers can now order its handles and save time and the cost of shipping. “This has been an exciting and fun adventure and we look forward to a successful venture into the European canned beverage market,” says Andrew Powell. In the Americas too PakTech has been serving the Central American market for several years with some success, and is confident it can continue growing the market there. It also has several Canadian and Caribbean customers. Looking to the immediate future, Mr Powell says, “We want to continue growing at a steady and comfortable rate. We are in an advanced stage of planning for another manufacturing facility in Eugene to keep up with our growth. So, we will continue providing winning products, and keeping costs low by expanding as needed. Our strategy is essentially to keep up the good work!” Visit: www.paktech-opi.com

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LINPAC, the global multi-material manufacturer of rigid and flexible plastic packaging solutions, aims to become the market leader in lightweight flexible films for the food industry, with the unveiling of a new £7 million investment at its Pontivy site in France.

he new world leading film production investment will reduce the weight of a number of LINPAC barrier films by up to 45 per cent, along with delivering new production capabilities to the supplier, to support its reengineered rPET, EPS and PP lightweight tray ranges. By increasing the performance of a number of new and existing products in its films portfolio, the LINPAC line investment will drive cost savings and a lower carbon footprint for the range, in line with retailers’ sustainability strategies and the LIFE (‘Light weighting For Excellence’) programme, that the supplier has been pursuing in recent years. Based on the new breakthrough one-shot film extrusion technology, LINPAC is widening its high quality, controlled orientation range of shrink films for tray lidding applications and has developed a new innovative range for flow pack applications for the fresh food sector. Erwan Cadoret, LINPAC Barrier Films Business Manager, commented: “This is a really exciting time for the business. The line has been built and tested and we are now ready to introduce five new films to the packaging market. “LINPAC already supplies an equivalent amount of film to the number of foam and rigid barrier trays that we sell into the market and this further investment will take us into the premier league of flexible film manufacturers globally. We’ve invested circa £7 million for five films but the potential opportunity for growth, as you can imagine, is far higher.”

What makes this investment significant? The new LINPAC extrusion line will move the company from typical barrier film lamination technology to a co-extrusion solution, where the film will be produced using complex one-shot film technology which accelerates the weight saving process. Traditionally the production of a multilayer barrier film laminate takes four processing steps: • Extrusion of the film • Extrusion of the sealing film • Barrier coating of the carrier film • Lamination of sealing layer to carrier layer or layers As the main driving factor in the film packaging supply chain is so often cost, it is advantageous to save material by reducing the gauge of a film. However, all the barrier and functional performance of the film must be maintained, including the sealing properties. This can now be achieved by using the new one-step extrusion process. Through improved film performance characteristics, packers will benefit from a reduction in line rejects and retailers will have less leaking packs in store, thanks to the excellent seal through contamination performance the new films achieve. Leak proof packs mean clean dry shelves for retailers, minimising store-cleaning costs. The range has also been designed with a wide seal window and when combined with the appropriate lightweight LINPAC trays, they ultimately deliver more packing flexibility and a total pack solution. Packaging Europe | 275 |

High barrier films and trays from LINPAC will also ensure longer shelf life performance across a range of food products. Whilst the new film range may be lighter and thinner than ever before, the robustness and strength of the films has been maintained and puncture resistance has been improved, again minimising product waste. Films currently being produced on the new co-extrusion line at Pontivy are around 20 per cent lighter than LINPAC’s previous specifications. However, in terms of the standard packaging industry lidding and shrink film specification, the overall range is 50 per cent lighter than current competitor laminate offerings. The end result benefits the consumers’ and retailers’ pocket, as well as the environment – lower packaging taxes and green fees are therefore also minimised. The investment also delivers additional new capacity for the supplier and the ability to produce film roll widths up to 900mm. The plastic flexible and rigid food packaging markets are growing thanks to continued substitution of glass and metal and global population growth; LINPAC is benefiting from this continued increase in demand. The new additional capacity installed will also therefore provide LINPAC customers with an improved, consistent quality product portfolio and secure global supply. Finally, LINPAC customers will now benefit from improved film planarity and tear resistance. The newly developed films will provide packers with much better line productivity as the films are easy to use on both Tray Sealing and Form, Fill, Seal lines resulting in reduced line downtimes, reducing costs and waste.

The new LINPAC barrier film range LINtop PE HB OSL New low shrink barrier film including anti-fog offering a thin, robust solution for outside & inside cut tray sealers and thermoforming lines • Excellent seal through contamination performance • Low weight/low carbon footprint – 20–30 per cent thinner than equivalent laminated films • Maximum flexibility with minimum inventory – suitable for both vertical and horizontal pack display

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LINform HBS 40 New high barrier flexible plain or printed shrink vacuum film for bulk or case-ready packs produced on a horizontal flow packing machine with a vacuum chamber and shrink tunnel • Designed to replace manual or automatic shrink bag loading operations for bulk-meat, processed meat and cheese • Delivers production reliability and consistency through improved vacuum efficiency and seal performance • High product integrity and extended shelf life performance reduces waste in the supply chain

LINtop Star PE HB New low gauge, high barrier, medium shrink film for tray sealers and case ready (MAP) pack formats requiring a PE sealant layer and vertical display • Excellent seal through contamination performance • Low weight/low carbon footprint – 20–30 per cent thinner than equivalent laminated films • Maximum flexibility with minimum inventory – suitable for both vertical and horizontal pack display

LINtop Star PE CXO High barrier, medium shrink film for outside cut tray sealers and case ready (MAP) pack formats requiring a PE sealant layer • Excellent seal through contamination performance • Low weight/low carbon footprint – 20-30 per cent thinner than equivalent laminated films • Maximum flexibility with minimum inventory – suitable for both vertical and horizontal pack display

LINtop PP HB F 27 Low gauge, high barrier, medium shrink film for outside cut tray sealers and case ready (MAP) pack formats utilizing PP trays • Excellent seal through contamination performance

• Low weight/low carbon footprint – 20–30 per cent thinner than equivalent laminated films • Maximum flexibility with minimum inventory – suitable for both vertical and horizontal pack display

‘Fresh Thinking’ From LINPAC

With over five decades of experience in food packaging design and a deep understanding of the demands of today’s fast moving consumer goods markets, LINPAC, and its sister company Infia Srl, lead the global packaging industry in the development and production of innovative packaging solutions. In particular, the company delivers fresh thinking packaging to help retailers, packers and food service clients sell a diverse range of products that meet the desires of the 21st century consumer for fast, fresh and healthy food. LINPAC is an international market leader in the production of primary fresh food packaging and food service solutions. The multi-material technology provider has a turnover of more than £550m, operating across a network of 18 manufacturing sites and 23 sales operations, servicing 71 countries globally. LINPAC champions the reduction of food waste through continuous innovation in packaging technology for the protection, preservation and presentation of products. It works to the highest standards of research and development, operates lean manufacturing processes and holds a best in class health and safety performance across its businesses. Its stringent implementation of an Environmental Policy also means that it constantly looks to all parts of the business to ensure its environmental footprint is as green as can be. The company is focused on reducing its CO2 emissions, minimising its use of energy and water and moving all its sites to zero-to-landfill status.

Partnership drives innovation Developing and delivering innovative and efficient packaging solutions which help to reduce the amount of food and packaging entering the waste stream has always been a key objective of LINPAC, but it has been underscored further by the injection of a ‘Fresh Thinking’ philosophy that has revolutionised the company in recent years and runs through every aspect of the business, both internally and externally.

Fresh Thinking is about LINPAC employees creating new ways of thinking and doing, and in turn creating a sustainable business, which has a forward direction and a ‘future focus’. The innovation team at LINPAC is always working towards creating new, diverse yet sustainable products. For example, LINPAC has recently partnered with Sacchital, leading Italian flexible packaging experts, who have 70 years of experience in the manufacturing and supply of paper & plastic printed laminates to the food industry. Together the companies have developed LINKraft®, a new film laminate for maximum consumer pack appeal. LINkraft offers a complete packaging solution for sliced meat, fresh pasta, chocolate goods and many more products, combining outstanding strength and presentation characteristics with environmental credentials. The robust and reliable laminate offers a natural yet traditional look and feel for contemporary packaging design and is suitable for organic and fresh products. The laminate can also be designed with a see through window giving consumers a chance to view the pack contents, which improves pack shelf appeal and drives retail sales. The LINkraft laminate secures the freshness of the pack contents and extends product shelf life through the inclusion of a high performance barrier layer fit for MAP and vacuum technologies. Product safety is also enhanced through the use of hermetic sealing but packs are designed to open easily meeting the needs of consumers. From an environmental perspective, LINkraft is both renewable and sustainable; thanks to FSC (Forest Stewardship Certification) certified paper and ultra light LINPAC films. Notably the product is also recyclable, as it has been designed with the correct proportion of paper and plastic content to be included in consumers’ home waste collections – though this is dependent on the final formulation of the product.

Total packaging solutions There are challenges ahead for the packaging industry but companies like LINPAC are constantly increasing their efforts to design packaging solutions that minimise the use of materials, energy and water and their environmental impact throughout the product lifecycle, whilst maintaining pack functionality.

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A key product development for LINPAC demonstrating this commitment is Rfresh Elite®, a ground breaking, super lightweight mono-material tray, which was first launched in 2012 and has continued to evolve. The revolutionary tray uses a sealant on the tray flange to create a secure seal with the lidding film, removing the industry standard laminated PE base film and creating an rPET tray which is 100 per cent recyclable at the end of its service life. Also developed in conjunction with the LINPAC L.I.F.E light-weighting programme, it means the weight of Rfresh Elite trays are reduced by more than 10 per cent. The removal of the PE base film lamination reduces tray weight by approximately 3 per cent and CAD/CAM redesign of the tray, with advanced process engineering, has delivered a minimum 10 per cent reduction relative to standard PET/PE trays; the carbon footprint of an Elite tray is typically 5 per cent less than the average rPET/ PE tray. Combining Rfresh Elite with the new range of lightweight flexible lidding films from LINPAC Pontivy means the company is truly leading the way in cost effective, environmental packaging design. Another efficient packaging solution from the Fresh Thinking innovation strategy is LINstar®. It is a premium EPS foam tray designed with a highly absorbent core to lock away unsightly product juices, doing away with the need for the use of additional soaker pads, so disliked by consumers and typically used with standard EPS trays. Available in a variety of sizes and vibrant colours, LINstar has been designed for both manual and automatic stretch wrapping machinery. The absorbent core again reduces shelf cleaning and waste due to leaks in store and drives efficiency for the retailer. | 278 | Packaging Europe

In 2013, LINPAC carried out a significant study with a leading Dutch retailer to assess the benefits of switching to premium LINstar EPS foam trays from standard EPS trays in one retail store. Despite a 12 per cent premium to invest in the higher quality LINstar EPS foam tray solution, the savings identified in one store were in excess of €50,000, more than offsetting the additional pack costs. Suffice to say LINstar has now been rolled out across the chain saving significant in store operations costs.

A commitment to Fresh Thinking, L.I.F.E and the future The entire flexible films investment project in France falls under LINPAC’s continuous L.I.F.E programme. With its continuing commitment to the Fresh Thinking innovation strategy, LINPAC can only go from strength to strength in development of consistent, high value products that meet the needs of the entire food packaging supply chain, from packer to retailer and consumer. The company is driving this philosophy across its tray business with the evolution of its Rfresh Elite, new MAP rigid and foam tray ranges and its exciting developments in rigid Vacuum Skin Packaging. However, the strategy is entirely reinforced with this new significant investment in thin gauge flexible films. In particular, LINPAC is a market leading solutions provider for protein packers in Europe. The investment project will reinforce the company’s leading position in the case ready segment and will also increase the business’ exposure overseas in America, Australasia, Middle East and Africa, where the new technological know-how will also be available for key protein players. The future looks bright for the company that is balancing the needs of its customers and the environment.

Leading the

way in automation

Founded in 1997, InduSoft is a global provider of HMI-SCADA software and embedded intelligent device software for the automation market. Headquartered in Austin, Texas, InduSoft has delivered more than 250,000 HMI software licenses to more than 700 customers worldwide, mainly industrial computer manufacturers and machine and system builders. Today, its strategy is to empower people and companies to develop graphical interfaces, integrate web browsers and take advantage of Internet connectivity. Eugenia Fiusco reports.

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nduSoft provides leading-edge HMI software technology that uses the Internet to access data that is stored on industrial devices and test and measurement equipment. In addition, InduSoft tools and technologies convert personal computers, web browsers and remote productivity devices such as smartphones and tablets into industrial automation and test and measurement systems.

Products and applications The core product is InduSoft Web Studio, a complete SCADA/HMI (Human Machine Interface and Supervisory Control and Data Acquisition) solution for any industry. It includes all the tools and functionality necessary to create solutions ranging from single-unit HMIs to sophisticated SCADA solutions. Melinda Corley, marketing director for InduSoft Web Studio, Schneider Electric Software, explains the main features of the software: “Applications can be deployed easily to the cloud, with remote viewing on smartphones and tablets to allow operators and maintenance staff to work efficiently and reduce downtime. InduSoft Web

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Studio includes tools for trends, reports, recipes, alarms, mobile configuration, patented database communication, redundancy, scripting and security.” InduSoft Web Studio is the most flexible solution on the market, with over 240 native communication drivers, supporting every major brand of PLC and controllers, as well as support for OPC and driver toolkits that allow users to create their own communication drivers. InduSoft has recently released InduSoft Web Studio version 8.0, which offers enhancements to the SCADA/HMI software capabilities of InduSoft Web Studio, including improved collaborative capabilities, better mobile configuration options and enhanced driver integration offerings.

Outstanding contribution to the packaging industry From OEE tools to modular solutions, InduSoft Web Studio provides easy-to-use tools turning data into high yield production. Regardless of the type of process needed, InduSoft Web Studio has the tools and the flexibility to monitor, track

and improve any packaging line. The advantages of using this outstanding tool are wide-ranging, including saving time in development, reducing errors in production, packing and shipping more products to name just a few. This powerful software can be scaled for every step of a customer’s operation, from the smallest touch-screen HMI to fully visualised dashboards available in the board room, or on-the-go via smartphone. Every step of the process, from monitoring fill and buffer capacity to maintaining machines, can be performed using this powerful SCADA/HMI solution. InduSoft Web Studio has tools available for a variety of specific processes in the packaging industry, ranging from feeding, capping, conveyor and material handling to forming, filling, sealing, cartoning, labelling and wrapping.

Geographical presence InduSoft is a lean software company with offices in the USA, Brazil and Europe. “As InduSoft grows and develops with our parent companies, it intends to offer more support and availability of services worldwide,” explains Ms Corley. “InduSoft is supported by channel partners, certified system integrators, distributors, OEMs and Value Added Resellers. The combined reach of these partners has been steadily increasing and will continue to add market share worldwide.” InduSoft Web Studio enjoys strong markets worldwide, but is particularly looking to strengthen offerings in Europe and APAC. In addition, it is investing heavily

into Industrial Internet of Things (IIoT) and Industry 4.0 technology through the development of its small-footprint embedded software platforms. These platforms include the InduSoft Embedded View (for Windows Embedded), InduSoft CEView (for Windows Compact Edition) and the recently introduced InduSoft IoTView (for Linux and VxWorks platforms). These solutions allow connection to control platforms, support data logging, and remote viewing.

Positive future outlook “InduSoft’s growth model has always come through continuous improvements to the product, with an eye on protecting user investment in software and hardware,” says Ms Corley. “Systems can be scaled easily with InduSoft Web Studio, and continue to operate throughout the entire lifecycle of the hardware. Much of InduSoft’s growth comes from cultivating new expansion while retaining current customers.” She concludes by underlining the strength of the InduSoft brand: “Despite many changes in ownership of InduSoft’s parent companies, Invensys and Schneider Electric Software (which will soon be Aveva), InduSoft Web Studio has remained a strong and independent brand with a clear roadmap for the future. InduSoft will continue to evolve and develop the strong core offering that makes InduSoft Web Studio so reliable and flexible today.” Visit: www.indusoft.com

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High performance

and sustainable With its head office in London, Petainer has a long and successful heritage of supporting dynamic local and global brands. Elisabeth Skoda spoke to Annemieke Hartman-Jemmett, Petainer’s Group Commercial Director, about the journey Petainer has undergone to become a pioneer in high performance plastics packaging, about the company’s expansion beyond Europe and exciting new product developments.

“This vision has been the foundation of the Petainer team focused on building and expanding the business ever since, at its core sustainability and what we refer to as ‘economics’ – i.e. working with brand owners on creating valuable business propositions fueled by principles of sustainability based on reducing the total cost of ownership.” Ms Hartman-Jemmett explains. Petainer’s portfolio is made up of the product groups petainerSmallContainer™ (from 200ml to 2L), petainerKeg™ (15,20 and 30 liter), petainerCooler™ (bulk watercooler containers, 5 gallon, 20 and 20.5 liter, with or without handle) and petainerJar™ (110ml and 120 ml from 1L to 8L). “One thing that all of our products have in common is that they are created in preform format first (two-stage process), through a unique polymer engineering process. This enables bulk transportation of preforms, allowing brand owners to blow in close proximity to filling location; which means that we can take many lorries off the road. When shipping blown kegs, around 2000 fit in a lorry, but with preforms, 30,000 fit in a lorry,” Ms Hartman-Jemmett remarks.

International presence

etainer was originally a part of Rexam, the leading beverage packaging manufacturer. At the time, the business was focused on small containers between 200ml to 2L for carbonated soft drinks and water. Petainer’s current CEO, Nigel Pritchard, took ownership of the business in 2009 together with a number of private equity partners. Nigel’s vision was to turn Petainer into a business dedicated to a sustainable offering of high performance PET and plastics packaging solutions, developing bespoke products focused on delivering on brand owner business objectives.

Since 2009 Petainer has focused on expanding its European base and is now able to provide global reach supported by local teams. The company’s corporate head office is situated in London, UK, in addition to which it has manufacturing plants and R&D centres in Aš, Czech Republic and Lidköping, Sweden, supported by global sales teams. A new manufacturing site in Russia opened in 2013, producing recyclable PET beer kegs and water cooler bottles for the local market in Klin, 40 miles from Moscow. In 2014 Petainer started working with a partner in Australia where it is now blowing petainerKeg™ in the local market. Meanwhile, a recent joint venture in India with partner Innopac brings Petainer closer to Asian markets and with the USA business expanding rapidly, a USA based facility will open later this year in California. Petainer has appointed G3 as its distribution partner, in the USA supported by the recruitment of additional team members. “Our partnership with KHS, a well-known and respected German filling equipment company, offers international reach through a well-developed network of global offices,” Ms Hartman-Jemmett states. “In certain territories we have appointed additional distribution partners to provide additional local expert support - Benelux, South Africa, Italy are just a few examples. Thanks to our dedicated team, we have been successful in introducing our global footprint - we are now able to supply all over the world: global reach with local support.” Packaging Europe | 283 |

Innovations The industry and markets are changing, and Petainer has been at the forefront of this development, as Ms Hartman-Jemmett explains: “Wine and beer have traditionally been transported in steel kegs. As an alternative, Petainer developed the petainerKeg™, a 15L, 20L or 30L keg for the transport of beer, wine, cider or other drinks, which from its introduction has seen great adoption from Russian brewers with global markets now following wide spread acceptance of the PET packaging solution in the packaging mix. petainerkeg™ offers many advantages that appeal to brand owners of all sizes. Firstly, they don’t have to invest in expensive steel kegs, which cost up to 100 euros, and up to 30 per cent of which do not get returned, which means an immediate loss. The steel kegs also have to be shipped back empty, which is expensive from a freight perspective and not very environmentally friendly. Petainer can offer brewers the option to buy a keg, fill it, distribute it, ship it, and there are no return costs for PET packaging as it can go straight into local recycling streams.” Petainer is expanding from PET to using other plastics materials. “Thanks to advanced polymer engineering has now made 2-stage production in HDPE possible, offering significant material reduction, of 25+ per cent. We can ship in bulk and blow in local markets. On small containers we find that what was traditionally a 35-gram container can now be made offering the same performance, top strength, side strength and packaging performance with a material saving of 50 percent to 17 gram. Due to the neck structure closures allow hermetic sealing after opening even after removing the seal, offering shelf life improvements to brand owners. This will be launched in to the marketplace in October 2015,” says Ms Hartman-Jemmett. The petainerKeg™ innovation from Petainer has supported the Roberson Wine business model of wine on tap to the UK market; a growing trend in the UK. For more information on this, readers can look at the press releases from Roberson’s Wines and view this video: https://www.youtube.com/watch?v=IKCc_sMv78c Finally, and also on the topic of environmental protection, Petainer has helped Orkla with its award-winning sustainability programme, reducing its CO2 emissions by 90 per cent through the joint development of the Felix ketchup bottle.

Joint ventures Early in 2015, Petainer completed a joint venture in India with partner Innopac in order to further increase its global footprint, focusing on introducing game-changing PET/ plastic packaging solutions to brand owners in India. Innopac, established by Saket and Atit Bhatia (the promoting family of a leading metal packaging group in India), provides | 284 | Packaging Europe

innovative packaging solutions to the food, beverage, pharmaceutical and non-food sectors. Atit Bhatia is the managing director of PetainerInnopac, supported by the local management team and expertise and resources from the wider Petainer team. “Petainer recognises that it needs local expertise in a market such as India and our partner is of key importance to delivering on our promise in an exciting and market with continued growth. We are very excited to be represented by such a experienced, committed and well-presented local team. To effectively support our customers in India, we will be opening our first PetainerInnopac plant in Mumbai in September 2015,” Ms HartmanJemmett is delighted to share. Petainer has developed significantly since 2009. “Today we are a global player,” she continues, “expanding our product and service offering with well-known brands, offering our legacy products off the shelf, and additionally offering bespoke packaging solutions. Our expert product development team works hand in hand with brand owners, improving shelf life, maximising the supply chain and adding value,” she adds. Ms Hartman-Jemmett sees a bright and successful future ahead for Petainer: “We continue to focus on understanding customer needs, match our innovations to secure enhanced outcomes that deliver on our customer business objectives Additionally, we focus on adding new products to our portfolio and continue to aim to make a difference and add value to brand owners in both local and global markets.” Visit: www.petainer.com

Safeguarding supply chains Systech is the global technology leader in anti-counterfeiting, product safety, consumer and brand protection. Libby White spoke with Darryl S. Brown, vice-president of strategic marketing, to discover the latest developments from a company with a strong pioneering background celebrating its 30th anniversary this year.

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arryl Brown is proud to share, “Systech has been involved since the beginning in the development of solutions for the supply chain. Originally, it focused on producing vision systems to help identify products in the supply chain. We were the first to offer a single solution that combines vision technology with procedural management and device communication. Since then, Systech has progressively advanced its technology, continuously developing ground-breaking advances.” He adds, “Today, we work globally with 19 of the top 20 pharmaceutical companies and we are not providing our solutions for just a couple of lines, we work with these companies on a grand scale.”

Leading the way Systech pioneered serialisation and is defining the future of authentication. It unifies and optimises authentication, enterprise serialisation and track-and-trace technologies to ensure regulatory compliance, mitigate risk, and drive efficiency and profitability. For 30 years, Systech’s innovation has led best practices for key brands representing industries across consumer packaged goods, food and beverage, aviation, automotive, and life sciences. “Our solutions are very configurable, and modular at software levels. We are not in the hardware business. We provide software that interfaces with over 200 preconfigured models, this allows our solutions to work on different types of equipment on a line, site, and multiple sites up to the enterprise level,” Darryl Brown explains.

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Systech’s solutions are ideal for sectors such as contract packaging, which Darryl Brown spotlights as an accelerating market. “A lot of the pharmaceutical companies are outsourcing to re-packagers who need very configurable solutions whereby they can adapt from packing one product to another.” He continues, “We can provide virtual environments and run simulations generating random data as if a line is running to ensure everything works before it is validated and certified. Our solutions allow our customers flexibility, as rather than needing to invest in a new piece of hardware when they add a new printer, camera system or packaging unit to a line for example, our software can be reconfigured and does not need recertifying.” Its offerings are designed for both serialised and non-serialised environments, as Darryl Brown explains, “Our foundation was really in the pharmaceutical industry due to compliance and regulations, but obviously our solutions can also add value to other markets. We are starting to see a need for authentication, and customer engagement. On top of this, the business intelligence and insight companies receive from the data collected is invaluable in achieving more streamlined and efficient operations.”

Configurable solutions Darryl Brown is pleased to share that 2015 will see three new major developments in solutions introduced by Systech. Internationalisation, outsourcing, e-tailing and the expansion of international trade zones have created counterfeiting and complexities throughout the supply chain like

never before. The ability to uniquely mark, track and identify products is the only avenue for brands to prevent these risks and drive value through revenue protection. Systech UniSecure™ takes advantage of these microscopic variations by detecting specific measurable patterns, and harnesses them to generate an inherent, covert security feature from an existing, standard and overt print mark. UniSecure™ leverages existing packaging line infrastructure with the image of the data carrier being captured by a vision system, Systech UniSign™, readily found on packaging lines. Once analysed, the UniSecure signature is extracted and the original image discarded. Once extracted, the ‘UniSignature’ is sent as code and stored in a secure cloud-based repository, Systech UniStore™, where it remains until it is referenced for authentication. With a simple smartphone application to authenticate, Systech UniScan™, the image is captured, extracted and sent to the UniStore platform where it is cross-referenced against the original ‘UniSignature’. The verification results are returned to the investigator and the product is immediately verified as authentic or counterfeit. Systech has also developed its core serialisation offering by refreshing its UniSeries™ platform, heading into its eighth generation, to be launched in August 2015. As a cross-level, all-encompassing enterprise platform, UniSeries offers all capabilities required for brands across their lifecycle, from manufacturing to retail, to serialise and track-and-trace products throughout the supply chain, meeting with regulatory compliance requirements, while providing the capability to authenticate. The UniSeries™ suite is based on patented, configurable software that offers manufacturers the flexibility to adapt to new regulations without extensive reworking or revalidation by developing solution standards across common packaging use cases. This reduces implementation, training and support costs. “We are also launching a refresh of UniTrace™ which is our track and trace cloudbased solution,” Darryl Brown comments. UniTrace™ is an enterprise platform that offers all the capabilities necessary for manufacturers to meet compliance requirements. Enabling brands to serialise, as well as track-and-trace products throughout the supply chain, Systech’s solutions future-proof serialisation by providing the capability to add and adapt to the latest in regulatory changes and authentication technology.

UniTrace delivers scalability, performance and uptime, not easily or cost-effectively attainable with an on-site solution. With a pay-for-usage modular system, customers benefit from affordable, globally-accessible data storage solutions unique to their projects, regardless of the scale of deployment.

Forward-thinking Systech’s headquarters are based in Princeton, New Jersey, with international offices in Brussels, Belgium. Darryl Brown adds, “Roughly, we have in the region of 35 to 40 per cent of our head count based in Europe.” The Systech sales, technical support and services team guide, partner and support leading brands globally. In support of its rapid expansion Systech has opened a new 52,000 square feet (4800 square metres), state-of-the art campus in Princeton, New Jersey, in the second quarter of 2015, with expansion capabilities up to approximately 80,000 square feet to accommodate Systech’s expected growth over the next few years. The new campus is home to a new training centre, and a new laboratory for innovation. Darryl Brown adds, “Systech has invested in this very modern, high-tech, and polished new campus which is strategically based in the technological heart of New Jersey. We are very excited to be holding our Uniquity 2015 global conference here October 8th and 9th this year.” In addition to the new campus, Darryl Brown explains that Systech has gone through a complete rebranding exercise worldwide, which will clearly express the company’s ethos of putting the customer first. “For the past couple of years, Systech has been strongly focusing on the development and implementation of UniSeries™ and the new UniSecure™. Now is the time for us to really reinstate our leadership of the marketplace with our rebranding strategy,” Darryl Brown says. He points towards the trends of brand protection and engagement as the natural progression Systech’s solutions will cater towards. “We are not moving away from serialisation, rather we are adding value to it.” He concludes, “Fundamentally, the end consumer drives the market. We buy products by emotion and we buy by branding, so we can add a lot of value in the area of brand protection to our customers who are already dealing with serialisation as well as those who are not.” For more information, visit www.systechone.com

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Packaging solutions for fragile products Dentas Paper Industry Inc. manufactures cellulose-based moulded fibre packaging products for eggs and other fragile goods. These are marketed through an extensive European sales network. Dentas is the third biggest moulded pulp producer in Europe and a moulded fibre technology leader. Philip Yorke reports on a company that continues to expand and gain market share through investment in people, plant and the latest technology.

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entas Paper Industry was established under the name of Dentas Wood Products in 1972 in Denizli, Turkey. Initially the company focused on the production of corrugated cardboard packaging and boxes. However, in 1985 the company installed its first moulded fibre production line designed to produce egg trays. In 2003 Dentas Romania was established and Dentas Paper Ind. became a global company in 2007. In 2014 the company commissioned its latest state-of-the-art facility in Aksaray, Turkey. Today Dentas’s customers for industrial packaging products can be found in Turkey, Romania, Bulgaria, Germany, Italy, Portugal and Sweden and many other European countries. Company is a subsidiary of Abalıoğlu Holding, Turkey.

In-depth R&D capability Dentas has always considered innovation and R&D to be a priority and a key driver for growth. The company operates an extensive R&D facility, as well as a modern design and product development department. It has also established the most advanced and sophisticated pulp and paper R&D laboratory in Turkey in order to support its intensive R&D activities. As one of the founding members of the European Moulded Fibre Association (EMFA), in 2012 Dentas also became a permanent congress member of the International Moulded Fibre Association (IMFA).

As an environmentally friendly company, Dentas Paper Industry ensures that all its waste products are recovered within a closed system during the entire manufacturing process. Company General Manager Ferruh Erguney said, “Dentas Paper Industry has the most advanced pulp and paper laboratory in the moulded fibre industry. It is capable of making very specific measurements related to the performance of cellulose fibres. In this laboratory regular measurements are carried out on an existing product’s physical properties such as cushion dynamics and load strengths in addition to detecting the reaction of cellulose fibres with different chemicals. “Dentas has achieved a sound and impressive growth rate with sales volumes increasing by more than 300 per cent during the past ten years. We also look continuously for acquisition opportunities, mainly in eastern Europe. We have also added a number of new production lines to cope with increasing demand. Within the past ten years we have moved our original factory to a location three times bigger, built Romania factory in 2006 and Aksaray-Turkey in 2014.

Custom-moulded products Dentas is not only a leading moulded fibre packaging producer, it is also a packaging solutions provider. Mr Ferruh Erguney added, “Until now we have offered our Packaging Europe | 289 |

customers creative and beneficial packaging alternatives across a broad range of applications with special emphasis on sectors such as medical, furniture, electronics, durable goods and home appliances. Corner protectors and cushion pads are a particular speciality of ours. Another important product range that we focus upon is ‘wave sheets’, which are used mainly in the textile industry to pack roll-formed products. “With our specially designed products, mattresses are able to withstand slopes of 27 degrees of slope without deformation, whereas the limit until now has only been 10 degrees with traditional ‘wave sheet’ products. In addition, there is increasing demand in Europe for custom-moulded pulp products. As a result we have installed an extra industrial moulded fibre line in our plant in Romania. “Depending upon demand, we are also planning to install a further one or two new industrial moulded fibre lines by the end of 2015 in both Turkey and Romania. We have been working closely with Kadant Lamort for our pulping equipment and for our vacuum generation we utilise Nash-Gardner Denver vacuum pumps and have done so for many years. For the printing process we are collaborating closely with Volker GmbH, and for our pressuring and mixing and gluing processes we work with Sulzer and BIM Central Europe accordingly.”

Superior properties Fragile products such as eggs are very easily affected by mechanical vibrations and impacts during transportation. Moulded fibre packaging offers superior cushioning properties compared to conventional polystyrene and extruded plastics to absorb these effects. Moulded fibre is also a soft lightweight material, which will not scratch or erode the product that it protects. It also has a unique ability to allow air circulation, which helps to eliminate moisture and heat deposition on the product concerned. This in turn also means that the product will enjoy a longer shelf life. Moulded fibre’s anti-static characteristics also make it particularly suitable for products in the consumer electronics sector. | 290 | Packaging Europe

Today moulded fibre products offer considerable environmental and sustainability advantages, as these products can decompose in a short time frame, unlike petroleumbased packaging products. Dentas manufacturing facilities produce their products from recycled fibre sources such as newspapers, corrugated cardboard, old magazines and used office paper. Furthermore, unlike some other processes, there is no production waste in cellulosic moulded fibre processes and therefore any production waste can be re-used time and again in the production process by simply feeding the waste back into the original production process. For further details of Dentas’ moulded fibre packaging products and services visit: www.dentaskagit.com.tr

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Revolutionising production flow FlexLink is a leading provider of automated production flow solutions, giving improved production efficiency to a wide range of industries. Viktor Hermanson, the company’s marketing manager, tells Elisabeth Skoda about the company’s product range and recent innovations.

eadquartered in Göteborg, Sweden, FlexLink has operating units in 30 countries and is represented in more than 60. In 2014, FlexLink had 840 employees and a turnover of SEK 1649 million. “FlexLink is part of Coesia Group, an innovation based group consisting of 14 companies specialised in automated machinery and industrial process solutions. For 2013, the Coesia Group had a turnover of €1450 million and 6175 employees,” says Mr Hermanson.

Efficiency boosting product range With automated production flow solutions from FlexLink, manufacturers’ total cost of ownership is minimised thanks to several improvements, including an increase of sellable throughput, an elimination of bottlenecks by balancing the production flow, an improvement of quality assurance, increasing yield and product safety, a minimisation of process waiting time and a reduction of changeover time, which increases line flexibility and available production capacity. Operational costs are reduced through minimising non-value adding operations, lowering power consumption per produced unit, reducing manual handling and administration, space efficient solutions, i.e. more capacity per factory square metre and after sales services aimed at reducing the Total Cost of Ownership (TCO). Capital employed is reduced thanks to lowering stocks of finished goods, reducing work-in-progress and a better utilisation of the factory floor. From conveyor components to turnkey solutions, FlexLink delivers automated production flow solutions that will enhance the efficiency of production processes. “FlexLink has the widest range of standardised conveyors systems, ranging from 45mm up to over 1000mm in both aluminum and stainless steel. In additional we develop handling functions and flow solutions like buffers, elevators, high speed mergers and diverters. We also have structural and profile systems in aluminum,” Mr Hermanson says.

International presence FlexLink is proud to be a reliable partner to its customers. “With our 35 years of experience, we are well equipped to serve our customers with high quality products thanks to our industry knowledge and the wide standardised range of conveyor systems we offer.

We are close to our customers thanks to our operating units in 30 countries and our partner network of more than 60 countries. In total, we have more than 8000 installations worldwide ¬– many for leading brands within FMCG, healthcare, automotive and electronics,” Mr Hermanson adds. FlexLink’s main warehouse is situated in Poland, with two additional ones in the US and in Asia. Furthermore, there are engineering centres in Poland and Malaysia.

Innovations FlexLink recently launched a new chain cleaning unit designed for production processes. The unit is designed to run continuously in production lines where product spillage or dust from the process, products or equipment are an issue and the washing process must be maintained in a dry environment. “This protects sensitive product areas from the risk of being contaminated by dirt or debris. The unit is especially suitable for the pharma industry and high value products or packaging,” Mr Hermanson explains. FlexLink also recently unveiled its latest innovation for safe, clean and efficient handling in primary and secondary packaging for the food industries. The new modular wide belt conveyor, addresses some of the higher hygienic requirements associated with primary and secondary packaging. It sets new standards for cleaning results and cleaning process time. Both product safety and hygiene have been optimised to a very high level, following the industry requirements and regulations. For instance, flat surfaces have been eliminated and there are no hollow bodies or crevices where bacteria can grow. Finally, FlexLink launched a new high-speed diverter, which perfectly balances production flows of more then 1000 products per minute in a continuous motion. It is suitable for a wide range of products – even sensitive, flexible packaging. It is ideal for the balancing of high capacity production flows. “Products get distributed according to downstream process and capacity requirements, enabling a demand-driven production at higher capacities than ever before, irrespective of the features of the products handled. The patent-pending solution is able to balance flows at rates over 1000 products per minute,” Mr Hermanson points out. Packaging Europe | 293 |

Expanding markets FlexLink serves a wide customer base, ranging from local producers to global corporations, and from end-users to machine manufacturers in markets in Europe, Asia, and North and South America. “We are a leading provider of high-end solutions to manufacturing industries such as food, beverages, personal care, healthcare, automotive and electronics,” Mr Hermanson says. “Customers are served through our own operational units in 30 countries and a global network of strategic partners. The partner network has been an important strategic element of FlexLink’s business model since its beginnings in 1980, enabling the company to enhance efficiency at factories in more than 60 countries worldwide. Moving into new geographical markets is key, as being close to the market and mak-

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ing sure our customers are satisfied is essential for a sustainable company. This is one of the reasons why we have opened up three new offices lately, in Turkey, South Korea and South Africa. Mr Hermanson is optimistic that FlexLink is on the right track for future development and innovation as long as the company keeps working closely with its customers. “Flexible factory automation is a trend that can provide us with significant growth. Our customers demand higher efficiency and quality. The challenges of high labour costs and complex products creates substantial opportunities for us. But we need to be humble and really understand what our customers need. Increased use of mechatronics and software in our solutions will be key, as will an improved service offering.” Visit: www.flexlink.com

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Focused on customer success The success of US-headquartered ITW Pillar Technologies is based on skillful execution and integration. Rory Wolf, Business Unit Manager, talks to Barbara Rossi about the company’s two core product lines – surface treatment and induction sealing technologies – and discusses future developments.

illar Technologies is a division of ITW, a multi-billion dollar company with more than 90 years of history, which today designs and manufactures fasteners and components, equipment and consumable systems, as well as a variety of speciality products and equipment for customers around the world. ITW’s vast array of business units are small, decentralised and focused on their customers. Founded in 1966, ITW Pillar Technologies leads the industry in new product development for the packaging, converting and plastic film-printing markets. As a business unit of ITW, the company has access to literally hundreds of products manufactured by over 600 business units within the family.

Products and technologies As mentioned, ITW Pillar Technologies has two core product lines – surface treatment technologies and induction sealing technologies. Within its surface treatment technology division the company manufactures state-of-the-art corona discharge, atmospheric pressure plasma, ozone destruction and ozone generation systems. In fact, its solutions include the only true universal design for conductive, non-conductive and dual dielectric corona treatment. Its surface treatment equipment can be manufactured for wide web and narrow web applications, along with applications for controlled gas (CGA) and modified gas atmosphere (MGA).

The induction sealing technology division manufactures the most versatile range of fully-automatic induction cap sealing systems, employing the industry’s latest technology. Its air-cooled induction cap sealers reduce the cost and maintenance required with traditional water-cooled induction cap sealers. With regard to new and recent products, Mr Wolf explains, “We have a number of new products in the pipeline which are nearing launch on both sides of our business. One recent accomplishment was the introduction and successful installation of the world’s highest speed atmospheric plasma treatment system, known as our Protean1™ system. Another game-changing innovation on the induction sealing side of our business is launching this month and will be announced soon.” The company, whose headquarters and main production facility is in Hartland (Wisconsin, USA) has a unique and highly lean manufacturing strategy –leveraged by strategically located operating centres in Europe, Asia and S.A. – as well as a global network of manufacturer’s representatives and distributors. ITW Pillar Technologies regularly invests in advanced technologies which develop new solutions for its customer applications. It does this because it aims to consistently deliver superior value to all customers and contribute to their success. In order to achieve this purpose it has to have exceptional operating performance and aligned, high-performance teamwork. ITW Pillar Technologies strives to forge lasting relationships with customers by helping them to be more satisfied, profitable and efficient. Packaging Europe | 297 |

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Expanding into new segments “Our focus is primarily on the consumer discretionary, consumer staple, industrial, energy and healthcare sectors. The segments served by the induction sealers division include the health & beauty, automotive, chemical, pharmaceutical, nutraceutical, food, dairy and beverage sectors. Our surface treatment solutions include printing, coating, extrusion and laminating, polymers, textiles, foils and consumer products. However, we are serving a much wider range of industry sectors. As these sectors and sub-sectors become more familiar with the attractive return on investment that our technologies offer, we find that early adopters emerge quickly. We deliver products designed to each sector’s specific and essential requirements. And we do this globally with application and service support worldwide.” In terms of geographical markets the company has a true global footprint. Sales of packaging systems are concentrated in Asia, which accounts for a growing percentage of total turnover. North America and western Europe share equal activity. Eastern Europe is becoming a larger purchaser of packaging technology, but still with a global share in the single digit percentages, followed by South and Central America and the Middle East. “We see this segmentation of our principal markets changing significantly before 2020, with Asia ultimately representing a greater percentage of global demand for our products. “As mentioned previously, we participate in all geographical markets but we are shifting, and in some cases adding, resources to meet customer needs. Our preference is to expand into adjacent customer segments, introducing new products to them, and developing new distribution channels to support them. Only then will we move into adjacent geographic markets.”

Future development may include both organic growth and acquisitions. In fact, the company employs a skillfully executed growth strategy, opening the door to increased opportunities. “In the end, our success comes down to skillful execution and integration. Our work in this regard can sometimes resemble a puzzle of many pieces. But when we have assembled them properly, we expect to achieve a bright future of value creation for our customers and accelerated growth for our organisation.” Talking about company development over the next few years, Mr Wolf adds, “As a business unit of ITW, we develop and refine a long-range business plan annually. As such, ITW Pillar Technologies already has its course set for the upcoming years. That course is one which focuses on leveraging our core strengths in surface treatment and induction sealing, which we have developed over the past 45 years.” Visit: www.pillartech.com

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Moving solutions OCME is one of the leading suppliers of automated handling systems and machinery to the packaging industry. In an interview with marketing and communications officer Laura Leglise, Packaging Europe finds out about the company’s wide range of packaging line solutions and strategies for growth.

OCME has been on the market for over 60 years: What have been the most significant milestones in its development? How would you describe OCME’s heritage as a company thanks to these decades of experience?

Innovation is key to meeting our customers’ needs and sometimes also anticipate them. Our R&D department has constantly improved over the years in order to satisfy more and more customer requirements. This is because we always take care to study the market’s needs in order to respond with targeted and premium solutions – so as to reduce the TCO of machines, for example. We deal mainly with engineers, buyers and heads of production, and our machine have advantages for all of them. We always offer the highest quality, engineering for innovation, great work on TCO and high safety standards. Those are our priorities but the market sees new trends emerging, one of which we are meeting with our latest innovation: PackettoTM. This solution meets the needs of beverage customers, who are all now looking for the perfect shrink-wrapped package. The new packaging system eliminates the wrinkles and fold-backs normally found when using shrink film – even on packs with intricate graphics. PackettoTM (in part thanks to OCME’s VEGA shrink-wrapping machines) represents something of a revolution in the world of packaging. With this, custom-

LL In more than 60 years of work we have come to be among the world leaders in our sector thanks to all our machines ranging from packaging, palletising and up to material handling technology. The company’s strong points are the high quality standards of the products and the large budget allocated for research and innovation. We also have a strong post-sales service which is always aimed at complete customer satisfaction.

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ers now have access to tools that can upgrade the image of their brands, save money and raw materials – all whilst respecting the environment. The PackettoTM solutions are divided in three categories: • SMART PackettoTM: this is a solution that enables OCME’s customers to save up to 30 per cent on film compared to standard packs, whilst also increasing aesthetic pack quality; • PackettoTM ECO: An innovative pack offering both ecological and economic benefits. Packetto Eco is a new type of package, enabling the use of very thin film through the integration of an easy-to-carry handle that forms part of the pack’s structure. • PackettoTM Party: With a unique ‘friendly-sharing’ design, PackettoTM Party allows customers to chill their cans or bottles on the move, enjoying their parties either at home or outdoors. Packetto™ Party is therefore a perfect solution for an innovative marketing campaign or merchandising tool, presenting great value to the final customer.

PE Ocme produces a wide range of packaging line solutions, from filling to end of line. Could you please outline the main areas of your product range?

LL Thanks to its long-standing experience in the beverages sector, OCME can provide customers with complete support for turnkey solutions. The main ma-

chines included on the beverage line are designed and manufactured by OCME, providing a further guarantee of the highest quality standards and minimal integration difficulties. OCME places entire teams of specialized engineers at the disposal of its customers to develop solutions that respond to specific bottling and handling needs.

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Each beverage filling machine manufactured by OCME and any integrated device manufactured by external suppliers are the result of in-depth studies and a rigorous selection process, with the sole aim of guaranteeing that the performance level demanded by each customer is fully met. For some time now, OCME has been implementing avant-garde technologies into its range of palletising systems, guaranteeing high efficiency levels without compromising on flexibility. Machines such as Perseus, Orion and Pegasus allow for such rapid servicing operations that a very high level of availability (meaning time available for production) is guaranteed even in the case of breakdown. Furthermore, guided tools for the creation of new palletising patterns and assisted format change procedures have made production rates less sensitive to frequent changeover of products and package types.

ism which all combine to give us the leading edge in today’s constantly moving, competitive markets. Each machine, each complete line, each activity undertaken by OCME represents the synthesis of a unique experience in the sector, as well as a way of working that focuses on the needs of the client.

What is OCME’s vision for the short to medium term future? What is your strategy for achieving your growth targets?

Those first 61 years of our company’s history have served as preparation for any future challenges. We can count on our highly advanced structure, on people who have been working for OCME since the beginning as well as new employees who believe in the company. We have created an environment that allows ideas to grow! Today, as in 1954, industries all over the world know that if they want to accomplish an ambitious project or to solve a problem OCME is a serious long-term partner.

OCME’s aim has always been keen to provide its clients with ever more efficient and flexible equipment. By this we mean the tools, technologies and professional-

Visit: www.ocme.com

PE What are the USPs of OCME solutions: what is it that makes customers come back to you time and again?

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Passion for Print

Established in October 1984 and with more than 30 years of experience in printing flexible film for packaging, ENVAFLEX has become one of the leading converters in the Spanish market. Libby White spoke with sales director Carolina Jiménez Juárez and Oscar Orensanz to find out more about the company’s ambitious plans and latest investments in cutting-edge technologies.

NVAFLEX has continuously increased its turnover year on year, posting in 2014 a figure of 22 million Euro. It is a family business with more than 100 employees and 16,000m² of facilities located in Zaragoza, Spain. Testament to its professional credentials, ENVAFLEX holds BRC and ISO certifications. Since starting its activities, ENVAFLEX has achieved different technological milestones, no doubt helping build its ongoing success. ENVAFLEX’s wide ranging capabilities include central drum printing technology and gearless printing machines, flexo printing machines with sleeves, advances in fast washout and the latest screening technology, mobile pallet racking, ink formulations widening the spectrum of colours available to print, and rotogravure printing.

Flexible solutions “Our target market is the food industry,” Carolina Jiménez Juárez comments. “At the moment this represents up to 95 per cent of our turnover. Security of the food in contact with the packaging we print is a priority for our customers. We guarantee the maximum food safety of our film in all our production processes, from our suppliers to their installations. Our customers can also expect flexibility, production | 304 | Packaging Europe

capacity and high printing quality. Other industries such as pharmaceutical, chemical and paper can be considered as expansion markets, due to continuous innovation in materials and technologies.” Solutions range from lid film for trays or thermoformed reels, and flow-packed films for foodstuffs such as cold meats, slices and cheese, and fruits and vegetables. ENVAFLEX prides itself on providing optimum conservation during shelf life, maintaining colour, freshness and flavour. For prepared dishes, ENVAFLEX offers a stand-up pouch that allows product manipulation and integrity depending on its applications. It also offers solutions for dry products ranging from bakery and confectionary, sauces and condiments, to pet food. ENVAFLEX prints flexible films using rotogravure and flexographic techniques for both vertical and horizontal packaging equipment. Carolina Jiménez Juárez explains, “We print substrates from: mono and bioriented polypropylene, low density polyethylene, polyester both chemically and PVdC treated, bioriented polyamide, to high barrier materials such as PE/EVOH, PA/PE.” To meet the ever growing demands of the food industry, ENVAFLEX has the ability to also offer the lamination of some of these materials to create multilayer

films for high-barrier packaging. “This is becoming an integral part of the food industry, due to its ability to protect against oxygen, water vapour, odour, light and contaminants,” Oscar Orensanz points out.

Active partnerships Oscar Orensanz highlights ENVAFLEX’s partnerships with reliable and well-known producers: “An impressive partnership and collaboration is with LINPAC, a multinational film producer, and we are their ideal partner for printing in Spain. Furthermore, a full HD certification was awarded by ESKO for higher quality printing, with better colour intensity and higher resolution.”

As a leading example of ENVAFLEX’s commitment to development and innovation, it was also an active partner in the NAFISPACK project within the Seventh Framework Programme of the EU. Carolina Jiménez Juárez explains the objectives of the project: “Developing innovative and safe packaging systems in order to increase fresh products shelf life by using antimicrobial active packaging and intelligent packaging; and developing a safety assessment methodology.” The new materials created by the NAFISPACK project offer real opportunities. In the production line no performance differences between the new materials and those currently used were observed, so there is no need to adapt existing food packaging Packaging Europe | 305 |

production lines. From a commercial point of view, the new packaging solutions extend, in a mild but effective way, the commercial life of the most perishable products, such as those selected in the NAFISPACK project (minimally processed vegetables, fresh fish and fresh chicken).

Latest technologies ENVAFLEX ensures it provides the best service to its customers by using the most efficient production processes and by consistently updating its equipment and technologies. For example, ENVAFLEX has the advantage of four flexographic printers with eight colours. Carolina Jiménez Juárez comments, “Our latest acquisition in 2015 was a cutting edge COMEXI F2MP printer. This will increase our printing capacity by around 40 per cent.” In addition, ENVAFLEX has two rotogravure printers, an eight colour ROTOMEC printer since 2007, and an UTECO printer with an online lamination modulus. It also has nine slitters, the latest cutting edge technology slitter being the COMEXI Proslit S1 DT. Relying on well-known names in the industry, with three laminating machines, the latest addition is a 2013 BOBST CL850D. A focus on improving quality and precision is evident in all aspects of the production process, as Carolina Jiménez Juárez shows, “With the DuPont Microflex system, we mount directly onto cylinders or sleeves the flexographic printing plates, which allows a significant improvement in printing quality and register precision.” ENVAFLEX also has the advantage of a warehouse with a mobile pallet racking system capable of storing up to 1700 tonnes, which includes raw materials, in process and finished goods, and 4200 gravure cylinders. It also benefits from its own inks laboratory with a computerised dispenser (INKMAKER) for the formulation of all the inks used in all the printing processes, with a production capacity of 500 tonnes per year. Carolina Jiménez Juárez adds: “Other technical equipment consists of a spectrodensitometer, colour scanning system, and an automatic analyser of residual solvents. An important investment we made in 2013 was on a regenerative thermal oxidizer which provides a highly efficient solution to minimise the pollutant emissions of all Volatile Organic Compound (VOC) generated in the process.”

Expanding presence Beyond ENVAFLEX’s main geographical market of Spain its exports, representing around 10 per cent of its business, primarily encompasses other European countries such as Switzerland. However, a share of ENVAFLEX’s exports are global, with markets as far afield as Australia. | 306 | Packaging Europe

Its presence this year at the world’s largest plastics exposition, the NPE Orlando 2015, illustrates its ambitions on a global scale. Oscar Orensanz explains: “Obviously, our intention is to move into other markets, although it is a hard step onwards. Our presence at NPE Orlando 2015 was, precisely, with the intention of doing a market prospecting in order to determine potential markets in which ENVAFLEX could settle. We saw this as an interesting platform to introduce our company in other countries and to seek potential customers.” With an ambitious growth plan from 2015 onwards, Carolina Jiménez Juárez concludes: “In the short term we are strengthening our position in the printing sector, with a sales increase of over 15 per cent projected for the next two years, including higher weight in export activity. We will continue to invest in cutting edge technology and equipment in order to fulfil and improve our customer´s needs.” For more information, visit www.Envaflex.es

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Passion for prestige packaging Established in 1998 by David Houghton and David Harrison, D2 Printing was created to challenge traditional attitudes to printing and to provide exceptional levels of service and professionalism. Operating from a state-of-the-art facility based in Surrey, UK, D2 specialises in producing prestige carton packaging. The focus is on packaging that grabs attention through the use of imaginative and creative ideas combined with glamorous finishes such as embossing, foiling and window patching. Libby White spoke with the two enthusiastic directors about their passion and drive to expand D2’s creative packaging division further.

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lready valued as a high quality print supplier for prestige work and POS, D2 started receiving requests to produce bespoke packaged items, gift sets and other forms of promotional packaging. The packaging division was set up two years ago to deal specifically with this growing demand from existing clients for luxury packaging requiring extremely high levels of print production quality. Mr Houghton comments, “The more we did, the more we learned. One of the big differences was that coming from a commercial print background we translated commercial print lead-times into the packaging sector. It was all we knew, and clients couldn’t believe how quickly we could respond.” Packaging soon became the company’s fastest growing sector, with significant scope for future growth. With clients predominantly from the beauty, cosmetics and fragrances industries requesting luxury gift set packaging, D2 has provided solutions for such esteemed clients as Gucci and Lacoste.

from our customer service department, a faster response from manufacturing, and a faster delivery (shorter lead-time).” “If you ask any of our customers, they`ll say we give them the best response and service levels of anyone they deal with. If we don’t, we just ‘step it up’ until we do,” adds Mr Houghton. “Our clients expect a high end luxury solution to reflect their own brand values. We work within a high quality threshold coupled with low tolerance levels, and are consistent with the high quality we provide.” From the beginning, D2 has held the ethos of putting the customer first, placing service and client satisfaction at the very core of its foundations. “Rather than give the client what we wanted when we wanted because we were the experts , we set out to create a business that actually gave the customer what they wanted when they wanted it, no matter how silly the lead-time or request may appear. Whilst our business has evolved our core principles remain and are as relevant today as ever,” underscores Mr Houghton.

A fresh perspective

State of the art facilities

“We don’t think outside the box, we think about the box,” Mr Houghton says. “We focus on creativity and pushing the boundaries, without taking our eyes off the brief. We can add a lot of value to our client’s product due to the skills we possess and expertise in the finishes we can provide.” Originally starting out as a sheet fed printer, D2 developed relationships with marketing departments whose approach to printing meant it was supplying an on-demand printing service for products that were not normally on-demand. Transferring this same attitude in to the packaging environment has proved to be extremely successful. Mr Houghton stresses, “Our clients receive a faster response

D2 benefits from its own 20,000 sq ft. factory, supported by 35 employees. Everything is housed under one roof. Reliable and high quality Heidelberg equipment is used from printing through to finishing, and Agfa front end and Zund for CAD work supports D2’s ambitious projects. Mr Houghton is proud to point out, “The factory is spotless, we have branded uniforms and the machines all have a strict preventative maintenance schedule. The advantage of in-house printing and finishing means we retain control at all stages of manufacture.” Flexibility offered from D2’s carton diameter B2 &B1 litho presses enables the choice of a wide selection of different carton boards to be used. The flexibility and technological

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advancement of the Heidelberg presses means that run lengths can vary from small runs of 1000 copies to runs in excess of 500,000. “The competitive advantage gained from our in-house laminating, cutting & stripping, glue lines, hand manipulation and so on provides us with many opportunities to gain new clients on a regular basis,” adds Mr Harrison

Web to print D2 has recently won a major web to print contract from a global blue-chip healthcare company, meaning a large investment to design and build the site and also further investment into digital personalisation. Mr Harrison comments, “Digital personalisation is a growing trend, and we are receiving more requests from our customers for specialised, personalised packaging. It can be used beneficially by the luxury gift set market in particular, and can add a lot of value to the customer’s products. Mr Houghton adds, “Building this web-to-print solution and software is going to open up a whole new area of expertise for us which we can then in turn offer to existing and potential new customers. We aim to launch in November 2015.”

Industry recognition Year on year D2 is nominated for awards and in consecutive years won ‘SME company of the year’ and ‘customer services team of the year’ at the Print Week Awards. In 2014, it was also shortlisted for the ‘brochure printer of the year’ award exemplifying the depth of ability within the business. This year, D2 will be entering the category of ‘packaging printer of the year’ in the Print Week awards due to the exciting and adventurous packaging it has created over the last 12 months. Mr Houghton observes, “Receiving public and industry recognition for our services and quality is important to our business two fold. Firstly our customers are proud to be associated with a company that takes pride in its performance and exhibits such a high

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level of attention to detail throughout the manufacturing process. Our customers share our enjoyment of industry wide recognition and fills them with confidence and complete reassurance offered by D2. Secondly it engages all staff, from the office to the factory floor and generates a proud sense of achievement throughout. “Recognition of achievements can also mean that creative ideas are forthcoming from all staff members in pursuit of the next accolade, whether it be a new environmental award, a quality award, service or business performance award. It shows the industry how committed and passionate our company really is.” Ultimately, D2 considers every job as award winning, ensuring the team focuses on excellence at all times.

Exciting prospects Thriving from its continuous organic growth, D2 has plans to grow its packaging division into a stand-alone Pan-European business. Mr Houghton says, “We are always planning for the future and our factory investments have meant we can now grow our business by 100 per cent within our existing premises. We engaged with the BPIF with regard to our growth strategy and we identified that our existing factory capabilities would sustain 100 per cent growth.” D2’s clients are mainly UK and European based, however due to the nature of the business, it has a global reach, distance and location are not defining factors. Mr Houghton exemplifies, “We have clients everywhere and they all get the same customer service experience , whether they are in Humberside , London ,New York or Geneva . We distribute globally on a daily basis.” Mr Harrison concludes, “We are very passionate about what we do, particularly since we delved into the packaging industry and embarked on setting up our own packaging division, a satisfying, rewarding and creative field we are proud to be a part of and of which we look forward to expanding into further.” For more information, visit www.d2printing.com

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PET BOTTLE LABELLING – TODAY AND TOMORROW Research indicates that consumers take only an average of around three to seven seconds to pick their drink of choice from the shelves of our supermarkets. In those instances where a shopper is looking to make a spontaneous choice, the packaging plays a particularly significant role – and labelling today is an area of growing importance in the overall bottling of liquids, according to Raffaele Pace, Labelling Product Manager at Sidel.

ears ago, the bottle label was simply a vehicle for carrying the beverage or product name, a little corporate branding and the little product information that was required by law. In today’s sophisticated marketplace however, much greater emphasis is placed upon the label and its marketing value as an important interface with the consumer. A label design that is striking and memorable will place its brand firmly in the memory of the customer and reinforce its position in a very competitive marketplace. Furthermore, in common with most manufacturing industries, the beverage industry is naturally looking to cut its operating costs in order to minimise overheads and maximise profits in a changing and challenging marketplace. The beverage producers are looking to increase the efficiency of their production lines, focusing these days on the overall TCO (total cost of ownership) of all their equipment. They are also striving to reduce power consumption, maintenance costs and to cut the use of raw materials and all other resources used throughout the production process. For some time now, in order to protect the world’s diminishing natural resources, consumers have grown more vocal in their demands for greater sustainability in our manufacturing processes. This naturally applies to the labelling of our beverages as it does to other parts of their production. | 312 | Packaging Europe

Rollfed and thinnest label solutions As well as being easy and practical to transport, handle and use, beverage producers want packaging to be distinctive, versatile and attractive. A consequence in PET bottling production is the increased use of rollfed labels which are either paper or plastic and applied with hot glue. With rollfed, if the body of a transparent, colourless, plastic label with a high-gloss finish remains unprinted, the bottle can be made to look as if the lettering is applied directly onto its surface. The simple step of reducing the thickness of labels on the many millions of PET bottles produced can drastically reduce the total amount of raw materials and resources used to create them. Sidel, the leading global provider of PET solutions for liquid packaging, has focused its efforts in this direction when it comes to sleeve labelling solutions to offer efficient, high-speed machines capable of handling ultra-light bottles with a label thickness of less than 20 microns.

Labelling without glue The amount of glue used to adhere the labels to the finished bottles is something that most producers would like to reduce substantially. Eliminating the gluing process would make it possible to keep machines cleaner, more hygienic and less maintenance intensive. The cost of glue is another factor. More importantly, the complete removal of glue from

the entire labelling process would be beneficial to the production of PET bottled beverages because its presence can make the recycling process more difficult. The recycling of PET is fundamental in confirming its position as a sustainable material. However, the use of label glues has sometimes affected the uptake of material in food grade applications, so work is underway to overcome the problem. In Japan, for instance, researchers are trying to develop a glue that adheres mainly to the label yet is readily released by the surface of the PET bottle. Elsewhere, some manufacturers of labelling equipment are already eliminating the use of glues altogether. Some developments, for example the design of shrink sleeve labels (SSL) with perforated seams, allows the simple removal of the label before recycling.

The growth of sleeve labelling As more companies discover the potential of SSL, the market for this kind of labelling is growing faster than any other labelling process. In 2014 it accounted for a projected 12.5 per cent share of global label consumption by area. According to a Smithers PIRA Market Intelligence report, it continues to develop, with global consumption forecast at a compound annual growth rate (CAGR) of 5.6 per cent from 2014–2019. The introduction of new substrates and technologies has brought about the potential for significant cost savings in SSL production. Until recently, substrates were heatshrunk after being turned – or ‘oriented’ – in a ‘transverse (lateral) direction’ (TDO) and pre-formed into a tube, ready for further processing. However, substrates in PET or Oriented Polystyrene can now be shrunk ‘machine direction oriented’ or MDO. As the step of creating a tube is removed from the production process, the cost for each label is less. By applying film sleeves to entire bottles or parts of bottles, the SSL application involves shrinking the film with heat, causing it to follow the shape of the container to

which it is being applied. As it shrinks into place, it adapts to any surface and eliminates any irregularities or restrictions due to container shape.

Labelling onto ultra-lightweight bottles Within most labelling equipment, labels are applied to the bottles by machinery separately handling each bottle. This handling might weaken an ultra-light bottle in some manufacturers’ systems. To overcome the problem, some producers are ‘nitrogen-dosing’ their beverages – that is adding liquid nitrogen to the filled bottle prior to capping. This greatly increases the pressure within the bottle and has the effect of strengthening the bottle. Naturally, leading equipment manufacturers are already building labelling machines that can handle even the most lightweight bottle and manage the extra demands of bottle lightweighting – without the need for nitrogen dosing. Compared to traditional Transversal Direction Orientation (TDO) where sleeve labels are already formed in tubes on the reel, the sleeve labelling solution from Sidel, the Rollsleeve, can apply labels with a Machine Direction Orientation (MDO) on very lightweight bottles as the final tube creation and welding are performed directly in the labelling machine.

More sustainable labelling There is more to successful labelling than the efficient application of an attractively designed label. Labelling solutions need to be designed to maximise both the impact the packaging makes on the consumer and to minimise the commercial and environmental cost of production. This requires boosting productivity through accelerated label application and cutting costs in terms of both materials used and in production maintenance. Visit: www.sidel.com

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Taylor-made coloured hotmelt adhesives

Smart Bonding The family-owned Swiss company Collano Adhesives AG develops and markets specialty adhesives for innovative applications in labels, tapes, packaging, graphics, security, construction, ballistic protection, textiles and foams. It is passionately committed to creating new, intelligent bonding solutions and technologies that improve quality, productivity, and reliability, and is equally committed to sustainability in product development. Libby White spoke with Thomas Griebel, Head of Sales and Marketing for the Label, Tape, Packaging, Graphics and Security division, to discover the latest innovative technologies Collano has to offer. | 314 | Packaging Europe

ollano’s core competence is focused on the development and marketing of four types of adhesives: adhesive films (thermoplastic single- and multi-layer films); hotmelt adhesives (conventional, moisture-curing and radiation curable hotmelt adhesives); reactive adhesive systems (1- and 2-component polyurethanes and silanes); and dispersion adhesives and coating systems. The headquarters in Switzerland purely focusses on the development and sales of its solutions. Outsourcing of production processes ensures there are no restrictions on R&D due to lack of production capabilities. In 2014 Collano had 77 employees and achieved a turnover of EUR 36 million worldwide. Today the company is organised into four business divisions. Focusing on the Label, Tape, Packaging, Graphics and Security division, this offers a wide portfolio covering applications from food packaging to security solutions. Thomas Griebel states, “We are pioneers in the field of bio-based hotmelt adhesives and specialists in UV curable adhesives. We provide tailor-made, customised products and services and are reliable partners regarding product quality and consistency.”

Pressure sensitive hotmelt adhesives integrated in sealing foils enable easy opening and multiple reclosure of the packaging

UV-curable pressure sensitive hotmelt adhesives on seal labels ensure reliable Solvent-free, high-solids dispersion adhesives

Comprehensive portfolio Collano offers much more than just an adhesive with a wide range of characteristics, performance and applications tailored to the customer’s specific needs. A broad portfolio includes pressure sensitive adhesives (conventional hotmelt adhesives, UV-curable hotmelt adhesives, water-based dispersions) for permanent, removable or ultra-removable applications, UV curable pressure sensitive adhesives for printing applications, e.g. for partial adhesive coating (for flexographic and screen printing, for offset printing is under development), heat sealable adhesives (conventional hotmelt adhesives, water-based dispersions, adhesive films), multilayer films, combining film and/or adhesive characteristics, to coloured adhesives and adhesive films. One such solution which offers innovative features is the coloured pressure sensitive hotmelt adhesive which changes colour triggered by temperature; it is designed for a wide range of uses and applications, such as tamper-evident display for security applications, or as an indication of temperature changes. “The adhesives turn from yellow into red. Some features already exist as solutions on labels with printing colours and inks, however there are some applications where it is more beneficial to have the indication in the form of or integrated in an adhesive,” Thomas Griebel explains. “The Collano colour changing adhesives are also valuable for use in security bags and packaging, implementing a closure system that can indicate attempts at cold tampering.”

reclosability of the packaging even for oily or alcoholic wet wipes

Another innovative solution from Collano is adhesives for resealable heat sealing foils for food packaging, giving a practical and convenient solution to the end-users. This portfolio ranges from rubber based to UV-curable pressure sensitive hotmelt adhesives (which have an upcoming planned launch). Thomas Griebel explains, “With different characteristics regarding performance, compliance with food regulations, odour, migration and price, Collano can offer the right type of adhesive for the right application.” Always looking to answer the issues of its customers, Collano also focuses on developing solutions to problems raised by customers. To address the issue of curling in self-adhesive film labels coated with pressure-sensitive adhesives for example, Collano has developed the Collano® L1 2020 to ensure reliable labelling. This is a rubber based, pressure sensitive hotmelt adhesive that possesses high initial tack and final adhesion, but does not cause curling of the film labels.

Green adhesion Environmental friendliness and sustainability are key interests for Collano, as is apparent in its range of solvent-free adhesives, 100 percent solid adhesives and odourless and low emission products. Collano will continue to create adhesives based on renewable resources and to develop energy efficient curing concepts for UV hotmelt adhesives. Indeed, the company has played a pioneering role in the replacement of solventbased adhesives with ecologically friendly aqueous and 100 percent adhesive systems Packaging Europe | 315 |

Mitsui Chemicals Europe Mitsui Chemicals, as major producer of adhesive resins, is proud to be Collano’s supplier of functionally modified tie resins (ADMERTM). This cooperation even goes back to the year 1988, when business was established with the help of Swiss KASA AG, being the distributor for ADMERTM resins in Switzerland. Since then, ADMERTM is the preferred extrudable tie resin used within the Collano Group and Mitsui Chemicals appreciates to be the supplier of their choice. During the past 27 years of cooperation, there has always been a trustful and efficient way of collaboration. Mitsui Chemicals would like to thank Collano for the close and fruitful cooperation and is looking forward to continuing the supply of ADMERTM resins during the upcoming decades.

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New generation of bio-based UV-curable hotmelt adhesives minimizes dependence on petrochemicals and preserves non-renewable resources

ITW Dynatec

ITW Dynatec is a global leader and supplier of adhesive application equipment for traditional hot melt formulations, headquartered in the U.S. with offices in Mettman, Germany and Cherisy, France to serve the EMEA market. A long-time partner of Collano, Dynatec has recently restructured their operations to establish a dedicated Packaging Group focused on the needs of packaging OEMs and manufacturers around the globe. This is in addition to their focus and expertise in segments such as Disposable Hygiene Products and Coating & Laminating. It is important for industry partners within the same value chain to work together to understand key market trends and movements in order to provide customers the best combination possible for both the equipment and the consumable. EMEA contact: Email: info@itwdynatec.fr, Phone: +33 237625647

Headquarters of Collano Adhesives AG in Sempach-Station, Switzerland

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Multifunctional single- and multi-layer heat-sealable adhesive films

which require neither water nor solvents as a carrier agent. For label and packaging applications, the Collano UV N1 series which is a UV-curable hotmelt pressure sensitive adhesive for reclosable wet wipe pouch seals, offers a solvent-free, safe and ecologically friendly solution. Collano’s new generation of UV-curing adhesives consist of renewable and bio-based materials and can be used for label applications. Thomas Griebel is proud to point out, “More than 95 percent of the constituents are from renewable resources, compared to other solutions on the market which generally reach the range of 70 percent. We will be highlighting these solutions on our booth at Labelexpo Europe in Brussels this year.”

Innovation focus One third of Collano’s employees are dedicated to working on development and application technology. With 24 people employed in this area, this is a powerful driving force in Collano’s innovative capacity. To encourage partnerships, Collano organizes innovation workshops with customers and partners, and also offers exclusivity for products, applications or regional distribution on demand. Networking and cooperation with customers, parallel suppliers, institutes and consultants will also help to encourage partnerships, and Collano offers the corporate development of products and product concepts, e.g. in the form of joint development agreements. Thomas Griebel adds, “As a small, flexible company, we aim to bring customers into the loop from a very early stage. We always look into enquiries from the marketplace, and aim to delve into the niche areas of the market.” “In recent years, Collano has invested continuously. With a focus on research and development, we have invested in processes and equipment, in order to increase effectiveness and efficiency of the development of intelligent bonding solutions for our customers,” Thomas Griebel states. He continues, “We have also invested in other ways, for example our IT system was modernised using a cloud solution and our old CRM system was replaced by a new system in which selected customer relationship processes and our existing ERP system were also integrated. This has enabled us to record the needs of our customers efficiently, ensuring we can act quickly and proactively.”

Forward thinking Collano’s focus markets are in Central Europe although the geographical attention varies between the different business divisions. For the Label, Tape, Packaging, Graphics and Security division, the European turnover in 2014 was 79 percent. Secondly, making up | 318 | Packaging Europe

12 percent of the turnover, was North America. The Asia/Pacific region contributed to 5 percent of the turnover and lastly Africa and the Middle East made up 4 percent. Thomas Griebel comments, “Europe will continue to remain as our core market and focus, however we have expansion plans in Asia/Pacific and especially in North America. In 2014 we founded the sales organisation Collano Adhesives Inc. in Tucker GA, USA, in order to enforce our market presence in North America.” As a forward thinking company, Collano has a business plan in place to encourage and support continuous growth. Thomas Griebel states, “We will continue to focus on five key elements: innovation, specialization, market development, partnership and sustainability. R&D, technology management and sales are applicationoriented and we will continue to distinguish ourselves with better products and services with a focus on product performance, quality, consulting, and customer service.” With regards to innovation, Collano’s competence centre will continue to breed extensive know how and experience in designing UV-curable adhesives and single and multilayer film products. Collano will focus on developing adhesives with additional functions, such as adhesive films with integrated barrier or membrane, and adhesives which change appearance on demand such as through colour change or with a transparent/opaque switch. Another area of focus is adhesives which change performance on demand, e.g. bonding on demand, or de-bonding on demand. Thomas Griebel sums up, “For a relatively small company we possess a large and unique portfolio of technologies. The use of the technologies not only individually but also in combination gives us a strong position for the development of unique products that we will continue to maintain and develop.” For more information, visit www.collano.com

Making Good Things, Better As one of the highest volume producers of plastic components and assemblies, Amaray knows its business is driven by customer experience and therefore sets out to achieve extreme customer satisfaction as a solutions-focused provider bringing insight, innovation and cost effective manufacturing alternatives to select markets.

maray’s multinational manufacturing operations, working to standardise processes and procedures, enables it to provide all levels of project support with consistent quality and production outputs. A decade ago, media packaging was the main source of revenue for dozens of companies around the world. However, with the growing movement of consumers acquiring content digitally, the industry is now experiencing erosion. Amaray is one of the few global injection moulders that have been able to sustain profitability in this market. With a focus on increasing market share and extending product and service offerings, it has maintained its competitive advantage through innovation, ingenuity, customer orientation, lean manufacturing processes and increased integration of automation. Amaray’s drive into lean manufacturing stems from the aggressive market demands experienced by the home entertainment and media packaging world which have created opportunities for operational efficiency gains and waste reduction. With continuous improvement embedded into Amaray’s DNA, it has become greatly effective in generating tool transfer opportunities for major brands in multiple consumer markets through reverse engineering initiatives on current designs.

High volume production with improved cost savings Although Amaray remains profitable in the media market, the company has a determined approach towards diversification. With a clear vision to ‘Make good things, better’, it has introduced a highly motivated Develop and Diversify team whose main focus is on the delivery of new innovative products to make consumer lives easier. Having identified functionality as a major concern within packaging, Amaray is developing new closures with opening and closing characteristics designed to engage use and ease the process for consumers. These closures will lend themselves to multi-use products used by consumers

every day within personal care and home care markets. Other opportunities sought will likely involve plastic technologies which Amaray has pioneered in the media market and will include living plastic hinges and snap fit closures. Jamie Tinsley, managing director of Amaray Europe advised “With the introduction of a focused Develop and Diversify team we have blended creative, innovative and commercial talent with broad experience across many sectors. Our key focus is on the delivery of new products, extension into new market sectors and adding value to our customers and consumers.” Amaray has recently launched a new company video created to help and inspire those brands and companies striving to optimise efficiency and enhance sustainability, overall performance, product development and innovation. In collaboration with BlackBox Creative, Amaray has generated a stunning and inspiring portrayal of its manufacturing philosophy and approach. Contrasting the skill, precision and repeatability of dance with machines and plastic manufacturing is undoubtedly bold; this underlines Amaray’s fully automated and high performing machinery along with the team’s commitment, dedication and a superior working ethos that has already delivered many benefits to customers. Motivated and engaged, Amaray continues to invite major brands to challenge or collaborate with them in order to develop packaging solutions that satisfy consumer demands. Combining Amaray’s promise to ‘make good things better’ with a manufacturing foundation built on high efficiency and performance, the company is well positioned as a solutions provider to aid long-term cost improvement initiatives and sustainable growth. Visit www.amaray.com to learn more about Amaray or visit www.amaray.com/making-good-things-better to see their new video. Packaging Europe | 319 |

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The voice of Bioplastics European Bioplastics is an association which serves as both a contact platform and catalyst for advancing the objectives of the growing bioplastics industry. Libby White spoke with its passionate and knowledgeable deputy managing director Ms Kristy-Barbara Lange, about the most recent developments in the bioplastics industry, and how the association represents the interests of around 70 member companies throughout the European Union.

stablished in 1993 with 12 founding members, the originally German association focused solely on biodegradable plastics, with an interest in making waste disappear and getting rid of litter. Ms Lange explains, “We evolved into an association in 2005 with around 50 members who produce all kinds of bioplastics. There was a huge shift in our focus from making waste disappear, to treating waste as a valuable resource. The whole notion of biodegradability also underwent a change. The focus is now on increasing efficiency of waste streams by using biodegradable plastics to collect biowaste separately.” 2005 was also the year the association was renamed to European Bioplastics to help further the interests of the industry. Ms Lange comments, “Since then, we have gathered intelligence from a broad scope which has allowed us for the last few years to be in a strong lobbying position in Brussels, supported by our resources and strong membership profile.”

Diverse membership Today, European Bioplastics covers the entire value chain of the complex bioplastics industry, of both biodegradable and durable bioplastics, and from biobased polyethylene to biobased high technical performance polymers. “Furthermore, there are younger biodegradable polymers such as PLA, and there are even some fossil-based polymers that are biodegradable,” Ms Lange adds.

Packaging is currently the largest field of application for bioplastics where it e.g. plays an important role in the overall reduction of waste, particularly food waste – a major source of CO2 emissions. For example, there are bioplastic packaging materials on the market, which better protect food and prolong its shelf life. The EUBP serves members from feedstock manufacturers such as Cargill Inc. to brand owners, and also has waste disposal management companies and universities amongst its varied members. The main focus of its membership, however, lies on manufacturers and converters. The association has also evolved from solely German membership, to today’s mix of one third German, one third European, and one third from the rest of the world. It includes Brazilian, American and Asian members with an interest in the European market. Ms Lange points out, “The market is very strong in Europe for bioplastics, and also we are leading the way with Research and Development, which is why the rest of the world looks towards us.”

Representing bioplastics at a European level On a European scale, legislation is now touching on bioplastics, the bioindustry and the bioeconomy, therefore the association concerns itself with a high level of political lobbying. In 2014, European Bioplastics took note of the Commission’s decision to withdraw the Circular Economy package and since then supports the commitment to present a more

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LANXESS Deutschland GmbH, BU Rhein Chemie Additives BioAdimide® additives improve the hydrolysis resistance and the processing stability of your bio-based polyester, especially PLA, and expand its range of applications. Due to its vulnerability to hydrolysis, PLA is only rarely used in highly technical applications. But Rhein Chemie Additives, a business unit of the specialty chemicals company LANXESS, offers a superior hydrolysis protection of your bio-polyesters with the BioAdimide® product line, thus enabling their long-term use in durable and technical applications. But BioAdimide® does not only achieve a longer lifetime of your technical products, it also protects the polymer against degradation during compounding by stabilizing the melt. Additionally, BioAdimide® extends the biopolymer’s shelf life during storage and transportation and helps to save time and money with a reduced drying time prior to injection molding. Contact: Dr. Martina Schoenhaber, martina.schoenhaber@lanxess.com

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ambitious proposal in 2015. EUPB calls on the Commission to introduce concrete provisions that stimulate the bioeconomy and further use of responsibly sourced renewable raw materials. It states that using biomass for industrial purposes, such as the production of bioplastics, can help provide solutions to the current resource efficiency challenges that the EU is facing. The EUBP also calls for an increase in waste management efficiency by promoting the separate collection of biowaste for organic recycling. It states that clear and harmonised definitions are key to smart legislation, which is why EU waste legislation also needs to include clear definitions of biowaste as well as organic recycling. As an important waste management method, organic recycling ¬– in the form of composting and anaerobic digestion – should be included in the definition of recycling. EUBP also supports a progressive phasing out of landfilling in the EU. For industrial composting there is already a very reliable standard, but home composting is another development with initiatives starting to crop up around the EU. Ms Lange points out, “France is currently developing a standard for home composting, and it just passed a law that will further the use of plastic materials that are biobased and biodegradable at the same time. They are the first country in the EU developing a complex home compostability standard, and we think the European Commission might use this as a blueprint for the future.” Ms Lange adds that the industrial use of agricultural feedstock is another important topic for discussion on a European level. “Everybody’s talking about the cascading principle right now, and it is a very important concept for establishing a truly circular economy. Using biomass for industrial purposes such as the production of bioplastics has major benefits. For example, it reduces the dependency on limited fossil resources mainly imported from beyond Europe and reduces greenhouse gas emissions. Through the implementation of use cascades, bioplastics can also make an important contribution to resource efficiency.”

Tenth anniversary EUBP will be celebrating its tenth anniversary this year for its prominent European Bioplastics Conference. A two-day programme with networking events, a product exhibition dedicated exclusively to bioplastics, and a diverse programme covering the latest trends, insights, and innovations in and around bioplastics will make for yet another great event. “We are proud to say this our tenth year of bringing the industry together at an informative and progressive event. Within the last few years, eyes have been directed more and more towards the bioplastics industry, and our leading networking and conference programme addresses the needs of the industry,” Ms Lange comments. “We are expecting a full event this year, and usually attract from 350 to 400 attendees.” | 326 | Packaging Europe

Discussing the programme, Ms Lange hints at a diverse range: “Attendees can expect policy sessions and perspectives from speakers from countries where specific measures are being sought, and we hope to receive an inside scope from the European Commission. We have added a session this year with brands and retailers giving their perspective on our industry, and M&S and Carrefour will be contributing information. A session of great importance will be focused on the end of life of bioplastics and the development of waste streams.”

Future developments Ms Lange spotlights a recent unveiling of an innovation, Coca-Cola’s pioneering 100 per cent biobased PET bottle. She points this out as a very positive step towards a product viable in the circular economy. One of the main tasks of the EUBP is to work towards creating a framework that gives the industry a good basis for growth and to attract investments from outside the EU. Ms Lange comments, “Europe is at the forefront with its R&D, but we need to be careful of losing the harvest of what we have sown.” Clearly bioplastics have many benefits and potential solutions, and European Bioplastics will continue to spearhead the promotion of an invaluable resource. For more information, visit www.european-bioplastics.org

Valves with value International solids handling specialist TBMA is well-known for its broad range of rotary valves for niche applications. Emma-Jane Batey spoke to sales manager Ted Van Bavel to gain an insight into how its worldwide success in selling components is set to grow further in the coming years.

ased in Holland and Belgium and active worldwide, TBMA is an internationally operating company. Focused on dry solids handling and process engineering for the design, supply, installation and commissioning of components and automatic process plants to a wide variety of industries, TBMA is known for its ‘better in bulk’ slogan. Sales manager Ted Van Bavel spoke to Packaging Europe to update the magazine on the recent developments in the company and its plans for continued success. Mr Van Bavel said, “Essentially, TBMA stands strongly on two legs; our engineering projects in Europe and our worldwide selling of components. It is the second ‘leg’ that we have identified as being the most important for our future growth strategy as we know that our sales of components to OEMs is a market with exceptional opportunities across new and active territories.” TBMA has developed and designed an extensive range of standard processing equipment with proven reliability in practice. Its rotary valves are its bestselling and most important product, particularly owing to its own unique product development initiated 40 years ago that still is proving relevant today. Mr Van Bavel continued,

“Of course, we’re never standing still. Our rotary valves are not the same product that we developed 40 years ago! We are always developing, always taking care to listen to our customers and to understand exactly what type of rotary valve they require and how they need it to perform – even if they don’t know themselves, our dedicated and experienced team can ascertain that information and then the perfect solution is created.” While Mr Van Bavel noted that there are plenty of European producers of rotary valves, he is clear that the added value of TBMA’s rotary valves is easy to explain. He said, “Our rotary valve USP is all about quality, certification and development in certain niche markets. We have developed exceptionally high quality rotary valves for niche applications in the starch industry for example, and we have won desirable contracts with major starch producers. Take potato starch: it’s a product that tends to grow on the rotary valve, forming a hard, glassy layer that quite quickly makes the rotary valve stop, which is terrible for production. TBMA have a special rotary valve for potato starch applications that means it always keeps running. I can’t tell you how though, it’s our secret!” Packaging Europe | 327 |

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Special solutions For many years TBMA has been certifed for using its rotary valves as an autonomous protection system suitable for explosion and flame containment up to 10 bar for Kst2 Dust, as well as various high temperature-based solutions. Mr Van Bavel added, “We work a bit differently to other rotary valve producers. Whilst we’re not the biggest in our field, I’m pretty sure we’re the most flexible. Our success is built on the promise of always taking care to find the right solution for our customers. We totally understand the processes our customers go through so we look deeply into their operation and create the perfect rotary valve solution for their specific application.” With a complete test facility available to ensure that all customer solutions meet their purpose precsisely, TBMA offers an extensive range of rotary airlocks, blowing seals, diverter valves and shut-off valves with numerous execution possibilities. These possibilities can vary from a simple gravity feed diverter valve to rotary valves for hazardous environments. Mr Van Bavel said, “We also have the complete certification of our explosion-proof rotary valve, which offers a considerable safety protection to our customers as it can function as an autonomous protection system. If an explosion happens in the customers’ system, it cannot pass the TBMA rotary valve so there is no chain reaction. It’s a great safety feature that not all rotary valves offer as it’s a highly complex process to be approved.” In terms of future growth, TMBA is focused on bringing its range of standard and unique rotary valves to a wider audience. It is especially keen to enter the UK market as it has identified a number of interesting opportunities and has stepped up its marketing strategy to promote its rotary valves in the UK. Mr Van Bavel concluded, “We are looking to expand our OEM partnerships both for rotary valves and for bag emtying, big bag filling and big bag emptying systems in our bulk handling activities. It can be harder to export the big engineering projects outside Europe so we very much see our future success in working with worldwide OEMs and a network of local distributors for n our components.”

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Positive labelling Labels are becoming increasingly sophisticated. Barbara Rossi spoke to an expert in the field, Mr Paolo Santi, MD of Neri Labels Srl, about his company, the range of high-quality labels it offers and recent and future developments.

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ased in the Florence area of central Italy, Neri Labels Srl started its activities in 1977, when it was established by three founding partners: Gianpaolo Neri, Giancarlo Rebecchi and Paolo Santi. At the time the company, which specialises in labels, mainly produced quality products for the pharmaceutical sector. Today the pharmaceutical industry still generates 80–85 per cent of its turnover, but the range of products has widened to include labels for the personal care and food industries. Mr Santi is the only surviving partner of the original founders and today he manages the company with the help of his staff. He explained, “The pharmaceutical industry is still our core sector, for which we produce high quality products. Since the late 1980s the company has sustained a slow but continuous growth, purchasing increasingly sophisticated printing machinery and diversifying production so as to extend our offer to other sectors demanding high-quality label products. We offer a range

of printing technologies: offset, screen and flexo. We carry out both cold and hot foil printing. We are going to implement a digital printing line in October of this year.” The product range on offer includes paper and film self-adhesive labels, multilayer labels (booklets, funfolders and coupons), Braille labels, non-adhesive labels and films with a depth ranging from 15 to 450 microns, handle labels, peel-off labels. It also offers holograms produced using the patented Neri Labels system, tamper-proof labels and seals (made with special paper and film, using the void system), food labels complying with current legislation (HACCP), and progressive numbering and random Datamatrix code labels. “While self-adhesive labels are still our core business, we are also very good in other recently introduced niche areas, such as booklets (which we introduced in 2011), singlelayer film/paper printing (non-adhesive) for the food industry, partly detachable coupon labels for the pharmaceutical sector and forensic labels (for DNA testing).”

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A digital future The company operates from a single production site in Barberino di Mugello, which is currently perfectly adequate for its production needs. Expansion work on the Barberino di Mugello site has just been completed, involving the reorganisation into separate divisions, thus complying with pharmaceutical sector requirements. Furthermore, all processing rooms have been climatised with monitored temperatures, thus complying with the requirements of the sectors served. However, further development plans are in the pipeline. These comprise the previously mentioned introduction of a digital printing line in the autumn of this year, as well as the purchase of a new printing press for medium-high lots which is planned in 2016. The company’s processes are fully computerised, allowing for total production traceability. Neri Labels holds the UNI EN ISO 9001:2008 certification and is working towards UNI EN ISO 15378 (it expects to achieve this by the end of 2016). All products are checked and tested after each production phase, from initial file creation to final testing and shipment.

Global outreach “Geographically our main market is still Italy, but I have to say that we mainly supply pharmaceutical multinationals. Therefore, although our direct clients might be based in Italy our products actually reach many foreign markets. We also have some direct clients abroad, for instance in Germany, the UK, Israel ad Africa. Last year we participated in East 2014 Africapack and in May of this year we were present at the Milan Expo. While our products for the personal care and food sectors are mainly Italy based and will probably continue to be so in the future, we intend to increase

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our export share, especially with the implementation of our digital printing line which will enable us to start supplying the beverage and wine sectors.” The company expects to grow, but this will be achieved organically rather than through acquisitions. Growth could involve the opening of new sites in foreign markets, should the market demand it. “We will always maintain a strong link to our roots. I think that the balance between the different segments served will be unaltered. We see ourselves as a precious jewel and do not intend to lose our niche specialism.” While not being shy when price competition comes into play, the company’s main focus and asset is its high quality. Because of this, requests for its products are mainly concentrated in ‘rich and demanding’ segments, such as the pharmaceutical sector. “We do a lot of preparatory work during the initial phase. We do this so as to avoid encountering problems later. I believe that initially some of our clients might have found us slightly pedantic, but then they realised the value of operating in this way and have appreciated our attitude. We have a high customer retention rate and for us high quality is vital to our success. R&D is also an important part of our work and is carried out on a continuous basis, both at technical and market development levels. “Our suppliers are also very important for our success. In particular I would like to mention Avery Dennison and 3M, which thanks to their focus on new products and research are really in tune with our market approach and what we do. Ritrama and UPM Raflatac are also very important to us, thanks to the high quality that they offer. The Anchor Group and Billerud Korsnäs, a Swedish pulp and paper manufacturer, also play important roles.” Visit: www.nerilabels.it

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Customised packaging solutions

DS Smith is a European leading producer of customerspecific packaging with an emphasis on state-of-the art packaging design and local services close to customers’ facilities. With a product portfolio that includes transit packaging, consumer packaging, displays and promotional packaging, customised protective packaging and industrial packaging, DS Smith answers every market requirement.

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orking in collaboration with HP to develop and deploy digital preprint solutions for high-volume corrugated packaging, DS Smith took delivery of the bespoke HP T400 Simplex Color Inkjet Web Press in March 2015. The narrow-width press, which will print four colours onto the liner prior to corrugating, precedes the delivery of a wide-web machine – currently in development – which is more size-compatible with high-volume fast-moving consumer goods (FMCG) corrugated packaging needs. The investment will enable DS Smith to deliver products to market faster, customise batches to support brand and marketing initiatives, deliver short and long print runs, and ensure consistent print quality. The HP T400 Simplex Color Inkjet Web Press is installed at the Belper site, part of DS Smith’s UK packaging division, which has been chosen as the test site given its long pedigree of print innovation and will act as the digital preprint R&D centre for the company. This installation is a big step in DS Smith’s collaboration with HP towards deploying a high-volume, digital preprint solution to meet the corrugated packaging needs of FMCG markets. DS Smith will also be the world’s first user of the HP T1100 Color Inkjet Web Press, HP’s recently announced wide-web digital preprint solution. DS Smith intends to lead the corrugated packaging industry with this game-changing technology. Stefano Rossi, divisional CEO for DS Smith, commented: “We invest in the latest printing technology at an early stage to ensure our customers have unrivalled access to the highest quality and widest range of printing techniques. “We look forward to developing digital alongside our other print processes; the combination of speed, quality and agility provided by our extensive range of printing options opens up many opportunities for our customers. “This is a big investment; it shows our determination to be at the forefront of technology, to lead the market and to continually enhance the service and support we provide to our customers.” HP looks forward to the DS Smith solution deployment in Belper. “We believe our HP T400 Simplex Color Inkjet Web Press and the HP T1100 Color Inkjet Web Press preprint solution will provide DS Smith with innovative new capabilities, and that combined with DS Smith’s vision and focus around quality and customer service will help us sharpen our packaging presses offering to the market,” said Eric Wiesner, General Manager for HP’s Inkjet High-speed Production Solutions division. Fujifilm has announced that UK-based DS Smith has made a significant new investment in a flatbed digital printing system that will deliver further improvements in quality for its customers, as well as ensure greater production efficiency. The supply cycle specialist has chosen Fujifilm‘s corrugated solution – a combination of the Inca Onset S40i digital printer, Uvijet OL inks and fully automated handling system

– which has been installed at a Display production site in the UK. DS Smith is the first packaging company in the world to place an order for the complete offering, which will enable it to produce a range of single and double-sided corrugated display and packaging applications, at a productivity of over 500m2/hr. David Atchinson, Display Manufacturing Manager at DS Smith, said the automatic handling system was a big factor in their decision to opt for Fujifilm. He said: “The fully automated handling system will maximise productivity and allow our operators, after starting the run, to focus their attention elsewhere as the print job is running. “We were also very impressed to see how effectively the system handles single or double sided print, enabling a wide variety of board types to be perfectly printed whilst being held flat on the table. He concludes: “Exceptional print quality, production speed and reliability were other key drivers when we reviewed the various offerings. Fujifilm’s solution was the only one that easily ticked all these boxes for us. Finally, the Uvijet OL low odour ink will allow maximum functionality, delivering a superb gloss with excellent finishing properties. Overall, a brilliant solution.

DS Smith completes acquisition of Duropack Further to the announcement on 22 May 2015 confirming receipt of unconditional competition clearance from all of the relevant authorities, DS Smith Plc, the leading provider of recycled corrugated packaging in Europe, announced on 31 May 2015 that it had completed the acquisition of Duropack. Miles Roberts, Group Chief Executive said: “We are delighted to complete the acquisition of Duropack, a business that is highly complementary to DS Smith’s geographic footprint and transforms our position in higher-growth South Eastern European geographies. We look forward to integrating the business into the DS Smith Group and are excited about the excellent opportunities for customers, employees and shareholders.”

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Innovative labelling solution for maximum flexibility

An innovative process solution

With an innovative laser labelling process DS Smith, together with Videojet Technologies, a manufacturer of high-quality label solutions, is opening up completely new dimensions in the area of late stage customisation of packaging for its customers. With laser coding, correspondingly pre-printed packaging can be individually and quickly labelled to the highest quality directly on the production line. The result is a far more efficient process design. At a well-known manufacturer in the FMCG sector, the packaging and display Specialist reduced the complexity and process costs significantly with the new procedure. “With the significant reduction of packaging types, which we have achieved with a project for format and print layout harmonisation through the use of laser coding, there are a whole list of benefits: lower storage costs, less logistical and administrative effort, larger runs, greater planning reliability and maximum flexibility. At the end of the project there was a palpable increase in efficiency and cost effectiveness,” says Michael Lamprecht, Sales & Marketing Director at DS Smith l Packaging Division D-A-CH.

With its innovative process solution, DS Smith offers its customers the highest level of flexibility when adding texts, images or codes to packaging. The quick implementation of varying country versions or content information that changes at short notice can be directly made on the packaging line. In the flexo direct printing process on corrugated cardboard packaging, the field that is designated for later individual labelling is printed with laser paint. The paint includes laser-sensitive pigments that turn into black upon contact with a laser beam through a chemical reaction. This allows pre-printed packaging layouts to directly print the individual information on the fly, or during down time, in no time at all. “Labelling using lasers generates a stable reproduction of plain writing and codes. The printing result is convincing with its permanent durability and outstanding quality,” says Robert Zimmermann, Key Account Manager at Videojet Technologies.

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“We are able to significantly reduce the complexity and costs of packaging processes for our customers with this process,” says Lamprecht. “At the same time, we are increasing the efficiency and effectiveness of their processes.”

Innovation in print DS Smith demonstrates its commitment to innovation after taking the pre-print category gold, technical jury, and outstanding awards at the ‘Flexostar Awards 2014’. After unveiling a high definition print of a quality never seen before, the company didn’t just scoop the award for its own pre-print category; it also took home the prestigious ‘Super Flexostar’ award along with the ‘Prix du Jury Technique’. Founded in 1982, ATF Flexo seeks to enlighten the world of packaging to the wealth of possibilities enabled through flexographic processes. The association’s members include printers along with ink, machine and board manufacturers – primarily specialising in packaging print. Each year, ATF Flexo organises its Flexostar competition to reward the best in flexographic printing. The 2014 event was its 28th. A total of 39 companies entered 150 prints divided into 14 categories, according to their usage: cardboard, paper, films, and labels, to name just a few. Entries were judged by two juries: a technical jury, focusing on the complexity of the design, and an artistic jury that judged the aesthetics of the design. Two representatives from DS Smith’s packaging division stepped up to receive three awards at the flexography gala evening at the Palais des Congrès de Biarritz on 18 December 2014: • The gold award for the pre-print ‘pré impression pour carton ondulé’ category • The ‘Prix du Jury Technique’, which rewards exemplary technical achievements across all categories • The ‘Super Flexostar’ award, which rewards the top design and print in all categories The winning ‘Envoûtante’ (which means ‘bewitching’ in English) pack was designed specifically for the event. The challenging full colour print and varnish was produced using a 175 lpi high definition print on coated white kraft paper.

Valco Melton

Offering 60+ years of technical experience, Valco Melton is a leading manufacturer of adhesive dispensing equipment and vision inspection systems across a wide range of converting industries. From packaging and corrugated, to folding carton, Valco Melton’s ClearVision® Camera Inspection System offers an all-in-one quality assurance program that guarantees zero defect boxes and offers remote analysis. Featuring GlueChek™, which analyzes glue patterns to ensure no problems exist, FoldChek™, which identifies manufacturer’s joint gap issues, and the new, award-winning PackChek™, which offers real time hot melt inspection for end-of-line packaging. When any of these systems detect a flaw, BundleChek™ works to quickly divert that bundle to an alternate conveyor. Together, Valco Melton’s ClearVision® System is helping manufacturers everywhere to deliver The Perfect Box™.

Envoûtante was printed on the Bobst Fischer & Krecke machine recently installed in DS Smith’s packaging plant in Velin. Equipped with latest technologies – including a GPS RFID for ensuring perfect pressure and registration between up to eight colours – it is one of only two such machines in Europe, and one of three in the world. The machine allows for HD printing with very specific criteria and the prints it produces are comparable in quality to offset prints – but at significantly lower cost. It may have been the pack’s technical complexity that led the technical jury to award it with the ‘Prix du Jury Technique’, but it was the company’s ability to also impress the artistic jury that brought it the coveted ‘Super Flexostar’ award, the highest honour to be received at the ceremony. The company plans to continue pushing the boundaries, bringing its customers the latest in technical and design innovation. Visit: www.dssmith.com Packaging Europe | 337 |

A strategic

alliance Cartiera dell’Adda and Cartiera di Bosco Marengo have joined forces to become one of the major players on the European market for cardboard and multi-layer paperboard. Daniele Garavaglia looks at their investment plan and their plans for growth.

artiera dell’Adda SpA has been a constant market presence since the fifties, and this is no small achievement. Based in Lecco and owned by the Cima family, the Italian paper manufacturer is today run by CEO Giuseppe Cima. He begins: “Our company has a long-standing tradition but is also strongly future-oriented. We specialise in grey board production for different industries, especially for the packaging and tube sectors.” Cartiera dell’Adda is currently worth €45 million annual turnover and, with its 85 employees, has an overall production capacity of 150,000 tonnes a year. It is a consolidated presence in the Italian market whose exports, mainly to the eurozone, are growing steadily (currently accounting for 50 per cent of volumes). | 338 | Packaging Europe

Maximum versatility The paper and board market is becoming increasingly diverse when it comes to both board quality and volume Cartiera dell’Adda has long been able to meet the demand for increased versatility, whilst choosing to use recycled paper as its main raw material and producing large quantities of medium-quality paper and cardboard. “A major turning point for us was in 2009 when we invested nearly €10 million to modify what has become one of the biggest machine for multi-layer grey board production in Europe,” says Mr Cima. The online slitting and cutting machine, with its 4.50 m working width, moulds the final product (greyboard), obtained from mixed waste, into

various formats including boards for spiral and straight tubes, edge protectors, interlayer separators, and for graphic and converting purposes. The implementation of this cutting-edge equipment led to a tremendous increase in production capacity and flexibility, almost doubling the company’s revenue in a five-year period. It also has a beneficial influence on the visual quality of the board produced. “We asked PMT Italia, a world leader in paper machinery manufacturing, to take care of the design and construction of a new section of the machine. They thoroughly analysed together with us our needs and technical issues and developed solutions using a highly innovative approach,” says Mr Cima.

pre- and post-sale customer care. Furthermore, says Mr Cima, “our company is committed to cooperating with universities by promoting academic education and professional training.” Cartiera dell’Adda has also implemented valuable social and environmental responsibility plans, the importance of which is all the more evident since its premises are located into the natural park of the Adda river. The company produces all its energy on-site from its own co-generation plant. Waste water is purified in a state-of-the-art, constantly monitored treatment plant to ensure maximum efficiency.

Quality, technology and responsibility

Strong partnership

The company’s ability to offer the highest levels of quality comes from several factors: the use of state-of-the-art technology; respect for the environment; research on different product applications; production flexibility; product tracking; and excellent

“In order to become an international leader in the industrial use of waste paper, we partner with different Consortia for waste separation to promote environmental awareness and increase the percentage of waste collection and recycling.”

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OLEODINAMICA SABATINI srl Strong of its 25 years of experience in the paper-making industry, Oleodinamica Sabatini designs and manufactures power and lubrication hydraulic units, using the best world brands of components and the latest available electrohydraulic technologies. The company’s on-going research, numerous applications produced, demand for new technical solutions and level of attention paid to energy saving- which the paper making industry demands- have allowed Oleodinamica Sabatini to become the sector leader. The company’s range of hydraulic units covers a number of areas, ranging from mixture preparation (valves control, compactors) and continuous machines (presses, jumbo presses, shoe presses, size presses, gearbox bearing lubrication) to grinders, rewinders, finished reel handling and strapping, and reel converting machines (presses, embossers, unwinders);covering tissue and flat paper machines. The products supplied by the company include small to large hydraulic units, made of steel, carbon or stainless steel; as well as other equipment used in units, namely normalised hydraulic cylinders, valves cabinets, flowmeter panels, electrical components and control panels. Oleodinamica Sabatini is based in Ponte Stella (Pistoia), where it has two sites, occupying a 6000sqm overall covered area. It employs 15 staff, who are specialised in manufacturing products according to client’s requests.

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The strong growth it has experienced in the past few years has encouraged Cartiera dell’Adda to broaden its horizons and look for a production and commercial venture with a qualified partner. Cartiera di Bosco Marengo SpA was chosen because of its similar long history in the paper sector, for its €29 million turnover, 50 highly qualified employees and annual output of 90,000 tonnes. Traditionally owned by the Ghigliotti family, Cartiera di Bosco Marengo specialises in products such as coreboards used for high-strength tubes and the packaging sector. This partnership has led to the formation of a joint venture company that has taken over both the sourcing of raw material and consumables and the development of marketing and commercial strategies. The vendor pool is wide and well structured: from waste paper sellers to filter manufacturers (Albany, Filcon Filters, Cristini Feltrificio, Marone), and chemical industries (Cargill, Siral, Sacchetto, Chemiba, Basf, Nimco).

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Opening new markets This new integrated business structure is helping Cartiera dell’Adda and Cartiera di Bosco Marengo to achieve their long-term goals: increasing production and expansion on foreign markets. “The higher technology standards we have reached will lead us to increase production volumes: +15 per cent for Cartiera di Bosco Marengo, now only a step away from its full potential; and up to 30 per cent for Cartiera dell’Adda. In addition, we can now look for new applications for our products,” explains Mr Cima. Another key to future success will be an increased focus on internationalisation. “We need to increase our exports and open up new markets. Our joint venture company is hiring new staff to build a more dynamic, effective, and customer-oriented marketing and commercial strategy.” Visit: www. cartieradelladda.com

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AIMING FOR NEW HEIGHTS Following a series of investments in infrastructure and machinery, Neograf d.o.o., a Croatian producer of lightweight cardboard packaging, is working on projects to secure further market opportunities. Mrs Galja Milošević, Neograf ’s production manager, spoke to Vanja Švačko about the company’s strategies for growth.

nitially established over seven decades ago to provide bookbinding services, familyowned Neograf moved into the world of packaging in 1990. Whilst the lightweight packaging it produces is used today in the cosmetic, food and electronics industries, the company’s predominant focus on the pharmaceutical sector is the result of a long-term collaboration with its main client, JADRAN-Galenski laboratorij d.d. (JGL). Today Neograf produces packaging for the majority of Croatia’s leading pharmaceutical manufacturers, including JGL, Belupo and PharmaS. “Our portfolio mainly covers the pharmaceutical sector, namely secondary packaging, which includes boxes and patient information leaflets. All our production processes are compliant to good manufacturing practice (GMP) and our products strictly adhere to the guidelines of the pharmaceutical industry,” explained Mrs Milošević. “Nevertheless, over the past few years there has been an increasing interest in our products for the food (confectionery) industry. Being more proactive in that sector is also part of our business strategy, since demands for food packaging can be covered by the

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machinery we already own. Among our major customers from the food sector are Kandit and Mardešić.” Neograf’s service offering includes offset printing, water-based coating, hot foil stamping, embossing, die-cutting, folding and gluing.

Forward-thinking In 2011 Neograf relocated to new and larger premises. In just a few years the company has invested almost €4 million in building, the air conditioning required for stable production environment, advanced technology and a modern machinery park. Its facilities boast state-of-the-art printing and finishing machines suitable for small to medium size jobs which is corresponding to the global trends in pharma sector where batches are getting smaller and smaller due to frequent regulatory changes and marketing requirements. The investments in expansion and modernisation came about as a result of the anticipated surge in demand for pharmaceutical packaging. “In an industry that is rapidly

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evolving, the organisation of space and production has to be adjusted to provide reliable, prompt and secure packaging solutions,” pointed out Mrs Milošević. Neograf now has the expertise and technology to ensure its packaging addresses the main requirements of the market. So far the company has been certified according to the ISO 12647-2, ISO 9001:2000/2008 and ISO 14001:2004 standards. Bearing in mind that every stage of production has to be carefully monitored in the pharmaceutical sector, the company is preparing for more compliance certifications to meet the necessary standards.

Mechanisation at its best After moving to its new production facilities, Neograf invested in printing machinery and pre-press technology, carried out on Apple Mac computers. It has also installed Epson Stylus pro 4900 technology alongside EFI Colorproof XF software in order to ensure that ISO 12647 requirements are met. In order to boost its business opportunities abroad, in 2013 Neograf invested in an Omega Allpro 70 folder gluer with Braille embossing system and HHS quality control components. The machine has been built and designed according to Neograf ’s specific requirements by one of the leading producers of quality folder gluers, the Turkish company Duran Machinery. One of Omega’s main advantages is its ability to be upgraded to meet evolving demands. The company also owns small format Heidelberg presses for leaflets and is currently exploring possibilities to add more products such as self-adhesive labels to its portfolio. When asked about the company’s suppliers, Mrs Milošević stressed that in Neograf nourishes a long-term cooperation with reliable partners in order to maintain its high quality standards. “Among those are Croatian wholesalers such as Radin grafika and

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Igepa-plana papiri, and Finnish cardboard manufacturer Metsä Board. The German company Huber supplies Neograf with inks, while tooling solutions for packaging production are purchased from Marbach and Systembox.”

Standing out in the market Apart from machinery upgrades and the installation of modern printing technologies to increase output, the company’s success is also owing in part to its relentless focus on customer service. “As a unique selling point, I would like to mention a high degree of quality assurance, but also our readiness to easily adapt to customer requirements and flexibility with delivery times,” added Mrs Milošević. “Being a smaller-sized company with less than 50 employees, we consider our current market position to be very strong. Our primary market is Croatia, but ever since we moved into our expanded facilities we have been exploring new opportunities. Apart from business deals in Croatia, we are now involved in projects in Italy England and Switzerland.” What Neograf is experiencing at this moment in Croatia is a discrepancy between demand and supply within the pharmaceutical industry. Croatia is a small country where the production capacity for packaging exceeds demand. That is the main reason for the company’s decision to expand its export business. With Croatian EU accession, handling trade regulations have become easier, logistics have advanced and the transport of goods has become simpler and cheaper. Taking into account the trends that favour single-source supply, it is understandable why Neograf is continuing to build its reputation as a reliable and accredited partner beyond the domestic market. Visit: www.neograf.hr

Rigid Plastics Specialist Logoplaste is an industrial group, manufacturing rigid plastic packaging for some of the most reputable brands in the world, in the food and beverage, personal care, household care and oil and lubricants sectors. Founded in 1976, the company has for over 35 years pioneered in-house manufacturing in Europe and beyond with the ‘hole in the wall’ concept, supplying plastic bottles just-in-time from factories installed directly on the site of the client.

eadquartered in Cascais, Portugal, Logoplaste today oversees more than 60 factories, more than 350 machines, with locations in 16 countries: Brazil, Belgium, Canada, Czech Republic, France, Italy, Malaysia, Mexico, Netherlands, Portugal, Russia, Spain, Ukraine, United Kingdom, USA and Vietnam. The most up-to-date technologies in injection moulding, stretch-blow moulding and extrusion moulding are used to produce packages across the wide range of market segments. Logoplaste’s product development and range revolve around the packaging design and packaging engineering work of its Logoplaste Innovation Lab. This formidable R&D resource is the engine behind the company’s ambition, which is to be the natural choice in the supply of rigid plastic packaging solutions.

Innovation is green The focus of much of Logoplaste’s innovation and activity today is a commitment to improving the environment. Logoplaste is implementing environmental practices throughout the organisation, as well as in conjunction with its partners. The company regards weight reduction in rigid plastic packaging as an important contributor to sustainability in the FMCG supply chain. As such, Logoplaste’s R&D facility dedicates considerable effort to the study of ways to reduce the raw material content in its original packaging designs and products. A 2007 project saw Logoplaste significantly reducing the tonnage of PET and HDPE used in packaging products, through the creation of an innovative ‘short neck’ bottle. As a result, a total of 377 tons of PET and 226 tons of HDPE has been saved per year.

In addition, Logoplaste has been active in promoting sustainability initiatives, such as the ‘Green Dot Society’ Portugal, set up by Logoplaste’s Chairman in 1993. This national initiative is aimed at matching the commitment and actions taken in other countries that promote the Green Dot philosophy. Plastic recycling is another important activity that Logoplaste, in collaboration with its partners, is keen to promote and develop. In particular, national food and beverage packaging standards linked to the use of recycled feedstocks are increasing the scope to use recycled materials for rigid plastic packaging. In the UK for example, Logoplaste is working with some of its clients to incorporate greater use of recycled HDPE and PET in our production. Meanwhile, Logoplaste is paying attention to carbon emissions and is using energy usage studies to help address environmental performance with proactive initiatives in all areas of the business. This has led to renewable energy installations such as a photovoltaic station being installed in the company’s Cascais headquarters, which is set to help Logoplaste approach its aspiration of creating a fully autonomous energy generation source for the plant.

Ocean Bottle One of Logoplaste’s most widely celebrated, recent sustainable packaging projects came about as a result of a collaboration with Ecover, which famously launched last year the first ever bottle containing waste plastic fished out of the ocean. The Ecover ‘Ocean Bottle’ is made entirely from recycled plastic, with 10 per cent of that plastic coming from the sea.

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POSIMAT, S.A.

POSIMAT, S.A. is the world’s leader in design and manufacturer of empty plastic bottles unscramblers and handling systems for more than 30 years. We manufacture a full range of unscramblers that offer the best handling conditions for empty bottles, flasks and vials, from the smallest to the largest sizes. Even those bottle formats which have difficult and unstable shapes, also for low and high speeds. MASTER unscramblers for low maintenance and easy operation. MULTICHUTE and MONOCHUTE unscramblers for high speeds. POSIPUCKS unscramblers specially for customers who use puck lines. POSIPHARMA, MICRO and ACCESS, unscramblers for the pharmaceutical and cosmetic industries. BOTTLE ORIENTORS to turn asymmetrical bottles. Unscrambler with BTU (Bottle transfer unit) combination,which orients and inserts bottles in pucks. DEPALLETIZERS to depalletize plastic bottles automatically. POSISILO storage bottles. AIR CONVEYORS. AIR OR WATER RINSERS.

The bottle represents an exciting joint initiative between Ecover, Logoplaste and other leading innovators. Using existing fishing boats kitted out with innovative technology, Waste Free Oceans’ ‘catch of the day’ project enables European fishermen to earn money by collecting between two and eight tonnes of waste plastic per catch for cleaning and recycling. As part of a trial project, this waste was sent to Closed Loop Recycling’s plant, where it was processed and turned into plastic used by Logoplaste to make the new Ecover bottles. “Logoplaste previously created a showcase in Leixoes Port (in Portugal) of how to collect ‘plastic waste’ from the Oceans,” commented Marcel de Botton, chairman of Logoplaste. “We are fully aligned with the Ecover approach and are delighted to support them in this initiative. The majority of the waste coming into the oceans is delivered by our rivers. By highlighting the ocean waste problem, we are reaching out to communities and villages by the rivers, who don’t always understand where their waste is going – straight into the sea!”

Another important feature of the Ocean Bottle is the design, for which Logoplaste applied the principle of used biomimicry. The Logoplaste Innovation Lab was the first and, for the time being, is the only rigid plastic packaging company in the world that uses the methodology of biomimicry thinking to fully support the innovation process of packaging development. The resulting Ecover Ocean Bottle is an exclusive, distinctive and already widely celebrated design, one which was inspired by the skeletons of unicellular aquatic organisms, Diatoms and Radiolarians, whose design principles helped optimise the mechanical performance of the container. The Ocean Bottle project, which has already won multiple industry awards, stands as a the perfect example of Logoplaste’s commitment to marrying sustainable materials with innovative, eco-efficient engineering, while delivering stunning structural design that is coveted in the consumer marketplace. Visit: www.logoplaste.com

Logoplaste Innovation Lab won the sought-after Red Dot in the Red Dot Award: Communication Design 2014, one of the largest and most respected design competitions, for the outstanding Ecover Ocean Bottle project. The international jury judged each of the 7096 entries live and in situ in sessions running over several days. Only the best works win this seal of quality for design.

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Making the most of sustainable moulded-fibre packaging The International Moulded Fibre Association (IMFA) is spearheading the global drive for more sustainable and environmentally friendly fibre-based packaging products. Philip Yorke reports on a professional trade association that delivers unique benefits and the latest technological know how to its members worldwide.

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he IMFA was founded over 30 years ago as a non-profit organisation dedicated to providing its members with industry intelligence for moulded fibre packaging products. The IMFA is the clear leader in its field as well as in its mission to promote, educate and improve the moulded fibre industry. In particular, the company values its key role in promoting environmental sustainability. As the definitive resource for the evolving and fast growing moulded fibre industry, it is dedicated to increasing the use of moulded fibre products for the benefit of its members and for the packaging industry worldwide. With its unparalleled access to research and its unique expertise in moulded fibre packaging (MFP), the association has become a primary source of information for packaging companies globally. Thanks to its on-going commitment to the dissemination of information concerning sustainability, production efficiency and technology, IMFA’s global membership continues to grow, particularly in the fast-food and chilled food sectors.

These well-attended IMFA seminars are the only global events that are able to bring together the single largest group of experts in the moulded fibre industry. These meetings also represent the bulk of new and existing MFP knowledge, with delegates from over 20 countries taking part in a creative exchange of ideas across the entire spectrum of fibre packaging manufacturing. The seminar also provides a unique opportunity for delegates to network across the broad base of moulded fibre packaging companies that will be in attendance at the seminar in Vancouver. At the IMFA’s last Seminar in Canada, professor Saklly of the Kingston University of Toronto introduced an entirely new model fibre treatment that increased product strength and his innovative presentation was complimented by other valuable contributions from Neil Darin of HAVI Global Solutions and Meredith Sexton, a packaging engineer from Clemsen University. One can expect more ground-breaking innovations at the forthcoming IMFA seminar next April.

Focus on innovation

Increasing demand and diversity

In April next year, the IMFA is set to host its 19th international moulded fibre seminar in Vancouver, Canada. The forthcoming annual seminar will address the latest innovations and ideas in MFP from around the world and provides an unprecedented opportunity for the industry’s professionals to stay ahead of the competition, something that is impossible to find anywhere else.

The increasing global demand for moulded fibre packaging products (MFP) has led to many important advances in the technology and manufacturing of MFP products. Furthermore, many new types of moulding machinery have been developed that offer significantly improved production efficiency and quality. Many new natural fibres have also been introduced to the industry. These include such exotic

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natural and sustainable materials as bamboo, sugar cane, reed and palm. Today the IMFA continues to drive the quest for greater dissemination of knowledge and efficiency within the moulded fibre packaging industry. An example of the industry’s evolving product diversification was highlighted recently by ‘Stratasys’, the 3D printing and production system company. In a recent press article on Fused Deposition Modelling (FDM) the company informed Packaging Europe that this system provided an alternative method for producing moulded pulp tooling that can offer dramatic time and cost savings and significantly improve the appearance of the finished product. The latest FDM technology is an additive manufacturing process that builds parts layer by layer, utilising the data from computer aided design files (CAD). FDM moulded pulp tooling can be produced in a fraction of the time and cost of conventional tooling because the FDM tool can be manufactured as both porous and rigid items. FDM also eliminates the need to attach the screen to the mould. In addition, FDM moulds can be run alongside traditional moulds with no alteration to the slurry formula, cycle time, vacuum pressure or other process variables, thus making it easy to integrate FDM tooling into any moulded fibre operation. Renewable fibre packaging products are currently being used for the handling and packaging of thousands of different manufactured products throughout the world every day. They provide ideal protection for product shipments, and offer customers greater convenience and a sustainable and more economical alternative to plastic packaging. The main markets for MFP products are food related packaging, and industrial or engineered packaging, as well as packaging for pallets, film roll cradles and nursery containers. All of today’s fibre packaging products are bio-degradable and com| 354 | Packaging Europe

postable, as well as being able to be integrated without the risk of toxic or hazardous waste materials entering the atmosphere. The four basic types of MFP products are Thick Wall, Transfer, Thermoformed (thin wall) and processed products. Today the IMFA continues to provide an invaluable advisory service to its members and the moulded fibre manufacturing industry worldwide. For further information about the unique range of services on offer at IMFA visit: www.imfa.org

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