The Packman | May-June 2021 by The Packman

Volume 3 l Issue 6 l may-June 2021

Rs. 150

IntervIew wIth AmIt LAhotI of BALL BeverAge PAckAgIng IndIA

Pinnacle Traxim installs Konica Minolta AL230

Numex invests in Esko platemaking technology

Trigon installs Asia’s first HP Indigo 25K

Editorial

PAMA’s governing council, which met on 22 March 2021, decided to significantly subsidize exhibitor participation in the Printpack India event from 20 to 24 December 2021. The council took a bold decision to charge exhibitors the minimum space rentals, only to meet the basic requirements of the exhibition. Dayakar Reddy and Prashant Vats of IPAMA insisted that becoming members of the IPAMA is straightforward. Both stressed that subsidizing exhibitor participation is their responsibility and the need of the hour as the industry is going through a testing time. Reddy insisted, there will be no impact on the event’s quality in terms of construction and facilities due to the subsidization – it would be even better than earlier Printpack events. In addition to providing various discounts, IPAMA may also consider extending complimentary services to exhibitors and business visitors during the exhibition. Meanwhile, virtual.drupa made history as the first purely digital version of the leading global trade fair for printing technologies, which took place from 20 to 23 April 2021. The virtual event successfully bridged the gap between the previous and forthcoming face-to-face event in 2024. The new format of Print & Packaging Community received excellent feedback internationally, as demonstrated by the impressive final statistics. According to the organizers of the event, 212 exhibitors from 35 countries and team participants from global subsidiaries presented their product portfolios and innovations within the online showrooms and more than 125 live web sessions with an average of 140 participants. In our cover story, we take a closer look at Ball Beverage Packaging India’s journey in India so far. We spoke with Amit Lahoti, vice president and general manager, Ball Beverage Packaging, India and South-East Asia Region, who says, “An increasing number of beverage companies are using aluminum cans for packing and serving their products.” This edition of The Packman also highlights several innovations and new developments directed towards sustainability. Ryan Carvalho, head of R&D and chief medical officer for Nestlé Nutrition said, “Bio-based packaging from sugar cane is an excellent example of how we can make good use of plant-based raw materials that are renewable to develop better alternatives to traditional plastic while ensuring that our products maintain a high level of safety and quality.” Nestlé has announced that it will introduce bio-based lids and scoops made from sugar cane and its byproduct for a range of its nutrition products for infants and children. The main advantage of these bio-based plastics is that they are made from a renewable plant material that can be continually replenished and that absorbs carbon dioxide from the atmosphere. In another development related to sustainability, Stora Enso and Pulpex have joined forces to industrialize the production of eco-friendly paper bottles and containers made from wood fiber pulp. The renewable products will offer an alternative to PET plastics and glass. The exclusive partnership leverages Stora Enso’s formed fiber technologies and ability to convert end-products at an industrial scale. In addition to stories from our regular packaging segments, the current issue also highlights some looming issues that kraft paper and metal packaging industries are going through currently. Stay safe in the meantime, and thank you all for your continued support. – Mahan Hazarika, Editor, editor@thepackman.in

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Contents Design and Marketing

PAGE 14

PAGE 19

PAGE 28

EDITORIAL

FLEXIBLES

PHARMA PACKAGING

DESIGN AND MARKETING

Constantia India installs 5-layer blown film line from Rajoo Engineers----------------------21

CAPS AND CLOSURES

Editorial----------------------------------------------- 3

Danone launches formula milk in pre-measured tab format--------------- 6 Syntegon’s innovative paper packaging for cosmetics industry-------------- 7 Henkel’s toilet cleaner pack portfolio gets a redesign------------------------- 8 Quadpack reveals new range of mono-material closure systems---- 8

PREPRESS

Miraclon and Zecher deliver successful project with Kodak Flexcel NX-----------------10 Mumbai-based Numex invests in Esko platemaking technology----------------- 11

Brückner in 2020 – second most successful business year ever----------------20

Yansefu strengthens its water-based product segments---------------22 Multisac Flexible Packaging invests in Comexi ML2 laminator-------------23

LABELS

Trigon installs Asia’s first HP Indigo 25K----24 Pinnacle Traxim installs Konica Minolta AL230---------------------------25 Michelman partners with HP for high-performance digital labels------25 Siegwerk inaugurates new ink blending center in Bangladesh----------------26

Asahi and Esko unveil automated flexo platemaking solution---------------------- 11

Vinsak installs ABG RTS sheeter at JK Fine Prints----------------------------------27

OpenGate Capital acquires Kongsberg PCS from Esko---------------------12

Pragati adds Baldwin Guardian PQV--------28

L&E International selects X-Rite ColorCert and PantoneLIVE-------------------13 DuPont introduces new plates and flexo platemaking system-----------------14

MONOCARTON

Radico launches Triple Eight whiskey in Asepto’s foil stamping aseptic pack-------16 Solar Printers strengthens post-press portfolio with Bobst Ambition A1--------------17 Demand for kraft pulp rolls puts Indian box makers at stake---------------------17 Heidelberg surpasses its own forecast------18 BillerudKorsnäs launches new generation of coated liner-----------------------19 Huhtamaki acquires leading folding carton manufacturer in China--------19

AM Etichette installs Nilpeter FA-17---------28

MATAL PACKAGING

An interview with Amit Lahoti of Ball Beverage India------------------------------------30 MCMA asks govt to hold off steel quality control order-----------------------34

AUTOMATION

The perfect packaging future with advanced automation----------------------36

FOOD PACKAGING

GEA to supply one of the largest standalone UHT milk plants in India---------38 Mintel’s report on food packaging trends and sustainability------------------------41 Tetra Pak to deploy its portfolio of tethered cap solutions------------------------42 Convenient nearline sachet printing for food packaging---------------------43

M ay - J une 2 0 2 1

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Turning 1 into 3------------------------------------44

United Caps unveils ‘Define Your Circle’ initiative--------------------46

SUSTAINABILITY

Amcor’s recyclable blister packaging begins trial phase------------------48 Mondi packages potatoes in paper bag with Sustainex--------------------48 Siegwerk and Kotkamills join forces to develop fibre-based packaging----------------49 H.B. Fuller launches compostable adhesives for flexible packaging--------------50 Nestlé launches bio-based lids and scoops made from renewable resource---------------51 Stora Enso and Pulpex partner to produce fiber-based bottles-----------------52

EVENTS

15th Printpack India offers special discounts to exhibitors-----------------54 The date for interpack 2023 is set------------54

INDUSTRY NEWS

Scholle acquires Bossar------------------------55 XSYS launches Nyloflex FTM digital flexo plate----------------------------------55 AGI glaspac invests in German tech to build new furnace-----------------------56 Reifenhäuser acquires Kdesign---------------56 BillerudKorsnäs and Aisa pioneer new horizons in paper tube packaging------------57 Max Speciality Films to invest in new CPP line-----------------------------------57

The right paper for Indian snacks

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Design and Marketing

z Convenience for formula feeding parents

Danone launches formula milk in pre-measured tab format

anone has launched the first-ever formula milk in the United Kingdom to be sold in a pre-measured tab format. The company has introduced this format innovation in the UK in response to parents’ desire for greater convenience and ease when preparing formula milk feeds. Gustavo Hildenbrand, general manager UK and Ireland, Danone Specialized Nutrition, explained, “Breastmilk is the gold standard when it comes to feeding babies. But if parents feel they need to move on from breastmilk, they tell us they’re looking for ways to make a formula milk feed simpler and more convenient.” According to research conducted in 2018 with more than 1,300 UK mums, ‘convenient for feeding-on-thego’ was the 2nd most important criteria mums cited. Close to a third of those surveyed (31%) also said they looked for ‘greater convenience when preparing a formula feed’. The new formula milk tabs dissolve easily, with one tab equal to one standard scoop of powdered formula. The new pre-measured tab format will be made available in packs of 24 sachets, with each sachet containing five tabs. Danone expects the new format to help cut down on mess when preparing a formula feed, making the new format useful – in particular for night-time feeds. The new format will be available exclusively via the UK’s leading health and beauty retailer, Boots, under the Aptamil brand. “We hope bringing to market formula milk in a premeasured tab format will offer added convenience and support for formula feeding parents – especially in the ‘new normal’, when parents are often stretched and trying to juggle balancing family and work-life from home,” Hildenbrand added. Danone is producing formula milk in a pre-measured tab format at Danone’s formula milk production facility in Wexford, Ireland, through a manufacturing

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Danone has launched the first ever formula milk in the UK to be sold in pre-measured tab format

partnership with Japanese food manufacture, Meiji. The exclusive memorandum of understanding (MOU) between Danone and Meiji covers the production of this format innovation through which Danone is combining its formula milk recipes with Meiji’s patented tab production technology. Jean-Michel Lequin, director of Danone’s Wexford, Ireland, formula milk production facility,

explained, “At Danone, we’ve seen how in other food categories – like coffee and culinary stocks – introducing portion-controlled and dosed formats has been a game-changer for consumers, who look for more convenience and ease. That’s why we’ve worked with Meiji to set up a production line for pre-measured formula milk tabs at Danone’s formula milk production facility in Wexford, Ireland to serve the UK market.” z

Design and Marketing

z Shaped Paper Pods

Syntegon’s innovative paper packaging for cosmetics industry

kincare products and cosmetics fill countless shelves in drugstores, pharmacies and perfumeries. Confronted with an overwhelming range of products, more and more consumers are basing their purchase decisions on one feature – the product’s environmental footprint. This is where personalized packaging plays a key role, as it helps to create a positive brand experience. With its Shaped Paper Pods, Syntegon offers an environmentally friendly paper packaging solution for viscous and liquid cosmetics. These embossed structural pods can be individually shaped to manufacturers’ requirements and are made almost entirely of paper. In many countries, they can be conveniently recycled in the wastepaper stream.

brand experience. Particularly sustainable products can be packaged in leaf-shaped pods, for example, or lipstick samples for younger target groups can be pressed into a butterfly shape.

Practical, personalized and beautiful to look at The Shaped Paper Pods are particularly suitable for single-use products, testers, and refill products, offering maximum flexibility and convenience. And since they take up little space, consumers can easily take their favorite creams or makeup products with them on trips. At the same time, the Shaped Paper Pods fulfill the usual barrier requirements and hygiene standards, ensuring maximum product protection. Its customizable, high-quality appearance opens the door for interesting designs and creates a unique

Flexible and cost-efficient

The Shaped Paper Pods can also be personalized with a unique embossed pattern, even when packaging dry products, such as face powders. They can also be used for liquid refill products. To date, manufacturers have used them for concentrates that are later diluted with water. The concentrates can be packaged as capsules, tablets or liquids. Moreover, the Shaped Paper Pods can be equipped with smart QR codes on their lids to provide additional information and further reinforce customer loyalty.

MDC GAMUTSTAR

Another advantage of the Shaped Paper Pods is the innovative, more sustainable production process. While classic paper packaging is formed from pre-cut sheets, this method allows the paper to be processed directly from the roll, eliminating high storage costs. The TPU paper form, fill and seal system from Syntegon used here can precisely cut the required packaging on the line, allowing manufacturers to flexibly produce different packaging sizes. z Syntegon’s Shaped Paper Pod sketches

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Design and Marketing

z Recycled polyethylene increased in the packaging

Henkel’s toilet cleaner pack portfolio gets a sustainability-focused redesign

he amount of recycled polyethylene (rPE) in the packaging for Henkel’s toilet cleaner gels has been increased – reaching 50% for toilet cleaners in the standard range, for example from the Biff brand, and, in the case of cleaners from the Pro Nature range, as much as 75%. The material used is recycled plastic from end-user households. “It is an important step for us that we have been able to increase the proportion of recycled PE in our toilet cleaners so significantly. After all, the availability of high-quality recycled materials of this plastic is still limited,” says Ulf Timmann, head of global packaging innovation for Henkel’s toilet care and hard surface cleaning operations.

In addition to increasing the use of recycled plastic, Henkel has also reduced the weight of the bottles by 11% - reportedly saving 480,000 kilograms of new plastic per year. According to the company’s calculations, this corresponds to a saving of 800 tonnes of CO2 annually. Henkel also claims that the new compact bottle design allows around 10% more bottles to fit on a transport pallet, which saves on CO2 during transport. Henkel hopes that this redesign will help it to achieve its packaging targets, with a central pillar of this being the company’s goal of reducing the amount of virgin plastic from fossil sources in its consumer product packaging by 50% by 2025. z

z Functional properties and stability as plastic

Quadpack reveals new range of mono-material closure systems

nternational beauty packaging manufacturer and provider Quadpack has unveiled Woodacity – a new range of closure systems for fragrance packs, each cap crafted from a single piece of sustainably-sourced wood. “Our experts have effectively mechanized wood,” said Quadpack’s head of categories, Pierre-Antoine Henry. “Woodacity elevates this natural material beyond the aesthetic, to become a fully-functional component of a beauty packaging solution. This full-wood innovation is the first of its kind, bringing sustainable added value to beauty brands.” Quadpack claims that its new closure solutions offer the same functional properties and stability as plastic, along with the qualities of wood. In addition, the designs of the products obviate the need for a plastic insert, making them mono-material structures.

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managed forests.” ‘Solo Snap’ is a globally patented snap-on cap, with a unique pattern of interior ribs and a secure ‘click’ closure. Meanwhile, ‘Solo Push’ is a friction-fit cap that closes the pack with a smooth push gesture.

Each Woodacity cap is crafted from a single piece of sustainably-sourced wood

Three systems are available, all made in Europe at the Quadpack Wood factory, using wood sourced from what the company describes as “sustainably

The last member of the range, Solo Turn, is a thread cap with a screw closure, which matches with Quadpack’s Regula Glass jar, also made in Europe. Woodacity was conceived following a two-year research and development project to turn wooden fragrance caps into working packaging components. A team of designers, engineers, and technicians investigated the material in different conditions, shapes, and combinations at Quadpack Wood, to achieve the first three closure systems available today. The company says that more variants are currently under development. z

Prepress and Software

z Consistent, high quality results with variety of packaging applications

Miraclon and Zecher deliver successful project with Kodak Flexcel NX

echer, manufacturer of anilox rollers for the printing and coating industry headquartered in Paderborn, Germany, successfully completed a project to demonstrate how consistent, high quality results can be achieved with a variety of packaging applications that are produced on flexo using CMYK process colors and advanced technologies. The project, executed in cooperation with a range of partners, including Miraclon that provided the plates, aimed to prove that uniform color and image reproduction on a range of different substrates can be achieved using flexo, to ensure that the packaging communicate a brand’s identity and message consistently and provide consumers with an incomparable, positive shopping experience.

An ambitious undertaking To maximize the practical relevance, complex images typically found on packaging for foods, coffee, tobacco, cosmetics and animal food were chosen. Subtle gradients in the highlights and fine details in the high tonal ranges were features shared by all the designs. A subject rich in contrast and showing a woman’s face completely covered in gold make-up proved to be a particular challenge for CMYK flexo printing. It was this subject that also inspired the motto for the project – “Together for Golden Results.” Three applications were produced – flexible packaging (printed on BOPP film), corrugated preprint on 135 g/ cm2 paper fully coated on one side, and a paper carrier bag made from 100 g/cm2 white-coated kraft paper. Zecher anilox rollers equipped with Zecher’s SteppedHex engraving technology were used to print all three applications. This innovative engraving method is characterized by a unique, specially staggered cell geometry which helps optimize print quality. Three applications, one Flexcel NX plate technology All three applications were produced using Flexcel

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NX plates, made with Kodak Maxtone SX Screening – which is optimized for the Flexcel NX System – and a 60l/cm (152 lpi) screen. “We selected Flexcel NX Plate technology based on its strong presence in the flexo market and the controlled ink transfer it delivers,” explains Jörg Rohde, head of application technology at Zecher. The technical resources for producing the flexible packaging application were made available by machinery and systems manufacturer Windmöller & Hölscher (W&H) at its Printing Technology Center in Lengerich, Germany. And, as the facility houses a Flexcel NX Ultra Solution from Miraclon, the flexo plates could be made on the spot. The corrugated preprint application was produced at Christiansen Print in Ilsenburg, Germany, using Flexcel NX plates from Schawk Goslar, while the paper carrier bag was printed at Stenqvist Austria with Flexcel NX Plates from Flex-Punkt Druckformen.

Golden results convince in every aspect There were delays executing the project owing to the COVID-19 pandemic. However, there was no denying the brilliance of the results once it was completed. Everyone involved was excited – not only by the color

consistency with remarkably close tolerances across all substrates, but also by the outstanding image quality in the gradients and fine details. The striking reproduction of the golden face using just the capabilities of CMYK flexo printing with no additional spot colors was similarly impressive. “We succeeded in demonstrating the high color consistency and comparable results that are achievable across a range of products and substrates with flexo printing today,” says Rohde. “The project confirmed that our Zecher SteppedHex anilox roller engraving technology facilitates the highest levels of color consistency in different flexo applications, and the Flexcel NX plate technology from Miraclon helped us do that. Provided all process parameters are precisely matched, ‘golden results’ like these are entirely feasible under real production conditions.” “We are delighted to be part of a project that pushes the boundaries of flexo printing,” adds Nilgun Turan, marketing manager, Europe at Miraclon. “With their unmatched stability, optimized ink transfer and the wide tonal range it delivers, Flexcel NX plates enable the large color gamut that is a condition of applications like gold in CMYK – every time. The results of this project are clear evidence that innovation will continue driving flexo’s growing success in the market.” z

Prepress and Software

z virtual.drupa 2021

Mumbai-based Numex invests in Esko platemaking technology

ndian prepress trade shop Numex Blocks has invested in the full Esko workflow and Crystal line of platemaking solutions following the recent virtual.drupa event. The Mumbai-based specialist in flexo and letterpress plate production, which serves customers in the flexible packaging, labels, letterpress and corrugated markets in India, has boosted its capacity with the Esko CDI Crystal 5080 plate imager and XPS Crystal 5080 exposing unit, together with extended gamut printing software Equinox, and the award-winning Print Control Wizard.

Combining UV main and back exposure, the XPS Crystal uses LEDs which do not require warm-up time and always emit even light, producing excellent consistency of plate quality and subsequently on press.

“Almost 20 years ago, Numex became the first trade shop in India to offer digital flexo platemaking,” said Murad Kalal, Esko’s flexo and software regional sales manager. “This trend continued throughout the years, with the company investing in the Esko CDI Advance Cantilever 1450 with HD Flexo to guarantee its customers the highest quality print results, before pioneering again in 2013, when Numex became the first company in South Asia to install the Esko CDI 5080 with HD Flexo & Pixel+.

Nitin Patil, owner of Numex Blocks, said that the new acquisition was part of the company’s ongoing commitment to delivering the best quality plates to its customers, and would be a key part of its continued growth and development.

“Over the years, Numex Blocks continuously upgraded its workflow software and works today with the full range of latest software from Esko, including Automation Engine, DeskPack, Imaging Engine and more than 20 seats for PackEdge,” Kalal said. “We have recently agreed a deal which will maintain their position at the leading edge of technology with the acquisition of the full Crystal line. “With the innovative Crystal technology from Esko, the platemaking process – in terms of imaging and exposure – is now much less complex and has significantly fewer steps. The integration of our workflow solutions and hardware technology means that the Numex team are now completely in control of the quality and performance of their plates and subsequent print consistency.” At the heart of its system, Numex has installed the award-winning Esko XPS Crystal exposure unit.

“As well as the latest imaging technology, the team is using Esko Automation Engine and the Print Control Wizard – with its Crystal Screening technology – to automate the workflow,” explained Kalal. “They have a full Esko Crystal ecosystem in operation, producing consistently high quality plates.”

“The ability to produce the highest quality plates, that deliver consistent print quality, improves our agility to meet the ever-changing needs of our customers,” said Patil. “Obviously, this is particularly valuable to us in terms of meeting the demands of those urgent,

Murad Kalal of Esko with Nitin Patil of Numex Blocks

short runs with shorter lead times, but also on longer runs where consistency is key. “Following our success with Esko integrated hardware and software solutions across the last two decades, we are delighted to have been able to install the entire Crystal line into our platemaking facility,” he said. z

z virtual.drupa 2021

Asahi and Esko unveil automated flexo platemaking solution

sahi Photoproducts and Esko have showcased their breakthrough, fully automated flexo platemaking line CrystalCleanConnect at this year’s virtual.drupa event. Asahi

Photoproducts, a pioneer in flexographic photopolymer plate development, has collaborated with Esko, the global developer of integrated software and hardware solutions for the packaging and labels markets, on THE PACKMAN | May-JUN 2021

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Prepress and Software the innovative flexo platemaking solution. CrystalCleanConnect fully automates the entire flexo plate production, from imaging to plate cutting, reducing the number of steps in the flexo platemaking process from 12 to just one which equates to a reduction from 36 min operator plate making time to only 2,5 min. “With CrystalCleanConnect we have brought together key hardware and software technologies from both organizations to deliver a number of breakthrough advantages from design to print,” said Pascal Thomas, director of flexo business with Esko. “CrystalCleanConnect delivers a cleaner, more environmentally balanced operation that simplifies the flexo platemaking process, improves safety and boosts print quality consistency.” According to Pascal, CrystalCleanConnect offers operational as well as environmental benefits to businesses. “With the removal of so many process steps, there’s an immediate 90% reduction in required operator time, which not only eliminates the potential for human error but also delivers immediate efficiency gains. Quality is assured through Asahi and Esko technologies working in complete harmony, and the combination of improved efficiency and quality delivers an average increase of 25% in press OEE.”

A holistic approach to connecting technologies Dieter Niederstadt, technical marketing manager for Asahi Photoproducts said, “Flexo needs to simplify its processes while improving quality, consistency and profitability. In doing so, flexo can create new business opportunities and positively transform into a printing technology in balance with the environment.” “This breakthrough innovation is different in many ways to other solutions on the market,” Dieter said. “It is not just an assembly of available plate making processes delivered inline, but rather a holistic approach to connecting technologies, up and downstream of the prepress value chain, using an intelligent automation hub as the backbone and heart of the solution. CCC

z Transforming into a standalone company

OpenGate Capital acquires Kongsberg PCS from Esko

ongsberg, one of the most trusted and established names in the digital finishing industry, entered a new era on 6 April 2021, transforming into a standalone company, Kongsberg Precision Cutting Systems (Kongsberg PCS). The transformation follows the acquisition of the business by OpenGate Capital. The transformation of Kongsberg PCS brings with it the opportunity to innovate and expand the business into new markets. This marks a new chapter for Kongsberg PCS, a brand with a rich heritage spanning more than half a century.

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is truly pushing boundaries to the current scope of plate automation delivering a mount-ready plate as well as being the first automated production solution without the need of VOC based washout solvents in the plate making process.” Thomas added, “At Esko, we have long been dedicated to improving the platemaking experience, in terms of quality, productivity and connectivity. Together with Asahi Photoproducts, we are taking the flexo platemaking process to a brand-new level, enabling our customers to be even more competitive while also ensuring they can meet today’s demands for flexible and sustainable supply. With CrystalCleanConnect, our ultimate objective is to improve our customers’ overall business performance and profitability.” z

Prepress and Software “This is truly an exciting day for everyone at the company,” said Stuart Fox, president of Kongsberg PCS. “Since 1965, the Kongsberg name has been synonymous with innovation. Our systems have led the industry in delivering precision, reliability and quality through seven decades. Following the acquisition by OpenGate Capital, we will now focus on our future, and the next generation innovation and growth.” Founded in Norway in 1965, Kongsberg was purchased by Esko (then Barco) in 1998. In December 2020, Esko agreed the sale of Kongsberg to private equity firm OpenGate Capital. The acquisition includes

the original research and development facility in Kongsberg, Norway, and the production facility in Brno, Czech Republic. “This is an opportunity for the Kongsberg team to realize its ambitions, and to explore new markets,” added Fox. “We will be developing strategic initiatives to further innovate our digital finishing hardware and software solutions, as well as growing the Kongsberg brand beyond the packaging industry. “Whilst we are excited about the future, we are also committed to ensuring we honor our heritage. We have

an incredible team of 400 people, many of whom have been a part of the Kongsberg family for more than 30 years,” said Fox. “The Kongsberg values that are important to our customers – the strength, the performance, the longevity of the machine – will endure. “Sales, service, consumables and spare parts will all continue as usual,” added Fox. “Customers will receive the same level of service during the transition and they can look forward to business as usual throughout 2021. We will continue investing in our table technology, and in the coming months we will be showcasing the latest developments with our automation solutions.” z

z Print quality control platform

L&E International selects X-Rite ColorCert and PantoneLIVE

-Rite Incorporated and Pantone LLC, global leaders in color science and technology, has announced that L&E International, a global provider of sustainable, innovative packaging solutions, has selected the ColorCert Suite as its print quality control platform. ColorCert will be used across all L&E locations to monitor, control, and report packaging quality to brands and suppliers across China, India, and elsewhere in Southeast Asia. L&E also selected PantoneLIVE, a cloud-based digital color standard database, to communicate accurate and achievable colors for package printing as part of its digital color workflow. L&E complies with strict brand color standards as a certified packaging supplier for adidas, Verizon, Amazon (APASS vendor in Asia), Target, and many other brands and retailers. This investment moves the company toward an end-to-end digital color workflow for communicating, approving, and reporting on color quality to improve efficiencies and visibility. The journey of continuous improvement strengthens L&E’s ongoing efforts to augment sustainability in packaging while improving overall quality. “We were introduced to the ColorCert Suite and quickly saw its potential as a print quality control platform

and access reports for actionable advice to improve results. With the ColorCert ScoreCard Server, L&E has one dashboard for instant job scoring and reporting print performance across suppliers and manufacturing facilities to validate and monitor packaging quality and report compliance to brands.

L&E selects X-Rite ColorCert and PantoneLIVE for print quality control. Photo: L&E International

that could provide us increased visibility into our color performance while also delivering real-time data to help us optimize manufacturing efficiencies and reduce waste,” said Vikas Gupta, director of creative solutions and development for Asia, L&E International. “We are excited to roll out ColorCert and PantoneLIVE across all our supply locations over the next few months.” The cloud-based ColorCert Suite is a set of digital tools used to define color requirements and collect pressrun color data to report color performance across the supply chain. L&E will measure color values during production, compare them with the expected target,

PantoneLIVE syncs directly with ColorCert to enable L&E access to digital Pantone and brand packaging color libraries for accurate color regardless of substrate, printing technology, or ink type. PantoneLIVE will enable the L&E team to reduce packaging makeready times by targeting realistic packaging colors before going on press. These digital packaging color libraries by Pantone reduce rework and press sampling associated with matching physical references on different packaging materials. “We are excited to be working with one of the leading packaging solution providers in Asia-Pacific as they build a digital print quality program across their packaging supplier network,” said Cindy Cooperman, vice president, brand global strategic accounts, X-Rite. “Integrating color management as part of digital workflows helps package printers improve delivery times while supporting sustainability efforts to reduce waste and rework.” z THE PACKMAN | May-JUN 2021

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Prepress and Software

z virtual.drupa 2021

DuPont introduces Cyrel Easy R plates and Cyrel Fast 3000 TD flexo platemaking system

s part of its participation as a Gold Event Partner at this year’s virtual drupa show, DuPont has introduced its new Cyrel Easy R plates family as well as the DuPont Cyrel Fast 3000 TD thermal flexographic plate processor. Cyrel Easy R is the family of new formulations that maintain the benefits of Cyrel Easy flat top dot photopolymer plates while adding on new attributes to help improve plate handling and on-press performance, especially for flexible packaging and tag and label applications. The plate family is comprised of photopolymer plates suited for thermal and solvent development and come with smooth or structured surface to provide the best match for a large variety of print conditions. Cyrel Easy R offers increased dot robustness for high resolution, reliable long-run print consistency as well as great ink transfer and superb print quality on a wide variety of substrates. Liming Zhu, general manager of Jielong Art Printing, said, “The Easy R plates enabled us to maintain a high level of customer satisfaction because the EFXR plates have a great performance on dot, line and ink transfer.” The Cyrel Fast 3000 TD system is the latest addition to the range of solvent-free flexographic printform processors and offers superior productivity and performance while helping reduce processing costs, processing time, and environmental impact compared to existing solvent-based platemaking methods – now at plate sizes up to 50×80 inches. By eliminating the use of solvents – including water – from the platemaking process, the Cyrel Fast 3000 TD system produces maximum-sized plates that

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Dupont’s stand at drupa 2016

require no drying time and can be prepared in under 30 minutes. With the same efficiency as other Cyrel Fast systems, the 3000 TD offers flexible packaging customers and other users with large-sized jobs and high productivity needs a platemaking solution that helps reduce downtime, energy consumption, and environmental footprint. Tucker Norton, global business leader for Cyrel Solutions, said, “DuPont is very excited to showcase the many advantages of the innovative Cyrel Easy R formulations and Cyrel Fast 3000 TD processing system at drupa 2021. Although this year’s show is entirely virtual, we look forward to showing our customers and industry colleagues the powerful performance, time and cost savings, and environmental benefits of the expanded Cyrel portfolio.” z

Cyrel Easy R is the family of new formulations that maintain the benefits of Cyrel Easy flat top dot photopolymer plates while adding on new attributes to help improve plate handling and on-press performance, especially for flexible packaging and tag and label applications.

Monocarton

z Elevates packaging standards for IMFL

Radico Khaitan launches Triple Eight whiskey in UFlex-Asepto’s foil stamping aseptic pack

ndia’s largest Indian-made Foreign Liquor (IMFL) maker, Radico Khaitan, has launched its whiskey brand Triple Eight in an iconic pack imbibing foil stamping feature, manufactured by UFlex-Asepto, rejuvenating its aseptic packaging story for its consumers. Triple Eight whiskey aseptic packs launched in Karnataka is the outcome of a packaging partnership between both companies to elevate the packaging standards for the IMFL category products and embellish the packs to make them aesthetically superior using unique design blends for brand differentiation. Elaborating about the unique packaging development, Ashwani Kumar Sharma, president and CEO, UFlex-Asepto said, “We are extremely proud to have associated with Radico Khaitan which is known for quality blended whiskey. The packaging will certainly accentuate its class to create an aspiration reach for its customers. While differentiation through unique packaging experience has always been Asepto’s key focus, the steal is the anti-counterfeit quality that is pertinent to prevent the consumption of adulterated liquor – a grave concern for the liquor makers.” While the brand Triple Eight will focus on a better count of blended whiskey inside, the startling effects of gold foil stamping and black color will impart the packs a unique identity. Amar Sinha, chief operating officer, Radico Khaitan said, “We are extremely happy with the results of this association. This is, in fact, the first time that an alcoholic beverage company has ventured into the foil stamping effects in the aseptic packaging space.” This has been a result of long labor by both the companies to enter with a unique identity for their Triple Eight brand. “Radico has always been ahead in the innovation and Triple Eight has created a buzz in the market with its iconic aesthetic shelf appeal encouraging repeat sales.”

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Triple Eight whiskey aseptic packs is the outcome of the packaging partnership between UFlex and Radico to elevate the packaging standards for the IMFL category products

UFlex–Asepto, through this partnership, is proposing uniqueness in aseptic packaging which was very basic until now, remarked Sharma. He added, “Asepto’s aseptic liquid packaging is a true example of an offering with top-class functionality as well as visually elegant packaging apt for alcoholic beverages.” The new-age packaging works in more ways than one by curbing adulteration in the segment, creating great choices for customers on retail shelves and retaining the quality flavors that Radico Khaitan is known to offer. Triple Eight is a premium whiskey and to cater to the growing demand in Karnataka it is now made available in 90 ml and 180 ml sizes. The 6-layered aseptic packaging creates room for an experience for customers to get a great taste of classic blended whiskey in the above price range bracket. The premium whiskey maker has again gone with the names around their signature style with the number ‘8’. z

The

new-age

packaging

works in more ways than one by curbing adulteration in the segment, creating great choices for customers on retail shelves and retaining the quality flavors that Radico Khaitan is known to offer.

Monocarton

z Rs 10 crore investment in past two years

Solar Printers strengthens post-press portfolio with Bobst Ambition A1

ammu-based Solar Printers opted for the Bobst Ambition 76 A1 folder-gluer to expand its post-press portfolio. “The folder-gluer is proving to be very robust and technically sound. We can run specially designed cartons and complex, intricate jobs very easily on the machine,” said Manoj Wadhera, managing director at Solar Printers. Wadhera added, “We are based in a remote location and as a result, after-sales service was a big challenge for us. Bobst has a vast and quick after-sales service network across India compared to all other available options in the market.

and we were on the right track, but the nationwide lockdown delayed our plans and meant that we only began running the machines and production in October 2020,” Wadhera said.

L to R: Manoj Wadhera from Solar Printers and Chandrashekhar Dhote from Bobst

for crash-lock bottoms and 4- and 6-corner boxes. “Another important reason to choose Bobst was the great experience of its process engineers to provide lifetime technical support to ensure machine performance, which no other manufacturer in the market can offer. The brand value of Bobst will also help us to provide our customers with confidence in our ability to consistently provide high-quality packaging.” Able to handle most materials and box styles, Bobst Ambition is pre-equipped with two complementary devices

Solar Printers was established in 1989 by Rakesh Wadhera with a treadle printing press. In 2001, the company installed its first mini offset printing press and in 2017, the Wadhera family diversified to packaging printing, alongside its existing commercial print production facility. “Our anticipation for packaging was completely right

The company has invested around Rs 10 crore in the last two years. This includes greenfield expansions and machinery, including the new Bobst Ambition 76 A1 folder-gluer and a Bobst SP 102 die-cutter. The packaging unit converts around 500-tonnes of board per month and the capacity is around 700 tonnes. A team of 70 people is employed, working 8-12 hour shifts per day. In anticipation of future expansion, the company has also acquired another 30,000-sq ft of land. “Right now, we are operating two units – one dedicated to commercial printing and the other for packaging,” Wadhera said. “Our geography has enough potential. The government of Jammu & Kashmir provides relaxation on freight as well. We are serving our clients in Punjab, Haryana, Jammu & Kashmir, and other neighboring states.” z

z 20% box makers on the brink of closure

China’s burgeoning demand for kraft pulp rolls puts Indian box makers at stake

he corrugated box industry has urged the government to ban the exports of recycled kraft paper pulp rolls to help availability of raw materials in the country and control the surge in prices. The industry is reeling under the twin blows of sharp rise in raw material

as well as disruptions in its supply, stated Sandeep Wadhwa, president of Indian Corrugated Case Manufacturers’ Association (ICCMA). “The exports of kraft paper from India to China have surged as China has banned import of waste paper

from 1 January 2021. Exports from India are in the form of recycled kraft paper pulp rolls. This has created a huge shortage of raw material for the domestic corrugated industry,” Wadhwa added. According to Wadhwa, there is a need for the govTHE PACKMAN | May-JUN 2021

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Monocarton ernment to step in and ban exports of recycled kraft paper pulp rolls as the domestic corrugated industry that gives employment to over 6 lakh people, is on the verge of closure. Harish Madan – vice president of ICCMA said, “The demand gap and attractive pricing in China is diverting the output of Indian kraft paper from the domestic market and driving up the domestic prices of finished paper and recycled fiber. Exports of recycled kraft paper pulp rolls by Indian Kraft paper mills would touch about 2 million tonnes this year, roughly 30% of total domestic kraft paper production in India.”

Madan added that this development, based on zero export before 2018, is a game-changer in supply-side dynamics going forward. In addition to the increase in the costs of kraft paper, he said other conversion costs like man-power costs, starch and freight have also witnessed a huge increase by 60-70% over the past few years. According to Madan, at least 20% of Indian box makers is on the brink of closure due to China’s burgeoning demand for kraft pulp rolls. The corrugated box industry in India has over 350 automatic corrugators and more than 10,000 semi-automatic units, mostly in the MSME sector. z

z Strong final quarter in FY 2020-21

Heidelberg surpasses its own forecast

ccording to preliminary figures (unaudited), Heidelberg has exceeded its own forecast in terms of net sales and operating margin for the financial year 2020-21 just ended (1 April 2020 to 31 March 2021). Thanks to a strong final quarter, sales of around € 1.913 billion were slightly above the forecast range of € 1.85 billion to € 1.90 billion. Due to rising demand particularly in China, parts of Europe and, in the final quarter, also in the US, incoming orders rose to a high level of around € 2.0 billion by the end of the financial year. In the fourth quarter alone, the order intake improved significantly to €579 million, from € 462 million in the same quarter of the previous year. The order backlog thus increased to a level of € 636 million, providing a favorable basis for the new financial year. “With a strong final spurt, we have been able to continue our recovery in business volume since the Corona-induced low in the summer,” said Rainer Hundsdörfer, Heidelberg’s CEO. “The upturn in the regions makes us confident that we will be able to continue our upward trend in net sales and margin in the future.” As a result of the positive effects realized under the transformation program and the higher sales volume in the final quarter, the operating return exceeded the company’s own forecast. At € 146 million, EBITDA

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Rising demand particularly in China, parts of Europe and, in the final quarter, also in the US, incoming orders rose to a high level of around € 2.0 billion by the end of the financial year

excluding restructuring result in financial year 202021 was significantly higher than in the previous year (€102 million). The EBITDA margin of around 7.6% exceeded the company’s own forecast of around 7%, even though the expected income from the sale of land at the Wiesloch site will only be recognized in the new financial year. “The consistent and rapid implementation of our transformation program has stabilized Heidelberg during the pandemic and, with the tailwind of the market recovery setting in, provides the foundation for profitable growth,” said Marcus A Wassenberg, the company’s CFO.

As expected, the preliminary result after taxes in financial year 2020-21 has improved significantly year-on-year. Due to the favorable final quarter, the loss is expected to be somewhat lower than previously anticipated. Thanks in particular to the sharp reduction in net working capital and income from asset management in the reporting period, free cash flow for the financial year as a whole will be clearly positive and net financial debt will be kept at a low level. The company will publish its financial statements and annual report for financial year 2020-21 on 9 June 2021. z

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z Decorative corrugated packaging

BillerudKorsnäs launches new generation of coated liner

ith Pure DecorX, BillerudKorsnäs is introducing the latest development in White Top Kraftliner. The launch opens up great improvement potential for decorative corrugated packaging, in terms of strength, print appearance and sustainability. Pure DecorX is a 3-ply construction made of 100% primary wood fibres, which makes the liner strong, stiff and with high thickness. In practice, the company says that this means great lightweighting opportunities, high runnability in converting machines, reduced risk of washboarding, and enhanced packaging performance. According to BillerudKorsnäs, the use of only primary fibres also makes Pure DecorX a climate-smart choice: it is renewable, recyclable and biodegradable, and

the fibres can be traced back to responsibly managed forestry. Pure DecorX is coated for surface smoothness, yielding excellent print results in terms of lifelike image reproduction and colour fidelity. This makes the product very competitive in applications such as shelf-ready packaging, displays, and packaging of food and beverages and premium consumer goods. “Thanks to our knowledge, experience, and state-of-theart technology we have been able to secure the quality parameters needed for the highest pre- and post-print demands in one product,” says Rolf Gustafsson, director product management containerboard BillerudKorsnäs. “Customers can use just one coated quality for pre-print as well as for post-print – an extra benefit.”

The new liner is produced on KM7, the world’s most modern board machine. Product quality parameters are monitored in real time using advanced sensor technology, which ensures unique product consistency and at a capacity of 550,000 tonnes a year. z

z Debt-free purchase price EUR 27 million

Huhtamaki acquires leading folding carton manufacturer in China

uhtamaki, a key advanced manufacturer of sustainable packaging solutions for consumers around the world, has entered into an agreement to acquire the assets of Jiangsu Hihio-Art Packaging, a leading manufacturer of paper bags, wraps and folding carton packaging in China. The company currently serves international quick-service restaurants (QSR) as well as national bakery chains. With this acquisition, Huhtamaki continues to strengthen its position as the leading foodservice packaging provider in Asia and expands its product portfolio in China allowing it to better serve its existing and new customers in this exciting growth market.

Jiangsu Hihio-Art Packaging currently employs approximately 200 people in its manufacturing unit in Xuzhou city, Jiangsu. Employees will be offered an opportunity to continue to work for Huhtamaki after the transaction is closed. In 2020 the annual net sales of the privately owned business were approximately EUR 20 million. Following the acquisition, Huhtamaki will have altogether four manufacturing units in China: in Guangzhou, Shanghai, Tianjin, and Xuzhou. “I am excited with the opportunities that this acquisition represents for our core business in China. Urbanization, middle class expansion and innovation into more

sustainable packaging solutions drive growth across Asia. The acquisition of Jiangsu Hihio-Art Packaging extends our product portfolio and access to new channels. This enables us to accelerate growth in China in line with our strategy,” says Eric Le Lay, president for Huhtamaki’s Fiber Foodservice EAO business segment. The debt-free purchase price is EUR 27 million. The acquisition is expected to be completed by the end of the third quarter 2021, following the fulfillment of certain customary closing conditions, after which the business will be reported as part of the Foodservice Europe-Asia-Oceania reporting segment. z THE PACKMAN | May-JUN 2021

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Flexibles

z Food safety drives worldwide demand for packaging films

Brückner in 2020 – second most successful business year ever

rückner Maschinenbau, based in Siegsdorf, Germany, is the world market leader for large production lines for the manufacture of a wide variety of flexible plastic films, used as high-quality packaging materials and in technical applications. In terms of incoming orders, the past fiscal year was the second most successful in the company’s history. More than 45 lines sold by the end of 2020 (2019: more than 30) mean an order intake of almost 800 million euros, a significant increase compared to the previous year (approx. 500 million euros). As the new orders will only become relevant for sales in the following year, a significant increase in sales to over 550 million euros is expected for 2021 (2020: around 400 million). One reason for the very pleasing business development is certainly that topics such as hygiene and food safety have become much more important in the packaging sector worldwide – and particularly in Asia. In addition, food retailing and mail-order trade have recorded international growth. This also increased the demand for Brückner film stretching lines, on which the highest quality packaging films are produced, and also for the corresponding services. The outlook for the next few years also gives cause for optimism. Stefan Neumann, chief financial officer, says, “Our order backlog extends well into 2023. In addition, we are currently pleased about two major orders from China.” With the long-standing customer Jiangsu Hengli New Materials, the quality leader in the polyester film industry in China, multiple contracts with a term of five years were signed, with an order volume that significantly exceeds the average annual volume of Brückner Maschinenbau. The complete package comprises dozens of BOPET lines for packaging films, optical and industrial films as well as ultra-thin specialty films and special BOPET thick film lines. The framework agreement

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Brückner’s highly efficient film stretching line. Photo: Brückner

covers a total of 15 different line types, including a very special laboratory line. In addition, one of the leading manufacturers of battery separator films, Shenzhen Senior Technology Material Co., Ltd., has now ordered eight further special lines from Brückner. Here, Brückner was able to convince with the latest technology, which will also be used in battery production in Europe in the future. In any case, Brückner Maschinenbau is certain that, in addition to the booming packaging sector, technical films and their production lines are also on the rise. Future topics here include not only battery separator films but also films for medical and hightemperature applications, solar panels or organic and printed electronics. Fittingly the company from Siegsdorf recently received an award for its innovation management: Brückner Maschinenbau convinced

in a scientific selection process for the innovation competition ‘TOP 100’ and is now officially one of the 100 most innovative companies in the German medium-sized businesses. When it comes to plastics and the environment, Brückner is convinced that the future will continue to belong to plastics if they are used and reused sustainably. Helmut Huber, COO sales and project management, says, “As part of a circular economy, the undeniable advantages of plastic can be combined absolutely well with the sustainability goals of a modern society. We are working intensively to ensure that films can be produced on our machines with the lowest possible use of resources and the highest possible recyclability.” In doing so, Brückner also cooperates in various consortia with partners along the entire value chain, from raw material manufacturers to brand owners. Examples of this are the R-Cycle or PrintCYC initiatives.

Flexibles Plant commissioning and service even during pandemics To ensure that the lines sold are also installed and commissioned on schedule all over the world, Brückner coordinates all trips as part of a special Corona crisis management system. Huber says, “In close coordination with our company doctor and our teams in the respective countries, we make sure that all rules and precautionary measures are observed – before, during and after the trip. Employee safety always takes precedence

over short-term business success. Nevertheless, traveling in these times demands a lot from our employees – keyword quarantine. We are therefore more than grateful that the willingness of our colleagues to travel abroad remains high – this is extremely appreciated by our customers.” The service provider for film stretching technology, Brückner Servtec, also based in Siegsdorf, was even able to increase its order intake by an impressive 60% in orders for line upgrades. Overall, incoming orders are at a record level of around 70 million euros, again a significant increase on

the previous year (60 million euros). This naturally has a positive impact on sales in 2021, for which a record figure of around 71 million euros (2020: 53 million euros) is expected. A major global customer has also recently placed extensive modernization orders with Brückner Servtec, to significantly increase the sustainability of production. This involves a total of four production lines in the packaging film sector, spread over three continents. In addition, the plant modernization will ensure the processing of raw materials, enabling a circular economy. z

z ‘Appropriate Technology’ for business

Constantia India installs 5-layer blown film line from Rajoo Engineers

onstantia Creative Polypack, a part of Constantia Group, has recently installed a 5-layer POD blown film line from Rajoo Engineers at its Kolkata plant. The line had a dream commissioning at Constantia’s Kolkata plant when the total start-up wastage was a mere 700 kg; many times lower to what they normally witness; a significant achievement of the Rajoo’s Pentafoil – 5-layer co-extruded blown film extrusion system. The choice of Rajoo as a preferred brand to Constantia India, was the outcome of a total evaluation in terms of technical, commercial and service support and a survey covering all the suppliers. “A buyer needs to understand whether high-end specifications are essential or desirable, and its impact on the end product quality; consistency definitely is an important parameter that is always considered. Another crucial aspect that needs to be considered when it comes to deciding on a solution as this is the after-sales support, response to emergencies, costs of spares and services,” well explains Srikanta Khatua, head of operation ‘Creative Sub-Cluster’, Constantia Flexibles –India.

Khatua adds, “During the last years, we have also experienced Rajoo in context to its supply, service and support at the Puducherry plant. I must say, we were extremely satisfied.”

Time to identify the right technologies and its mix “The agenda of ‘excellence in extrusion’ globally stems from the unique concept embarked on by Rajoo as offering ‘Appropriate Technology’ for business. For us at Rajoo, gone is the era to build specifications for competitive advantages, it’s now time to identify just the right technologies and its mix, to add value to the client business. Over specifications only add on to customer costs and not his business,” says Khushboo Chandrakant Doshi, executive director, Rajoo Engineers. The supply to Constantia included a blown film line with 5 grooved feed barrier screw extruders, hydraulically actuated screen changers, cylindrical spiral die (CSD) for film width of 2,500 mm, rated output of 750 kg/hour. The unique ‘flatness enhancer’, a first for the Indian industry, improved the film flatness for converting processes. A dual

Rajoo’s 5-layer blown film line

station fully automatic load cell-controlled surface winder was also an integral part of this solution. In addition, the supply to Constantia India also included an elaborate automation package including material conveying system, material dosing system, automatic thickness profile control and more. z

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Flexibles

z Eco-friendly, fire-safe and low VOC

Yansefu strengthens its water-based product segments

rowing solvent prices, rising fire hazards at workplace, and increased VOC content in the conventional solvent-based inks, coatings and adhesives are the main reasons behind the shifting the dominance towards waterbased products in the flexible packaging market segment. As organic solvent contents are reduced to a minimum – it’s becoming better for workers health and overall solvent retention in the food packaging is getting reduced.

Water-based technology covers a broad variety of different application areas with specific ink series. Water-based systems are printed mainly in the flexo and gravure processes. Currently, Yansefu team has designed suitable water-based reverse ink series for polyester substrates as well as water-based surface inks for major absorbent substrates such as on metallized paper, chromo art paper and paper foils. Some substrates to be coated with its water-based primers before printing.

In addition, Yansefu’s inventive water-based adhesives for multitude of substrates as well as heat-seal lacquers are gaining market potential day by day. Another important product segment in the water-based domain is various type of effect coatings such as to get tailor made gloss and matt effects, soft touch, sand-touch kind of special properties. Furthermore, this is also suitable for offset printing segment. z

z Producing high barrier metallized film

Kalyar Replica invests in Bobst Vision K5

alyar Replica based in Bangladesh has purchased their first metallizer to bring their metallizing process in-house. The Vision K5 1650 mm will be up and running by April 2021 and is equipped with Bobst AluBond for the production of CPP and BOPP with high barrier and high adhesion levels, as well as Bobst Hawkeye. Established in 2008, Kalyar Replica is one of the leading flexible packaging companies in Bangladesh. With a highly experienced team and technologically advanced machinery, Kalyar provides its customers with products which are almost defect-free in a competitive time period.

Bobst AluBond on polyolefins The Bobst Vision K5 is equipped to handle a wide variety of different film types including heat sensitive

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barrier metallized CPP and BOPP mono-material laminates.

and thin gauge films and will be used for processing the very latest specifications of polyolefins.

The machine also includes Bobst Hawkeye which is an in-line optical density deposition control and defect monitoring system. At full metallizer speed, Hawkeye detects, counts and categorizes pinholes and other defects, alerting the operator so the issue can be rectified immediately resulting in less film waste.

Bobst AluBond is well known in the industry as a metallizing process for polyolefin-based substrates. Initially developed to increase metal adhesion on the most commonly used substrates, when applied to CPP and BOPP films, AluBond also provides enhancement of oxygen (OTR) and water vapour (WVTR) barrier performance. With the latest market demands in relation to sustainable packaging films, AluBond is also being used to produce high

Tasneem Sinha, managing director of Kalyar Replica, said, “When we decided to purchase our first metallizer, we needed a machine which could process a range of substrates. We chose Bobst and the Vision K5 as it is able to handle heat sensitive films and for the AluBond process which will enable us to produce CPP and BOPP films with both high barrier and high adhesion. The machine will be arriving very soon and we look forward to it being installed and running in the factory.” z

Bobst Vision K5

Flexibles

z Company’s third laminator from Comexi

Multisac Flexible Packaging invests in Comexi ML2 laminator

ultisac Flexible Packaging, a leading company in the Portugal’s flexible packaging sector, has invested in a Comexi ML2 laminator. Multisac’s relationship with Comexi dates back to 2008 when Multisac Flexible Packaging purchased a Comexi Compack 2 slitter. Presently, the company has six Comexi machines – one flexographic press, two laminators, and three slitters. The new Comexi ML2 will be the company’s third laminator and the seventh Comexi machine. Multisac Flexible Packaging which is dedicated to the production and selling of flexible packaging, primarily uses the following technologies – flexographic printing, digital printing, solventless and solvent-based laminating, and rewinding. In addition to operating in

the domestic market of Portugal, Multisac exports its products to Spain, France, and Portuguese-speaking African countries. The company is based in Vouzela, approximately 30 km from the city of Viseu. “We are very satisfied with our Multisac Flexible Packaging partnership. The sale of seven machines conveys that the trust between the two companies is extremely good, and we must continue working daily in order to maintain it,” says David Morera, regional sales director of Europe at Comexi. “Yearly, Multisac Flexible Packaging is growing. We are happy that Comexi can contribute to this growth with our machinery, as is the case of Multisac’s ML2 laminator purchase.” The Comexi ML2 offers complete versatility with

Comexi ML2 laminator

various types of flexible packaging applications. The machine allows applications such as heat seal, cold seal, matt and gloss varnish coatings, solvent and water-based laminating, solventless laminating, and many more possibilities, all in one laminator. With its ergonomic design, daily operations can be rapidly performed, thus maximizing production. z

z Water-based dual cure solution

Actega launches dual cure soft touch coating for laminate tubes

ctega, manufacturer of specialty coatings, inks, adhesives and sealing compounds for the print and packaging industry, has announced the launch of, Galacryl 89.501.14, the world’s first ‘soft touch’ effect decorative coating for laminate tubes. The new water-based dual cure solution solves the previous issues of long-term scratch, abrasion and stain resistance associated with soft touch effects on laminate tubes and provides manufacturers of laminate and extruded tubes with a brand-new revenue stream to diversify their business. The highly desirable soft touch effect coating has previously been used successfully on different flex-

ible packaging. However, attempts to create an effect coating that provided both the soft texture and optimal technical production properties for laminate tubes have previously been unsuccessful. Actega has overcome this challenge by combining an environmentally friendly, water-based dual cure varnish coating, achieving the long-term durability required of this effect on laminate tubes. André Soterio, head of sales, labels, EMEA, Actega, says, “Soft touch effects on packaging are very appealing to consumers as they add a feeling of prestige and quality - proven to increase product engagement and sales. Thanks to the expertise and talent within

the Actega R&D team, we’ve been able to bring these effects to laminate tubes for the first time, transforming the cold and clinical laminate substrate into a warm, comfortable and tactile consumer experience. Replicating rubber, leather or even velvet soft touch effects, this new capability represents a new and profitable service offering for customers.” Ideal for packaging containers used within cosmetics or pharmaceuticals, house-hold goods and the food industry, new Galacryl 89.501.14 features a water-based and milky matte finish varnish. Once applied, the coating is UV cured to protect and seal the container. z THE PACKMAN | May-JUN 2021

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Labels

z Transforming digital printing and packaging

Trigon installs Asia’s first HP Indigo 25K

aking a new leap in digital printing, Trigon Digital will be using the HP Indigo 25K to meet the growing flexible packaging demand. This is the first customer installation of the flagship HP Indigo 25K digital press across Asia. A leading print and packaging solutions provider with an ‘all-digital’ set-up, Trigon Digital has been addressing the needs of customers from across India, Middle East, Europe and South East Asia. The HP Indigo 25K digital press installation with a 30-inch printing width will allow Trigon Digital to venture into customized pouch, shrink sleeves, IML printing on a large scale. The HP Indigo 25K installation features an inline slitting option, which will enable Trigon Digital to print label media of up to 30-inch width and then slit it inline to smaller rolls for further finishing. In a world where customers demand highly personalized solutions, the HP Indigo 25K digital press offers the agility to meet rapidly evolving customer needs, across all types of packaging requirements. With the HP Indigo technology, Trigon Digital will be able to support brand owners with innovative solutions in packaging while supporting them throughout the product development process – from prototype to marketing test samples to production and shelf. Trigon is a long-standing partner of HP, having invested in the HP Indigo 6900 press in 2018. Speaking on the installation, Anil Namugade, managing director, Trigon Digital, said, “We have been servicing our customers with print and packaging solutions since 2007. With the industry evolving and growing exponentially, we required a solution to add value to our business and support the increasing demand of small and medium quantity packaging runs with NO MOQ. Today, the package is the messenger, the brand and storefront, all integrated into one. With our new HP Indigo 25K, we are ready to bring the power of the digital transformation to label and flexible packaging.

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Anil Namugade, managing director of Trigon Digital

Furthermore, we are on a mission to transform our business, achieving the most exceptional standard of print quality, sustainability, and quick service experience to our customers, and the installation of the HP Indigo 25K is an important step in that journey.” A Appadurai, country manager, HP Indigo, HP India said, “India is fast becoming a hub for startups and small brands, especially in food and beverage sector. It is crucial for brands and businesses to have high-quality packaging for their products to be placed on shelf for visibility. A high-quality printed package

increases the brand value and gains trust from the consumers. Due to the nature of digital printing there is no MOQ concept with HP Indigo. Also plates or cylinders are not required to be made, so along with HP Indigo, Trigon can support such brands to launch their product in the market faster, digitally printed pouches can be turned around in as low as 5-7 days from the approval of artwork to physical pouches. With the first HP Indigo 25K installation in the region, Trigon Digital will be able to help its customers to get to market faster with their innovative services and products.” z

Labels

z Digital label press

Pinnacle Traxim installs Konica Minolta AL230

onepat-based Pinnacle Traxim recently installed a Konica Minolta Accurio Label 230 digital label press. Started in in 2008, Pinnacle supplies labels, stickers, packaging and promotional material to various businesses such as liquor, cosmetics, and pharma, among others.

Surender Kumar, director, Pinnacle Traxim with the newly installed KM AL230 digital label press

Surender Kumar, director, Pinnacle Traxim, said, “While researching about the best digital label equipment for the past two years, we realized that Konica Minolta is one of the market leaders in this category and has launched its debut machine. Back then, it had already witnessed a good number of installations as compared to other players. And most importantly, it was the affordability factor that helped us finalize this decision.” “The Konica Minolta Accurio Label 230 is a very user friendly and cost-effective digital label press. Besides, it provides job flexibility, enhanced productivity, and unmatched image quality. We have been witnessing

a positive growth trajectory over the years, especially after the installation of Accurio Label 230. Even the bigger brands have started opting for digital label printing for their short-run jobs.”

Pinnacle’s existing setup is equipped with Nilpeter 330 installed in 2008 and Bobst M1 installed in 2016 along with two Rotoflex slitter rewinders and other finishing equipment. z

z Endures harsh environments during packing and transport

Michelman partners with HP Indigo for high-performance digital labels

ichelman has expanded its suite of high-performance label solutions, used with UV overprint varnishes (OPVs), permitting HP Indigo digitally-printed labels to endure harsh environments, including extreme heat, chemicals, water, or friction during packing and trans-

port. These solutions allow press owners to increase their addressable market size and produce more with their HP Indigo digital label presses in applications such as packaging for personal care and cosmetics, household cleaners, automotive oils and fluids, wine and beer bottles, and industrial and electronic equipment.

According to a statement by Michelman, label printers can better serve high-performance label markets with digital print technology designed to enhance the mechanical, water, chemical, and thermal durability of digitally printed labels on HP Indigo label presses. THE PACKMAN | May-JUN 2021

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Labels Lisa DiGate, Michelman’s global business vice president, HP Indigo, explains, “Michelman has partnered with HP Indigo for nearly 20 years to bring innovation that offers press owners digital print versatility to enter new markets. We are excited to introduce new solutions that protect HP Indigo printed labels, address more demanding label applications, and open up new market opportunities throughout the label industry; for our customers and partners.” According to Michelman, its new suite of DigiGuard Plus UV OPV strengtheners is economical and easy to use compared to lamination or other complex solutions. The entire portfolio, designed to improve UV OPVs’ performance combined with Michelman’s DigiPrime priming solutions, allows press owners improved ease-of-use by using off-the-shelf varnish with the strengtheners added. They can use their current UV curable OPVs without investing in additional products or finishing equipment. Furthermore, their performance has been tested via the Sutherland Rub and other ASTM, Finat, bottle-to-bottle, and submersion tests. All have

achieved digital print industry resistance standards for label durability. DigiGuard Plus 902 provides water, thermal and chemical resistance for high-performance labels and is an economical substitute for DigiGuard UV OPV 901. DigiGuard Plus 920 provides mechanical and rub resistance for high-performance labels. DigiGuard Plus 921 provides water and chemical resistance for high-performance labels. DigiGuard Plus 920 and DigiGuard Plus 921 can be used in combination to provide mechanical, water, and chemical resistance. Eli Mahal, head of L&P products and solutions at HP Indigo, says, “This new technology allows press owners to extend their application range by meeting the industry’s durability and resistance standards for high-performance labels.” HP Indigo print service providers can learn more about these new products at the upcoming Dscoop Edge Fusion hybrid event 17-20 May. Michelman has scheduled an education session on 19 May featuring

Digitally-printed labels using DigiGuard Plus UV OPV from Michelman

high-performance durable labels as part of the event’s main agenda and will have additional information as part of their solutions showcase. z

z Annual capacity of 3,600 MT with close to 50 employees

Siegwerk inaugurates new ink blending center in Bangladesh

iegwerk, one of the leading global suppliers of printing inks for packaging applications and labels, inaugurated its new blending center in the Dhaka region in Bangladesh. Spread over 65,000 sq ft, the center will host customized solutions for the Bangladesh market. The state-of-theart blending center will generate direct and indirect employment for close to 50 people in Bangladesh. Ashish Pradhan, president Asia, Siegwerk, said, “In the next couple of years, we expect the plant to reach 80% capacity utilization opening avenues for more employment. We are very clear that we will only employ local talents. Also, over the next few years, we may look at the possibility of hiring a managing director from Bangladesh.” Siegwerk, through the new center, aims to significantly

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reduce inventory costs to customers and allow Siegwerk to provide immediate technical support for local customers.

Siegwerk’s new blending center in Bangladesh

boost its domestic business in Bangladesh while enhancing its market leadership position across the Asian region. The new blending center will also

Siegwerk is supplying printing ink in Bangladesh since the mid-nineties. “The blending center will not only allow us to be closer to our customers in the Bangladesh region but will also allow us to expand our offerings. We can now offer customized, individually formulated safe ink solutions through our latest blending technology,” said Pradhan. “Siegwerk used to supply inks from its plant in India until recently. The new center is already commissioned and has completely taken over the supply of blended inks from February 2021. This facility will help us solve technical issues locally and provide additional technical support with less turnaround time. Our customers now have

Labels the advantage of receiving a faster response to their technical issues and selecting custom-made solutions that match their printing requirements. The blending center will supply toluene-free safe inks and is at par with global standards,” added Pradhan. The blending center manufactures and supplies toluene-free inks, to ensure health and safety to consumers of packaged food. Toluene or any raw materials containing toluene won’t be used as intentionally added ingredients in this facility. The inks produced will be compliant with global regulatory and brand owner requirements to ensure products are safe for end-use packaging applications. Siegwerk has a robust global production and service network and has

offered customers consistently high-quality products for close to two centuries. As a supplier of high-quality printing inks and varnishes with a strong emphasis on customer service, Siegwerk has built long-term customer relationships with a high degree of trust and interaction. The company is also conscious about sourcing environment-friendly and sustainable raw materials for its products. Siegwerk manufactures its basic colors and varnishes in a standardized process at the fifteen dedicated Siegwerk – Centers of Excellence worldwide. The raw materials and intermediate products are as close to identical as possible, ensuring consistent product quality. With the addition of the center in Bangladesh, Siegwerk currently has more than 31 blending centers worldwide. z

Siegwerk’s new blending center in Bangladesh

z Servo driven sheeter

Vinsak installs ABG RTS sheeter at JK Fine Prints

insak, the distributor of ABG International in India, has installed a new ABG RTS sheeter at Mumbai-based JK Fine Prints. The company, a family-run business, is a specialist in self-adhesive label printing and is an accredited label supplier to leading companies in India and overseas. The RTS is a servo driven sheeter with a guillotine style cutting action and is available in three web widths – 330 mm (13 inches), 430 mm (17 inches) and 530 mm (21 inches) – and can cut to mark, to length or to interlabel gap with an accuracy of +/-0.15mm. The standard machine is equipped with an electromagnetically braked unwind c/w 76 mm (3 inches) air expanding unwind mandrel, splice table with interlocked web clamps, and servo driven infeed nip roller, guillotine cutting mechanism and a 1000mm (39 inches) long shingle delivery table which has an accelerator/jog function for batch separation. The machine is controlled via a 152mm (6 inches) color TFT touch screen HMI with multilingual operating instructions. Optional equipment includes alternative unwind man-

Himanshu Kapur of JK Fine Prints with the new ABG RTS sheeter

drel diameters, razor and slitting units c/w 5 sets of knives, Venturi trim extraction and a fully programmable inter-sheet waste trim function. Himanshu Kapur, director of JK Fine Prints, had evaluated other equipment but selected the ABG RTS sheeter

for its accuracy in the sheeting process especially of difficult to handle filmic materials. ABG has long business relations with JK Fine with multiple installs of the label finishing equipment over the last 20 years. The company claims to be environmentally conscious and has applied practices for recycling waste. z THE PACKMAN | May-JUN 2021

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Labels

z “A spaceship has landed in Palermo”

AM Etichette installs Nilpeter FA-17

talian converter AM Etichette has installed a new Nilpeter FA-17. The self-adhesive and shrink sleeves label converter aims at faster job changeovers with the new press. “A spaceship has landed in Palermo,” says Marco Mussumarra, of AM Etichette, “Yes, the new FA-17 is installed with great pride in our company, confirming the professionalism and friendship that connects us with Nilpeter, ever since the installation of our first press, the workhorse Nilpeter FB-3300.” A family-owned business based in Palermo, Sicily, AM Etichette was founded in 2000 and specializes in the production of self-adhesive labels and shrink sleeves. The company claims to have always chosen the best and most innovative presses in the market to provide quality products.

“For that reason, and for more than 20 years now, we have chosen only Nilpeter. Their presses are always on the forefront of the industry, reliable over time, never losing printing quality. We see that in our new FA-17 too, a combination of technology and speed. It really is the press of the modern operator,” concludes Mussumarra. According to Nilpeter, the Nilpeter FA-Line provides a maximum level of stability, the tightest register tolerance, and excellent printing results on multiple substrates – all normal self-adhesive materials, including flexible packaging films, polymer films, metallic films, and paper. The press is built around the modern print operator, with an intuitive user interface and fully mobile print controls.

AM Etichette was founded in 2000

The FA features Nilpeter’s lightweight, easy-load sleeves for reduced setup times, easy handling, increased production speeds, higher printing quality, and impressive durability, not to mention a lower cost per label. z

z 100% print inspection system

Pragati adds Baldwin Guardian PQV

ndore-based Pragati Graphics and Packaging has taken another large step forward in ensuring perfect print quality to its customers and brand owners. After positive results with Baldwin Vision Systems’ Guardian OLP offline proofing and inspection, Pragati increased its print quality capabilities by adding the inline Guardian PQV 100% print inspection. Guardian PQV, which can inspect all types of materials and substrates, enables printers to eliminate every defect with a more efficient, accurate, data-connected workflow. The system provides unique ‘Object-Based Inspection’ throughout the entire printing process – ensuring tighter tolerances and fewer false defects. Areas of interest on the printed substrate can be defined for enhanced or reduced levels of inspection. Operators can easily spot errors and make adjustments in real time, as well as manage defects throughout the entire process. Defect positions and images are recorded and can be accessed at multiple post-press processes.

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“Besides helping our operators find and remove even small defects quickly, the Guardian PQV system is also very powerful in helping monitor our processes to prevent defects from occurring in the first place,” says Rajesh Nema, Pragati’s executive director.

Rajesh Nema, Pragati’s executive director, with the inline Guardian PQV. Photo: BVS

Nema continues, “We have been very happy with the increased productivity achieved after installing the OLP offline inspection system. After speaking about the performance of the inline Guardian PQV system with Shreedhar Labels, we saw the potential to improve our print quality and our productivity even more. We are now very pleased to see the benefits and efficiencies of connected communication between the two systems – offline and inline. We are the first company in India to use the two technologies in this way.” Ahmedabad-based Shreedhar Labels achieved a ‘zero rejection’ level of print quality, after installing India’s first Guardian PQV inline technology in February 2021. z

Metal Packaging

z An interview with Amit Lahoti of Ball Beverage India

“India has tremendous potential to achieve sustainability goals by shifting to aluminum cans” – Amit Lahoti Ball Beverage Packaging India is a part of Ball Corporation, USA. Ball’s beverage packaging has made significant investments in the country by setting up two state-of-the-art beverage packaging manufacturing plants. Ball Corporation and its subsidiaries employ 21,500 people worldwide and reported net sales of US$ 11.8 billion, in 2020. We recently spoke with Amit Lahoti, vice president and general manager, Ball Beverage Packaging, India and South-East Asia Region to take a glance at India’s metal packaging market and Ball’s journey in India so far. Here is an excerpt from the interview.

Mahan Hazarika: Please tell us in brief about Ball India.

Governments are taking several steps to reduce the usage of single-use plastics.

Amit Lahoti: Ball Beverage Packaging India is a part of Ball Corporation, USA. Ball Corporation and its subsidiaries employ 21,500 people worldwide and reported net sales of US$ 11.8 billion, in 2020.

Aluminum stands out among the packaging substrates from a sustainability point of view as it can be recycled infinitely, easy to transport, and stock. While aluminum cans are trendy, they significantly increase energy efficiency as they chill faster and stay cool for a longer duration. Cans made from aluminum are also tamper-proof and safeguard manufacturers, retailers, and consumers from loss due to breakage. Ball aluminum allows brands to innovate with 360-degree printing capability, including a variety of innovative printing capabilities like matt, HD printing, glow in the dark, and thermochromic ink.

Headquartered in Bengaluru, Ball India manufactures innovative and infinitely recyclable aluminum beverage cans. Our plants are capable to produce 185 ml, 250 ml, 330 ml, 355 ml and 500 ml cans. The customers are all key brands in the Indian beverage market in various categories like carbonated soft drinks, juices, dairy, energy drinks, and alcoholic drinks like beer, wine, flavored alcoholic beverages, and hard spirits. Exports are also made to South Asia, ASEAN, Africa, and the US markets. Ball Beverage Packaging has made significant investments in the country by setting up two state-of-the-art beverage packaging manufacturing plants – the Taloja plant on the outskirts of Mumbai, which was set up in 2006, and the beverage can manufacturing plant in Sri City, Andhra Pradesh that was set up in 2016. Ball additionally has an aerosol can plant in Sanand, Gujarat.

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Amit Lahoti, vice president and general manager, Ball Beverage Packaging, India and South-East Asia Region

Mahan Hazarika: Why should India look at aluminum as an innovative packaging solution? Amit Lahoti: Packaging plays a major role in the beverage sector. The world is witnessing an increase in consumer demand for circular packaging solutions where the brands are judged based on their sustainability credentials. Both the Central and State

Mahan Hazarika: What is the potential of metal packaging in India? Amit Lahoti: The metal packaging market in India is expected to register a CAGR of 6.52% over the forecast period from 2021 to 2026. This is backed by the Government’s push to eliminate single-use plastic aligned with the consumers’ preference for sustainably packed products. India’s consumption rates are rising steadily with the growing middle-income group population, changing lifestyles, and evolving consumer preferences. Conscious consumers are now looking at products that will help them preserve the

Metal Packaging Amit Lahoti: Aluminum beverage cans are the perfect example of a circular packaging solution as aluminum can be recycled infinitely without any loss of quality. A great proof of this is the fact that around 75% of all aluminum ever produced in the world is still in use today. Another interesting data point shows that used beverage can be recycled and returned to the shelf within 60 days. This ‘design for circularity’ combined with high end-of-life economic value makes recycling of cans viable and should be the goal to move from a linear ‘take-make-waste’ society to a fully circular economy.

environment. There is increased awareness around how plastic packaging is adversely affecting marine life, polluting the rivers and ocean, and ending up as non-degradable heaps of waste at landfills. The current penetration of aluminum cans in India is as low as 1 beverage can per head per annum compared to 70 cans in Vietnam, 40 cans in China, and 140 cans in Brazil. This data itself shows India’s tremendous potential to achieve its sustainability goals by shifting to aluminum cans for beverage packaging. Mahan Hazarika: What makes aluminum a better packaging material than other available materials?

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Aluminum beverage cans supplied by Ball are a naturally sustainable and eco-friendly choice as aluminum is an infinitely recycled, permanent material that reduces energy consumption and CO2 emissions. Recycling reduces the energy needed for primary metal production by nearly 95% and significantly lowers greenhouse gas emissions. Additionally, aluminum packaging is tamper-proof and assures zero breakage, thereby giving manufacturers and consumers the full value for their money while creating a greener and cleaner world. Mahan Hazarika: Please tell us about your latest developments directed towards sustainability. Amit Lahoti: We are taking various steps towards further strengthening the sustainability credentials of aluminum cans: ASI certification – We are working towards certifying the plants in India with the Aluminum Stewardship Initiative (ASI). The ASI performance has been developed, designed, and applied globally across the value

chain to boost the aluminum industry’s responsibility and provide performance assurance independently and credibly. Increase in recycled content – Aluminum beverage cans manufactured by Ball India have about 70% recycled content aluminum can sheet, and we are regularly working with our suppliers to increase this number. We have additionally partnered with Recykal, a waste management agency to collect used beverage cans (UBCs) across Bengaluru. The objective is to collect all UBCs from housing colonies, business parks, hotels, and restaurants, and have them recycled. Renewable energy – Ball India is actively evaluating of moving all its manufacturing facilities to renewable energy to further reduce its carbon footprint. Light weighting and down gauging – The specification of the aluminum beverage cans produced by Ball India is one of the lightest available in the world. Mahan Hazarika: What are some of the significant trends you have noticed in metal packaging? Amit Lahoti: Looking at the sustainability and operational efficiency it offers, we see an increasing number of beverage companies using aluminum cans for packing and serving their products. These cans are rapidly becoming a sustainable style statement in the country. New beverage categories are now adopting aluminum beverage cans as their package of choice, including spring water, wine, and hard spirits. z

Metal Packaging

z No respite for the metal packaging industry

MCMA asks govt to hold off steel quality control order

he 10,000-crore metal packaging industry of India which has already been in a tight spot as they have hardly any option left to secure raw material as most of the global players and suppliers of tinplate/tin free steel have preferred to keep out India from supplying raw material in the wake of imposition of BIS standards effective 17 April 2021. Also, the rising cases of COVID 19 and possibilities of lockdown and short working hours due to curfew have further pushed the industry in the dark. In addition, the forceful implementation of BIS standard on import of tin plate is a stumbling block for the metal packaging industry which may lead to complete shutdown of the Industry. Despite repetitive representation and meeting with concerned ministry and department, there seems to be no relief for the industry which is largely operating under MSME sector. Net impact would be exorbitant increase of prices of packaging material specially pharma, food and beverages. Another setback would be shutting down of small units and ultimately job losses. This industry which is largely dependent upon the import of tinplate/tin-free steel from various countries is under tremendous pressure with the shortage of raw material and the prices have escalated more than 35% already with an indication that it is likely to increase further. Apart from prices other major issue of concern is availability of material as domestic is not geared up to meet domestic demand. As per the report of Industry body PHDCCI, steel and steel products QCO will restrict the supply of input materials to crucial industries such as the tin can making industry, metal packaging industry and processed food industry which is not in the wider interest of the nation considering the food loss is already up to 30% in the country. Therefore any move to ban imports of such

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material will result in production shortage, significant loss of job opportunities especially in MSME sector as well as lead to increase in defaults to banks. India’s primary organization that represents the interests of companies involved in the production of metal containers, packaging and allied components Metal Container Manufacturers’ Association (MCMA) – has urged the government to put on hold the implementation of Steel and Steel Products Quality Control Order dated 17 July 2020. The association has requested the Ministry of Steel to postpone the implementation of the QCO till sufficient quantity of tinplate/ tin free steel is produced locally to meet the industries’ demand of 700000 tonnes per annum as the industry is already under the pressure due to the second wave of the pandemic with lockdown being implemented in few states will only worsen the situation. The Association has also requested the ministry of steel to allow use of equivalent ISO certified materials in addition to BIS certified material. MCMA requested from the Ministry to allow the use of materials which are aligned to ISO. The same has been included in FSSAI order and also recommended by the Ministry of Micro, Small & Medium Enterprises (MSME). Following representations by the MCMA, the government had postponed it till 17 April 2021 but the industry has sought time till March 2022 so that issues affecting survival of metal packaging industry can be discussed again with the government in order to resolve the issue. Due to the unprecedented situation imposed by the spread of pandemic COVID-19 with ban on international travel as well as fear in the minds of people, the foreign tinplate mills are unlikely to get the relevant BIS licenses. Furthermore, the cost for getting such licenses and the fees payable to BIS would potentially be included in the selling price being charged from

the businesses, thereby, raising their landed prices and requirement of more funds at a time when trade and industry is already struggling to reset their wheels and is facing liquidity constraints. Similar kinds of Quality Control orders had been issued earlier also in the year 2008, 2015 and 2017 but keeping in mind the demand supply gap, practical difficulties in implementation and requirement of the MSME sector particularly in the metal packaging the Government withdrew the draft quality control order on tinplate/ tin free steel. The situation has not changed since then. There is still a demand supply gap of 250,000 tonnes per annum and the industry mainly continues to be in the MSME sector. Therefore, MCMA once again suggested that the QCO dated 17 July 2020 on tinplate/tin free steel and the products should be withdrawn completely. z

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Ashutosh Manohar Managing Director South Asia Markets, Tetra Pak India

Sudhanshu Vats Managing Director and CEO Essel Propack Limited

Gajanan Khot Director Aqua Chill Systems India Pvt Ltd

Saket Kanoria Managing Director TCPL Packaging Ltd

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Mahendra Patel Chairman Mamata Machinery Pvt.Ltd.

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Automation

z Smart manufacturing

The perfect packaging future with advanced automation Pooja Patil

he Indian packaging industry is always a step ahead in adapting to market requirements. These changes are being influenced by many factors like digital transformation, new regulations in the packaging process, non-availability of skilled laborers, etc. The industry has learned to transfer these challenges into opportunities. Indian machine manufacturers are increasingly relying on advanced technology solutions such as smart edge computing, digital remote access, human-robot collaboration, intelligent transport systems which are influencing the packaging industry and are expected to shape its future. Market demands and keeping pace with competition are the key factors for bringing about any change in conventional manufacturing practices. In addition, an organization primarily looks at engaging in long-term partnerships not only with their customers but also with their vendors. Technology is changing rapidly and strong partnerships act as a foundation for long-term continued success. The use of advanced automation improves productivity, quality, and safety. Technology has become a crucial investment for packaging facilities. Advanced automation and digital technologies are driving the need for innovations and fueling the need for smart manufacturing. Automation and robotic technologies are not only helping the industry to respond to rising customer demands but also are enhancing the position of the Indian packaging industry on the global map. However Indian machine builders ask a common question, “Where do we start from?” Here are some key considerations while choosing the right automation partner for packaging applications.

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Embracing advanced automation The concept of using automated systems is not new for the packaging industry. The industry is already reaping the benefits of automation in terms of flexibility, higher production, regulatory compliance,

reduced cost, eliminate human error and make up for labor shortages. Digitalization is further fueling a move towards enhancing system availability with 24 x 7 monitoring, optimized facilities, and secure data capture for optimized decisions and analytics. Advanced automation concepts address all these requirements creating opportunities for eliminating

Automation errors, resulting in quick decision making, reducing losses, and becoming more efficient and profitable.

Inspection with automation

Connected facilities are expected to generate and process enormous volumes of data further boosting performance. Machine-to-machine and machine-to-IT connectivity are essential elements of a connected facility and achieving smart operations. Connectivity is the lifeblood of advanced manufacturing, with open source, vendor-independent communication being a way forward for satisfying these needs without placing any dependencies on any automation vendors. Also, factories would have the necessary data from individual machines enabling them to calculate overall equipment effectiveness, monitoring energy consumption and line condition for improving availability and productivity.

Vision inspection plays an increasingly important role in the packaging industry with the rise of regulations and standards. Any discrepancy in product packaging be it a defect or incorrect labeling if it goes unnoticed, can damage any product’s image. Inspecting every process during manufacturing helps in the earlier detection of errors and rejections. Until today, inspection systems were conventional and independent of the installed automation systems. Also, installing inspection systems was high on investments with machine builders needing to have an independent automation system and an independent PC-based vision system. These systems were required to communicate with each other over a bus or I/Os for exchanging variables and data. Usually, such system architectures were not only expensive but also relatively very slow.

Reducing unplanned downtime To gain benefits of modern manufacturing, facilities should always be up and running, because even a minute of unplanned downtime results in losses, incurs an extra cost, and reduces product quality. So far, most companies have taken reactive or preventive approaches towards maintenance. However, these strategies fail to provide a real solution for the maintenance dilemma. Eliminating unplanned downtime to avoid risking product quality is not an option but a must-have in the packaging industry. With intelligent sensors, condition-based predictive maintenance helps facilities to extend maintenance intervals and schedule required work for when it is most convenient or required. By utilizing information about the condition of production equipment, condition-based maintenance solutions help to optimize the scheduling of maintenance work, which results in achieving maximum production quality and minimized maintenance cost. Over the past decade, during breakdowns, facilities have relied on manual machine and plant floor monitoring which is labor-intensive and time-consuming. Collected data is shared with service technicians for analysis and problem resolution. This takes more time and is prone to human errors. Today with advanced automation, remote monitoring and data logging have evolved significantly. With connected facilities, service engineers can monitor and analyze the real-time status of each machine. Remote maintenance solution makes machines and systems securely accessible to service technicians from anywhere across the globe. This solution makes it easy to respond to unforeseen problems as well as accelerates commissioning.

B&R has successfully brought the worlds of vision and automation together. Unlike conventional vision sensors, B&R’s smart solution is not restricted to a single function. How the sensor will be used – whether as a code reader or measurement device – is a question to be answered later in the application, not at the time of purchase. In addition, streamlining logistics brings welcome agility to meet changing requirements. Depending on the complexity of the tasks involved, it is even possible to create industry-specific solutions. A smart camera offers the same flexibility, which can process a sensor’s entire image processing functions sequentially. If the functional requirements of the sensor change, the system makes it easy to upgrade the platform without adding unnecessary new development work.

Human-track collaboration B&R has developed its mechatronic systems specifically for 24/7 industrial operation. They are designed for high availability under demanding conditions. The innovative mechatronic systems, ACOPOStrak, SuperTrak, and ACOPOS 6D, transport workpieces through a machine individually and without being bound to rigid timing. The result is unprecedented productivity. B&R’s human-track collaboration opens up new dimensions in safe productivity at collaborative workstations. Intelligent safety technology keeps these workstations reliably risk-free without the need for safety barriers. B&R’s mechatronic systems can be fully integrated into any machine. This not only reduces the overall

footprint of the line but also improves processing precision. Overall, manufacturing processes can be accelerated by up to 50% with mechatronic systems from B&R delivering a substantial boost in productivity.

Ensuring data integrity The advantages of connected machines and facilities are immense, however, are accompanied by heightened susceptibility to data sabotage and tampering. Data security and integrity are critically important aspects of the packaging industry. Open source, vendor-independent OPC UA meets all these requirements. OPC Unified Architecture (OPC UA), a vendor-independent communication protocol for industrial automation applications being based on the client-server principle and allows seamless machineto-machine and machine-to-IT communication. The protocol is platform-independent and features built-in security mechanisms. Since OPC UA is flexible and completely independent, it is regarded as the ideal communication protocol for the implementation of Industry 4.0 concepts. OPC UA bridges the gap between the IP-based world of IT and the production floor.

Advancing in the future Whether the machine or process is large or small, there are options to automate. From adding sensors that provide information to machine operators, to adding robotic processes to existing machinery, automation cannot be overlooked in packaging. Automation concepts have a huge potential to change the day-to-day activities in any pharma facility. The only concern is how quickly these technologies become a reality. B&R Industrial Automation partners with various pharma machine builders and facilities to cost-effectively implement these technologies and remain competitive. B&R offers complete hardware and software solutions, comprehensive service, and expertise in automation and digitalization of machinery and facilities. Cutting-edge technology together with open source communication standards such as OPC UA, Ethernet POWERLINK, and openSAFETY as well as the powerful Automation Studio software development environment, B&R serves as a perfect partner to the packaging industry, helping them expand their footprint across the globe. z

Pooja Patil is responsible for corporate communications at B&R Industrial Automation THE PACKMAN | May-JUN 2021

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Food Packaging

z Processing capacity of 15,000 liters of milk per hour

GEA to supply one of the largest standalone UHT milk plants in India

EA India has won an order to supply a complete ultra-high temperature (UHT) production line for Creamy Food in Uttar Pradesh. Best known for its brand ‘Madhusudan’, Creamy Foods is one of the leading dairy players in the country – the new plant is one of the largest of its kind in India. It opens a new market for UHT technology for GEA in the region. Creamy Foods manufactures a wide range of dairy products at its processing unit in Khurja, Uttar Pradesh including plain milk, ghee, paneer, curd, cooking cream, buttermilk and milk powder. GEA maintains a strong relationship with the company, having supplied a wide range of state-of-the-art dairy processing equipment in the past. GEA’s experience with similar standalone UHT plants across Asia Pacific was a key factor in Creamy Foods’ decision to choose GEA in a highly competitive market. The scope of work includes supply of a complete UHT line with a proprietary direct steam infusion technology. The line will have a milk processing capacity of 15,000 liters of milk per hour making it one of the largest standalone UHT milk processing plants in the Indian dairy sector. The complete system, which consists of an indirect UHT combined with a direct infusion high heating module, will be designed and supplied by the GEA Aseptic Competence Center in Ahaus, Germany. The aseptic tank, one of the most critical pieces of equipment, will be delivered from the company’s state-of-the-art manufacturing facility in Vadodara, Gujarat.

Creamy Foods facility in Khurja, Uttar Pradesh. Photo: Creamy Foods

ing through special tubular heat exchangers, designed by GEA for a high heat recovery of about 88% over the entire production run, allows cost savings and an environmentally friendly solution for today’s ecological needs. It provides a highly effective ratio of volume to heat exchange area to guarantee optimized product quality and high heat recovery with low steam and cooling water consumption. “We appreciate the innovative and sustainable technologies from GEA and are very satisfied with the

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performance of dairy processing equipment supplied in the past. For this reason, we are convinced that we have chosen the right partner for our new plant,” said Amit Agarwal, managing director, Creamy Foods.

Partnering for more sustainability “We are really happy to partner with Creamy Foods once again with our most innovative solution for UHT technology. The dual mode operation makes it a perfect fit for the customer to differentiate their product along with taking care of consumer’ taste preferences. It has the lowest utility consumption, making it more economical and sustainable in the long run,” said Suket Gohil, country managing director, GEA India. The contract was signed in February 2020 and the plant is under delivery now.

Growing popularity

Environmental efficiency This plant is characterized by its hybrid type. While it can process high quality products with the gentle direct infusion technology, it can also switch to the highly efficient indirect mode for processing of standardized quality products. In addition, indirect heating and cool-

UHT plant from GEA for aseptic product treatment. Photo: GEA

Madhusudan, the best known brand of Creamy Foods. Photo: Creamy Foods

Around 34% of liquid milk consumption worldwide is UHT with Asia Pacific being one of the top three regions and one where consumption is increasing. Once packed, the product has a shelf life of up to nine months at ambient temperature, making it as practical as it is nutritious, especially where cold chain distribution is difficult to maintain. z

8th Edition

2021 5 - 6 August 2021 New Delhi

Network, learn, rebuild & expand the business of F&B packaging Industry. Download brochure

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For more information on Partnership or Registration contact:

Shantanu Baraskar +91 98673 10585

shantanu.baraskar@informa.com The conference will be held as per govt directives and SOPs along with Informa AllSecure a Global initiative by Informa to ensure sophisticated safety measures for all its stakeholders.

Food Packaging

z An interview with Rushikesh Aravkar of Mintel

Mintel’s report on food packaging trends and sustainability According to a report by Mintel, 7 in 10 Indians say snack food packaging has to be resealable, and many link the ability to reseal with freshness. Resealability is even more relevant in the post-pandemic era as it allows consumers to buy larger packs to stock at home while retaining freshness for longer between shopping occasions. 43% of consumers said, going forward while choosing food it is important to have proof that the product is produced in a safe and hygienic environment. Reusability of packaging appeals to almost half of women aged 18-34. We talked with Rushikesh Aravkar, associate director, food and drink consumer reports South APAC, Mintel, to get further insights on the findings of the report.

Dev Kumar Dutta: What are the significant trends in the report that you think will define the years ahead and how? Rushikesh Aravkar: The three important consumer trends in food packaging that brands need to take heed of include: 1 Conscious consumerism warrants the responsible use of plastics. To tackle this, brands can evaluate their packaging portfolio to ensure that plastic is used responsibly. This may require the removal of longstanding packaging elements such as trays, overcaps, or a simple redesign to enable lighter weight. 2 Develop an early-mover advantage by staying ahead of the recycling curve. This is an opportune time for brands to contribute to a packaging circular economy by investing in innovations that make plastic packaging as simple to recycle as possible and enable recycling infrastructure so that what’s discarded is fed back into the recycling stream.

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3 Keep an eye on India’s zero-waste movement. Brands can tap into this trend with shelf-ready solutions that offer simple, branded dispensing in-store. Brands can engage consumers with premium collectible reusable containers. Such a feature would appeal to the 47% of women aged 18-34 for whom reusability of packaging is an important attribute. Dev Kumar Dutta: What are the immediate changes that food brands need to bring to their packaging to appeal to the masses? Rushikesh Aravkar: Even though plastics remain the most versatile, functional and cost-efficient package materials, they suffer from an image problem. But half of Indians associate plastics with pollution; this association is even stronger among eco-conscious Indians. Mintel Global New Products Database (GNPD) highlights that 82% of food launches in India in the last five years have used plastics as a primary packaging

Rushikesh Aravkar of Mintel

Food Packaging material reflects how it’s largely not viable for food packaging to eliminate plastics entirely. Brands need to make responsible use of plastics in their packaging. At the same time, it’s important to inform and involve consumers in the sustainability journey. Hence it is important for companies and brands to: 1 Underscore the fact that plastics are inherently beneficial, the issue lies with waste management 2 Drive efforts to collect, segregate and recycle discarded plastic packaging 3 Improve product-to-package ratio; make packaging that is easier to recycle. Brands can focus on optimizing over-engineered packaging and minimizing material usage at the design stage. 4 Engage consumers via on-pack messaging and marketing communications. 5 Finally, brands can strive to help close the recycling loop by promoting mono-material plastics’ recyclability and educating consumers on how to dispose of them; Encouraging and enabling consumer participation with incentivised plastic take-back initiatives and use recycled plastic content to drive a circular economy. Dev Kumar Dutta: What are the packaging design and changes that brands can adapt to increase their appeal to consumers? Rushikesh Aravkar: According to 2019 Mintel Global Packaging Trend ‘Connected Packaging’ multiple technologies are enabling brands to connect physical packaging to the virtual world. Easy access to smartphones and cheaper internet has boosted the number of tech-savvy consumers in India. Moreover, the rise in digital payments is making consumers familiar with the practice of scanning a QR code. By using digital technologies such as QR codes, augmented/ virtual reality and other forms of connected packaging, brands can drive transparency and traceability to tackle the issues of food safety and at the same time deliver promotions, experiences or product-specific information. As the issue of packaging waste remains in the spotlight and consumer awareness rises, brands can use eco-friendly packaging to create a stand-out for their products on the shelf. According to Mintel GNPD, in India, on-pack ethical claims such as environmentally friendly packaging and recycling in food launches have doubled to 10% of total launches in the last five years. In comparison, there still remains room for progress globally. This is especially true when we look at the

UK market, where one in every two food launches in the last year has made these claims. Finally, Indian consumers prioritize healthy lifestyles and look for natural and nutritious food and drink, both of which are factors that suggest a clean label could emerge as a trend in India. Brands that want to be at the forefront of this trend can declutter the pack design and emphasize a short ingredient list and nutritional panel on the primary display, in line with Mintel’s 2018 Packaging Trend Clean Label 2.0. For example, the Indian snack bar brand ‘The Whole Truth’, claims to be the ‘cleanest snack ever’, and has an essentialist design focusing on only 5-7 ingredients. Dev Kumar Dutta: What efforts do you see brands and packaging producers are putting in so that their packaging can follow Reduce, Reseal and Reuse? Rushikesh Aravkar: Brands can focus on optimizing over-engineered packaging and minimizing material usage at the design stage. For example, Britannia has reduced the amount of plastics used in its products by 15% per tonne of finished goods. It has also eliminated the plastic trays from its Treat Cream biscuits. Food brands can also take inspiration from Dow’s Rethink+ digital plastics take-back program and incentivize recycling. In collaboration with Recykal, Rethink+ aims to prevent post-consumer plastic waste from going to landfills by digitally connecting waste generators, aggregators, processors and recyclers. Using Recykal’s UZED app consumers can list their recyclables and schedule a collection or drop off their items at collection centers, earning reward points for online vouchers. The waste collected is streamlined to different recycling processes such as upcycling and pyrolysis (converting plastic waste into energy).

elaborated in this trend, consumers want the packaging to deliver convenience and plastics is often the material of choice thanks to their versatile material properties. However, consumers will also no longer accept ‘excess’ packaging, with a growing clamor for brands to use less. Mintel 2020 Packaging Trend ‘Ahead of the Recycling Curve’: This trend highlights that successful brands and package manufacturers will be those with firstto-market technologies that set the stage for future recycling opportunities. There exists an opportunity for brands to contribute to a packaging circular economy by investing in innovations that make plastic packaging as simple to recycle as possible and enable recycling infrastructure so that what’s discarded is fed back into the recycling stream. Mintel 2020 Packaging Trend ‘In-store Refill’: This trend discusses how the fast growth of independent packaging-free stores is driving retailers to consider how to bring refill in-store. In May 2020, Nestlé tested reusable and refillable dispensers to sell soluble coffee products in unpackaged formats in Switzerland. In India too, zero-waste stores selling organic products are sprouting across the country. Brands can tap into this trend with shelf-ready solutions that offer simple, branded dispensing in-store. Brands can engage consumers with premium collectible reusable containers. Mintel 2019 Packaging Trend ‘Connected Packaging’: Easy access to smartphones and cheaper internet has boosted the number of tech-savvy consumers in India. Moreover, the rise in digital payments is making consumers familiar with the practice of scanning a QR code. The use of on-pack digital technology such as QR codes to boost consumer engagement remains underused in India. Connected packaging can help tackle issues of food safety with authentication and traceability, and enable gamification, promotion and other fun ways to drive engagement. z

Brands can also look at making packaging reuse fun and can find creative ways to encourage consumers to reuse the packaging and use on-pack communication to educate on various ways to go about it. Dev Kumar Dutta: Any packaging trends that you think brands need to keep in mind? Rushikesh Aravkar: To summarize, a few global trends that brands in India need to take note of include: Mintel 2020 Packaging Trend ‘Plastic Responsible’: As THE PACKMAN | May-JUN 2021

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Food Packaging

z Accelerates action towards sustainable future

Tetra Pak to deploy its portfolio of tethered cap solutions

etra Pak had announced it is ready to deploy its portfolio of tethered cap solutions. The portfolio brings numerous benefits to food and beverage manufacturers and consumers, as the company builds on its vision of the most sustainable food package. These benefits include minimizing litter, as the cap will stay attached to the package. The carbon footprint can also be reduced because the company’s tethered caps are planned to become available as a plant-based option, therefore increasing the renewable content of the package. In tandem, the company is accelerating the expansion of its paper straws offering to ensure further renewable and low carbon materials across the range of packaging solutions. The aim of this is to address a broad range of customer sustainability needs without compromising on food safety, while still delivering on the end-user drinking experience. Lars Holmquist, executive vice president packaging solutions and commercial operations, Tetra Pak, says, “These are key milestones in our journey towards the world’s most sustainable food package: a carton that is fully made from renewable or recycled materials, is fully recyclable and carbon-neutral. We consistently strive to deliver products and services that adds value to food and people while protecting the planet. Our promise, ‘Protects What’s Good,’ allied with this strong purpose means we are providing customers with innovative products that also meet the rapidly changing demands of society.” Tetra Pak’s tethered caps and paper straws developments mark the latest additions to its range of responsible end-to-end solutions, allowing manufacturers to achieve their ambitions in three essential areas – food safety, food waste and the environment - simultaneously. Holmquist continues: “Approximately 32% of all plastic packaging is not collected and plastic can

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Tethered cap on Tetra Pak carton

take hundreds of years to degrade[1]. We focus on recycling by design, committing to invest approximately €100 million per year over the next 5-10 years to develop more sustainable packaging solutions. This includes alternatives to replace fossil-based plastics and avoid littering, as well as maximising the use of renewable, responsibly sourced materials in our packages. Addressing people’s needs for recycling is a critical component for not only becoming more sustainable but making food more available and safer for all consumers.” These steps are also central to ensuring that Tetra Pak’s customers in Europe will be ready to comply with the Single Use Plastics (SUP) Directive, an integral part of the wider approach announced in the Plastics Strategy and an important element of the EU Circular Economy Action Plan.

Lars Holmquist, executive vice president, product management and commercial operations

U-paper straw on Tetra Pak carton package

With this in mind, Tetra Pak has accelerated innovation in the caps domain. Holmquist adds: “The significant challenge of deploying tethered caps is the scale of the change that this brings across the value chain. If we look at Europe alone, more than 1,000 packaging lines supplied by us will be potentially transformed, translating into over 20 billion packages which are expected to be converted. All of that in three years, while minimising impact on our customers’ operations, optimising the consumer experience and contributing to both minimising litter and creating a carton package with increased plant-based and recycled content.” Tetra Pak is progressing on this complex journey by working seamlessly across various project streams. Overall, this covers approximately 40 different packages with tethered caps. Those caps are all planned to become available as a plant-based option. The first one to be released on the market is the HeliCap™ 26 Pro closure. This product features a new screw and flip concept with a self-locking hinge, securing food protection while providing convenience for in-home consumption. Its opening and closing mechanism has proven popular with consumers, demonstrating that the solution is delivering further benefits in addition to meeting legislative requirements. z

Food Packaging

z V-Shapes introduces VS dflex inks

Convenient nearline sachet printing for food packaging

-Shapes, an innovative supplier of vertically integrated products and services for convenient, hygienic and sustainable single-dose packaging, has announced the launch of the V-Shapes VS dflex nearline reel-to-reel printer for printing the top layer of its unique single-dose sachets that are opened with a single gesture using one hand. This compact, professional-grade printing system, powered by Memjet DuraFlex, makes it easy to print flexible packaging on site, eliminating the need to outsource printing or to tie up other printing equipment in the plant, especially for shorter runs of customized sachets. VS dflex inks were designed for food packaging and specially formulated for quick drying after printing, allowing the substrate to be ready for use with the V-Shapes ALPHA fill and seal packaging/converting machine. The VS dflex touch screen interface makes it easy for operators to efficiently manage the printing process with minimal training required. “We have always had an objective of making highquality printing available for our packaging/converting machines, to meet customer demand for faster time to market, personalization and more,” says Christian Burattini, CEO of V-Shapes. “We accomplished that earlier this year with the integration of the TrojanLabel T2 high volume digital label press into our V-Shapes PRIME single-lane packaging machine, and we have plans to integrate in-line printing into our six-lane ALPHA machine as well. But for those ALPHA machines already in the field or that will be acquired prior to the availability of inline printing, we have developed VS dflex, a more productive reel-to-reel printing solution that makes it easier for packaging converters/fillers to accomplish the complete manufacturing process for our unique single-dose sachets under one roof with a compact footprint. In this configuration, the bottom layer of substrate is printed inline in black only.” The VS dflex reel-to-reel nearline printer takes advantage of the speed and image quality of Memjet’s

Printing on top layer of single-dose sachets that are opened with a single gesture using one hand

DuraFlex multicolor A3+ printhead and water-based pigment inks, along with the advanced features and color management capabilities of the ColorGATE Packaging Productionserver, a RIP and color management solution for industrial packaging printing to deliver high quality, color-accurate printing at 1600 dpi at a speed of up to 27.4 meters per minute (90 feet per minute). It uses certified recyclable substrates, either sourced from industry leader SIHL or with V-Shapes proprietary materials. “Our strategic partnership with SIHL is particularly valuable thanks to the ability to print very high quality with aqueous ink and no pre-treatment on SIHL Artysio laminates,” adds Burattini. “They also have our specific materials stocked in Germany and the US to ensure fast and timely delivery.” z THE PACKMAN | May-JUN 2021

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Pharma Packaging

z More flexibility in capsule filling

Turning 1 into 3 The market for tablets filled into capsules has been growing for years. This dosage form is proving particularly advantageous due to its controlled dissolution behavior. Moreover, the capsules are easier for patients to take. The long-standing business partners Recipharm and Syntegon are breaking new ground for this type of product by upgrading a GKF 2500 capsule filling machine from one to three tablet stations – and are celebrating a successful premiere.

ablets filled into capsules are enjoying increasing popularity in the pharmaceutical market. One of the reasons is that encapsulated tablets are much easier for patients to take. Some tablets could not be administered at all without the protective capsule because of their aggressive effect on the mucous membranes of the mouth and stomach. Pharmaceutical manufacturers avoid this problem by filling the coated tablets into a capsule that dissolves in a controlled manner after overcoming gastric juice resistance. However, this trend confronts pharmaceutical producers as well as contract manufacturers with new challenges regarding their equipment. Recipharm was no exception when a customer approached the contract manufacturer with a very special request. He wanted Recipharm to fill three differently colored tablets of the same size into one capsule. “The customer project was and still is a novelty in many respects,” explains André Trommer, supervisor mechanic at Recipharm. “We have never before filled several tablets into one capsule. We did not yet have the necessary machine in our production facility. So we had to come up with a solution that was technically feasible and has a small footprint.”

Long-standing partnership Recipharm (formerly Consort Medical) and Syntegon are old acquaintances and look back on a long business relationship. At its German locations in Zwickau,

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Successful tests with placebos show that the GKF 2500 can now fill three different tablets into one capsule.

Monheim and Wasserburg, the contract manufacturer produces pharmaceutical products for customers all over the world. Syntegon’s GKF machines have been in use here for over 30 years. The last one was put into operation at the beginning of 2017. It is a GKF 2500 ASB 100% capsule filling machine in the highperformance segment. The machine is equipped with an automatic trouble-shooting system (ASB) and a capsule weighing machine (KKE).

Recipharm has so far used the GKF 2500 mainly for pellets and powder products.

Pharma Packaging With an output of up to 150,000 capsules per hour, the capsule filling machine is suitable for powders, micro-dosing, pellets and liquids. The exact filling quantity is pressed into a capsule via a dosing disk before the integrated checkweigher examines each individual capsule and sorts out any that are incorrectly filled. Thanks to the modular design of the machine, products with changing parameters can be quickly processed and precisely dosed. Recipharm has so far used the GKF 2500 primarily for pellets and powder products. Moreover, Recipharm fills pellets in combination with a tablet using the existing tablet station and the retrofitted pellet station. The GKF 2500 is also suitable for filling tablets and micro-tablets into capsules – but up to now only with one tablet station.

A first for both Recipharm and Syntegon: the upgrade of the GKF 2500 from one to three tablet stations.

All good things come in threes When the new customer contacted Recipharm, engineering specialist Jens Muhsold soon realized that he wanted to give the existing GKF 2500 a try. “I have been working with the GKF platform for over a quarter of a century and still have great confidence in the quality and reliability of the machine and its manufacturer.” Recipharm decided to realize the demanding project together with Syntegon and to upgrade the capsule filling machine for the new customer project.

To be entirely on the safe side, the identical weight of the tablets requires a further control stage. Since the space inside the capsule filling machine was already used up by the three tablet stations, the second step had to be transferred. The color inspection of the tablets is therefore not carried out on the GKF, but on the downstream blister machine (by the way, an older TLT 3060 from Bosch) by means of color recognition. “We also looked for the best possible solution for this step together – and found it by efficiently using an existing technology,” says Trommer.

“We needed a creative solution which, in addition to the filling itself, also took into account the limited space available on the machine,” says Muhsold. “This project depends on the successful upgrade. Hence, the pressure on both us and our colleagues at Syntegon was very high. Flexibility was a priority throughout the entire project. And the Syntegon team truly demonstrated its flexibility.”

In the meantime, extensive tests have confirmed the reliable and high quality of the dispensed capsules. In the future, Recipharm will be able to process capsule sizes 0 and 00 with different tablet sizes on each of the three tablet stations of the GKF 2500 capsule filling machine. What sounds simple in retrospect required a lot of courage and commitment from both sides within a short time. “The task was tricky because there were no parameters for comparison with previous projects. However, the tests proceeded without any problems. I am very satisfied with the technical implementation and the commitment of the entire service team,” says Muhsold. The upgrade of the GKF 2500 from one to three tablet stations was a first for both Recipharm and Syntegon. Nevertheless, the project partners completed the conversion in around three weeks, during which time three Syntegon service technicians were on duty at the Zwickau plant. In this way, a specific customer inquiry turned into a challenging project with great future potential. Recipharm can now fill various tablets into capsules, and Syntegon can offer the right equipment for a growing market trend. z

Dual control for quality assurance Although the three tablets contain different active ingredients, they are identical in size and weight. The only difference is their different colored coatings. It is therefore all the more important to ensure that only one of each tablet ends up in each capsule. The existing tablet station had already proven its worth in practice thanks to its reliable dosing process. Mechanical filling via a dosing disk makes sure that only the desired number of tablets reach the capsule base. In the unlikely event of a tablet getting stuck in the chute, the integrated gravimetric weighing cell automatically issues an alert.

Teamwork for flexible problem solving

Mechanical filling via a dosing disk makes sure that only one tablet falls into the capsule base at a time

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Caps and Closures

z Contributing to development of circular economy

United Caps unveils ‘Define Your Circle’ initiative

nited Caps, an international manufacturer of caps and closures, has unveiled a new initiative, ‘Define Your Circle.’ As part of the company’s ongoing commitment to sustainability, ‘Define Your Circle’ is designed to provide United Caps customers and their customers a simpler way to calculate full life-cycle environmental impact of their products, from before the materials enter the plant right through to its performance in the hands of the end user. In addition, ‘Define Your Circle’ offers a means to customers of contributing to the development of a truly circular economy, in which plastics are too valuable to waste, and are wasted when they are considered single-use. “At United Caps, sustainability has always been at the core of our values,” said Benoit Henckes, CEO. “We are constantly looking for actions we can take to reduce the environmental impact of our caps and closures – how they are made, the materials they are constructed from, their weight, how they are sold and how they are distributed. With our industry-first ‘Define Your Circle’ initiative, we have extended that ability to our customers, providing easy-to-use tools that allow us to help them calculate their carbon footprint more accurately, taking actions where appropriate to reduce their life cycle environmental impact and make data-driven informed decisions about their products. We consider this to be a responsible approach to doing business in this era of climate change and negative human impact on the environment.”

What makes ‘Define Your Circle’ different? United Caps are seeing a growing interest in the use of sustainability certified bio-based and recycled resins as part of an approach to product composition. At the same time, both customers and consumers have been seeking to better understand the weight of decisions they make in the realm of sustainability.

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United Caps’ KINDCAP is a proven sustainable alternative to standard snap cap solution

Caps and Closures One way to measure environmental effect beyond just making assumptions about impact, which is probably the most frequent approach, is through a process called Life Cycle Assessment (LCA) that assesses the environmental impact of food packaging, including material used, end of life (waste), as well as other environmental impacts, such as the overall effects of fossil-fuel-based or bio-based feed stocks. The process also shows the impact on the overall carbon footprint by using lighter-weight (but equally as effective) caps and closures, smaller neck sizes and more. Especially for smaller to mid-sized companies, this can be a challenging, complex and expensive process that requires specialists to complete. In addition, there are many misconceptions about the lifecycle environmental impact of various types of plastics, including those manufactured from fossil-fuel feed stocks and those manufactured from bio-based feed stocks. “Our goal with ‘Define Your Circle’ is to give our customers a tool to make informed choices in consideration of their environmental impact and to compare our products with each other and with competitive products to reach the most sustainable solution possible,” Henckes explained. Instead of depending on the complexities of a full LCA assessment, United Caps has chosen to leverage one of the industry’s largest life cycle assessment databases, GaBi, which is constantly updated as new technology and new insights come to the fore. GaBi stems from the German words ‘Ganzheitliche Bilanzierung’ for holistic balancing and has been around for a quarter of a century with the goal of easing the process of life cycle assessments. The United Caps ‘Define Your Circle’ tool gives customers access to this extensive database, delivering insight and guidance that leads to better sustainability decision making. As part of this holistic approach, ‘Define Your Circle’ allows customers to analyze the environmental footprint of caps, closures, and the containers they are used with, making better decisions about many aspects of product manufacture and distribution. “It’s important to recognize the complexities that surround making the right sustainability choices. United Caps have adopted an approach that places an emphasis on data-driven transparency to aid decision making,” says Henckes.

‘Define Your Circle’ offers manufacturers a data-based decisionmaking process to sustainability of product packaging

“Take for example, our KINDCAP for infant nutrition products” adds Henckes. “We designed it to be the lightest product on the market, but we wanted to dive deeper to help people understand what that really means”. “By comparing our KINDCAP closure using the GaBi indicator with a standard 99 PE snap cap from Competitor X, we can see that KINDCAP is more than 20% more environmentally friendly in pretty much all aspects. From Water Scarcity to Climate Change and Resource Use, it is verifiably better for the planet.” “But then if you wanted to go even further, we could ask the question, “What if, a customer wanted to make that closure from bio-based or recycled resins?” It is a common belief that bio-based feed stocks that can be used for making plastic resin, such as corn or sugar cane, are the most sustainable approach.

This unique-in-the-industry approach that has been taken by United Caps and enables fact-based decision making quickly and easily. The end-user solution adopted was to work with ISCC Plus Certified bio-based and recycled resins. Suitable for food applications, this certification allows brands to communicate the partial use of certified resin (less than 100%). So, for example, a closure may have been produced with ISCC Certified Resin but the bottle was not. In this example, the closure certification can be displayed on the packaging, aiding the consumer in making an informed choice. “We often talk in terms of caps and closures that have to perform in the plant and in the hand; it is our hope that ’Define Your Circle’ will also encourage people to talk about performing for the planet as well.” z

“If we further compare a typical PE snap cap made in the normal way versus a KINDCAP made with 50% bio-based resin, we can now have much greater understanding of the trade-offs involved in that decision. For example, the effect of reducing climate change would be substantial but the use of fertilizers and other chemicals can contribute to drinking water contamination.

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Sustainability

z Eliminates PVC from packaging

Amcor’s recyclable blister packaging begins trial phase

mcor has announced customer trials of the world’s first recyclable polyethylenebased thermoform blister packaging. The new packaging is designed to meet the stringent requirements of highly specialized and regulated pharmaceutical packaging and creates a more sustainable alternative for the most in-demand healthcare packaging type. This innovation also benefits from up to 70% reduction in its carbon footprint, when compared to packaging alternatives on the market today. AmSky eliminates PVC (PolyVinyl Chloride) from the packaging by using a polyethylene (PE) thermoform blister and lidding film. PVC can make packaging recycling more difficult or contaminate other materials if consumers attempt to recycle it. By removing PVC – whilst retaining all the benefits of pre-existing blister packaging – Amcor has created a new, recyclable solution that benefits the entire recycling process.

Amcor is currently working with several leading pharmaceutical companies to bring AmSky to market globally. The company expects AmSky to be available in the healthcare market by the second half of 2022. Peter Konieczny, Amcor’s chief commercial officer, said, “Amcor is deploying our unique innovation capabilities to solve the biggest and most significant issues in packaging today. With AmSky, Amcor has signaled our commitment to breakthrough innovation in the healthcare space – this is why we remain the packaging partner of choice for our healthcare customers, generating close to US$ 2 bn in annual sales in this market. This new blister packaging solution will significantly enhance the ability of healthcare and pharmaceutical brands to put sustainability at the heart of their businesses.” William Jackson, Amcor’s chief technology officer for Flexibles, said, “This exciting solution is

AmSky eliminates PVC from packaging by using a PE thermoform blister and lidding film

a result of Amcor’s continued focus on advanced technology and growth, using the entire power of our global R&D network to bring recyclable solutions to our customers.” z

z Paper-based high-strength packaging

Mondi packages potatoes in paper bag with Sustainex bio-based coating

ondi, a global leader in packaging and paper, has partnered with SILBO, a Polish leading producer of compostable packaging, to create a paper-based high-strength packaging for the Irish farm potato business Meade Farm Group. The innovative bags replace hard-to-recycle plastic with paper, a renewable resource enhanced with a bio-based coating and are certified as compostable.

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Working closely for two years, SILBO, Meade and Mondi developed the FSC-certified bag using speciality kraft paper to ensure strength in handling while providing barrier properties to keep the produce fresh. The bag has multiple sustainability features: a corn starch-based netting for a small cut-out window, water-based ink and Mondi’s biodegradable Sustainex coating, which provides heat sealing and moisture barrier protection.

The packaging has been launched across Ireland, Poland, France and Germany, winning the silver Fruit Logistica Innovation Award. The new solution helps Meade to achieve its sustainability goals: using packaging that is reusable, recyclable, renewable or compostable wherever possible. Jan Murzyn, extrusion solutions and speciality kraft paper sales manager Poland, Mondi, says, “The bags

Sustainability need to withstand very heavy weights, while providing a solution that is kinder to the planet. Our EcoSolutions approach means we work very closely with our customers to reach their sustainability goals and create a bespoke solution that represents the best possible option for the customer, the consumer, and the environment.” Marcin Śpiewok, SILBO business development manager, explains, “The hybrid solution combines the excellent strength of speciality kraft paper and the tailor-made barrier and heat-sealing properties of compostable materials. Mondi’s speciality kraft paper in combination with our net, water-based print, and unique technology was a long sought solution in the food industry and allowed us to substitute the conventional combination of plastic and mesh. We created the worldwide first compostable form-fill-and-seal

potato bag with net window to deliver strong, durable, breathable, eco-friendly packaging for Meade.”

Jeni Meade, sustainability manager at Meade adds, “We believe in sustainability not only because it’s the right thing to do for the environment and future generations, but because it’s the right thing to do for any growing business that is forward-thinking and values efficiency. This new potato bag is an excellent example and was integral in our winning the Best Sustainable Packaging Strategy at the Green Food & Beverage Awards. By changing from the previous plastic pillow pack to this bag, we completely eliminated hard-to-recycle plastic. Additionally, when compared to a traditional block bottom paper bag of similar size, our compostable paper pillow pack reduces paper usage by 34%. As a food producer, our company focuses on supplying the best-tasting potatoes to our customers, and as a packaging user, we are committed to reducing the climate impact of our packaging for the wellbeing of the planet.” z

z Replaces traditional polyethylene coated board

Siegwerk and Kotkamills join forces to develop fibre-based packaging

iegwerk, one of the leading global providers of printing inks for packaging applications and labels, and Kotkamills, a Finnish paper and paperboard manufacturer, have joined forces to create innovative solutions for printers and producers of fibre-based packaging to further drive packaging circularity. Under the motto ‘Together we accelerate change for good’, the strategic partnership aims to provide the market with sustainable and eco-friendly solutions by combining the latest technologies of both companies. The collaboration is based on the potential of water-based dispersion barrier coated paperboard to replace traditional polyethylene (PE) coated board. Thus, the switch in coating not only offers an economic driver to collectors and recyclers, it also reduces the environmental impact of the packaging.

Since 2018, Kotkamills has used its state-of-the-art technology to produce barrier boards for hot cup and food packaging end uses, in addition to folding boxboard grades, providing the markets with a real sustainable alternative. The new water-based dispersion barriers make the paperboard compostable, repulpable and easy to recycle; the fibres used are from sustainable PEFC and FSC certified sources. Siegwerk’s newest sustainable inks and coating intensify the superior printing properties of Kotkamills’ paperboard, resulting in excellent printing performance and high-quality surface protection. “With UniNATURE, our recently launched water-based ink system formulated with renewable and natural components, we add a sustainable ink and coating solution for improved packaging recyclability,” says David Charquet, international key account director Europe business unit paper and board at Siegwerk. For the ink expert, sustainability means progress. That

Siegwerk’s sustainable new solutions can be utilized on the fully recyclable paper cup made of Kotkamills’ innovative ISLA barrier board

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Sustainability is why the company has been driving the development of eco-friendly solutions for decades. “As a pioneer developing innovative and easily recyclable water-based dispersion barrier paperboards for various packaging solutions, we are very pleased that our collaborative effort with Siegwerk is bearing fruits that the packaging industry and printers can benefit from by offering to brand owners and consumers high-quality and genuinely sustainable products. Together we accelerate change for good,” says Päivi Suutari, VP RDI at Kotkamills.

Together the two partners offer the packaging markets a viable alternative to replacing traditional plastic coatings in fibre-based packaging, improving recyclability and circularity and resulting in an increased value of wastepaper, improved fibre recovery, and a noticeable reduction of waste. The partners’ solutions are designed to help converters and brand owners to deliver more sustainable packaging alternatives and thereby create value for a circular economy going forward.

Kotkamills’ innovative paperboard products enables the partners to develop cutting-edge solutions for packaging printers and producers, and thus together build a sustainable and circular future. The two companies are committed to continued close collaboration to identify further potential projects in which they can bring other innovative solutions to life and to pursue opportunities with customers in order to shape the future of sustainable printed packaging. z

The combination of Siegwerk’s profound ink expertise and packaging application know-how and

z Flextra Evolution

H.B. Fuller launches compostable adhesives for flexible packaging

.B. Fuller has launched two new compostable solutions for the flexible packaging market – Flextra Evolution SF1000CP/XR2000CP and Flextra Evolution WB1200CP/XR2200CP. Flextra Evolution SF1000CP/ XR2000CP is a 2K solventless adhesive that offers excellent design benefits, such as outstanding sound dampening and excellent adhesion, to a variety of biodegradable film substrates from bar wrap to snack packaging and much more. Flextra Evolution WB1200CP/XR2200CP, a waterbased two-part system that works best with paperto-film laminations, is fully compostable according to EN13432, ASTM D6400, and is certified through the Biodegradable Products Institute (BPI), North America’s leading certifier of compostable products and packaging. “When people ask for a compostable adhesive, what they are likely asking for is a package with components that can be composted and, now, this can be brought to life with the help of our compostable adhesives throughout the supply chain,” says Wayne Eklund, research scientist. “These new solutions from our Flextra Evolution product line have similar performance to conventional multi-layer packaging adhesives,

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novation-driven scientists and engineers at H.B. Fuller are highly capable to provide unmatched knowledge and service in collaboration with customers to help them solve their adhesion challenges. For the company, this means going beyond simply developing products that fit a particular adhesive application. It means thoroughly understanding customers’ businesses and processes to respond to changing consumer demand, new product designs, and upcoming regulatory and sustainability efforts.

H.B. Fuller has launched two new compostable adhesives for the flexible packaging market under its Flextra Evolution brand

show great printability and appearance, and work seamlessly with standard equipment. Most importantly, in industrial composting facilities, the adhesives decompose with no toxic residue, microplastics, or other pollutants.” Compostable adhesives are difficult to formulate without the right polymers and expertise, but the in-

As part of the broader market move toward sustainability, compostable flexible packaging allows converters and brand owners another tool towards reducing, reusing, composting or recycling. Flexible packaging requires less waste than other packaging types, such as glass, uses less transit resource needs, and utilizes fewer natural resources. z

Sustainability

z Plant-based packaging

Nestlé launches bio-based lids and scoops made from renewable resource

estlé has announced that it will introduce bio-based lids and scoops made from sugar cane and its byproduct for a range of its nutrition products for infants and children. The main advantage of these bio-based plastics is that they are made from a renewable plant material that can be continually replenished and that absorbs carbon dioxide from the atmosphere. In addition, this packaging helps Nestlé reduce its use of fossil-based plastics.

as Beba and Guigoz. Wyeth Nutrition is launching the new bio-based packaging for its brands SMA, Littls Steps, S-26 and Illuma.

Nestlé Nutrition’s NAN infant formula packed in the new packaging materials was introduced in Hong Kong in 2020 and will be available in other markets globally from 2021, including for other brands such

“Nestlé continues to push the boundaries of science to provide nutritional solutions for children, and we are putting that same passion into pioneering new packaging that is good for our planet,” said Thierry

Nestlé Health Science is also introducing the new packaging material for its Althéra, Alfaré, Alfamino, Modulen and Peptamen Junior brands, which are part of its global range of pediatric food for special medical purposes.

Sustainability Philardeau, head of Nestlé Nutrition. “Families rely on us for support in the first 1,000 days of life – a critical time to shape a healthier and more prosperous future – and we are proud to be the first global brand to offer them solutions that maximize the use of renewable resources.” Greg Behar, CEO of Nestlé Health Science, said, “It is our responsibility to our customers and to our planet to innovate on packaging materials that contribute to a more sustainable future. We are pleased that Nestlé Health Science’s pediatric range is our first product group to include the new bio-based lids and scoops: new solutions for a new generation.”

The lids and scoops are made from 66% and 95% sugar cane respectively. They are certified as plantbased packaging and are recyclable in countries that have recycling facilities for polyethylene (PE). They have the same properties and functionalities as conventional plastic ones, without compromising the high level of hygiene and freshness required. The bio-based lids and scoops complement the tin can which is metal-based and is the most recycled material in the world. This innovation is one of the many solutions Nestlé is working on to address the issue of packaging waste.

Ryan Carvalho, Head of R&D and chief medical officer for Nestlé Nutrition said, “The development of innovative sustainable packaging solutions plays an important role in our journey to netzero. Bio-based packaging from sugar cane is an excellent example of how we can make good use of plant-based raw materials that are renewable to develop better alternatives to traditional plastic while ensuring that our products maintain a high level of safety and quality.” z

z Industrialize production of eco-friendly paper bottles

Stora Enso and Pulpex partner to produce fiber-based bottles

tora Enso and packaging technology company Pulpex have joined forces to industrialize the production of eco-friendly paper bottles and containers made from wood fiber pulp. The renewable products will offer an alternative to PET plastics and glass. The exclusive partnership leverages Stora Enso’s formed fiber technologies and ability to convert end-products at an industrial scale.

across a variety of market applications, from homecare and personal care products to alcohol- and non-alcohol beverages and liquid foods. All of Stora Enso’s wood fiber pulp comes from sustainable, verified sources. The customizable Pulpex bottle allows for embossing, labeling and colored pigments to fit brand needs and easily integrates into any packaging manufacturer’s existing filling infrastructure.

The joint development agreement is formed exclusively between Stora Enso and Pulpex, a sustainable packaging technology company established by Diageo (makers of Johnnie Walker, Smirnoff and Guinness) and Pilot Lite (a venture management company). The partnership aims for large-scale industrial production of renewable and recyclable paper bottles and containers that degrade readily in the natural environment. Produced with sustainably sourced formed fiber pulp, the bottles and containers would enable a significantly lower carbon footprint compared with glass or PET. A formed fiber product is manufactured by pressing various wood-based pulps into a three-dimensional shape in a moulding machine. The focus of the partnership now is on developing a high-speed production line which is expected to be operational in 2022.

“We are delighted to have Stora Enso involved with Pulpex and are looking forward to the tangible benefits of such a formidable collaboration that will undoubtedly help us over the coming months as we seek to make our new, high-speed production lines available to all our partners,” says Scott Winston, director, Pulpex Limited.

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“We see great potential in combining development skills of Pulpex with our industrial capabilities, says Sohrab Kazemahvazi, SVP Formed Fiber at Stora Enso. “This cooperation marks an important step in bringing to market a truly sustainable alternative to plastic bottles and containers, while offering end-user qualities that match those of traditional packaging in the beverage market.” Using Stora Enso’s formed fiber material, Pulpex will produce paper bottles for an array of global brands

The global beverage packaging market is worth an estimated US$ 117 bn and is forecast to grow by 4.5% and reach US$ 170 bn by 2027. Globally, plastic packaging is currently growing at 5% CAGR and represents about 40% of global beverage packaging. Across the EU and US today, only around 30-40% of all plastic bottles are collected for recycling. However, for paper and cardboard recycling, the average is nearer 80%, just ahead of glass and aluminum (75-80%). z

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Events

15th Printpack India offers special discounts to exhibitors

PAMA’s governing council, which met on 22 March 2021, decided to significantly subsidize exhibitor participation in the Printpack India event from 20 to 24 December 2021. The council considered at length the adverse impact of the Covid-19 pandemic on the economy and the global print industry and decided to maximize the relief it could extend to exhibitors and especially to its member companies.

Major players of the industry have already remitted the requisite amount for the 15th Printpack India event. Photo: The Packman

The council took a bold decision to charge exhibitors the minimum space rentals, only to meet the basic requirements of the exhibition. The basic charges for bare space at the Printpack India event are Rs 8,000 per square meter for bare space and Rs 9,000 per square meter for shell schemes. This time, there are six types of discounts being offered, including earlybird discounts and those for members and associate members. The council has also introduced special Covid discount for its regular and associate members – INR.2000 per square meter and INR 500 per square meter respectively. The Covid discount, however, is applicable for the upcoming Printpack edition only.

that subsidizing exhibitor participation is not only their responsibility but is also the need of the hour as the industry is going through a testing time. Reddy insisted, there will be no impact on the event’s quality in terms of construction and facilities due to the subsidization – in fact, it would be even better than earlier Printpack events. In addition to providing various discounts, IPAMA may also considers extending complimentary services to exhibitors and business visitors during the exhibition.

At a recent online press event, Dayakar Reddy and Prashant Vats of IPAMA insisted that becoming membership in the IPAMA is extremely easy. Both stressed

IPAMA acknowledges industry’s overwhelming response at this crucial period for participation in Printpack India 2021. Thus far, 70% area has already

been booked. Major players of the industry have also remitted the requisite amount for the 15th Printpack India event. The exhibitor’s and visitor’s registration portals have also been developed for the convenience of the participants. All services for exhibitor and visitor will be available online. Exhibitors can book their space after remitting the participation charges. After the remittance, the exhibitor can select the hall and stall. They can download receipts/invoices and can also place orders for additional services. Visitors can also fix up their meetings with exhibitors online. The portal will be functional by the first week of April 2021. z

The date for interpack 2023 is set

he next interpack will take place from 4 to 10 May 2023 at the Düsseldorf Trade Fair Centre. Messe Düsseldorf set this date in agreement with its partners and committees. Interested companies from the packaging sector and the associated processing industry will be able to register online at www.interpack.com from the end of March/beginning of April provided all goes to plan. Exhibitors who were approved for interpack 2021, which was canceled due to the pandemic, have already been able to reserve their stand positions for 2023 and will now be able to rebook when they register. components will take place in parallel with interpack. It is oriented towards the supplier sector for the packaging and processing industry. You can register for components in the same period as interpack by accessing www. packaging-components.com. z

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Industry News

Scholle acquires Bossar

cholle IPN, a leading global supplier of flexible packaging solutions, has completed the purchase of Bossar, a global supplier of flexible horizontal form-fill-seal packaging equipment. The new business combination will leverage the combined capabilities of both businesses to provide one stop shopping for vertically integrated, sustainable solutions for the global flexible packaging market. Ross Bushnell, president and CEO of Scholle, said, “This is an important next step in our continued evolution toward becoming a truly indispensable provider of total packaging solutions to our customers around the world. While the two companies have worked together for some time, the formal combination not only strengthens our global equipment footprint but it also allows for even stronger collaboration within our teams around the world. Our mission is to be

simply flexible in all that we do and the combination of these two great businesses will enable that mantra as we achieve our goal of being a world leader in film, fitments, and equipment to the global liquid packaging market.” Jeroen van der Meer, managing director of Scholle in EMEA, and CEO of Bossar, said, “The goal of Scholle IPN has always been to create lightweight, environmentally-conscious flexible packaging solutions for the circular economy. By combining Bossar and Scholle, we are able to truly focus our development activity to provide leading edge technologies that enable us to manufacture a complete range of sustainable packaging solutions for our customers. Already today, our products provide sustainable solutions through substantial reductions in packaging weight while extend-

ing shelf-life, reducing energy consumption and minimizing food waste.” The company will retain the Bossar brand and will continue to utilize Bossar’s operational headquarters in Barcelona, Spain, and their manufacturing facility in India. The combined business has operations across Europe, Russia, China, India, Australia, Brazil, Chile, Canada and the United States. z

XSYS launches Nyloflex FTM digital flexo plate

he new nyloflex FTM Digital plate with inherent flat top dots has been developed specifically for flexographic printing with water-based inks on different grades of paper substrates. The trigger for the development of this new plate solution is the acceleration in the demand for more environmentally friendly packaging production. As the market moves towards more sustainable substrates in response to those demands, XSYS is introducing the nyloflex FTM Digital plate to enable printers to use water-based inks on coated and uncoated paper for aseptic food packaging and corrugated preprint liner. “This latest addition to the nyloflex plate portfolio will have a broad appeal for printers serving different segments of the packaging production wishing to move to a more sustainable operation, but still retain the ability to produce the highest quality products,” said Simon Top, product manager at XSYS. “The nyloflex FTM Digital will help to fulfil the brand owners’ sustainability requirements by allowing printers to switch from printing on plastic

film materials to printing on paper substrates with water-based inks.” The nyloflex FTM Digital is a medium hard plate with a smooth surface, bringing a good ink transfer and ink laydown out of the box and capable of reproducing sophisticated surface screenings in case this is required. With no need for additional equipment or auxiliaries, the plate can be exposed in existing systems with standard tube lights or LED UV-A light exposure, before solvent processing. XSYS innovative inherent flat top dot technology ensures minimum dot wear and significantly less dot gain compared to round top dot plates, thereby also greatly improving press uptimes to reduce costs and start-up waste in the press room. Featuring advanced dot sharpening, the nyloflex FTM Digital presents fine highlights and a high solid ink density in print, increasing the shelf appeal of the final product.

“The nyloflex FTM Digital can be considered as the flat top dot counterpart of our well known nyloflex ACT Digital plate,” explained Top. “The plate enables printers to easily tackle both coated and uncoated papers without the need to use two different plate types. In the past, a hard plate like the nyloflex ACE UP and medium hard plate like nyloflex ACT were often combined to achieve the optimum result. At one customer case, we were able to reduce this complexity for up to 60% of the print jobs by using the nyloflex FTM Digital.” z THE PACKMAN | May-JUN 2021

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Industry News

AGI glaspac invests in German tech to build new furnace

GI glaspac, a leading global manufacturer of integrated container glass, has partnered with Horn Glass Industries, Germany, to build a new furnace of 154 TPD AGI speciality glass division in India for the company’s Bhongir plant in Telangana. The technology will cost INR 55 crores. It is a part of the recent investment raised by AGI glaspac from its parent company HSIL Limited, amounting to INR 220 crores. The facility will comprise end-fired furnaces with six forehearths for production. With the set up of the new furnace, AGI’s Bhongir plant will be able to produce 154 tonnes of premium flint and other colors. This high-quality speciality glass produced will cater to industries such as carbonated water, sparkling wine, pharmaceuticals, including vials and in cosmetics, such as beauty products, perfumery, and nail Polish among others. Rajesh Khosla, president and CEO of AGI glaspac,

Stephan Meindl, president and CEO, Horn Glass Industries, said, “India is an exciting market for our company, and we are happy to collaborate with a renowned brand like AGI glaspac to showcase our leading position in the global glass market. We are confident that with our technological support AGI glaspac’s will be able to thrive by its make in India vision of manufacturing world-class level specialty glass very effectively.” said, “Our investment in German technology is aimed to strengthen our units to make products more efficiently out of India for global markets. We thrive by the make-in-India concept, and it is important that we do not miss out on the great opportunities or technologies readily available – these technologies are to watch out for or invest in, so that the products manufactured in India can compete efficiently. We are happy to have found the right technology partner in Horn Glass Industries AG, Germany.”

The furnace will be heated by Piped Natural Gas (PNG ), with HFO backup firing. LPG will be the energy backup for the distributor and forehearths. Horn’s scope of supply includes the planning of the refractory, the combustion equipment, measuring and control, boosting, a new HVR 400 batch charger for the furnace, distributor, and forehearth as well as further furnace equipment. The entire construction and commissioning will be managed by AGI glaspac and Horn Glass Industries jointly. z

Reifenhäuser acquires air cooling ring specialist Kdesign

eifenhäuser has acquired a majority stake in Kdesign, a global leader in the manufacture of air cooling rings and measuring systems for blown film extrusion lines. With this purchase Reifenhäuser Group, a specialist in extrusion technologies, expands its in-house expertise in cooling, controlling, measuring and calibrating blown films and will give its customers in this segment an even clearer competitive edge in the future. Kdesign remains an independent company within the Reifenhäuser Group and its business and customer relationships will continue unchanged. Joachim Lange and Richard Zimmermann continue to head the company as managing directors. “In the blown film production process, cooling and controlling have a decisive impact on the quality of

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L to R: Bernd Reifenhäuser, CEO, Reifenhäuser Group; Richard Zimmermann, shareholder and managing director, Kdesign; Gerd Fähling, shareholder and head of sales, Kdesign; Joachim Lange, shareholder and managing director, Kdesign; Ulrich Reifenhäuser, CSO, Reifenhäuser Group. Photo: Reifenhäuser

the end product. Our colleagues at Kdesign already offer the best technology on the market for this, which

we are now bringing together with our extrusion technology. Customers will benefit from the ideal pairing

Industry News of cooling expertise and specialist knowledge in hot parts. From now on, we can perfectly harmonize our products for optimum performance and together we can develop technologies more quickly,” says Bernd Reifenhäuser, CEO Reifenhäuser.

Current Kdesign customers will also benefit. As a member of the Reifenhäuser Group, Kdesign now has access to a large international service network and the world’s largest privately run research and development center for plastics extrusion. Richard Zimmermann, managing director of Kdesign, says, “We will be able

to be closer to our customers in the future and have better development opportunities. Our location is just 20 minutes away from Reifenhäuser’s headquarters. We are looking forward to working together and having a close personal exchange.” z

BillerudKorsnäs and Aisa pioneer new horizons in paper tube packaging

illerudKorsnäs and Aisa have launched a collaboration that opens up outstanding new possibilities in tube packaging made of paper. With BillerudKorsnäs FibreForm, plastics on tube shoulder and sleeve can be replaced without compromising on user experience. BillerudKorsnäs FibreForm is a unique low-carbon material that allows the tube to keep its shape when squeezed, without traces, apparently making it unique compared to tubes made of other fibre material. According to the company, FibreForm allows for up to ten times deeper embossing than regular paper, resulting in unique 3D effects and a memorable tactile experience. “We will never compromise with user experience. FibreForm is a unique material and this collaboration is another application where we can help brand owners on their journey towards sustainable packaging,” says Lovisa Westergren, sales director FibreForm at BillerudKorsnäs. “Over the last few years we have seen an increasing demand for fibre-based packaging solutions including tube applications. This tube solution developed together with Aisa is utilizing the unique characteristics of the Fibreform material and is able to meet the high expectations from brand owners – from plastic reduction, to excellent functionality and exceptional branding possibilities.” Tubes made of FibreForm can be used in different segments as for example toothpaste and cosmetics. The company describes their new product as renewable biodegradable, cold-formable and it requires less energy in production than plastics. The companies also say that it is possible to replace the plastic with FibreForm in Aisa’s machines without them having to be rebuilt.

“FibreForm adds luxurious features to the already wide range of tube decorations and our clients can now offer higher end solutions to product marketers looking to differentiate from mass market packaging. By using FibreForm from Billerudkorsnäs, Aisa is now able to replace up to 70% of plastic in the functional shoulder component and together with the tube sleeve made of over 85% of paper, this hybrid shoulder contributes to a package that now is composed of more than 80% paper,” says Joachim Sander, director marketing and sales at AISA Automation Industrielle. z

Max Speciality Films to invest in new CPP line

ax Ventures & Industries Limited’s (MaxVIL) subsidiary Max Speciality Films Limited (MSFL), which manufactures specialty packaging films will be investing up to Rs. 500 million in a new CPP line with a capacity of 7.2 KTPA. The new CPP line expansion will be funded entirely through internal accruals. Work on the capex will commence in Q2FY22 and is expected to be commercialized in Q2FY23. Demand for the CPP Films has been robust and expanding the capacity will enable MSFL to cater to the growing market for such films. Apart from robust demand these films enjoy, they will also further enhance the sustainability factor of MSFL as these films are easier to recycle.

From the onset of FY21, MSFL has witnessed robust demand for its packaging films which have continued to improve quarter on quarter leading to strong revenue and profitability growth. This demand is led by increasing preference of customers for packaged products as hygiene and safety has taken over priority during this pandemic. Prior to this capex, MSFL had announced the commercialization of first of its two planned metallizer lines which enhances the speciality product capabilities of MSFL. With the expansion of the new CPP line combined with the increasing speciality product capabilities, MSFL aims to capture new growth opportunities enhancing the scale of the business and at the same time sustainably improving its profitability through better product mix. z THE PACKMAN | May-JUN 2021

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Services

Events Calendar Dates Event Name

Place

26 to 28 November 2019

CPhI India (P’Mec)

Greater Noida, India

3 to 6 December 2019

Paperex

Delhi, India

6 to 8 December 2019

Print & Packtech

Bangalore, India

12 to 14 December 2019

Pacprocess Food Pex

Delhi, India

6 to 9 January 2020

Pamex 2020

Mumbai, India

16 to 20 January 2020

Plastivision 2020

Mumbai, India

28 Feb to 1 March 2020

PacProTech

Kathmandu

19 to 21 March 2020

Asia Packaging & Printing Industry Expo

Shenzhen, China

PLEASE VISIT OUR WEBSITE FOR THE UPDATED EVENTS CALENDAR

20 to 22 March 2020

PackPlus South 2020

Hyderabad, India

21 to 23 April 2020

Label & Flexible Packaging & Film Expo 2020

Shanghai, China

24 to 26 April 2020

Food Pack India Expo

Chennai, India

5 to 9 May 2020

Metpack 2020

Messe Essen, German

7 to 13 May 2020

interpack 2020

Dusseldorf, Germany

3 to 4 June 2020

Innopack Pharma Confex

Mumbai, India

16 to 26 June 2020

drupa 2020

Dusseldorf, Germany

19 to 22 June 2020

Plastasia 2020

Bangalore, India

6 to 9 August 2020

PackPlus Delhi

Delhi, India

17 to 19 September 2020

Pharma Pro&Pack 2020

Hyderabad, India

30 September to 2 October 2020

IndiaCorr Expo

Mumbai, India

8 to 10 October 2020

ProPak India

Delhi, India

25 to 27 November 2020

CPhI & P-MEC India

Greater Noida, India

29 October to 1 November 2020

Labelexpo India 2020

Greater Noida, India

29 October to 1 November 2020

Brand Print India 2020

Greater Noida, India

9 to 11 December 2020

pacprocess India

Mumbai, India

3 to 8 February 2021

Printpack India 2021

Greater Noida, India

4 to 8 February 2021

PlastIndia 2021

Delhi, India

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RNI UPENG/2018/76741 Editor Mahan Jyoti Hazarika editor@thepackman.in Cell: +91 9910189285 Senior Desk Editor Sunil Jain Senior Associate Editor Dev Kumar Dutta Associate Editors Pranay Mathur Manash Das Guest Editor Anwesh Koley Design and Production Biswajeet Chaliha Sales and Marketing Mahan Jyoti Hazarika Subscription Address E448, Gaur City 1, First Avenue, Greater Noida West, Gautam Buddha Nagar 201301, Uttar Pradesh, India Issue Published on 8 May 2021 Printed at JK Offset Graphics Pvt. Ltd. Printed, Published and Owned by Mahan Jyoti Hazarika, and Printed at JK offset Graphics Pvt. Ltd., B278 Okhla Phase I, New Delhi 110 020, India and Published From E448, Gaur City 1, First Avenue, Greater Noida West, Gautam Buddha Nagar 201301, Uttar Pradesh, India Editor: Mahan Jyoti Hazarika

Industry News

THE PACKMAN | May-JUN 2021