You make it. We pack it. BPA loads your packaged and naked products into cases, master bags and various secondary containers including your hffs machines, wrapper chain in-feeds and indexing thermoform machines. We ASK. We LISTEN. We PARTNER.
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Diageo brand Baileys pilots a new paperbased bottle made using a new dry molded fiber technology that is less energy- and water-intensive than traditional molded fiber-making methods.
22 COVER STORY
How Baileys Paper-based Bottle is Made
An extraordinary network of inventors, developers, OEMs, and stakeholders emphasize ‘progress over perfection’ as they commercialize a breakthrough bottle.
28
Global Brands Experiment with Advanced Recycled Materials
Cadbury, Churchill Container, L’Occitane, and PepsiCo explore advanced recycling technologies to help meet their commitments for less virgin plastic and more PCR material in their packaging.
Mars’ Digital Pack Modeling Cuts Waste, Time to Market
Simulation solutions are supercharging the Mars packaging development process with potential to cut development time by up to 40%. Also, by March 2024, the software already had reduced the quantity of plastics purchased for testing by 246 tons.
36
Applesauce Maker Fortifies Supply Chain with Procurement Tech
Pouched applesauce producer Materne adds two carton suppliers to its network and cuts $1 million in annual costs by adopting procurement software.
40
Sugar Producer Emphasizes Flexibility in End-of-Line Solution
British Sugar replaces a 38-year-old end-of-line system with two tray packers and seven automatic palletizers with robotic layer preparation to handle a wide array of product formats and sizes.
Aladin Alkhawam Supply Chain Security Director, Endo International plc
Jan Brücklmeier Technical Application Group Packaging Technology Expert, Nestlé
M. Shawn French Director – Innovation & Packaging Engineering (Beverage), Danone North America
Patrick Keenan R&D Packaging Engineer, General Mills/Annie’s Organic Snacks
Mike Marcinkowski Director of R&D Material Science, Packaging & Sustainability – Nature’s Vault/Fesh Loop
David Smith, PhD Principal, David S. Smith & Associates
Brian Stepowany Packaging R&D, Senior Manager, B&G Foods, Inc.
Jasmine Sutherland President, Texas Food Solutions; Vice President, Perfect Fit Meals
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Packaging World columnists have made some bold predictions that have come to pass at a high clip. Our resident legal eagle Eric Greenberg reminded me of his now-validated prediction last month after the Supreme Court ruled on a case that shook continued adherence to the 1984 “Chevron” doctrine that grants deference to agencies like FDA and EPA. Greenberg presciently wrote about the topic almost a year prior (pwgo.to/8309). Good call, counselor. But I’m not sure I like the sound of your prediction about fallout from the decision: “…if the common prediction is correct that the doctrine will be undone, be ready next year for a rupture in the foundation of our regulatory system, and a huge increase in unpredictability,” he said then.
Just a few days later, on the 50th Anniversary of the Global Trade Item Number (GTIN) barcode’s first “beep” at a checkout counter, I sent an e-newsletter blast about data standardization body GS1’s Sunrise 2027. That project aims to replace the venerable but dated GTIN with 2D data matrices or QR codes on labels or packages. These codes not only make the products go beep at checkout, but also connect the consumer to the brand via website and have all sorts of behind the scenes advantages for supply chains and consumer behavior insight gleaning for brands who employ them. Not long after sending that email, I received a response from Dr. Bruce Welt at the University of Florida, directing me to a crystal ball prediction of his own. In a column written way back in 2008, Dr. Welt predicted the dawn of 2D data matrices as the dominant form of on-pack information relation and connection (pwgo.to/8316). “Vision systems coupled with a variety of identification symbologies, such as 2D data matrix barcodes, offer the ability to realize virtually all of the benefits promised by RFID, but with much lower cost, complexity, and environmental impact,” he said 16 years ago. Today, Welt’s putting his chips on regenerative robust gasification (pwgo.to/8317) of waste that produces several packaging feedstocks, and has recently been following a promising new pathway from methanol to PET.
This unusual two-fer of predictions coming true got me thinking about other examples of when columnists had picked winning horses. As I write this, I’ve only been back for a month from the massive drupa expo, where package printing was huge (more on page 14). One of my first stops was to visit Yarden Ben-Dor at the expansive Landa booth, where carton- and paperboard-printing S11 nanographic presses roared to life every half hour. Landa now has more than 60 commercial nanographic presses in the market, but that hadn’t always been the case. Founded in 2003 by Benny Landa, the defacto “father of digital printing” who had previously founded Indigo (now HP Indigo) in 1977, nanographic printing is a plate-free but ultra-high-quality nascent digital printing tech that took a surprisingly long time to find its in-market footing. The first U.S. installation of a Landa nanographic press was 2018.
One of the earlier champions of this finally emergent tech, though, was none other than my predecessor, Pat Reynolds. In 2013, we heard from him (pwgo.to/8312) even then awaiting the first commercialized project for the already decade-old company. “The first commercial user of Landa’s S10FC nanographic press is expected to be in production with folding cartons in Q4 of 2014. ‘The opportunities for conversion to digital are enormous,’ said Landa at the press briefing. Many of those opportunities, he added, are in packaging, where inventories can be minimized, packaging can be personalized, and the cost of printing can be reduced.”
The pandemic produced a spate of predictions, including some by PW editorial advisory board member Brian Stepowany of B&G Foods (Green Giant). He made four distinct calls about supply chains and reliance on co-man/co-packing reliance as early as July 2020 (pwgo.to/8310): 1. Secondary sourcing will become critical. 2. Speed-to-market will prioritize larger production runs. 3. Attention to the “unboxing experience” will drive opportunities. 4. Service providers will thrive running new packaging innovations. Brian wrote another column three years later to grade his predictive powers (pwgo.to/8311). Spoiler alert—his predictions were right on the money.
I’ve been bullish on smart packaging’s ability to prevent food waste (pwgo.to/8315) and reap upstream supply chain benefits (pwgo.to/8313) that affect brands’ bottom lines. The same tech should also have downstream benefits for material recovery and recycling in projects like HolyGrail 2.0 (pwgo.to/8308). Meanwhile, AI-based sortation of packaging and learning about packaging hold a lot of promise (pwgo.to/8314) for creating more and better bales of PCR feedstock.
We’ll see how accurate those picks are, but I like my chances. PW
mreynolds@pmmimediagroup.com
Over the next few years, a new 2D-code technology will become the universally accepted standard. Retail merchants, manufacturing companies, and consumers all around the world can profit from this change. Production processes will need to be adjusted. Businesses appear to be switching sooner rather than later to ensure that by 2027, 2D-codes will be fully supported at every step of the supply chain. The necessary quality can only be achieved by high-resolution printers and other devices that are part of Wipotec’s Traceable Quality System.
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Kraft Heinz has introduced 100% recycled PET bottles for its 12- and 22-oz sizes of Kraft Real Mayo and Miracle Whip, with the balance of its container sizes scheduled to launch in the new packaging by year-end. The move comes following the company’s announcement last year of a new goal to reduce the use of virgin plastic in its global packaging portfolio by 20% by 2030.
According to Kraft Heinz the switch to 100% rPET for its full range of container sizes will result in the elimination of about 14 million lb of virgin plastic. In addition, depending on the size, the transition to the new container will result in a 36 to 43% reduction in greenhouse gas emissions (GHGs) versus the current packaging, based on 2022 volumes.
To make the change, Kraft Heinz worked with long-time packaging partner Plastipak, a designer, manufacturer, and recycler of plastic containers. Says Chris Max, research lead, R&D – Packaging Development for Kraft Heinz, “For nearly four decades … they’ve helped us design and manufacture packaging that protects the product from our production facilities all the way to consumers’ tables.”
According to Max, when Kraft Heinz sets out to develop a new and alternative packaging solution, there’s a lot for the company to consider. “First and foremost, packaging is about protecting the product, so it must deliver against our food-safety requirements,” he says. “Packaging must also fulfill consumer expectations and function the way they have come to trust. And finally, we need to make sure we have the internal infrastructure to support the changes, meaning any new packaging developments need to fit seamlessly into our production lines.”
For the new Real Mayo and Miracle Whip containers, Plastipak optimized its manufacturing process to ensure the performance of the packaging remained uncompromised after the transition to recycled content and worked with Kraft Heinz to leverage best-practice quality protocols.
One concern with recycled content is whether it contains contaminants that may affect product safety. For Kraft Heinz, delivering highquality, safe foods is understandably one of its biggest priorities. “All materials used in our packaging must meet FDA requirements for food contact and be safe and suitable for the intended use,” Max explains. “At Kraft Heinz, we also mandate all recycled material be certified by an Association of Plastic Recyclers [APR]-approved body.”
Consumers can find Kraft Real Mayo and Miracle Whip in the new 12and 22-oz rPET bottles on U.S. retail shelves today. Kraft Heinz says its 8-, 15-, 30-, and 48-oz jars for the spreads will be available in rPET by the end of 2024.
—Anne Marie Mohan
Mondele - z International stalwart brand Chips Ahoy! has been launching some new recipes lately, including an update to its original cookie recipe alongside its first certified gluten-free chocolate chip cookie. A pair of new packaging designs with a combination of improvements including updates to the logo, an updated image of the cookies themselves, and more prominent background graffiti reflecting the brand personality with a matte packaging finish that all together makes it a more modern and fun design, the company says.
“The overall objective of the Chips Ahoy pack redesign was to evolve the visual language to be relevant with the target consumer, double down on the taste appeal of the cookie and to communicate the product improvements. We crafted the logo to ensure modernity and boldness against the backdrop. We amped up the graffiti to add personality and visual texture. We photographed our product as the hero on pack to drive the yum-factor. All of these elements work together to deliver an iconic experience at shelf for our Chips Ahoy consumers,” says Samantha Zellefrow, Global Design Excellence lead at Mondelez.
of the white and light blue on darker blue. This will help to make it immediately obvious which cookies are gluten free, and which are not, by a simple glance at the shelf.
“For the packaging, this is the existing adhesive laminated peel and reseal film structure with a rotogravure print method. Utilizing the existing printing technology, a matte over lacquer is applied to create differentiation on shelf and complement the new graphics. The metalized film layer provides the barrier required to achieve the appropriate shelf life of the new cookie formula,” adds Andy Clark, North American Biscuit Packaging lead, Mondelez. —Matt Reynolds
Specific to the even more recent gluten-free launch, packaging colors are reversed to light blue on a white background instead
Stony eld, known for its commitment to producing high-quality, organic yogurt, as well as its attention to sustainable packaging, has become the rst to use the CHEERCircle all-polyethylene spouted pouch. Although the “recycle-ready” pouch is not currently able to be recycled in the U.S., it is said to provide signi cant environmental bene ts versus a typical multi-laminate spouted pouch. It’s also well positioned for recyclability when the infrastructure becomes available. Stony eld developed the pouch in collaboration with Amcor and Cheer Pack North America for its YoBaby refrigerated yogurt.
Spouted pouches are traditionally made from a multilayer, multimaterial structure. The most common construction, according to Tom Schell, senior director – R&D, Amcor Flexibles North America, is an aluminum oxide-coated oriented PET/biaxially oriented nylon/ PE structure, whereby the AlOx-coated OPET provides the barrier and a printing substrate, the BON provides toughness, and the PE provides the sealing surface.
In contrast, the new Stony eld package uses Amcor’s AmPrima PE Plus, an all-PE lm that meets the APR Design Guide for recyclability. According to Amcor, high-barrier, heat-resistant
AmPrima PE Plus exible lm was engineered to address the challenges with producing an all-PE spouted pouch.
“Many liquid products packaged in spouted pouches require
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moisture and oxygen barriers to preserve the content,” says Amcor. “Highly durable and repeatable hermetic seals along the pouch edges and fitment seal are required to deliver a safe and desirable end-user experience.”
To allow for sealing and fitment insertion without distortion, AmPrima PE Plus features a heat-resistant outer web. For the Stonyfield yogurt application, the required oxygen barrier is delivered through the inclusion of ethylene vinyl alcohol, which is compatible in the PE recycling stream, while HDPE is used to enhance the moisture barrier to the appropriate level.
Also important for the project was the selection of the pouch fitment. The team chose the Cheer Pack Vizi PE cap to ensure the entire pouch would pass critical guidance testing as defined by APR. The Vizi Cap is said to improve tamper-evidence, as well as significantly reduce plastic use when compared with traditional pouch fitments. According to Cheer Pack, use of the Vizi Cap can result in a reduction of five-plus tons per 10 million caps, or the equivalent of 15,460 lb of CO2
To validate the AmPrima Plus structure in production environments, Amcor R&D worked closely with Cheer Pack North America’s pouching and spouting experts. Says Laura Stevenson, marketing manager for Amcor Flexibles North America, “This open collaboration resulted in a package that achieved all customer expectations, including standard line speeds for converting at Cheer Pack North America and filling lines at Stonyfield Organic.”
As noted, although the pouch is designated as recycle-ready, Stevenson explains that at present, the infrastructure to recycle flexible packaging via MRFs (municipal recycling facilities) in the U.S. is insufficient. “The AmPrima portfolio provides customers with a packaging solution that is designed to be recycled, if clean and dry, through existing store drop-offs,” she says. “Today, that is difficult for liquid products as materials need to be clean and dry prior to going into the PE-recycling stream. However, the recycling industry along with Amcor, are working to change that.”
Even when not recycled, significant sustainability benefits accrue from the use of AmPrima PE Plus film versus a three-ply foil structure incumbent, shares Amcor. These include a 5% reduction in non-renewable energy use, a 22% reduction in carbon footprint, and a 51% reduction in water consumption. Those numbers rise to 53%, 49%, and 66%, respectively, if the film were to be recycled.
In February 2024, when Stonyfield’s use of the pouch was announced, Sophie Schmitt, director of marketing for the organic yogurt company, said, “Stonyfield has been an environmental pioneer since the day we were founded as an organic farming school in 1983. Over the last four decades, we’ve been leaders in sustainability, and we take our commitments seriously. We’re thrilled to collaborate with Amcor and Cheer Pack North America on a sustainable pouch solution to help achieve our long-term packaging goals and make steps toward protecting the planet for generations to come.” —Anne Marie Mohan
• Quality Engineering
• In-House Fabrication
• Extremely Fast Turn-Around
• Smaller Footprint
• Industry-BEST Value
conveyor systems
With a design philosophy of “Improvise, Scavenge, Protect, and Adapt,” Nike sub-brand ISPA recently introduced a new shoebox that demonstrates its commitment to sustainability and cutting-edge innovation. Rather than using ink made from petroleum-derived carbon black to print the footwear box, Nike is decorating the package with Living Ink Technologies’ water-based, algae-pigmented ink, Flexographic Algae Ink.
As Living Ink explains, traditional carbon black is a powder pigment made from fossil fuels that adds color and structural stability to inks, textiles, plastics, and rubber. Despite its effectiveness, however, its use of fossil fuels results in both environmental and human health risks.
“Originating from the extraction and burning of dense petroleum substances like oils and tars, it [carbon black] is listed as a Class 2B human carcinogen,” says Living Ink. “The production and use of conventional carbon black is hazardous to human health, causes environmental degradation, depletes nite natural resources, and doesn’t break down naturally.”
To address these issues, Living Ink developed a bio-based, carbon-negative black pigment called Algae Black made from renewable algae waste and other agricultural wase sources. Through a proprietary process, the company repurposes the leftover algae and biomass from farms into a powder or liquid suspended form that is used to color a variety of industrial products, including its Algae Ink.
According to Living Ink Director of Partnerships Devon Murrie, a life-cycle analysis conducted by Sustainability Science and Colorado State University in January 2023 showed that the production of Algae Black pigment is a carbon-negative process calculated to reduce CO2 equivalent emissions by 200% compared to carbon black pigment. “Every kilogram of Algae Black pigment we produce keeps approximately 3 kilograms of petroleum from being used,” she says. “Additionally, because our pigment is carbon negative, using 1 kilogram of Algae Black can remove 4 kilograms of carbon dioxide.”
Nike began working with Living Ink in 2021, using its Standard Screen Algae Ink to screen-print items such as footwear and t-shirts. According to Murrie, Nike chose Algae Ink made from water and Algae Black for the ISPA project because “it was in line with the sub-label’s ethos.”
Introduced in late spring 2024, the ISPA footwear box is exo-printed with depictions of various types of algae. Murrie shares that Living Ink collaborated on the project with an approved printing partner from Nike’s existing suppliers based in Vietnam. “We worked with the manufacturing group to ensure our ink was able to hit the jet-black color specs requested,” she says. “Overall it was a drop-in solution to conventional exo ink.”
To inform consumers of its use of the algae-based ink, Nike added a QR code to the box that, when scanned, directs consumers to a TEDx Talk by Living Ink CEO Scott Fulbright, titled, “Is algae the ink of the future?,” which highlights the genesis and early stages of the company. The inside of the lid also provides the scienti c names of each type of algae illustrated on the outside of the lid.
While Murrie has not received word from Nike on the consumer response to the box, she shares that Living ink has seen some customer unboxing videos that comment on the uniqueness of the packaging. Nike could not be reached for comment. —Anne Marie Mohan
Driven by transparency, innovation, and collaboration, Bardstown Bourbon Co. waited six years before releasing its 100% estatedistilled line, the Origin Series, which according to Brand Manager Brandon Smith, was “highly anticipated by whiskey enthusiasts and produced by one of the best teams in the industry.”
To mark the launch of the six-yearaged line, the Bardstown, Ky.-based distiller worked with IPL Packaging to design a premium, limited-edition secondary package that elegantly reflects Bardstown’s brand values while maximizing the permanence of the packaging materials.
One issue plaguing the bourbon industry is a lack of transparency by brands on where their spirits are distilled. Bardstown Bourbon is a “pioneer of transparency in the category,” says Smith, adding that “there are no secrets, myths, or fabricated stories.”
“Each product proudly showcases the age, the mashbill [the recipe of grains used to produce the whiskey], and origin of each whiskey in the bottle, allowing consumers to dive deeper into the education and truly discover what they love about each product,” he says.
The resulting package from IPL and Bardstown featured a cabinet-like design with a large viewing window and a sturdy handle. Shares Odendaal, the design was inspired by the modern furniture and contemporary architecture used by Bardstown for its distillery.
Bardstown’s requirements for the limited-edition pack were that it be able to securely house the three offerings in the Origin Series—Bourbon, Wheated Bottled-In-Bond Bourbon, and Doubled Barreled Rye—while offering visibility to each bottle.
Explains IPL Head of Design & Innovation LB Odendaal, “Each pack was intended as a collectible, limited offer that they would be gifting to investors, and they wanted each pack to be uniquely identifiable.” The package would also include a certificate of authenticity from Bardstown’s CEO, Mark Erwin.
Says Smith, “The design of these cases was sleek, modern, and even had a glass panel to lean into our brand ethos of transparency. With one of the most beautiful distilleries in the country, we wanted to capture some of those elements in this uniquely designed presentation.”
Also guided by Bardstown’s brand aesthetics was the selection of packaging materials, which included oak, rose-gold electroplated aluminum, natural fiber lining, and tempered glass.
Although not specifically directed to by Bardstown, IPL also created the package to minimize its environmental impact by maximizing its lifespan—a strategy that’s consistent with IPL’s approach to embedding sustainability in all projects.
“We approached this design with longevity and a second life in mind, by staying true to the materials used, making sure all are recyclable, and that the pack when recycled can be disassembled for single-stream recycling,” says Odendaal.
The final package was given to 100 Bardstown investors and is described by Smith as “an exceptional product.”
“Everyone absolutely loved these commemorative gifts, and the reception was entirely positive,” says Smith. “Truly a special keepsake for all those involved in the creation of these magical whiskies, marking the beginning of one of the most notable stories in contemporary distilling. —Anne Marie Mohan
The percentage of packaging professionals responding to a survey held at the SPC Impact 2024 conference who admit they are falling behind on regulatory awareness because of the sheer volume of requirements 40+
The number of North American mills that now accept single-use PE-coated paper cups in bales of mixed paper or poly-coated cartons and aseptic packaging for recycling
The projected valuation of the packaging automation market by 2031, representing a CAGR of 7.8% from 2024 to 2031, according to SNS Insider; one driver of this growth will be the booming e-commerce industry
“For the food and beverage industries, the demand for colour changing packaging represents a huge advancement. This technology can revolutionize the food safety industry and strengthen brand identity while also improving the consumer experience. A rise in the use of Colour Changing packaging solutions is anticipated as research and development continue to advance, and production prices become more affordable. This will bring in a future where colour plays a dynamic part in guaranteeing food safety and customer happiness, revolutionizing the way food is packed, promoted, and ultimately consumed.”
–Ismail Sutaria, lead consultant, Packaging and Materials, at Future Market Insights, Inc., in a release from the company, “Colour Changing Packaging Market to Reach USD 2,178.5 Million by 2034, Driven by Food Safety Concerns”
The amount by which an electronics brand’s turnover increases for every ≈$127 it spends on packaging design, according to the Design Council
“Minnesota’s packaging producer responsibility legislation is a fair compromise that establishes a model of shared responsibility and is aligned with AMERIPEN’s key principles. This legislation supports a system that is reliable, efficient, and effective, and enables a strong producer responsibility organization (PRO) to ensure that producer fees will directly fund initiatives to increase recycling and composting even further in the state.”
–Dan Felton, executive director of AMERIPEN, in an article from Waste Advantage magazine, “AMERIPEN Supports Packaging Extended Producer Responsibility Legislation in Minnesota”
“Many companies within the packaging sector have been operating for decades and currently do not have the capacity to pursue innovative ideas whilst maintaining their regular manufacturing output which already satisfies a consistent demand. We’re noticing that companies who want to pursue innovation are running into internal barriers. In a period where budgets are extremely tight and layoffs are being made, unless a company can guarantee the ROI, there simply isn’t enough justification to assign resource to innovation.”
–Steve Davis, global director of product management at Industrial Physics, in a release from the company, “Perception vs reality: New research from Industrial Physics reveals that less than a quarter of organizations are currently taking an innovative approach to packaging”
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At drupa, the world’s largest printing expo last month, Packaging World tagged along with Uwe Melichar, European Brand and Packaging Design Association VP, and a handful of big brand owners on a personally curated expo tour. We sat down after the tour to get his impressions of the show.
How did you get into packaging?
I wasn’t sure it should be in graphic or product design. I decided graphic design. I learned all about communication, design, branding… But the first time I was confronted with was packaging, I said, ‘That’s it. That’s exactly the link between 3D and 2D.’ It’s so exciting to have the three dimensions and, also, the different requirements. It’s more than just communication. It’s protecting the product. It’s about convenience for consumers. It’s close to people, and I love people.
What do brands need to know about the printing space?
It’s not the technology behind these companies they care about, it’s the solutions they can get. And it’s better than ever. They really can make their dreams come true. Because the technology’s there. You need somebody [like a designer] to translate it into projects. I can just ask brands to talk to designers, not only to your suppliers. Be open for new solutions and try to find someone neutral. Also, they should read your magazine Packaging World, and your web posts carefully, because you are neutral. Then we together can find solutions. Working all along the value chain, this is my major interest.
Tell us more about the European Brand and Packaging Design Association, your role there, and your day job. The EPDA has existed for more than 30 years. I had been the president for four years, now I’m a VP. We are members from across Europe, brands and their packaging or branding agencies. We do two conferences a year that are about inspiration and information. They also to give us as an industry design voice… Brand owners who want to get inspiration or find innovation go directly to the supplier. And that’s
wrong. Their suppliers don’t lie to them, but they may tell them just the part of the truth, or just a little bit of the scope of what is there. And we as designers, we have a broader view. I can translate something that works well in the tool industry, to the toy industry—or the other way around. Brands get a chance to see more if they talk to designers or to design associations. My actual status is part of a company [based in the U.K.] called Touch, a structural packaging design company with a focus on sustainability... but also on streamlining processes. That’s why we toured software from companies like Esko and Dalim
What’s your biggest takeaway after 10 days at drupa?
What excites me is what’s happening with digital printing, that’s why we visited HP Indigo and Landa. How it has evolved, the speed, the machines are so much faster. The results, the quality is so much better. The vertical integration, they can print on nearly every surface without priming, it. It’s exciting to watch what happens. Let’s see what the economic side says, of course. And then, [large traditional printing] companies have digital solutions. But again, I’m not the one investing in machines. I’m just looking at it from a brand owner’s perspective.
Paper and paperization is a big topic, hence our visit to Koehler Paper. It’s a buzzword, and consumers are asking for paper. At least in Europe, they think paper is the most sustainable material in the world, which is not always true depending on the application. I don’t do plastic bashing. But brands have to follow consumer sentiment. They must follow, even though I think they know that it’s not the full story. But they want to meet the consumer’s demand.
I’m always trying to look through the eyes of the brand owners and what they are interested in. They don’t want to know how the sheet feed is constructed. They don’t want to know how many colors, or the kinds of fibers, and this and that. They want to see a result that matches their expectations and want to have a good solution that’s affordable and sustainable. That’s their interest.
Is there any kind or story arc between drupa 2016 and 2024?
The world has changed. Looking at 2016, sustainability didn’t play a major role in those days. And now you see that technology is evolving even more quickly, with digitalization, with AI components. Technology in this space is looking like the so-called hockey stick. It’s not a linear development, it’s really moving fast.
At the same time, there are new demands. For example sustainability or connectivity. The things we are talking about here at Touchpoint Packaging [pavilion at drupa] come from the consumers’ mind. Consumers now think paper is the best solution for everything, but it’s not true. Still, we have to look at those sentiments.
Why are events like drupa or PACK EXPO so important?
During COVID people learned that they can discover everything online. That’s lazy, and doesn’t give the whole picture. That’s just my very personal statement, but it’s a problem. I believe in people meeting people. I believe in bringing people to the booths, like we did today on the tour, I believe in personal contact —Matt Reynolds
By Sterling Anthony, CPP, Contributing Editor
Trade dress deals with visual appearance: how an offering in commerce (i.e., trade) looks (i.e., is dressed), for purposes of identifying the source of that offering. For CPGs, package design is trade dress. Trade dress is a type of intellectual property (IP), a creation of the mind (i.e., intellectual) and owned (i.e., property) by its creator. Package design as trade dress is protected by laws against infringement (appropriation) that set the requirements that a brand owner (as plaintiff) must satisfy to prevail. Those requirements reflect the interrelationship among the disciplines of packaging, marketing, and legal.
The first requirement is that the brand owner provides a definition of the package design/trade dress. In so doing, the brand owner cannot just cite the elements (e.g. colors, fonts, images, etc.). Instead, the definition must be based on how the elements combine for an overall visual effect. Separate from a legal setting, this requirement is akin to the gestalt school of design where the whole is more than the sum of its parts. Various package design research methodologies are based on that concept.
Another requirement is that the package design be inherently distinctive, meaning that its appearance itself sets it apart. That’s legalese for shelf appeal or shelf impact, which is at the core of packaging’s role as a marketing tool. The package design/trade dress at the time of product launch and all subsequent revisions will affect the brand owner’s ability to argue that the package design/trade dress is inherently distinctive. A package design that has been registered as trade dress with the U.S. Patent and Trademark Office (USPTO) carries the assumption of being inherently distinctive, because the application process imposes criteria in that regard. Even if the package design is not registered, the brand owner still can make the claim of inherently distinctive.
be non-functional. In the non-legal sense, a function of packaging is communication, whereby the packaging is a medium for conveying information. For many CPGs, packaging is the main—often only— medium of consumer-directed communication. In the legal sense, however, the concern is with appearance—how the package design/ trade dress looks and not what it does. The two focuses are not mutually exclusive nor contradictory. In the practical sense, they are inseparably linked.
The last requirement is the likelihood of confusion experienced by consumers. There, the brand owner is claiming that the infringement is so mimicking that consumers will confuse one source for the other. The likelihood of confusion can’t be evaluated in a vacuum, which is unsurprising given that a lot about packaging involves interrelation and overlap. The likelihood of confusion is affected by the definition requirement: how the overall appearance is perceived. The likelihood of confusion also is affected by the requirement of distinctiveness, which is supposed to serve against confusion, short of intentional infringement.
Package design as trade dress is protected by laws against infringement (appropriation) that set the requirements that a brand owner (as plaintiff) must satisfy to prevail.
In addition to having to satisfy the standards of proof for the aforementioned requirements, the aggrieved brand owner has to specify the type of harm incurred and the remedy sought. The accused brand owner, on the other hand, has available various court-recognized defenses. Although only lawyers can argue a case, they need to be assisted by personnel who have relevant knowledge about the history of the at-issue package design/trade dress.
A related requirement—more of an option—is that of acquired distinctiveness, wherein consumers associate the package design/ trade dress with a particular source, even in the absence of inherent distinctiveness. Acquired distinctiveness is achieved through a long presence in the marketplace, even achieving secondary meaning, in the form of additional positive associations made by consumers. Newcomers, therefore, don’t have the privilege of asserting acquired distinctiveness. Traditionally, it’s the province of category leaders and iconic brands. That said, what brand owner does not aspire to join such ranks, or if already a member, to retain membership? It can’t be done without optimal leveraging of package design/trade dress, essential for product positioning and mind mapping.
Yet another requirement is that the package design/trade dress
Packaging is interdisciplinarian and legal is one of the disciplines with an input. Packaging also is highly regulated, and a good deal of the packaging/legal interface is about compliance. Infringement is a different matter of less frequent occurrence. It’s not improbable for a package design or redesign to be created without top-of-the-mind awareness that trade dress also is being created. An example is a brand owner’s need to keep a package design updated and relevant with the times. Depending on where a redesign falls between minor and overhaul, its status under trade dress infringement law can be affected proportionately.
Any packaging design strategy should acknowledge certain truths about trade dress. Truth 1: package design is a potential source of competitive advantage. Truth 2: given that potential, any package design might be infringed upon, whether intentionally or unintentionally. Truth 3: IP law grants package design status as trade dress and governs related disputes. Truth 4: the party that has invested the greater amount of planning and foresight is more likely to prevail. PW
15 YEARS AGO, WE INVENTED BIODOLOMER. A bioplastic with limestone as the key ingredient. Biodolomer is fully compostable (certified by TÜV and BPI), and when decomposed, it will actually leave extra calcium from the limestone in the soil.
Biodolomer comes in granules that can be used for thermoforming, film blowing, extrusion coating, injection molding... you name it.
It does all the good stuff that plastic does. But not the bad.
It contains only ingredients that are approved by the FDA. It uses less energy in production and results in up to 80% less CO2 than traditional plastic.
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Biodolomer might just be the easiest way to make your brand more sustainable. For real.
By Anne Marie Mohan, Senior Editor
Kelly McBee, circular economy manager at As You Sow, a non-pro t investor organization focused on increasing environmental and social corporate responsibility, opened a recent webinar with a stark warning: “Plastic pollution is set to nearly triple by 2040 without drastic action, and we are not on track to take action against this growing threat.” This statement set the tone for the unveiling of the “2024 Plastic Promises Scorecard,” a collaborative effort between As You Sow and environmental solutions platform Ubuntoo. The report evaluates 225 major companies across 15 industries on their progress in combating plastic pollution, revealing a landscape where much remains to be done.
The urgency of the situation is underscored by emerging science linking microplastics to chemicals found in the human body. This has galvanized various stakeholders, including corporations, investors, and policymakers, to scrutinize their roles in addressing plastic pollution. Despite setting ambitious targets, companies are struggling to meet their goals, with the report showing that none of the evaluated companies received a score in the A range. Only nine companies, including The Coca-Cola Company, Keurig Dr Pepper, SC Johnson, and Unilever, managed to score in the B range.
Venky Kini, co-founder of Ubuntoo, delved into the granular findings of the report, noting that recyclability was the most common goal among companies. However, only 22 companies are on track to meet their 100% recyclable plastic packaging targets. Kini highlighted the gap between theoretical recyclability and practical, at-scale recyclability, emphasizing the need for companies to define recyclability in a way that allows consumers access to recycling facilities.
The report also examined recycled-content goals, with 145
companies setting explicit targets. Yet, the availability of recycled material remains a significant hurdle. Kini recommended prioritizing post-consumer over post-industrial content and pointed to beverage container deposit schemes as effective in improving recycled content availability.
One of the most ambitious goals evaluated was the recovery of plastic packaging waste post-consumer. Only nine companies have declared explicit goals to recover their packaging from the environment, with some committing to 100% recovery. This goal represents a crucial step towards reducing plastic pollution, though it remains a challenging endeavor.
McBee shared insights on the use of reusable packaging, including package-free and refillable formats. While 43 companies are piloting reusable initiatives, few have set quantitative, time-bound goals to integrate these pilots into their operations permanently. McBee emphasized the importance of uniform data tracking and greater transparency on reusables reporting to allow investors and stakeholders to assess corporate progress accurately.
Extended Producer Responsibility (EPR) for packaging was another critical area addressed in the report. EPR holds companies accountable for the end-of-life management of their packaging. The report found that 73 companies are proactively engaging in EPR, supporting recycling infrastructure and legislative efforts. McBee encouraged companies not yet involved to adopt public-facing support positions on EPR policies, potentially influencing the passage of more comprehensive regulations.
The highest scores in the report came from signatories of the Ellen MacArthur Foundation’s Global Commitment, the largest global voluntary effort to tackle waste and plastic pollution. Aisha Stenning, global commitment program manager for the Ellen MacArthur Foundation, noted that committing to the initiative led to signatories being better informed and taking more targeted action. The transparency and accountability created by publicly committing to these targets fostered a collective effort among peers, suppliers, and customers.
As the higher scores of the Global Signatories demonstrate, crosssector collaboration is crucial as industry continues to grapple with the plastic pollution crisis. Governments, corporations, non-profits, and consumers must work together to create a sustainable future. The As You Sow report serves as a crucial reminder that while progress has been made, there is still a long way to go. The collective efforts of all stakeholders will be essential in driving the systemic changes needed to address this pressing issue. PW
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By Patrick Llewellyn, CEO, 99designs
Whether it’s a holiday, important cultural moment like Pride month, or even a limited-edition product launch, there are countless opportunities to connect and celebrate with consumers in a joyful way that also boosts business.
Key dates and events throughout the year provide brands with a unique chance to embrace creativity in their branding and push the boundaries when it comes to smart packaging design. Creative branding and campaigns anchored to these events and moments enable you to differentiate your brand, create buzz, and ultimately drive sales in a timely and relevant way. Here are three strategies to capture attention and tap into the magic of seasonal opportunities.
When it comes to holiday branding, Starbucks leads the way, with the annual unveiling of the latest red holiday cup design making headlines and becoming a cultural moment in its own right. By running a promotion giving away free reusable red cups on Red Cup Day, they create the kind of hype that has consumers flocking to the nearest Starbucks as the temperature drops.
Whether you’re a Starbucks fan or not, the beauty of this concept is in its simplicity: A Starbucks cup is a piece of visual branding, instantly recognizable and synonymous with feel-good treats. The core visual brand elements remain central to the design, but a seasonal glow up makes the packaging feel special and elevates the overall experience.
This is a tactic that all brands can tap into, even with something as simple as adding festive elements to an existing logo design. Michael Mills, owner of Symmetry Coffee Co. in Florida worked with 99designs by Vista to add a Christmas twist to his already striking logos, printing them on everything from coffee cups to signage.
Michael couldn’t be more confident about the impact of this seasonal cheer. “In addition to the financial benefit, by putting a holiday spin on our branding, we’re anticipating that even more people will be interested in what we have to offer, even if they aren’t coffee drinkers,” he says. “Everybody gets so captivated by visuals. Spicing up your branding for a holiday is what really can catapult you to another level and capture people’s attention.”
Symmetry Coffee’s Christmas logos have already proved a hit with investors and focus groups. With the company set to expand to four locations, it is about to debut to a wider public than ever before, and seasonal designs differentiate them from other players in the market. “With our branding, we’ve leaned into nautical characters and wildlife because of where we are based in Florida. So, in that sense, we’ve made ourselves more locally relevant,” Mills says. “Now with our holiday-themed versions, we are becoming more seasonally relevant. That is a powerful combination that will work well for our business.”
Starbucks, watch out!
2. Launch limited editions for emotional connection
Gifts are all about making someone feel special—and there’s no better way of communicating that than by giving a loved one (or yourself!) unique, limited-edition products. Brands everywhere can easily lean into this trend through seasonal packaging design, but also by creating unique offerings tailored for a particular event or milestone.
One trend that seems to be growing in this space year-onyear is brands across varying industries releasing a limited run of advent calendars with beautiful seasonal designs. Products like these create in-home moments of brand connection with customers; they’re like tiny unboxing moments that count down to the holiday itself.
However, tying your products to any specific holiday or celebratory event expands the influence of your brand from the moment of purchase, associating it intrinsically with the positive feelings evoked by the celebration or event itself.
Some great examples include a bakery embracing 4th of July celebrations by peppering its packaging (and baked products) with patriotic designs and a distinctly red, white, and blue color palette. Or look to the brand SevenYays (facing page, bottom right), which created an advent calendar-style product that contains seven surprise gifts, perfect for building anticipation over the seven days leading up to any celebratory event, like a birthday.
These beautifully designed limited editions draw customers in with a sense of occasion and excitement, with brands becoming part of the celebration experience for consumers.
One of the most exciting possibilities when it comes to seasonal branding is the opportunity to embrace trends, have fun with your brand, and take bigger creative chances. Packaging is a bit of a creative sandbox. Experimenting with and leveraging elements of your visual identity—for example, your brand color palette or typography—and trying something new is much less of a risk when it’s for a special release and not a rebrand. This is an excellent opportunity to tap into visual trends that are of the moment, even if they don’t align completely with your brand guidelines or typical look and feel. The trick is to identify the design trends that will resonate with your target customers and demographics and leverage the shelf appeal that they will give your products.
For example, Sephora is embracing packaging designs that lean into the Gen Z checkerboard aesthetic overlaid with stickerlike motifs that tie directly into one of 2024’s hotly tipped “cluttercore” graphic design trends. While it isn’t a look the brand would necessarily want to commit to long-term, this tactic clearly targets a younger demographic that is a core pillar of Sephora’s customer base and helps the brand remain relevant and timely.
There is always opportunity around major events and milestones to push the boundaries of your branding and engage with consumers by tapping into upcoming celebratory experiences. Just remember, whether it’s your packaging design or a special edition of your logo for your website and socials, consistency across design, messaging, and any promotions you run will ultimately help, not harm your brand image. PW
Patrick Llewellyn is CEO of 99designs by Vista, a global creative platform that enables small businesses to work with professional freelance designers around the world.
An extraordinary network of inventors, developers, OEMs, and stakeholders emphasize ‘progress over perfection’ as they commercialize a breakthrough bottle.
By Pat Reynolds, Contributing Editor
London-based Diageo—the maker of Johnnie Walker Scotch Whisky, Don Julio Tequila, and Guinness—recently tested paper-based bottles for Baileys, the Original Irish Cream Liqueur. Made of 90% paper and including a thin PET liner, the bottles are designed for recycling in standard paper streams and do not require the consumer to separate the PET liner when disposing.
The packages were made by way of Dry Molded Fiber technology, invented by Sweden’s PulPac and covered by multiple patents. Completing the noteworthy package are an induction-sealed foil lid and a pressuresensitive paper label with hot-stamped gold used for the gold double B
Web to Blank
Unwind a roll of de brated pulp, spray it with a sizing agent, apply a layer of tissue and slice it into sheets
symbol at the top of the bottle. The trial took place May 25- 26 at Time Out Fest in Barcelona, Spain, where 2,000 mini Baileys containers each holding 80 mL were made available to those who attended the food fest.
To understand why Dry Molded Fiber is potentially such a game changer it helps to point out that the tried and true method of forming ber into packaging—think egg cartons, for example—involves considerable time, energy, and water. It begins with paper, typically recycled materials such as newspapers, paperboard, and other types of paper waste. These are pulped to break them down into individual bers, and the pulp is then mixed with water to create a slurry. This slurry is poured
Injection molding of the preforms which become the liners in the bottles
Take a at sheet of uff pulp and form it into semi-rigid half-bottle shapes
Take the half-bottle blanks and pressure form them into rigid bottles
Internal Lining Module
Blow liners inside the bottles
Spray the bottles with a hydrophobic coating and cure them in a tunnel oven
This schematic drawing illustrates the six main modules of the Demonstrator Line on which the Baileys bottles were produced.
into a mold designed to create a consistent shape and size for the egg cartons. Next is a press, which applies pressure to remove excess water from the pulp. Last comes drying to remove any remaining moisture.
This is a slow and resource-intensive process, one that Dry Molded Fiber technology is able to sidestep. PulPac claims that Dry Molded Fiber is 10 times faster than conventional wet molded fiber methods. Once it gets fully scaled up, say its backers, it will be a way of converting renewable plant fibers into fully recyclable packaging that can replace single-use plastic at a cost that is competitive. Other benefits include low energy use and almost no water demand in the molding process. This results in a package with strong sustainability credentials. Initial screening Life Cycle Assessment data for the Baileys bottle suggests it will have 25% lower CO2 emissions than the current rPET package.
It’s important to note that Dry Molded Fiber technology can be used to form almost any three-dimensional packaging product. (See sidebar on page 24 for a description of how the technology is used to make paper cutlery or cup lids used in the foodservice industry.) In this account we’ll focus on how the Baileys bottle was made. But before looking at the bottle-making technology itself, it’s essential to look at the PulPac business model and the network of partners and co-developers upon whose shoulders the Baileys bottle stands. First and foremost in that network is PA Consulting, a London-based company that takes new ideas from concept through design and development and on to commercial success. Jamie Stone, sustainability and innovation expert at PA Consulting, puts it this way: “We’re in the business of taking things from invention to industrialization.” In 2022, PA and PulPac formed something called the Bottle Collective to create the world’s first Dry Molded Fiber bottle. The Bottle Collective is inviting partners to join now. It’s a first-come-first-served deal and partners get commercial exclusivity in their product category for three years post launch. Current partners include Diageo; Paris-based Sanofi, a global healthcare and pharmaceutical company; Haleon, a global consumer healthcare product company based in Weybridge in the U.K.; and Portugal’s Logoplaste, a maker of rigid plastic containers.
As for the PulPac business model, they own the Intellectual Property behind Dry Molded Fiber but they are not builders of container-making machinery. They get a per part royalty fee from container-making converters who sign a licensing agreement with them. The converters buy container-making equipment built by OEMs that PulPac has identified as a turnkey provider. (See sidebar on page 24 for a look at one such turnkey provider, JOA.)
Getting back to the Baileys test, which at 2,000 bottles was small in scale to say the least, the bottles were made at PA Consulting’s Global
Innovation and Technology Centre in Cambridge, U.K. They were then transported to Ireland to be filled and induction sealed by the Baileys’ team at the filling site prior to shipment to the Barcelona test site. This was Diageo’s first consumer-facing trial with paper-based bottles. It tested not only how the bottles traveled from Ireland to Barcelona, but also how consumers interacted with the material and how they understood the sustainability credentials of a paper bottle.
The bottle-making line used at PA Consulting’s Cambridge facility, called the Demonstrator Line, represents Phase 2 in the Bottle Collective’s push toward full-scale commercial Dry Molded Fiber bottle production. In Phase 1, bottles were created using adapted machinery and manual transfer between process steps. With the Demonstrator Line comes more automation, as the process is divided into six integrated modules that work together with little human intervention. The Demonstrator Line not only increases efficiency and throughput for bottle production, it also provides a testing and learning environment to help the Bottle Collective prepare for production at true commercial scale.
The six modules of the Demonstrator Line can be seen in the illustrated schematic on the facing page. Module 1 is called Web to Blank. The large blue box is a mill into which rolls of fluff pulp are fed. The mill grinds the fluff pulp to separate the fibers from each other, and these fluff pulp fibers are “air laid” onto a rollfed tissue paper that rides on a conveyor belt running at an incline. Next is a series of rollers where a couple of things happen, including a spray application of AKD (alkyl ketene dimer), a sizing agent commonly used to bring hydrophobicity to paper substrates of all kinds. In other words, the sizing agent helps the paper resist absorption of moisture.
The last thing that happens in Module 1 is the continuous roll of material is cut into blanks. These blanks are fed into Module 2, the Blank Preparation Module. Here the flat blank that was created in Module 1 is folded and manipulated to form a semi-rigid half-bottle shape. Meanwhile, in Module 3 or Liner Preform Molding, a PET preform is injection molded. In Module 4, the pink one, the two bottle halves are enclosed in a mold so that heat and pressure can be used to join the two half bottles into one full bottle. A physical reaction called “hydrogen bonding” creates a firm bond where the two bottle halves meet at what would be called the “parting line” in extrusion blow molding of plastic bottles. In Module 5, bottle exteriors are sprayed with a hydrophobic coating followed by curing in a tunnel oven. Other coatings can also be sprayed on here depending on what kind of product is involved. Finally, in Module 6, the PET preform, now inside the bottle, is blown out to the interior sidewalls.
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Also forging ahead with Dry Molded Fiber technology is JOA, makers of machining and converting equipment for disposable hygiene products ranging from baby diapers to feminine hygiene products. Ryan Brown, business development manager at Sheboygan Falls, Wis.-based JOA, says they’re a natural fit for Dry Molded Fiber because fluff pulp treated with hydrophobic coatings and laminated between layers of tissue paper lies at the core of the hygiene products that converters make on machines built by JOA. “Much of the technology behind Dry Molded Fiber is just what we do with the machines we’ve always built,” says Brown. “We just had to repurpose it for Dry Molded Fiber.”
JOA is one of PulPac’s turnkey providers. (For more on the PulPac/PA Consulting/ JOA relationship, see surrounding story about the innovative Baileys bottle). The first converter to buy a Dry Molded Fiber system from JOA is Matrix Pack, a leading manufacturer of innovative and sustainable packaging solutions with factories in Greece, Bulgaria, U.K., and Thailand. Its North American footprint includes a manufacturing facility in Florence, Kentucky, and another in Portland, Ore., plus offices in Chicago.
And just how did an JOA, based in Sheboygan Falls, meet Athens, Greece-based Matrix Pack? At interpack 23, of course, at the PulPac booth. Matrix Pack will use the JOA-built equipment to produce cup lids and trays and will join PA Consulting as a co-developer in the industrialization of the post-production processing solution to produce sustainable cutlery for the foodservice business. Consistent with the PulPac business model, Matrix Pack will pay a per item royalty to PulPac.
The system made by JOA, called the PulPac Modula, does everything in a single pass, from mill to web to press to robotic removal of finished parts. The front end resembles the system on which the Baileys bottle is made. Rolls of fluff pulp are fed into a mill that produces fluff pulp fiber. Emerging from the mill the fluff pulp fiber with a thickness between 400 and 800 gsm is “air laid” into a dry web roughly 2 ft wide. A fine mist of water is sprayed on this web followed by a spray of AKD sizing agent. Then a 29 gsm paper tissue is laid on top.
Here is where the manufacturing process veers from the bottle-making setup that produces the Baileys bottle. The web is fed back in the opposite direction so that the opposite side of the fluff pulp fiber can be sprayed with the same water mist and AKD sizing agent. Then a second paper tissue is applied to form a sandwich of paper, fluff pulp fiber, paper. Then, instead of cutting the roll-fed material into blanks as we saw in the bottle-making system, the roll feeds into a 24-cavity stamping press from Seyi. If cutlery is the item being made, 8 tons of pressure are applied and each tool is heated to 150°C. According to PulPac, that’s a notably modest amount of energy being consumed. Or suppose cup lids are being produced, like the ones shown on the facing page, upper left. They can be formed 24 per cycle in 4 seconds. Also shown here is the tooling used for just such a job. Worth noting is that there is a silicone insert on the male side of the tooling that pushes towards the outer edges of the lid and helps it create an undercut that lets the lid snap tightly onto the cup.
When asked if PulPac invented a whole new method of stamping or if instead it copied existing technologies, PulPac Chief Operating Officer Viktor Borjesson says it was half and half. “This press is essentially a stamping press from the metal industry,” says Borjesson. “But it’s a very sophisticated stamping press so we can program it to behave in a certain way. The tooling also reminds you of what you might see in some thermoforming or injection molding systems, but it’s different because none of those systems is forming fibrous materials. It was a matter of relying on what’s already out there while still introducing unique ways of controlling pressure and temperature to create something entirely new.” PW
Built by JOA for Matrix Pack is the PulPac Modula shown here. The cabinet on the far left with the JOA logo on it (A) is the mill where a roll of uff pulp is ground into uff pulp ber. The section labeled B is where a tissue paper/ uff pulp ber/tissue paper “sandwich” is made. That three-layer material is indexed left to right at oor level beneath the cabinet with the green Seyi logo on it (C) until it reaches the cabinet on the far right. Here it rides around a large wheel (D) that takes it from oor level and sends it back in the opposite direction to the 24-cavity press at the height of that press (E). A robot picks nished parts from the tooling, and the skeleton trim material proceeds straight back into the mill to be ground up again into uff pulp ber. Inset top right shows a closeup of the 24-cavity press and inset top left shows nished parts.
High-speed Robotic Picking/Placing
Stretch Wrapping with Corner Board
Transfer Cars & Conveyor Systems
Material Handling
Collective to make it possible to do in-mold paper labeling in the Blank Preparation Module. Another firm providing valuable input in the injection-molding part of the puzzle has been Arburg. In describing the Arburg contribution, PA Consulting’s Stone says this.
“Throughout the ongoing development process we keep buying Arburg equipment and immediately invalidating the warranty by taking it apart and putting it back together in a different order. But we make sure we show them what we did and precisely why. This way, ultimately, we will show what needs to happen so that the ecosystem of machinery builders will make true commercialization happen. That’s how this technology will scale. It’s not like we’re not trying to hold the secrets. Instead, we’re trying to invent it and build mass scale very quickly. Throughout that process, our relationship with PulPac doesn’t change. And they still take a royalty per part on that business when it gets there.”
The Demonstrator Line is capable of something like 300 bottles/hr. The line PA Consulting would like to see running in the near future will produce more like 3,000 bottles per hour. Who will operate that line remains to be seen. Presumably it will be a converter funded by the Bottle Collective.
Words like “presumably” and “who will operate that line” permeate any current discussion of what PulPac, PA Consulting, and the Bottle Collective are trying to accomplish. All stakeholders involved readily acknowledge that there’s a ways to go. But the overriding attitude is perhaps best expressed by Diageo’s Ewan Andrew, president, global supply chain and procurement and chief sustainability officer. “When it
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comes to our packaging,” he says “we’re taking an approach of progress over perfection, knowing our packaging will need to evolve along with consumer needs and technological advancements. The consumer is becoming more sustainability savvy and we believe we can meet that need using our design and innovation to bring premium products and more sustainable solutions together.”
PW
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Cadbury, Churchill Container, L’Occitane, and PepsiCo explore advanced recycling technologies to help meet their commitments for less virgin plastic and more PCR material in their packaging.
By Anne Marie Mohan, Senior Editor
As the global consumer packaged goods industry nears its self-imposed sustainable packaging deadline of 2025, it’s clear the majority of companies will not meet their goals. For most, their commitments entail a significant reduction in the use of virgin plastic and an increase in the use of PCR. Therein lies the problem: The amount of PCR needed by these companies far outstrips what’s available.
According to a recent report from ICIS, in 2022, 500,000 tons of PCR was sourced; to meet CPG’s 2025 goals, 4 million tons will be needed.
While two of Cadbury’s largest competitors in the Australian confectionery market—namely Mars and Nestlé—have taken the paperization route to meet their sustainable packaging commitments, the Mondele - z brand is pursuing another equally innovative path: the use of chemically recycled plastic. In March 2024, the maker of such iconic brands as Cadbury, Pascall, and The Natural Confectionery Company announced it was collaborating with film converter Amcor and chemical company ExxonMobil to dramatically increase the circular plastic used across the wrappers for its core chocolate portfolio.
Cadbury first introduced biaxially oriented polypropylene PCR into the packaging for its family blocks, or bars, chocolate range in 2022, with 30% mechanically recycled material. However, the limited global supply of food-grade PCR content and an increase in demand for the
The advent of advanced recycling technologies, however, has opened up the potential for abundant new sources of PCR plastic. As reported by Research and Markets, the global market for advanced recycling technologies is projected to exceed $9 billion by 2031, up from $270 million in 2022, representing a 32% increase every year.
Following are examples of CPGs that are embracing advanced recycling as a source for PCR plastic as a means to meet their internal and external sustainable packaging commitments.
Watch this video to learn more about ExxonMobil Exxtend technology: pwgo.to/8304
material, including its own ambitions to expand its use of recycled plastic, drove the company to pursue a new source for rBOPP.
“Increasing the use of recycled content is a critical factor in the establishment of a true circular economy for sustainable packaging,” says Cadbury.
“Reducing our reliance on virgin materials will decrease the pressure we put on the planet’s nite resources and ensure that valuable materials are not lost to land ll.”
Cadbury found that new source of PCR with Amcor, which is converting BOPP using certi edcircular content resulting from ExxonMobil’s Exxtend technology. According to ExxonMobil, unlike mechanical recycling, which involves chopping or shredding plastics into smaller pieces and melting it down to form a limited range of new products, Exxtend’s chemical recycling technology, often referred to as pyrolysis, uses heat to transform plastic waste at a molecular level into raw materials used to manufacture new PP and polyethylene. As a result of this process, the subsequent resins are indistinguishable from virgin plastic, but with a smaller environmental footprint. According to a cradle-to-gate lifecycle analysis (LCA) from Sphera, for every 1,000 tons of waste plastics processed using Exxtend, 185 to 525 tons (19 to 49%) less CO2 equivalent emissions (CO2e) are produced versus processing the same amount of fossil-based feedstock.
Exxtend is capable of processing a range of hard-to-recycle plastic that mechanical recycling can’t, e.g., multi-material exible plastics, arti cial turf, bubble wrap, and motor oil bottles, with higher levels of contaminants. The company sources its feedstock from partner Cyclyx, which collects and processes plastic waste that is currently destined for land ll.
In Cadbury’s case, it will be using 1,000 metric tons of certi ed circular BOPP leveraging ExxonMobil’s Exxtend technology to package approximately 500 million family-sized Dairy Milk Chocolate blocks. Given the virgin-like quality of ExxonMobil’s Exxtend PP, the new lm enables Cadbury to meet the same consumer expectations for performance, safety, and product appearance as with its previous packaging.
The rollout of the new packaging for Cadbury’s chocolate blocks began in late Q1-2024. According to the company, it plans to expand the use of the material to other products, including Crunchie, Twirl, and Cherry Ripe bars. Says ExxonMobil, “Plans for 2024 include scaling up the use of certi ed circular plastics, with anticipated growth in 2025.”
A prime example of the scale of collaboration that’s required today to drive sustainable packaging innovation is a new snack bag that can be found on shelves in the U.K. and Ireland for PepsiCo Europe’s Walkers Sunbites chip brand. Introduced in late 2023, the new snack bag is made from 50% recycled content from chemical recycling technology
and is the result of a partnership between six supply chain partners: Green Dot, Plastic Energy, Ineos Ole ns & Polymers Europe, Irplast, and Amcor, along with PepsiCo.
The launch moves PepsiCo Europe closer to ful lling its PepsiCo Positive (pep+) commitment to eliminate virgin petroleum-based plastic in its crisps and snack bags by 2030. Speci cally, PepsiCo says the move to the new material will eliminate 200 metric tons of fossil-based plastic, based on 2023 U.K. annual sales volumes of Sunbites, across the snack packaging by end of 2025.
The pivotal piece of technology that enables the production of the certi ed circular packaging is Plastic Energy’s patented Thermal Anaerobic Conversion (TAC). Using this patented pyrolysis process, Plastic Energy heats plastic waste until it becomes a plastic melt, then pumps it into its reactors. There, the plastic melt is further heated in the absence of oxygen and changes from a liquid to a vapor. Condensed vapors are then re ned through a series of separators and ltration steps, creating a synthetic pyrolysis oil, branded Tacoil by Plastic Energy, that is then used as a feedstock for new plastics.
According to Plastic Energy, results of an LCA of its process show that to produce 1 kg of low-density PE, chemical recycling emits 0.86 kg CO2e, or 55%, fewer emissions than producing 1 kg of plastic from fossil origin. “Compared to virgin (fossil) LDPE plastic, chemically recycled LDPE has lower climate change and resource depletion scores,” the company says.
Tacoil is made from low-quality, mixed-plastic polyole n waste, including high-density PE, LDPE, polystyrene, and PP that would otherwise be incinerated, sent to land ll, or downcycled. This includes multilayer exible lms that can’t be recycled, as well as monolayer lms that, while recyclable, are oftentimes used for non-packaging applications such as synthetic lumber for decking or park benches.
GreenDot, which began as an EPR licensor in Europe and has since expanded its capabilities to collecting, sorting, and mechanically recycling packaging waste, is procuring the plastic waste feedstock for the Sunbites package. In May 2024, GreenDot announced that PepsiCo would be supporting its investment in new recycling solutions, including advanced recycling facilities.
Said PepsiCo Europe Chief Sustainability Officer Archana Jagannathan at the time of the announcement, “The partnership is critical to scaling our operations and working together towards our shared goal of creating a circular economy for packaging. Advanced and mechanical recycling are part of a broader suite of recycling we are leveraging to bring us one step closer to this goal. Closing the loop between plastic and recycled content is a central part of our PepsiCo Positive agenda. We aim to reduce the waste we send to landfill in our direct operations and across our value chain.”
For the just-released Sunbites packaging, after GreenDot supplies the plastic waste feedstock to Plastic Energy and following Plastic Energy’s conversion of the material into Tacoil, global chemical company Ineos uses the Tacoil as an alternative to fossil feedstock to produce recycled propylene, before turning it into virgin-quality rPP resin. The resin is then used by Irplast to produce BOPP film, which is finally converted by Amcor into Sunbites flexible film packaging. The recycled polymer content of the packaging is ISCC-Plus certified
Upon the launch of the new packaging, PepsiCo UK & Ireland Sustainable Packaging Lead Gareth Callan said, “The Sunbites transformation marks our ongoing commitment to offering products that are better for both people and planet. We’re proud of the progress we’ve made so far to reduce the fossil-based plastic we use and meet demand for healthier snacking options without sacrificing the taste.”
Since 1980, Churchill Container of Lenexa, Kan., has been designing and manufacturing collectible and reusable drinkware and snack containers for a range of entertainment venues, namely stadiums and arenas, but also restaurants, theatre concessions, convenience stores, and retail. Several years ago, while researching sustainable packaging alternatives, Churchill came upon PureCycle Technologies and its PureFive rPP, produced through a patented, solvent-driven purification technology. In March 2024, the two companies announced they had successfully produced a PP cup made with 50% PureFive rPP resin.
Churchill has always had a focus on sustainability, partially driven by its customers’ needs. “The brands we serve have a high public profile and are uniquely influential,” says Erik Johnson, director of Design & Product Development for Churchill Container. “Environmental responsibility is one of our core values, and as a supplier to these brands, Churchill is in a position to help make a difference. By developing sustainable solutions for our clients, we have an opportunity to contribute to their positive influence.”
By their very nature, Churchill’s reusable cups and containers offer a better sustainability proposition than single-use packaging. To enhance that positive environmental footprint, the company offers items with recycled material. However, working with mechanically recycled PP has been a challenge. “There are two main problems with rPP,” explains Johnson. “The first one for us is melt flow. Most mixed rPP falls into a very low melt range so it can only be blended at low percentages. The second problem we run into is the lack of purity. Typical rPP is streaky, speckled, and carries unpleasant odors. Even if the material passes safety
testing, no one wants to drink or eat out of a smelly, dirty-looking cup.”
Unlike rPP resulting from mechanical recycling, PureFive rPP is free of contaminants. With filtration and extraction at the heart of the process, PureCycle’s patented purification technology involves seven steps, during which color, odor, and other contaminants from plastic waste are removed, transforming it into ultra-pure recycled resin. In 2024, PureCycle received a Letter of No Objection from the FDA confirming the company’s PureFive Ultra-Pure Recycled resin is suitable for use in food-contact applications.
For feedstock, PureCycle primarily purchases curbside-collected and baled PP scrap from waste collection companies. Other waste plastics used as feedstock include PP raffia, food packaging film, and carpet fibers, traditionally destined for landfill.
PureCycle also actively supports the proper disposal and collection of PP, as well as other packaging waste, through its PureZero Program, established in 2021. Shares PureCycle Corporate Communications & PureZero Manager Christian Bruey, “The PureZero Program began as an effort to help professional sports organizations and entertainment arenas better recycle the plastic waste from their events.” At present, the Cincinnati Bengals, Cleveland Browns, and Jacksonville Jaguars are all PureZero partners.
As Bruey explains, one of the keys to improving recycling at the stadiums has been the implementation of a “stadium pick,” where stadium cleanup crews focus on recyclable materials, such as plastics and aluminum, and put them into separate bags from the food waste. “This helps to decrease the contamination levels for the waste haulers and also
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Over two dozen educational presentations will explore your biggest challenges and greatest opportunities. Packaging World’s 2024 Packaging Recycling Summit will bring together all segments of the circular supply chain, September 16-18 in Anaheim.
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Extended Producer Responsibility (EPR)Multiple sessions explore fundamentals, upcoming regulation, and lessons learned from current implementations.
Leading consumer brands share their recycling e orts and vision via presentations from The Coca-Cola Company, Danone and McCormick & Company.
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Research findings from NielsenIQ and PMMI reveal how sustainable packaging claims influence consumer behavior, and trends in U.S. packaging design.
Integrating recyclable materials with established machinery: implications and strategies
Advanced recycling technologies: transforming packaging waste into opportunity
Materials-specific sessions on glass, paperboard, flexible film and more Seats are filling fast! Learn more at:
• Advanced recycling, also referred to as molecular recycling, comprises three categories of technologies: purification, depolymerization, and conversion.
• The most common type of advanced recycling is conversion, or pyrolysis, which is a form of chemical recycling.
• While each technology requires its own specific feedstocks, all categories can recycle plastic materials that cannot be processed by mechanical recycling.
• The resins resulting from advanced recycling are indistinguishable from their virgin counterparts, making them fit for food- and pharmaceutical-grade packaging applications.
• When chemically recycled materials are mixed with virgin plastic during manufacturing, the mass balance approach is used to determine the amount of recycled content in a final product.
• ISCC Plus certification provides traceability along the supply chain and verifies that companies meet environmental and social standards. PW
increases the amount of material that is recycled,” says Bruey, adding that messaging and signage are also vital to the success of the program.
As Johnson recalls, it was the PureZero program that brought PureCycle to Churchill Container’s attention, and it was the quality of the material that sold them. “We were drawn to their material in large part because of the purity,” he says.
For the proof-of-concept project, Churchill produced a cup with 50% PureFive, using an additive from Milliken to modify the melt flow of the resin. “This gives the PureCycle material similar characteristics to Churchill’s virgin materials and allows Churchill to incorporate recycled content into their product at levels previously unattainable,” says Bruey.
Commenting on the choice to use 50% rPP, Johnson says the goal was to start with something the company knew it could achieve and build from there. “PureFive easily met our standard specifications at a 50% blend so that has been fully qualified,” he says. “It is possible for us to run closer to 100% [up to 98% with Milliken’s modifier], but we need to do some additional testing before we officially qualify it for testing.”
Now that the viability of the 50% PureFive rPP cup has been proven, Johnson says Churchill will begin to actively market it as part of the company’s latest product offering. “Our usage will be driven by customer demand,” he says, “but we would eventually like to offer it across our full line of in-mold-labeled products and possibly others as well.”
At a time when CPGs’ environmental credentials around packaging are being closely scrutinized, it’s not uncommon to hear a brand say that sustainability is part of their DNA. For L’Occitane en Provence, a French luxury retailer and manufacturer of cosmetics, wellbeing products, and fragrances made from natural and organic ingredients, this claim is verifiable. Upon the company’s founding in 1976, it offered a bottle return system and since then has added eco-refills, in-store collection, and refill fountains to its offerings. In addition, it has standardized the use of just three plastics—PP, PE, and PET—to ensure its packaging is recyclable.
The company has also been a pioneer in the use of recycled plastics. According to L’Occitane en Provence R&D Packaging Director David Bayard, in 2008, L’Occitane was the first to put shampoo in a 100% rPET bottle. Looking toward 2025, the company has committed to having 100% of its retail bottles in 100% rPET.
“So far we are around 55 to 56%, but we have some limits with mechanical recycling,” shares Bayard. “The main limit for us is color. As soon
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as you mechanically recycle the resin, there is an impact on color. And when we have a package for a product such as body lotion, for instance, which is mainly white, the impact for us in terms of image is not acceptable.”
Recognizing this challenge, in 2021, L’Occitane invested in Carbios, a French biotechnology company that uses enzymes to depolymerize waste PET, purifying the resulting MEG and PTA monomers and then using them to create new, virgin-quality PET. Interestingly, because depolymerization is a closed-loop recycling process, the material can be traced from feedstock to monomer, therefore it does not require a mass-balance approach to calculate recycled content.
In May, Carbios reported that it had successfully piloted a clear, 100% rPET bottle for L’Occitane’s almond shower oil. Bottle converter Pinard Beauty Pack produced the bottle using L’Occitane’s existing molds with no changes required to the equipment. Explains Bénédicte Garbil, SVP Corporate Affairs & Sustainability for Carbios, the pilot was a necessary step in scaling up the process, “especially to validate the material conversion and to confirm that the quality level corresponds to L’Occitane’s requirements.”
Carbios’ depolymerization process, currently taking place at its demo plant in Clermont-Ferrand, France, is unique in that it is the only one that uses enzymes. Says Garbil, “This makes it a soft biological process without the use of solvents, a process that depolymerizes PET in water under the action of our enzymes.”
He adds that, thanks so its highly selective enzyme, optimized for efficient PET degradation, Carbios’ depolymerization technology can handle all types of PET waste, including colored, multilayer, or textile waste that cannot be recycled with current technologies.
Bayard says that L’Occitane was attracted to Carbios’ biorecycling technology because of its impressive LCA. “When Carbios performed its first lifecycle analysis, it found a decrease of 57% in carbon emissions versus [the production of] virgin PET,” he says. “It [the biorecycled PET] is a way for us to speed up our commitment, to switch all our bottles to rPET.”
Having concluded validation of the 100% rPET bottle using Carbios material, L’Occitane plans to bring a product to shelf by year-end 2025 in the packaging, with the material coming from Carbios’ demo plant. With the completion of Carbios’ first commercial scale plant in Longlaville, France (expected in 2026), L’Occitane plans to convert the rest of its PET packaging to the material.
According to Bayard, once L’Occitane has moved all of its rigid PET packaging to the enzymatically recycled PET, it will reduce its use of virgin PET by more than 500 tons per year, as well as eliminate its use of mechanically recycled PET by 500 tons as well. PW
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Simulation solutions are supercharging the Mars packaging development process with potential to cut development time by up to 40%. Also, by March 2024, the software already had reduced the quantity of plastics purchased for testing by 246 tons.
By Matt Reynolds, Chief Editor
Earlier this year, Mars announced that it had adopted simulation software that stakeholders say has the multinational CPG primed to reimagine the packaging innovation process through digital technology.
The maker and packager of household brand names including M&M’s, Royal Canin, and Snickers is leveraging the new simulation approach to perform virtual testing and prototyping on new packaging innovation, initially across its Snacking portfolio. The multi-physics simulation technology from Ansys minimizes the need for extensive physical testing during the packaging development process.
“Modeling and simulation tools have historically been used broadly within the aerospace and automotive industries for years, and now, these cutting-edge tools are beginning to be used for everyday products, including fast-moving consumer goods and packaging. This is especially important as companies, like Mars, are seeking to optimize their sustainability goals and objectives,” says Darren Logan, VP, science research, Mars Science & Technology.
So how does it work? We asked Ansys to give us the quick and dirty version.
“Ansys uses digital data for model creation to perform analysis. This data can come from scans that would be converted to Finite Element Models [FEM],” says Amit Nair, Ansys’ manager, application engineering. “Ansys’ engineering simulation technology is used to design products that need to efficiently survive specific operating conditions and loads. To understand how a product will respond to real-world use, [brand]
customers [like Mars] use our multi-physics simulations to study the complex ways various physical forces, such as structural stress, fluid dynamics, and electromagnetics, interact. It’s like a virtual sandbox, allowing engineers to play around with their virtual prototype, getting predictive insight into how it will perform under certain operating conditions. That allows them to improve product performance and reliability and often eliminates the process of building a prototype that was doomed from the start due to its design, so it’s a huge saver of time and cost as well. … Our broad portfolio of simulation solutions spans the entire range of physics, allowing our customers to simulate just about anything, from a 5G antenna to the optical performance of systems.”
The technology also provides in-depth insights into various aspects of the complex production phases, including wrapping, drop tests, and failure scenarios, the companies say. On an enterprise-wide level, the investment ultimately aims to supercharge efforts to use 100% reusable, recyclable, or compostable packaging for its products.
“Mars initially used Ansys’ tools and engineering software to design our manufacturing and packaging processes and equipment due to our overall complexity,” says Logan. “With the understanding that Mars is a
Mars is beginning to apply and expand these types of Ansys modeling and simulation tools across the other Mars segments, including Mars Food & Nutrition and Mars Petcare.
global business of people and brands with a clear purpose, we believe the world we want tomorrow starts with how we do business today. It is the vision at the heart of our Sustainable in a Generation Plan—one where the planet is healthy, people and pets are thriving, and society is inclusive. To help us achieve and possibly accelerate our Sustainable in a Generation ambitions, Mars began to apply Ansys’ software engineering tools and simulations to improve its products and packaging for our consumers.”
The implementation of simulation software facilitates a more nimble, digital-first development environment at Mars, spanning from design to manufacturing, making the process easier and more efficient for its team of R&D experts as the company looks to expedite the pace of progress across its packaging ecosystem. Mars is hardly new to the company and technology, but its ability to both optimize for sustainability, and save testing material while doing it, is really coming into its own today.
“Our relationship with Ansys spans over 13 years. Throughout this time, we’ve successfully leveraged their tools in developing our proprietary wrapping machines, optimizing various processes, and designing innovative packaging solutions,” adds Elias Taye, principal scientist – R&D simulation, Mars Snacking. “In support of our NetZero initiatives, we’re exploring the use of sustainable paper for our chocolate bar wrappers. Ansys’ optimization tools have enabled us to run design of experiments simulations more efficiently to improve the paper wrapping process.”
“It’s important for us to look at new materials that are not going to be harmful to the environment. Through modeling and simulation, we can accelerate that process. The tools that Ansys brings to bear help us to understand that virtually, before we even bring the materials in house,” adds Jim Kennedy, computational science discipline leader at Mars.
Researchers at Mars have already reported reductions in development time of up to 40% through computer modeling and in the quantity of plastic purchased by Mars for testing by approximately 246 tons already by March of 2024.
“Our goal is to significantly minimize the
need for physical testing and have more accurate information of max load carrying capacity of our plastic bottle, as well as max fill level of our candies to meet the EU regulation,” Taye says.
The food and pet care provider says that it is also working to redesign more than 12,000 packaging types across its portfolio to fit with the recycling infrastructure that either exists today or is likely to exist in the future, making it easier for consumers to recycle their packaging.
“Similar to what we are doing with Mars Snacking, Mars is beginning to apply and expand these types of Ansys modeling and simulation tools across the other Mars segments, including Mars Food & Nutrition and Mars Petcare. This approach has allowed us to improve the quality and sustainability of our products and packaging, as well as optimize the efficiency of our product manufacturing,” Logan adds.
“In the world we want tomorrow, no packaging becomes waste,” says Qing Qi, VP R&D global innovation, Mars Snacking. “This vision is at the heart of our multi-billion dollar Sustainable in a Generation plan and will only become a reality by taking unconstrained strides, leveraging breakthrough science, innovative thinking and partnerships to push the boundaries of what’s possible.”
“We continue to see the impact and potential of simulation and digital engineering in progressing sustainability initiatives throughout the world,” adds Walt Hearn, SVP of worldwide sales and customer excellence at Ansys. “Mars has successfully implemented the pervasive insights of Ansys simulation to optimize its design and packaging processes. Mars’ more sustainable approach to development sets a terrific example for other manufacturers to adopt new solutions that move us all toward a cleaner planet.”
“As for data ownership, in this case, if it’s a Mars model, Mars owns that data exclusively,” adds Nair. PW
Modeling and simulation tools have historically been used broadly within the aerospace and automotive industries for years, and now, these cutting-edge tools are beginning to be used for everyday products, including fast-moving consumer goods and packaging.
Pouched applesauce producer Materne adds two carton suppliers to its network and cuts $1 million in annual costs by adopting procurement software.
By Casey Flanagan, Digital Editor
Applesauce-in-a-pouch leader Materne has modernized its request for proposal (RFP) process with Arkestro procurement software, strengthening its supplier network and finding major savings along the way.
Materne has over 140 years of history as an applesauce producer in France, initially packaging its product in cups until it became the first to offer pouched applesauce in 1998. The company expanded into the U.S. under the name GoGo squeeZ in 2008, operating from a New York City office and starting with a co-manufacturer.
“Long story short, now we have two manufacturing facilities, one in Michigan and one in Idaho,” says Mathieu Pappalardo, vice president of Materne Procurement. “We do roughly $600 million in sales and manufacture over 120,000 tons of product.”
GoGo squeeZ is available in a range of multipack sizes, from retail four-packs to 48-count cartons for foodservice, totaling around 50 million cartons and a baseline spend of about $20 million per year. In all, the company owns 70% of the market share for pouched applesauce.
Materne may be dominating the market now, but it still has ambitions for growth. “The goal for us is not so much to gain more market share, it’s to grow the category as a whole, to grow household consumption. We want to keep 70% market share, but on a bigger pie,” Pappalardo says.
To support this growth, Materne realized it needed to grow its supplier network, adding layers of continuity to support new products and protect against supply chain disruptions.
Materne had previously focused on the bottom line when strategizing its supplier network, but the COVID-19 pandemic and subsequent supply chain disruptions prompted a reprioritization. As a result, Materne’s focus shifted toward business continuity to withstand unexpected changes.
That said, Pappalardo knew supply chain resiliency often comes at a
Materne uses around 50 million cartons per year at a baseline spend of about $20 million for its pouched applesauce product.
price. Knowing that the addition of extra suppliers can bring a negative cost impact, he says that Materne was hoping to “maintain costs at the very least, or potentially realize some savings.”
Pappalardo was also looking for a way to automate the company’s procurement. Short-staffed on some categories and struggling with overly manual processes, he was looking for a solution that could save time. “Not just automating, but having a consistent way of doing RFPs, using the same tools over again, reusing the data from previous bids,” he explains.
Materne turned to Arkestro’s Predictive Procurement Orchestration (PPO) software as a potential solution, and initial results were exceptionally promising; starting with a small project, the software brought 40% savings.
When a three-year agreement with Materne’s carton suppliers reached its end, it was the perfect time to try Arkestro’s software on a larger scale. The same success achieved earlier with the smaller project carried over to the cartoning RFP. Materne used Arkestro’s software to not only add two carton suppliers to its network, but also achieve $1 million in savings per year.
“It’s a big success because we achieved both goals, which were not necessarily easy combined together,” says Pappalardo.
Arkestro’s PPO platform uses machine learning, game theory, and data science to help companies make fast and informed buying decisions. It centralizes procurement processes onto one platform and offers real-time insights and price comparisons.
One of the main draws of the Arkestro procurement software that Materne discovered during the cartoning RFP is its ability to streamline negotiations. The process started with Materne reaching out to its three incumbent suppliers to request new pricing.
“The prices we got were not satisfying, so then we said, ‘Okay, we have to bring everybody on this RFP,’” explains Pappalardo. “We invited eight suppliers in total, so the three incumbents, plus five prospects.”
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Materne entered the forecasted volume and specifications for its cartons into the Arkestro software and invited all eight suppliers to provide quotes through the system. Having every supplier offer quotes through Arkestro simplifies communications for Pappalardo’s team, replacing several back-and-forth emails with a single system containing each offer. All communication takes place in the system, from questions and comments to new bids.
It also promotes competition for suppliers. “The system will tell [suppliers] they’re 20% higher than the average bid,” Pappalardo says. “It triggers the fear of missing out, if you will, so suppliers will improve their price. That alone explains a big part of the success.”
Further benefitting Materne, Arkestro’s software uses AI to analyze bids against the market rate, comparing prices from previous bids and even other manufacturers.
“The combination of market intelligence and comparing suppliers between themselves really helps to push the price down,” says Pappalardo.
Materne conducted the RFP in three rounds. Suppliers entered their first submissions, and the company analyzed the results before giving them another chance to enter submissions in the second round. The third round allowed Materne to finalize details.
Five carton suppliers were awarded contracts, including the three incumbents and two new-
In all, the RFP took about six weeks to complete. “It was much faster than if we had done it outside,” says Pappalardo. “If every time we had a question, we had to schedule a meeting and get an answer, which triggers questions for another supplier, that takes a lot of time that we didn’t have to go through.”
As a direct comparison, Pappalardo says Materne’s previous carton supplier RFP from three years ago took four to five months without the help of Arkestro’s program.
In the beginning, some suppliers raised concerns about losing human touch in negotiations. Pappalardo notes that there is “always room for conversation,” and says suppliers were eventually very compliant. “I haven’t heard of any problems from my suppliers; I think everybody is getting used to it,” he adds.
After the clear success of implementing Arkestro’s procurement software for its carton RFP, Materne has its sights set on more projects with the software. That starts later in 2024 with another RFP, this time with shipping cases—a $10 million-per-year spending category for the company. “The cases aren’t as big a spend as cartons, but it’s significant,” Pappalardo says.
With the system established with Materne’s data, the next RFPs for carton suppliers will be even easier. “Three years from now, when I’m doing my [cartoning] RFP, all my information, all my specs are loaded into Arkestro,” says Pappalardo. “I don’t have to go to my R&D department to find the specifications, it’s all there. I just click a button and it triggers another RFP.”
Now that Pappalardo and his team have gotten past the learning curve in adopting this new technology, he’s excited for the extra efficiency it can provide. Say Pappalardo, “It’s just a training thing, and once you master it, you can’t live without it.” PW
British Sugar replaces a 38-year-old end-of-line system with two tray packers and seven automatic palletizers with robotic layer preparation to handle a wide array of product formats and sizes.
By Anne Marie Mohan, Senior Editor
The leading producer of sugar for the British and Irish food and beverage markets, British Sugar processes around 8 million metric tons of U.K.-grown sugar beet each year to produce up to 1.2 million metric tons of sugar. The company’s core offering is granulated sugar, but it also manufactures a wide range of other specialty products, such as icing sugars, brown sugars, and liquid sugars and syrups, among others.
With increasing consumer demand for its products and escalating sugar sales, the company recently replaced its 38-year-old end-of-line packaging equipment with new machinery from Sidel. According Sidel Account Manager Bastien Carcenac, Sidel custom-designed the solution for British Sugar, identifying its challenges to deliver a full end-of-line turnkey solution from the sugar bagging outfeed through to delivery at warehousing.
“British Sugar required an extremely compact and flexible casepacking and palletizing solution to be implemented within a tight plant area that would be capable of handling multiple pallet and format types to accommodate single sugar bags to new shelf-ready secondary packaging,” explains Carcenac. “Case-packer and palletizer flexibility, reliability, and output speed were central to the desired end-of-line solution for British Sugar, with Sidel’s design and equipment focusing on
British Sugar’s main product is granulated sugar, shown here in retail bags packed in a retail-ready trayand-lid package. The Cermex BC46 combines tray forming, loading, and lidding into a single machine.
achieving flexibility at a high speed using advanced robotics.”
The initial equipment installation included two Cermex BC46 tray and lid case packers and seven PalAccess palletizers with robotic layer preparation. Four stretch wrappers, conveyors, and elevators are scheduled to be installed at a later date.
As Carcenac confirms, flexibility was key in the selection of the new end-of-line equipment for British Sugar. “Flexibility is achieved through case-packing and palletizing systems that allow a large packaging
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range, from mini to maxi bags and also cases, as well as being easy to adjust when performing changeovers—either automatic or simple tool-less, when an operator is needed,” he says.
The Cermex BC46 combines tray forming, loading, and lidding into a single machine, making it suitable for shelf-ready or retailready packaging formats. The unit can handle a number of different lid styles, including Ushaped, cross, and others, with the lid and tray evenly pressed during operation, ensuring squaring of the package. The unit operates at 26 blanks/min, depending on the product and collation.
During operation of the Cermex BC46, lid blanks, which are stacked in an adjustable flat magazine with a 1,200-mm-long belt, are extracted and positioned by a rotating arm with suction cups in the lidding station. There, batched products are elevated onto the lid through a die, after which the lid is formed around the batch by the die, incorporated into the loading pusher. For products without counterpressure, blades are used to form the lid around the batch. Next comes tray loading of the lidded batch. Like the lids, the trays are stacked in another adjustable flat magazine. From
there, they are extracted and positioned in a U-shape between brackets by a rotating arm with suction cups. The blank is held between the brackets by folding or guiding the long bottom flaps. A bridge and loading funnel then deflect the flaps and guide the lidded batch onto the
tray blank. The lidded batch is then transferred into the blank with motorized front and rear guides. The lid can be tted inside (sealed with hot-melt glue or simply inserted) or outside the tray.
To palletize the nished trays, British Sugar added seven PalAccess palletizers. “The modular, layer-by-layer palletizing platform PalAccess, equipped with robotic layer preparation, was selected to guarantee high product integrity through sensitive and reliable handling of small and unstable packs,” says Carcenac. “This was a necessity for British Sugar, as it had many different format types that required sensitive handling.”
Before being palletized, cases—or single bags, depending on the pallet format—are grouped into layers using a robotic layer preparation system. It comprises a dosing conveyor that counts and separates packs, a transfer table made up of a mat of at chains for channeling and conveying the packs at the right speed, gripper heads that transfer and turn the packs into the correct position, and a layer forming table for positioning the packs according to the chosen palletization pattern.
The system allows for rapid format and pallet pattern changeovers, which are managed completely by software with no manual adjustments required, and enables a potentially unlimited number of pallet patterns to be created.
“The robotic infeed system prepares the layers by orienting and positioning the bags and cases according to the pallet pattern,” says Carcenac. “The complete layer is then delivered to the palletizer and then a pusher transfers the complete layer to the pallet, layer after layer, until the pallet is completed and sent to outfeed via roller conveyors.”
Are you in the market for case-packing equipment that leverages today’s top technology for zero changeover, or really fast changeover? Peruse our researched list of the various case-packing solutions available that t these criteria. Discover the solution name, changeover details like speed and tools needed, plus a sales contact that you can reach out to for more information. Scan the QR code to download our editorcurated list of zero/fast-changeover case packers.
Following installation of the new end-of-line equipment in 2023, James Warby, project integration manager at British Sugar, commented on the company’s experience with Sidel. “We needed a partner with strong engineering and design expertise as the challenge was more complex due to the building constraints combined with our high level of technical speci cations,” he said. “Sidel’s collaborative approach from the beginning was excellent. They have been agile and transparent where we have had to work together to nd solutions. Their shared vision of a packaging line with our engineering team strengthened the trust we had in their capacity for delivering a turnkey solution and led us to decide to partner with them for this project.” PW
Delkor’s HSP series case packer packs up to 340 bags and pouches per minute and switches through the full range of case styles in under 10 minutes, making this the first case packer for bags and pouches up to 32 oz with this range of speed, flexibility, and rapid changeover.
Delkor Systems pwgo.to/8296
Ranpak’s naturemailer is an eco-friendly padded mailer made from honeycomb paper, offering protective packaging that’s curbside recyclable and eliminates the need for plastic or foam interiors, providing a cost savings compared to traditional mailers with plastic interiors.
Ranpak pwgo.to/8297
Label-Aire’s Inline Series 6200-TS labeling system, ideal for high-volume production lines, features high speeds of up to 2,000 IPM, advanced compatibility with various applicators, and a rugged build for harsh environments.
Label-Aire pwgo.to/8299
Sabert Corporation’s Pulp Ultra molded fiber containers provide aggressive oil, grease, and moisture resistance and are commercially compostable, unlike traditional plastic containers.
Sabert Corporation pwgo.to/8298
Continue your search for the right packaging solution. Visit prosource.org
Mondi’s FlexiBag Reinforced is a line of recyclable and cost-effective, PE-based, mono-material packaging that protects a wide range of products due to their high-barrier protection, improved mechanical properties, and customizability.
Mondi pwgo.to/8285
think4D’s food container lids feature sculpted textures for a tactile experience and edge-to-edge graphics for maximum brand impact, all made from fully recyclable materials.
think4D pwgo.to/8301
Henkel, Kraton, and Dow join forces to reduce emissions in adhesive products with TECHNOMELT SUPRA 100 LE and 106M LE formulas designed with bio-based alternatives, which reduce the adhesives’ cradle-to-gate carbon footprint by 25% compared to legacy products.
Henkel, Kraton, and Dow pwgo.to/8302
At Alpek Polyester, we are more than the world’s second largest producer of PET Resin, we are producers of the innovative Direct-to-Sheet, Octal DPET® Sheet products for the packaging and Sheet products for the packaging and thermoform markets.
This unique technology This technology delivers delivers exceptional consistency and clarity with enhanced mechanical with enhanced mechanical properties, resulting in resulting in increased increased productivity for Therm for Thermoformers formers while allowing designer while designers the he flexibility to achieve stun flexibility to achieve stunning package ng designs that maintain the designs that maintain their shape. Octal rDPET® Sheet is avail available with le integrated post consumer re integrated post consumer recycle ycle content for circularity and content for and sustainability. su inability.
Designed for manufacturers and distributors who need to print on corrugated cardboard cases, cartons, shipping containers, and other porous materials, the Videojet 2380 is a high-resolution, large character inkjet printer that adapts to users’ unique marking and coding requirements.
VideoJet pwgo.to/8305
Innovia Films expands its range of sustainable BOPP lms under the name Encore; new options include chemically recycled PCR for food packaging and mechanically recycled content for non-food applications, all while maintaining performance of virgin materials. Innovia Films pwgo.to/8303
Shurtape Technologies’ CR 400 is a performance-grade, curbside recyclable, paper packaging tape for hand and machine carton sealing applications that solves the problem of non-recyclable box sealing tape by being recyclable along with the cardboard box.
Shurtape Technologies pwgo.to/8300
Pacteon Group acquires Descon Integrated Conveyor Solutions
Also, Pacteon subsidiary ESS Technologies is investing $1.6 million in a new, 40,000-sq.-ft. facility in Montgomery County, Va.
ProMach is further investing in Europe by expanding Zalkin’s capping and cap handling facility in France by 100,000 sq. ft. to increase production, shorten lead times, and drive overall growth.
Krones, driven by surging consumer demand for recycled materials and stricter government regulations, has established Krones Recycling GmbH, an independent subsidiary dedicated to advancing plastic recycling technology.
Mondi is investing over $200 million to convert equipment at a recently acquired mill in Duino, Italy, into Europe’s widest recycled containerboard machine, boosting sustainability and regional growth.
Douglas Machines receives the Silver Achievement Award for Excellence in Occupational Injury Prevention for the fifth straight year for its workplace safety record.
Golden West Packaging Group names Mark J. Favre the new chief executive officer, Brian McDonnell as chief financial officer, and Doug Keim as senior vice president of customer experience.
The Board of Korozo Group appoints Adam Barnett, former president of the Food Packaging Division of Klöckner Pentaplast (kp), as its new CEO, replacing Filip Lens, who led the Group the past four years.
Viking Masek founders Robb Leonhard and Scott Miller step down from active roles and transition to passive investors, handing leadership to the executive team of Ty Weinhold (COO), Nicole Piontek (CFO), and Bryan Lacy (CRO).
Weidmüller Group names Randy Sadler the new president & CEO of Weidmüller USA, as the industry veteran returns to the company where he began his career.
WLS, a ProMach brand, promotes Adam Rosenthal to director of sales while he retains his role as director of marketing for ProMach’s Pharma business line.
Change Parts, Inc. names Sally Dingman its regional sales manager for the Midwest territory.
Matrix, a ProMach brand, appoints Chris Shay as South-Central regional sales manager responsible for expanding the company’s growing vertical form/fill/seal packaging business in that region.
Monica Gimre steps down after more than five years as president and CEO of Sidel, and the Tetra Laval Group Board appoints Pietro Cassani as Sidel’s new president and CEO.
Jeff LaGrange, who spent nearly three decades as part of the packaging community and who helped Enercon advance induction cap sealing technology, has passed away.
By Ana Romero
In 2022, I wrote an article for Packaging World about sustainability (pwgo.to/8307). I challenged packaging professionals to promote the use of sustainable packaging not only to attract investors, but also to preserve the environment and resources for future generations.
Since 2022, the world of packaging and sustainability has undergone significant changes. Extended Producer Responsibility (EPR) laws have been passed in the U.S. and in foreign jurisdictions. The European Union, for example, is working on finalizing EPR regulations that include a target of 30% recycled content for plastics packaging by 2030. In the U.S., California, Colorado, Maine, and Oregon have already passed EPR bills, while Connecticut, New York, Massachusetts, Minnesota, New Jersey, New York, Washington are considering proposed EPR legislation.
Also, the U.S. Environmental Protection Agency (EPA) is proposing a National Strategy to Prevent Plastic Pollution, and has issued two proposed regulations under the Resource Conservation and Recovery Act to address per- and polyfluorinated substances (PFAS) pollution.
Now more than ever, sustainability in packaging is not just a choice but a mandatory requirement imposed by state, federal, and global regulations. As packaging professionals, it is crucial that we work together to develop strategies and infrastructure that align with these sustainability goals for the benefit of our companies and the world. This collaboration should be done by networking, participating in technical committees and professional organizations (e.g., the Institute of Packaging Professionals, the Sustainable Packaging Coalition), and attending conferences and other events.
To develop a strategy and infrastructure for sustainable packaging, it is important to consider the unique needs and enterprise goals of each company. The strategy should be aligned with enterprise goals, key business metrics, and business needs. It should aim to drive profitability by increasing revenue and reducing costs.
Contrary to popular belief, developing a strategy for sustainable packaging does not necessarily entail high costs. In fact, cost-effective strategies can be implemented, such as reducing packaging material and volume. When developing the strategy, it is essential to involve internal stakeholders from the corporate responsibility, procurement, product development and marketing departments. Sustainability in packaging cannot be achieved by a single department alone; it requires collaboration and involvement from various departments.
In terms of infrastructure, the support of executive leaders, such
as the CEO and CIPO, is crucial as they provide the necessary budget and guidance to achieve enterprise goals. Similar to the strategy, the infrastructure should be tailored to the specific needs and goals of each company and should align with enterprise goals and key business metrics. Corporate responsibility and citizenship should be involved in the development of the infrastructure, as they have goals and focus areas related to the environment.
For example, one of [my company] Altria’s responsibility focus areas is to protect the environment. Other important internal stakeholders, such as marketing, procurement, product development, and manufacturing, also should be included as they are decisionmakers and possess valuable knowledge about consumers, trends, cost analysis, suppliers, and project execution.
To mitigate risks and prevent financial losses, companies must stay up to date on regulations and advancements in sustainable packaging technology. As part of the infrastructure, it is crucial to develop guidelines that incorporate regulations from product markets (state, country, and global) and information from leading organizations in the sustainable packaging space, such as the Sustainable Packaging Coalition, How2Recycle, and IoPP. Given the rapid evolution of sustainable packaging technology, engaging with external organizations is essential to stay informed and current.
Regardless of budget limitations, developing a strategy and infrastructure for sustainable packaging is possible through collaboration and effort. Again, strategy and infrastructure should be aligned to enterprise goals. I recommend the following steps:
1. Seek support from executive leaders; without their support, progress will be difficult.
2. Engage with individuals who support the initiatives.
3. Collaborate with procurement to reduce costs and materials.
4. Establish partnerships with external organizations to explore collaboration and unified efforts.
To thrive in an innovative and sustainable world while maintaining regulatory compliance, it is imperative that we collaborate and develop strategies and infrastructure for sustainable packaging. The field of sustainability innovation in packaging is advancing rapidly, and it is crucial that we work together and stay connected. IoPP provides a great platform to initiate these conversations. To my colleagues, I just want to tell them packaging is awesome, and to keep doing the amazing job. PW
The author, Ana Romero, is Senior Packaging Engineer at Altria and passionate about sustainability and packaging. She earned her Ph.D. in Packaging Science at Clemson University. Any opinions expressed in this article are those of the author, and not necessarily those of Altria. For more information on IoPP, visit www.iopp.org.
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