PACK EXPO Las Vegas Show Daily—Monday by PMMIMediaGroup

Wherever you are and whatever your industry, there’s a PACK EXPO event to provide solutions you need today and the inspiration for tomorrow.

March 21–23, 2022 Philadelphia, USA

June 14–17, 2022 Mexico City, Mex.

Oct. 23–26, 2022 Chicago, USA

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June 13–15, 2023 Guadalajara, Mex.

Sept. 11–13, 2023 Las Vegas, USA

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Visit the PMMI Booth in the Central Hall Lobby or the Future Trade Shows Booth in the South Upper Lobby for more information or to reserve your booth today!

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2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

Association partners support show Groups provide unmatched expertise in many specialities.

he Association Partner Program returns to PACK EXPO Las Vegas and co-located Healthcare Packaging EXPO with many familiar faces and some new key organizations. The program connects leading associations dedicated to advancing the packaging and processing industry with PACK EXPO attendees and exhibitors, bringing significant resources, insights and expertise to the most comprehensive packaging event in the world this year. “The PACK EXPO Partner Program connects our attendees to leading associations from all segments of the packaging and processing industry,” says Laura Thompson, vice president of Trade Shows, at PMMI, The Association for Packaging and Processing Technologies (Central Lobby), the organizer of the PACK EXPO family of shows. “With more than 30 partners this year, making it our largest partner program to date, the breadth

and depth of industry knowledge brought by these partners is unrivaled and is an invaluable resource to attendees and exhibitors participating in the show.” This support is a sign of the industry’s excitement to reunite with the more than 1,500 exhibitors that are spread across four expansive halls at the Las Vegas Convention Center.

INTERNATIONAL PAVILIONS

• Adepta (France) (Booth SU-7846) • Confederation of Danish Industry (Denmark) (Booth SU-7716) • Expotim International Fair Organizations (Turkey) (Booth SU-8220) • Italian Trade Agency (Italy) (Booth SU-8159)

Students show off robot creations Rockwell support gives students the PACK EXPO experience.

t the Future Innovators – Robotics Showcase (Booth N-9820), FIRST robotics teams from Las Vegas area high schools demonstrate the robots they have designed and built. Forming part of the new, interactive PACK to the Future Exhibit (Booth N-11030) in the North Hall, demonstrations take place daily at the event sponsored exclusively by Rockwell Automation (Booth C-4742).

For more info, visit www.PACKEXPOlasvegas.com, www.HCPElasvegas.com. SD

2021 ASSOCIATION PARTNERS Adhesive and Sealant Council (Booth C-1243)

Flexible Packaging Association (Booth C-1341)

AIM North America (Booth C-1247)

Foil & Specialty Effects Association (Booth C-1344)

AIMCAL – Association of International Metallizers, Coaters, and Laminators (Booth C-1347) AIPIA, the Smart Packaging Association Australian Institute of Packaging Australian Packaging and Processing Machinery Association CANAINCA Cold Pressure Council (Booth C-1354) Composite Can & Tube Institute (Booth C-1351) CPA, The Association for Contract Packaging and Manufacturing (Booth C-1255)

Foundation for Supply Chain Solutions (Booth C-1252) Independent Bakers Association (Booth C-1248) In-Mold Decorating Association (Booth C-1346) Institute of Packaging Professionals (Booth C-1253) Instituto Argentino del Envase (Booth C-1146) International Dairy Foods Association (Booth C-1352) International Society of Beverage Technologists (Booth C1251) Koelnmesse

National Confectioners Association (Booth SU-7201) OMAC – The Organization for Machine Automation & Control (Booth C-1152) OPC Foundation (Booth C-1149) Paperboard Packaging Council PLCopen (Booth C-1150) Processing & Packaging Machinery Association Reusable Packaging Association (Booth SU-8201) SNAC International (Booth C-1349) Start Up CPG The Tube Council World Packaging Organisation (Booth C-1141)

Show attendees have a chance to meet students and discuss their robot creations.

This year more than 50 students, aged 14 to 18, are participating. Students not only have the opportunity to display their robotic creations, but also tour the show floor to learn about the breadth and innovation within processing and packaging. “We are excited to be the exclusive sponsor of the Future Innovators - Robotics Showcase and to continue our contributions to the PMMI Foundation this year,” says Steve Deitzer, vice president Consumer Products Industry, Rockwell Automation. “To be able to contribute to and support the development of future generations for this essential industry has always been the driving force behind our sponsorships during the PACK EXPO shows. . . . we look forward to continuing to support the industry for years to come.” In addition to its exclusive sponsorship of the Future Innovators - Robotics Showcase, Rockwell Automation also made a $10,000 direct donation to the PMMI Foundation (Central Lobby), earmarked for additional support for the participating teams. Each team receives grant money as well as travel assistance and food and beverage during their visit to the show. For more info, visit www.PACKEXPOlasvegas.com, www.rockwellautomation.com. SD

Redefining Machine Interactions for the Digital World What if you could gain real-time insights on machines and operations as soon as you lay eyes on them? Augmented reality is redefining interactions between people and machines, providing immediate, real-time access to machine settings, status and performance. With Movicon.NExT AR, operators can see device information, setpoints, and alarms as well as interact with controls and receive troubleshooting assistance. All of this is available right on-the-spot, by putting information in context on a wearable HMI to make faster decisions and keep processes under control. Visit booth SL-6307 to learn more about Movicon.NExT AR. www.Emerson.com/Packaging

2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

PMMI adds membership All membership categories contribute to the growth to 947 members.

Easy Palletizing with Collaborative Robot The standardized palletizing cell from FlexLink is compact, quick to install and easy to configure. The use of a collaborative robot significantly reduces the footprint, by over 50% compared to cells with industrial robots. 1. The collaborative cell is user-safe, making a fence system or cage unnecessary and instead lets the operator work side-by-side with the robot. It is a single pick unit, working at up to 8 boxes per minute with a maximum load of 8 kg each. 2. An internal vacuum pump is included which makes it possible to effortlessly move the palletizing cell, no external air supply is needed. 3. The smart design with quick connectors contributes to a fast and easy installation in only a couple of hours. Email us at info.us@ȋexlink.com or visit us at ȋexlink.com to find out more about the RC10.

MMI, The Association for Packaging and Processing Technologies, (Central Lobby) continues its sustained growth, adding 23 new companies at its Spring Board of Directors Meeting during the Executive Leadership Conference. Active membership now stands at 947. “Adding 23 new members at a time when so much is happening and changing in our industry reinforces the confidence packaging and processing companies have in the resources provided by PMMI,” says Andrew Dougherty, senior director, Membership, PMMI. PMMI’s Board of Directors also modified some qualifications for certain member categories. Materials Suppliers now need annual sales of $3 million to qualify for membership–down from $10 million. The Affiliated Supplier Membership also added the following product categories: • Container Engineering & Design • Product Heating & Steam Equipment • Lubricants • Transportation, Logistics, Software & Warehouse Service Providers. New members include:

GENERAL

Allied Technology (Booth SU-7677) Brother USA Machinery (Booth SU-7227) EAM-Mosca (Booth SU-7772) EMS Group USA (Booth C-5024) IMPAK (Booth SU-8458) JMP Solutions Paxiom Group (Booth C-1823) SideDrive Conveyor (Booth SL-6127) Spec Engineering (Booth SU-7764) VMek Group (Booth SL-5832)

ASSOCIATE

Fette Compacting (Booth SL-6610) Verbruggen Palletizing Solutions (Booth SL-6028)

AFFILIATED SUPPLIER

Inficon (Booth N-19006)

COMPONENT SUPPLIER

Visit FlexLink at

Booth #4400

Ashworth Bros. (Booth N-23004) Genesis Robotics and Motion Technologies M.R Machine Knives, now MRMK Weidmüller, USA (Booth N-23020)

MATERIALS SUPPLIER

Airguard Packaging (Booth SU-7161) Chicago Glue & Machine (Booth C-3630) ICPG Novembal Pemcor Packaging Polyplex USA For more info, visit www.PMMI.org. SD

Filling & Sealing Automation

End-of-Line Packaging Automation

Complete Automation Solutions

BOOTH: C-5222

2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

PACK to the Future debuts

New show feature takes a look forward and back.

he look forward comes on the PACK to the Future Stage (Booth N-9830). Daily sessions focus on future advancements such as sustainable solutions, smart packaging, artificial intelligence, digital heat-sealing and wireless automation communication. Of particular note is a presentation at 1:30 p.m. on Tuesday, Sept. 28, 2021, by Matthew Wright, founder & CEO of Specright (Booth SU-7356), who will discuss the Transition to a Digital World through Data. The nearby PACK to the Future Exhibit (Booth N-11030) takes a look back, exploring how packaging developed as civilizations and trade evolved and how industrial and scientific revolutions led to rapid innovations and mass production. Nearly 30 historic packaging machines dating from the 1890s to the 1990s are on display, surrounded by imagery supplied by consumer packaged goods companies, museums and packaging equipment companies, including one-of-akind displays, packages, photographs and videos. Highlights of the PACK to the Future Exhibit include: • Roby the Robot, the first dedicated packaging robot invented by Gerhard Schubert, courtesy of Schubert Group, parent company of Schubert North America (Booth SU-7651). Roby was introduced to the market in 1981 and used to package pralines and chocolates. • Omron (Booth SU-7537) has played a role in the evolution of the programmable logic controller (PLC), an increasingly vital component in packaging machines since Modicon introduced the first PLC in 1968. • One of the first liquid filling machines, dating from the early 1900s, courtesy of Septimatech Group (Booth C-4236).

• An early cartoning machine built in 1922 by R.A Jones (Booth C-4400) to package crayons. • One of the first automated glue labelers for the pharmaceutical industry manufactured by NJM, a ProMach product brand (Booth C-3514, SL6501) and sold to Abbott Labs in 1937. • An historic auger filler from All-Fill (Booth C-2203). • An early checkweigher/x-ray inspection combo from Anritsu Product Inspection (Booth SL-6319). • Early examples of the digital revolution in packaging machinery, including a carton former from Kliklok-Woodman, now Syntegon Packaging Technology (Booth C-2800), and an Ishida multihead weigher from Heat and Control (Booth C-1623). This area of the show floor also features the Showcase of Packaging Innovations® (Booth N-9720), sponsored by WestRock (Booth C-2023), and the Future Innovators–Robotics Showcase (Booth N-9820). The session schedule for the PACK to the Future Stage is outlined below. Other educational opportunities on the show floor include: the long-running Innovation Stage (Booth C-2051, C-2058, C-2151) program, including the first Processing Innovation Stage (Booth N-24020) sessions (see schedule, p. 26); and The Forum at PACK EXPO (Booth C-2158) (see schedule, p. 42). Updated schedules may be found on the show website or via the PACK EXPO Las Vegas/Healthcare Packaging EXPO App. For more info, visit www.PACKEXPOlasvegas.com, www:HCPElasvegas.com. SD

MONDAY, SEPTEMBER 27, 2021 USING AI TO ACHIEVE THE NEXT LEVEL OF OPERATIONAL EFFICIENCY

12:30–1:00 PM

Low margins and the pressures of a fully integrated supply chain mean the packaging industry needs highly efficient operations to sustain a profitable business. With machine aspects already performing close to their theoretical optimum, the human element is moving into focus: Skilled operators can keep processes at their best despite the inevitable shortfalls created by equipment failures or wear-and-tear. Vice versa, inexperienced operators cause delays by not recognizing process exceptions. A new class of tools can capture the impact of the human factor efficiently. Based on mathematical algorithms that often are called “artificial intelligence (AI),” these tools can use process data to capture the impact of the human operator, recognize and learn good human interventions and discern those from bad ones. Once deployed, these tools can create a library of human skills from expert operators that allow inexperienced operators to perform at nearly the same level and preserve these skills, even as the human source of the expertise is lost. Algorithms in ei3’s ConnectedAI process optimization suite work in conjunction with traditional IIoT methods to allow manufacturers to achieve “super-human” operation. Spencer Cramer OMAC Board of Directors ei3

UNPACKING THE CANNABIS OPPORTUNITY

1:30–2:00 PM

Cannabis is taking the U.S. by storm, with retail sales approaching $20 billion annually as more states legalize medical and recreational marijuana, mature markets grow and mainstream companies enter the fray. The explosive growth has created opportunities for packaging companies as consumers clamor for an increasingly diverse array of products, from infused sodas to cannabis gummies, chocolates, soluble powders . . . even bath bombs. With the possibility of federal marijuana reform, the market could enter a new era of growth. But there are challenges and pitfalls as well. Examine the latest data and trends that define the scope of the industry, opportunities, challenges to market entry and the impact of federal reform. Chris Walsh CEO & Founding Editor MJBiz

INNOVATIVE HEATING AND SEALING SYSTEMS PROCESS SUSTAINABLE MATERIALS

2:30–3:00 PM

Sustainability is a driver of innovation in the packaging industry. Many brand owners have ambitious sustainability goals to produce 100% recyclable or reusable packages by 2025. This has prompted rethinking current options. Mono materials, which are readily avail-

able, are an obvious choice, but have a small processing window, which is not available on much of the installed base of equipment. The result is high waste and significantly increased downtime. This is particularly true in critical sealing locations such as zipper, double-fold and spout areas. Patented cera2seal heating systems can overcome this deficiency. Markus Hoedebeck Technical Dir, Watttron North America Watttron

CAN SMART PACKAGING MAKE A DIFFERENCE?

3:30–4:00 PM

Supply chain management, consumer engagement, authentication, provenance, traceability and waste are some of the “pain points” facing brand owners. Savvy consumers want to know more about the products they are buying, and governments want better accountability from brand owners, packaging converters/manufacturers and distributors. All the while, fraudsters are getting smarter at counterfeiting, which can lead to enormous brand damage. Plus, we live in a world where sustainability and reducing waste are priorities, and product security is vital. Smart Packaging technologies already are addressing these issues across the globe. Andrew Manly Communications Dir AIPIA, the Smart Packaging Association

2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

TUESDAY, SEPTEMBER 28, 2021 REPOSITION PACKAGING AS THE ENVIRONMENTAL SOLUTION

10:30–11:00 AM

As concerns about the environmental impact of packaging increase, consumers, governments and some in industry see packaging as part of the problem. The industry is responding to reduce the environmental impacts of climate change and packaging waste. Changes are starting to occur with R&D teams innovating in overdrive, industry partnering in new ways and relationships with governments and consumers adapting in real time. Here’s a look at ways to minimize packaging waste and help consumers recycle more and recycle better. David Clark VP, Sustainability Amcor

HOW CAN THE INDUSTRIAL EDGE DELIVER NEW INSIGHTS FOR PACKAGING MACHINES?

11:30–12:00 PM

Edge computing brings new performance opportunities to packaging machine operations. Join us to learn how digital twin simulation can be utilized during machine runtime to make useful real-time predictions with artificial intelligence and generate insightful operation data with a Live-Twin. Colm Gavin Portfolio Development Mgr Siemens Digital Industries Software Siemens Digital Industries

THE TRANSITION OF PACKAGING TO A DIGITAL WORLD THROUGH DATA

1:30–2:00 PM

Increasing consumer demands, eCommerce and, of course, COVID-19 are just a few reasons packaging professionals are looking to “go digital.” Products are changing fast, so companies are looking to technology to help them go faster and work remotely to quickly prototype designs and reduce the development cycle from months to weeks. According to research, packaging and supply chain digitization is a burning platform for executives—and the longer you wait to start, the more challenging it can be to digitally transform your business. Learn how to transition your packaging to a digital world to drive innovation and collaboration—no matter where you are. Matthew Wright Founder & CEO Specright

THE ROBOTS ARE COMING! PACKAGING DESIGN FOR AN AUTOMATED ECOM WORLD 2:30–3:00 PM

Rapid eCommerce growth, labor shortages and sustainability pressure have led to increased automation and demands on packaging. Here’s a look at eCommerce packaging guidelines as well as automation considerations for your next packaging project! Brent Lindberg Principal & Founder Fuseneo

WEDNESDAY, SEPTEMBER 29, 2021 NEXT GENERATION INDUSTRIAL LIDAR SENSING TECHNOLOGIES COMING TO PACKAGING

10:30–11:00 AM

The packaging industry has been using photo sensors and camera technology for years. Although proven technologies, there are many applications where there is not enough area coverage or measurement accuracy or lighting conditions don’t allow the existing technology to work well. Next generation LiDAR technologies, derived from self-driving cars, are now available to the industrial market. This will allow more applications to be solved with simple LiDAR sensors, which can cover a large area and work in any environment. Tony Rigoni Dir, Industrial Mkt Development & Alliances Quanergy

SEEING THROUGH WALLS: HARNESSING AR FOR MAINTENANCE AND REPAIR

11:30–12:00 PM

Augmented reality (AR) was once a Hollywood fantasy. Now, it’s enabling industrial operators to peer inside machines and diagnose issues from a safe distance. Discover how one innovative machine builder uses AR to cut maintenance time by up to 50% and maintenance costs by up to 20%. Chanakya Gupta EcoStruxure Mktg Mgr John Partin Packaging Segment Business Development Mgr Schneider Electric SD

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2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

Craft brewer adds can format

Cartoner produces 10-packs, could easily handle other counts.

hen Bruggsmiðjan Kaldi Brewery was launched in 2006 in the small town of Árskógssandur in the north of Iceland, glass bottles were of course the format. But it seems that consumers in Iceland are just as mad about beer in cans as everyone else in the world. So, the craft brewer decided to install a canning line—just before the pandemic began. “The machines were due into our plant in March [2020], along with technicians from suppliers to get things up and running,” says Brewmaster Siggi Ólafsson. “We wound up doing most of the installation and commissioning ourselves, [but] we were only delayed about a month. By June of 2020, we were in production.” The equipment on the line comes from numerous parts of the world, including the U.S.-made end-of-line E-2000 cartoning machine from Econocorp (Booth C-4422). Ólafsson recalls, “We were led to Econocorp during conversations . . . with other machine suppliers who are familiar with the kind of machinery that’s suitable for craft brewers. It’s just the right size machine for our production, and it’s very simple in design and, subsequently, in operation.” Italy is also well represented in the new line, as Cimec supplied the automatic depalletizer, the twist rinser, the 12-head counterpressure filler and both of the can seamers.

Inspection Systems

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At the beginning of the line, the depalletizer automatically removes slip sheets and sweeps the 330-mL cans onto a conveyor that leads to the twist rinser. An inkjet coder from Hitachi, parent company of Hitachi Industrial Equipment & Solutions America (Booth N-9810), puts lot and production codes on the bottom of each can. Then comes filling and seaming. “In 2006 we started with a Cimec bottle filler,” says Ólafsson when asked what led to Cimec as the firm’s choice of filling and seaming equipment. “We haven’t been at all disappointed with it, so it was easy enough to specify Cimec again when it came time to fill cans.”

Bruggsmiðjan Kaldi Brewery, the first microbrewery in Iceland, opted for a cartoner from Econocorp when it installed a can line to complement its bottling line.

A SCALE FOR ANY APPLICATION

Automatic Weighing Solutions

LINE OPERATION

Two lanes exit the filler so that cans can be sent into two Cimec seamers. “Having two seamers in place helps us in reaching our goal of 3,000 cans/hr.,” says Ólafsson. Exiting the seamer, cans pass through a Cimec air dryer so moisture from the cans won’t spoil the carton material. Then a level inspection device from Filtec (Booth C-2006) ensures that anything with a bad fill will be automatically rejected. Right after the dryer, the cans make a right-angle turn and feed onto the conveyor to the cartoning machine. Line pressure causes the cans to spread evenly into five lanes. When a group of 10 cans in a two-by-five pattern is in place, an escapement device opens to let the collation advance into the transfer station so that a pusher arm can push all 10 cans at a right angle into an E-flute corrugated carton that has been pulled by vacuum arms and erected directly into the loading station. To eliminate backpressure that could interfere with the smooth transfer of cans, a second device holds the rest of the cans back while cans are in the transfer station. The E-2000 cartoner uses hot glue to close cartons. Glue pellets go into a pre-melting area. A hot plate melts the glue and then glue fingers dip into this “bath” to apply a series of dots of glue across the flaps. A mechanical plate closes on these trailing flaps and provides a solid backstop for the incoming cans. Then the filled carton is pushed forward into a sealing system; while it’s being pushed, a series of rails closes the remaining flaps. In the process, the glue fingers apply adhesive to these flaps, too. Then the carton is elevated and sits a moment in a compression station so the glue can set up. When the next filled and closed case is pushed up, the preceding case slides down an exit ramp. “We do 10-counts only for now, but this could certainly change, and the cartoning machine is fully capable of handling these changes,” says Ólafsson. Cans are printed by supplier Ball. “But we’re looking at adding a labeler to the canning line for small runs,” says Ólafsson. For more info, visit www.econocorp.com, www.hitachi-iesa.com, www.filtec.com. SD Editor’s Note: The original version of this article was published in March 2021 by Packaging World.

8/5/21 10:45 AM

2021 PACK EXPO Las Vegas

SHOW DAILY SEPTEMBER 27, 2021

Showcase presents winning packs

12 groups participate in 2021 edition of popular gathering spot.

he 2021 edition of The Showcase of Packaging Innovations® (Booth N-9720), sponsored by WestRock (Booth C-2023), offers an opportunity to see award-winning innovations from around the world, including the honorees in the Sustainability Excellence in Manufacturing Awards, sponsored by ProFood World (Central Lobby). In the AmeriStar section of the Showcase, attendees may help choose the People’s Choice Award. To vote, simply select your favorite AmeriStar award winner and scan a QR code before noon tomorrow. Attendees also may vote at the Institute of Packaging Professionals (Booth C-1253). The winner will be announced at 3 p.m. tomorrow. Located in the Containers and Materials Pavilion in the North Hall, The Showcase of Packaging Innovations features award winners from 10 other organizations. “At WestRock, we connect people to products through deep partnerships built to solve customer challenges,” says Patrick Lindner, chief innovation officer and president of Consumer Packaging for Showcase sponsor WestRock.

PARTICIPANTS IN THE 2021 SHOWCASE OF PACKAGING INNOVATIONS ABRE (Brazilian Packaging Association) Asociación Mexicana de Envase y Embalaje Association of International Metallizers, Coaters and Laminators (Booth C-1347) Flexible Packaging Association (Booth C-1341) Foil and Specialty Effects Association (Booth C-1344) In-Mold Decorating Association (Booth C-1346) Institute of Packaging Professionals (Booth C-1253) Paperboard Packaging Council ProFood World (Central Lobby)

The Digital Application of the Year honored Mars M&M’s NFL package for the Green Bay Packers. As part of a series of packages sent The Digital to stores during the Application of the Year 16-week NFL season, winner combines digital printing and AR technology to provide an the carton featured interactive experience for consumers digitally printed prior and a turnarond time that allowed packs and current game sta- printed with Sunday’s football scores to arrive in stores on Wednesday. tistics as well as the Packers’ record that week within the division. Highlights of the 65th annual Flexible Packaging Achievement Awards competition, organized by the Flexible Packaging Association (FPA) (Booth C-1341), include the Shield Pack® clear, high-barrier aseptic IBC (industrial bulk container) liner from Amcor Flexibles North America (Booth SU-7244, SU-7254), which captured a Gold Award for Technical Innovation. Another noteworthy winner in the FPA competition earned a Gold Award–Sustainability for an industrial compostable coffee pod lidding and mother bag for Maxwell House Coffee Canada. For more info, visit www.PACKEXPOlasvegas.com, www.westrock.com, www.placon.com, www. www.amcor.com/afna. SD

Reusable Packaging Association (Booth SU-8201) The Tube Council World Packaging Organisation (Booth C-1141) Custom medical package from Placon, a WorldStar winner, protects product sterility and handles easily yet meets all operating room protocols.

One winning package on display is a custom design from Placon (Booth N-9314). It received a WorldStar award in the Medical and Pharmaceutical category from the World Packaging Organisation (Booth C-1141). The sterile sealed inner and outer tray features a Tyvek® lid, which can be peeled back to access a sterile tube. The outer and inner sterile barriers have a unique grip feature on the edges for more secure handling when wearing medical gloves. The sterile tube uses Placon’s non-abrasive BargerGard® polyurethane to create a secure package for medical screw implants and other implant/instrument assemblies.

The tube design allows medical personnel to hold the tube without product contact prior to when the implant is needed during the surgical procedure. Each tube has an open-and-close top that allows access to the screw or device instrument inside. The sterile polyurethane tube prevents puncture or abrasion of the sterile barrier. Also on display are winners of the 77th Annual North American Paperboard Packaging Competition, sponsored by the Paperboard Packaging Council. In that contest, WestRock received 18 awards, including Rigid Box of the Year and Digital Application of the Year. The Rigid Box of the Year award honored a carton for Jung & Wulff Luxury Rums. The premium package features a perfectly flat foldover face panel and is designed to highlight and securely display the craft spirits. Winner of Rigid Box of the Year honors, this carton for premium rum is designed to prevent a 12-in. face panel from bowing. It features a pull-out handle, antique map graphics, gold stamping and engraving to highlight the brand’s 1883 origins.

The multilayer Shield Pack structure safeguards contents against moisture, oxygen and environmental contamination, while extending distribution range, reducing transit failures, improving product quality and maintaining product color and vitamin retention.

The Gold Award–Sustainability from FPA recognizes the circular design for coffee pod packaging. Sustainable elements include renewable inputs, a no-separation pod design to ensure easy consumer disposal into the organics collection and compostable lidding film and barrier structure of mother bag.

2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

Innovation Stage adds processing sessions

ducational opportunities, a central tenet of the PACK EXPO family of shows, take the form of several show-floor programs, including the ever-popular Innovation Stage (Booth C-2051, C-2058, C-2151, N-24020). The multi-track schedule features more than 50, 30-min. sessions focused on breakthrough technologies, best practices and case studies. Nearly one-third of the sessions are devoted to sustainability topics. New this year is the Processing Innovation Stage (Booth N-24020) with about a dozen sessions organized by the editors of ProFood World. Presenters rank as subject matter experts and represent a cross-section of exhibitors such as Beckhoff Automation (Booth SL-6149), Emerson (Booth

SL-6307), Markem-Imaje (Booth C-2232), Mettler-Toledo (Booth C-1814), nVenia, A Duravant Company (Booth C-4425), Siemens Digital Industries US (Booth SL-6356), Specright (Booth SL-7356), Syntegon Packaging Technology (Booth C-2800) and WestRock (Booth C-2023). Session descriptions, times and locations are listed on the following pages. Updated schedules may be found on the show website or via the PACK EXPO Las Vegas/Healthcare Packaging EXPO App. Other educational opportunities on the show floor include the first PACK to the Future Stage (Booth N-9830) (see schedule, p. 22) and another popular program, The Forum at PACK EXPO (Booth C-2158) (see schedule, p. 42). For more info, visit www.PACKEXPOlasvegas.com, www:HCPElasvegas.com. SD

MONDAY, SEPTEMBER 27, 2021 2021 AND BEYOND: WHERE PACKAGING SUSTAINABILITY MEETS ECOMMERCE 10:00–10:30 AM Innovation Stage 1 | C-2051

The COVID-19 pandemic has altered consumer behavior and trends, driving the development of eCommerce packaging and the Circular Economy that will sustain these changes into the future. Examples of Virtual Twin technology show how it will accelerate sustainable and profitable economic models using artificial intelligence and machine learning to optimize the package of the future. Discussion includes a customer case and explores pre- and post-pandemic shifts in consumer behavior, sustainability and the feasibility of a Circular Economy and the use of Virtual Twin technology in packaging for multiple consumer channels. Ray Wodar Global Industry Business Consultant Dassault Systèmes

HOW TO AUTOMATE A SUSTAINABLE, MINIMAL MATERIAL PACKAGING SOLUTION FOR CANS

10:00–10:30 AM Innovation Stage 2 | C-2058

10:00–10:30 AM Innovation Stage 3 | C-2151

The pressures of increased demand, coupled with potential for waste, have led manufacturers to opt for “speed over substance” when it comes to sealing machinery. But manufacturers don’t have to choose between speed and waste reduction, efficiency and sustainability, premium machinery and extra floor space. Bob Green Dir, Sales North America - Shemesh USA Shemesh Automation

STATE OF THE INDUSTRY: HOW FOOD AND BEVERAGE PROCESSORS MOVE PAST THE PANDEMIC

10:30–11:00 AM Processing Innovation Stage | N-24020

What is the state of the food and beverage industry? Report examines pandemic impacts and trends going forward. Aaron Hand Editor in Chief ProFood World

CONNECTING YOUR SUPPLY CHAIN NETWORK TO BUILD RESILIENCE

11:00–11:30 AM Innovation Stage 1 | C-2051

In the era of supply chain disruption, does your business have guardrails in place in case of disaster? Digitizing your supply chain network can help. From quickly recognizing supply chain gaps or meeting skyrocketing demand, digitally building out your supply

chain network enables recovery and turns disruption into opportunity. Matthew Wright Founder & CEO Specright

EYE ON THE ENVIRONMENT: COMBATING FOOD WASTE WITH FLEXIBLE PACKAGING

11:00–11:30 AM Innovation Stage 2 | C-2058

Combat food waste with flexible packaging. • Why food waste is an issue (especially in landfills) • Different structures and their benefits • Preserving/extending shelf life with flexible packaging • What converters and brands are doing to eliminate food waste. Evan Arnold VP, Business Development Glenroy

CONVENTIONAL VS. ROBOTIC PALLETIZING: MAKING THE RIGHT CHOICE

11:00–11:30 AM Innovation Stage 3 | C-2151

Will robotic or conventional palletizing dominate your foreseeable future? The answer depends on organizational needs and applications. This session examines the specific applications that favor each technology to chart the future of palletizing automation and help you determine the right approach for your operation. Michael Castor Offering Mgr, Palletizing Honeywell Intelligrated

Consumers are drawn to sustainable, convenient packaging, while brands need solutions that meet their efficiency and operational goals. Learn how to achieve these goals with alternative paperboard materials and technology. Douglas Hicks VP, Machinery, Beverage Design, Brazil Roxanne McSpadden Dir, Beverage New Product Development & Mktg Graphic Packaging International

SEALING THE DEAL: UNLOCK SAVINGS WITHOUT COMPROMISING SPEED

ASEPTIC FILL FINISH BLISTER PACKAGING BLISTER TOOLING

Pharmaceutical Packaging Manufacturing & Integration for More than 100 Years NJM COURSER® Vial/Syringe Labeler

C #3514

CARTONING CASE/TRAY PACKING CODING COLD FORMING

PHARMAWORKS TF1 Blister Machine

CAPPING

SL #6501 & C #3414

COTTONING COUNTING FEEDING FILLING

The Courser® Vial / Syringe labeler is designed to meet the growing needs from biotech companies and 503B pharmacies for personalized medicine packaging.

Compact, cost effective, low-volume production, requires minimal training and maintenance.

INSERT FEEDING ISOLATION TECHNOLOGY LABEL PRINTING

SERPA P100 Cartoner

C #3418

WLS VR-72™ Trunnion Labeler

C #3518

LABELING LINE INTEGRATION REBUILDS/UPGRADES ROBOTIC PALLETIZING SERIALIZATION

Horizontal cartoner with a small footprint and quick, no-tool changeover. Rugged frame build is ideal for three-shift per day operation. Serpa designed to be user-friendly and low-maintenance.

Designed for film or paper labeling onto vials with code vaccine for vials at high-speed, with quick changeover and improved OEE.

STERILIZATION THERMOFORMING UNSCRAMBLING

Four Brands – One Company – Total Pharma Solutions

VISION INSPECTION 800-811-6990 NJMPackaging.com

727-232-8200 Pharmaworks.com

800-348-5453 SerpaPackaging.com

856-273-3377 WeilerLS.com

WASHING

2021 PACK EXPO Las Vegas 28

SHOW DAILY SEPTEMBER 27, 2021

MONDAY, SEPTEMBER 27, 2021 (CONT’D) USING IOT TO IMPROVE PROCESS CLEANING SYSTEM EFFICIENCY

11:30–12:00 PM Processing Innovation Stage | N-24020

Learn how bringing the IoT to processing support equipment like automated clean-in-place systems and clean-out-of-place systems allows for higher efficiency in how the system operates as well as how data collection occurs. Peter Barrie Product Management Dir Sani-Matic

STATE OF SNACKING: OPPORTUNITY AND INNOVATION ABOUND

12:00–12:30 PM Innovation Stage 1 | C-2051

As consumers turned to snacking as a source of fun and comfort during the pandemic, they increasingly became focused on holistic health and wellness goals. With the return to more active lifestyles, shoppers continue to seek value-added benefits beyond nutrition in the snacks they choose. During the next year, innovation is set to explode in a snack category that continues to grow by providing new, healthful and tasty options, as well as reaching consumers faster than ever before through eCommerce. Learn which snack categories are growing, why they are growing and how snack makers are capturing opportunity for one of the fastest-growing categories in consumer packaged goods. David Walsh VP, Membership & Communications SNAC International

ADVANCES IN SUSTAINABLE HOT-MELT ADHESIVES

12:00–12:30 PM Innovation Stage 3 | C-2151

Sustainability is a prominent topic in the consumer goods and packaging industries and society overall. Join this session for a high-level overview of innovative solutions in sustainable hot-melt adhesives. Divya Mohan Sr Technical Mgr Henkel

CONTINUOUS IMPROVEMENT SUCCESSES FROM 700 F&B AND CPG MANUFACTURERS

1:00–1:30 PM Innovation Stage 1 | C-2051

Productivity in the food, beverage (F&B) and consumer packaged goods (CPG) industries has stagnated. While lean manufacturing has helped automotive and other discrete manufacturing sectors grow their OEEs from the 70s to the 80s in the past decade, OEEs for F&B and CPG manufacturers have leveled off. Research during that period shows that the average starting OEE across small and mid-size manufac

turers hovers below 50%, while even mature, continuous-improvement environments stall in the mid-60s. Matt Deffenbaugh Dir, Solutions Redzone Production Systems

HOW TO UPGRADE YOUR V/F/F/S BAGGER FROM HEAT TO ULTRASONIC TECHNOLOGY

1:00–1:30 PM Innovation Stage 2 | C-2058

Discuss the challenges and solutions to converting vertical/form/fill/seal machines to ultrasonic technology. Bill Aurand Ultrasonic Applications Mgr LAKO Tool and Manufacturing

PROTECTING YOUR PRODUCTS, BRAND AND REPUTATION IN AN ONLINE WORLD

1:00–1:30 PM Innovation Stage 3 | C-2151

COVID-19 has accelerated the shift toward eCommerce and online shopping, where products bypass the store, get packaged in individual quantities and are shipped directly to a consumer’s front porch. Explore the changing forces reshaping the role of the package and outline key considerations in designing the next generation of online packaging. John Wilson Dir, Mktg & Sustainability Amcor Flexibles North America

PETAINER KEGS

1:30–2:00 PM Processing Innovation Stage | N-24020

The Petainer Keg is the world’s first commercial polyethylene terephthalate keg for high-pressure processing (HPP) beverages. A breakthrough global innovation, the keg offers beverage manufacturers safe, sustainable and cost-efficient packaging. Petainer works with beverage customers in the nonalcoholic and alcoholic categories, which include carbonated beverages, water, juice, beer, cold-brew coffee, kombucha, cider, wine and spirits. Carole Tonello-Samson, Ph.D. Commercial & Applications Dir Hiperbaric Andrew Brewer Dir, Technical Services North America Petainer

SUSTAINABLE ADHESIVE-FREE LABELING

2:00–2:30 PM Innovation Stage 1 | C-2051

MOVING AWAY FROM SHRINK WRAP: HOW BUMBLE BEE SEAFOOD IS TRANSITIONING TO MORE READILY RECYCLABLE PACKAGING

2:00–2:30 PM Innovation Stage 2 | C-2058

Co-presenters describe how to navigate a major shift in packaging formats to provide more sustainable packaging without sacrificing quality. Learn how partnering with an experienced OEM for new packaging equipment is helping Bumble Bee Seafood achieve sustainability goals. Leslie Hushka Global Corporate Social Responsibility Bumble Bee Seafoods Jeff Wintring Chief Technology Officer R.A Jones

DEPALLETIZER MACHINE CONDITION MONITORING VIA IIOT SOLUTIONS TO MAXIMIZE OEE

2:00–2:30 PM Innovation Stage 3 | C-2151

Learn how Busse/SJI (division within Arrowhead Systems) and Emerson worked together to develop a high-level bulk depalletizer with a range of new IIoT machine health monitoring capabilities to help customers maximize OEE. Mark Densley Dir, Business Development Factory Automation Emerson Industrial Automation Tim Krueger President & COO Arrowhead Systems

FOOD SAFE FACILITY DRAINAGE DESIGN

2:30–3:00 PM Processing Innovation Stage | N-24020

Session covers the history and basics of sanitary drainage system design in food and processing facilities. Topics include: • How to lay out facility to facilitate sanitary design • What makes a drain “food-safe” • What difficulties face sanitary design? Viking Kristjansson Sales Exec/Product Development Lead FoodSafe Drains

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In the world of retail food, labeling is more than a means of advising the consumer about nutrition facts, ingredients and expiration dates. The food label is the voice of the brand, capable of creating an emotional connection with the consumer, making it a crucial part of the packaging. Common forms of labeling and sleeving, whether manually or automatically applied,

often require adhesives or glues, resulting in extra application steps and an increase in wasted materials. Discuss various forms of labeling in the food industry and take a deeper look at paper, plastic or compostable labeling that is adhesive-free, linerless, earth friendly, can be applied automatically and will catch the eye of consumers today. Lisa Barrieau Banding Sales Mgr, Food Felins

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PACK EXPO Sept 27-29, 2021 Las Vegas Booth C-2800

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2021 PACK EXPO Las Vegas 30

SHOW DAILY SEPTEMBER 27, 2021

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3:00–3:30 PM Innovation Stage 1 | C-2051

The viability of compostable packaging as a part of a sustainability program continues to gain momentum, and the demand is increasing. However, to bring this emerging solution mainstream, brands, packagers and suppliers must form collaborative partnerships to develop optimal structures and overcome current infrastructure and education challenges. Todd Meussling Fresh-Lock® Sr Mgr, Mkt Development Presto Products

EASY MACHINE DEVELOPMENT AND CUSTOMIZATION WITH AN OPEN AUTOMATION ECOSYSTEM AND APP STORE

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3:00–3:30 PM Innovation Stage 2 | C-2058

Imagine a new world of automation where pre-engineered solutions and ready-touse Apps speed time to market and reduce or entirely eliminate development effort. Learn how an open automation ecosystem fosters innovation and helps businesses perform automation tasks more flexibly and individually. Learn how a Smartphone approach to industrial automation can make automation easy and accessible for machine designers and support end users over the entire machine life cycle. Dave Cameron Dir Sales, Automation & Electrification Solutions Bosch Rexroth

TRAINING: INVESTING IN MANUFACTURING PERFORMANCE AND OPERATIONAL RESILIENCE

3:00–3:30 PM Innovation Stage 3 | C-2151

Does more packaging automation mean less training? Here are the reasons why investing in specialized and simulation-based training is the best way to support the transition toward automation and unlock the full potential of people and technologies. Philippe Bernatchez Training Mgr Premier Tech

SUSTAINABILITY EXCELLENCE IN MANUFACTURING AWARDS

3:30–4:30 PM Processing Innovation Stage | N-24020

Sustainability Excellence in Manufacturing Awards featuring Conagra Brands, B&G Foods, Smithfield, Liffey Meats and Graphic Packaging International. Meet the winners and learn about their cost-saving environmental practices.

ANALYTICS-BASED ASSET PERFORMANCE MANAGEMENT AND REMOTE MONITORING FOR THE ENTERPRISE

4:00–4:30 PM Innovation Stage 1 | C-2051

Data from machines, using OPC UA, MQTT or IIoT protocols with analytics and a rules-based platform, are used to provide monitoring and predictive machine performance management. Enterprises with dispersed locations can monitor critical assets in a predictive manner using a Google Maps user interface. Ed Garibian CEO LLumin

REIMAGINING PLASTIC MAILERS WITH INNOVATIVE FIBER-BASED POUCHES AND ONDEMAND AUTOMATION

4:00–4:30 PM Innovation Stage 2 | C-2058

Explore how the rapid growth of plastic mailers in the eCommerce space has

2021 PACK EXPO Las Vegas

SHOW DAILY

BOO VISIT TH US US- AT 834 6

SEPTEMBER 27, 2021

MONDAY, SEPTEMBER 27, 2021 (CONT’D) led to consumer pressure for more sustainable packaging and how companies can improve their sustainability, productivity and consumer experience by shifting to a fiber-based pouch system. Greg Magnell Sr VP, Box On Demand WestRock

OPTIMIZE PACKAGING OPERATIONS, ENSURE COMPLIANCE AND PROTECT YOUR BRAND

4:00–4:30 PM Innovation Stage 3 | C-2151

THE TIME HAS COME TO TURN THE INDUSTRY UPSIDE DOWN!

End-to-end brand protection begins on the packaging line with the right code, which delivers accurate, real-time insight, actionable product data and digital connectivity throughout a product’s supply chain journey. Learn how to improve package coding, product authentication and traceability to combat counterfeiting and diversion, optimize processes and meet compliance. Steve Tallant Sr Dir, Mkt Development Markem-Imaje

TUESDAY, SEPTEMBER 28, 2021 VINYL-FREE, FULLY RECYCLABLE BLISTER

10:00–10:30 AM Innovation Stage 1 | C-2051

Imagine a vinyl-free, fully recyclable blister that is completely compatible on all standard equipment, delivering optimal performance in health protection and environmental safety. Daniel Stagnaro Head of Technology Klöckner Pentaplast

GUIDE RAIL SYSTEM TACKLES SAFETY CONCERNS AND PRODUCT GUIDANCE ISSUES

10:00–10:30 AM Innovation Stage 2 | C-2058

Learn about a product guidance system with new and unique features that eliminate bulkiness, costly changeover time and safety hazards present in today’s standard guide rail systems. Steve Fye VP, Research & Design Span Tech

A LOOK BACK AT TRACK: THE EVOLUTION OF INTELLIGENT TRANSPORT TECHNOLOGY

10:00–10:30 AM Innovation Stage 3 | C-2151

Explore how packaging operations can boost machine throughput, flexibility and adaptability using the latest linear transport systems. Packaging application best practices will be covered to demonstrate how you can ensure success by implementing intelligent track technologies. Rick Forsgren Packaging Industry Specialist Beckhoff USA

IMPROVE PERFORMANCE WITH SPIRAL IMMERSION PROCESSING

FORTECH INTRODUCES

OEE

PA R T O F T H E m a n u - FA C T M E S S U I T E

MES SUITE

The Least Expensive, Most Accurate Overall Equipment Efficiency Tool in the World! Three Line Measurements: (1) Availability – Affected by Unplanned Stops (2) Performance – Running Rate and Target Rate (3) Quality – Affected by Producing Bad Product

Investment Fee Includes: • Plant License • Unlimited Number of Lines • One-time Fixed Cost • First Year Support • Installation Guide, Support • Configuration Guide, Support

46,20000 TOTAL

Simple Installation. No Integrators Needed.

10:30–11:00 AM Processing Innovation Stage | N-24020

A review of the technology and methodology of a spiral immersion system for chilling, freezing, cooking, pasteurizing and sous-vide food processing applications and how this revolutionary technology improves product quality and reduces energy consumption and labor costs. Steve Kelley Dir, Spiral Immersion System FPS Food Process Solutions

LLC

PROVEN RESULTS – PERSONAL DEDICATION

For Additional Information: solutions@fortech-usa.com www.fortech-usa.com

2021 PACK EXPO Las Vegas 32

SHOW DAILY SEPTEMBER 27, 2021

TUESDAY, SEPTEMBER 28, 2021 (CONT’D) IMPROVING PACKAGING AND LINE EFFICIENCY FOR FOOD BOWL AND TRAY APPLICATIONS

11:00–11:30 AM Innovation Stage 1 | C-2051

Hear about the newest automation technology for food bowls and tray applications that combine sustainable primary, secondary and tertiary packaging into one system. This innovative end-of-line solution increases line efficiency and lowers total cost through material and labor savings. John Perkins VP, Global Packaging Systems WestRock

COMBAT COUNTERFEITS WITH AMAZON AND DOMINO

11:00–11:30 AM Innovation Stage 2 | C-2058

Counterfeit products have risen during the last few years and now account for 3.3% of global trade. This has an impact on your brand and reputation. Be in the know. We here at Domino believe in transparency as a means to proactively prevent counterfeits from reaching customers. It’s why we are teaming up with Amazon as part of its Transparency program. Adem Kulauzovic Dir, Coding Automation Domino Amjet

SUSTAINABILITY IN HEALTHCARE PACKAGING: OPPORTUNITIES VS. CHALLENGES

11:00–11:30 AM Innovation Stage 3 | C-2151

Everywhere you turn you hear the buzzwords: recyclable, post-consumer recycled (PCR) content, biodegradable, compostable, etc. Consumers are demanding sustainable packaging, including end-of-life considerations beyond the landfill, and making purchasing decisions accordingly. What about healthcare packaging? To packaging professionals in this space, these words evoke thoughts of risk and compromise to patient safety. However, this is not necessarily true. Explore opportunities for designing packaging with sustainability as a critical-to-quality element without compromising the rigorous standards required for patient and product protection. Learn about key challenges faced when designing and implementing sustainable packaging and options to overcome these challenges. Brian Ingraham Sr R&D Dir Amcor

LATEST TRENDS IN HPP

11:30–12:00 PM Processing Innovation Stage | N-24020

12:00–12:30 PM Innovation Stage 1 | C-2051

Join this session to hear from Mike Wagner, Kevin Roach and Peter Barrie, who will discuss solving manufacturing challenges through advanced digital solutions. Mike Wagner OEM Segment Mgr Rockwell Automation Kevin Roach President Harpak-ULMA Packaging Peter Barrie Product Management Dir Sani-Matic

RESISTANCE IS FUTILE: TRAYLESS GROUND MEAT IS THE NEXT FRONTIER IN SUSTAINABILITY

12:00–12:30 PM Innovation Stage 2 | C-2058

Discuss the multi-faceted impact of trayless ground meat packaging. Gain insights into the current state of the technology and logistics, the range of sustainability benefits delivered and the substantial cost advantages producers stand to realize. Hugh Crouch Flow Wrap Product Mgr Harpak-ULMA

BOTTLING 101: ARE YOU GETTING THE MAXIMUM PERFORMANCE FROM YOUR PACKAGING LINE?

12:00–12:30 PM Innovation Stage 3 | C-2151

Many of us forget during our continuous day-to-day production operations the many basics for proper application of design theory. Relearn best practices for adhering to basic design applications to improve overall line performance and line efficiency. Calvin Blake Sr Packaging Project Mgr POWER Engineers

NEW AUTOMATION TECHNOLOGY SOLUTIONS

1:00–1:30 PM Innovation Stage 1 | C-2051

Today, the need for automation is more relevant than ever. When it comes to fully automated systems, there is no one-size-fits-all solution. Learn about key technologies to take automation in packaging to new levels. Andreas Schildknecht Global Product Mgr, Robotics Syntegon Technology

HOW HAS COVID-19 CHANGED THE WAY WE AUDIT OUR SUPPLIERS?

1:00–1:30 PM Innovation Stage 3 | C-2151

COVID-19 has dramatically changed the way we deal with food safety audits. It eliminated face-to-face audits with suppliers and forced us to use methods like virtual audits and Zoom calls. What were the key learnings from this process, and how will it change the way we audit going forward? Brian Stegmann Exec Dir International Society of Beverage Technologists

MANUFACTURING 2022 AND BEYOND–WHY AUTOMATION ALONE IS NOT ENOUGH

1:30–2:00 PM Processing Innovation Stage | N-24020

Manufacturing in 2022 needs to look beyond automation. Diane Wolf Operations & Engineering Consultant Board Level Food & Beverage Exec

SUSTAINABLE LABEL OPTIONS CAN HELP ACHIEVE GOALS

2:00–2:30 PM Innovation Stage 1 | C-2051

This comprehensive overview of sustainable label options covers inks, coatings and materials for cut-and-stack, inmold, pressure-sensitive, roll-fed and shrink/stretch sleeve labels. Discussion includes recommendations for materials that facilitate recycling for various container types. Tim Nicholson Sr VP, Technical Services Fort Dearborn

SMART INNOVATIONS FOR FOOD AND BEVERAGE MANUFACTURING

2:00–2:30 PM Innovation Stage 2 | C-2058

Industry 4.0 offers food and beverage manufacturers the agility to rapidly adapt to changing needs with high-quality products produced in a smarter way. Learn how to leverage innovations made possible by integrating the virtual and physical worlds with a digital thread. Nina Verstandig Digital Enterprise Industry Mgr, CP&R Siemens Siemens Digital Industries

ROBOTIC VALVE PLACERS FOR SAFE, CONSISTENT PRODUCTION

2:00–2:30 PM Innovation Stage 3 | C-2151

The placement of valve bags onto filler spouts is a highly repetitive, labor-intensive task often performed in challenging environments. Review the benefits of using robotics to safely automate this process and learn about ways to maximize uptime and increase

Discover the latest trends in high-pressure processing (HPP) including packaging, plant-based foods, pet food and red meat. Dr. Errol Raghubeer VP, HPP Microbiology & HPP Science JBT

BEYOND THE MACHINE: SOLVING MANUFACTURING CHALLENGES THROUGH ADVANCED DIGITAL SOLUTIONS

2021 PACK EXPO Las Vegas 34

SHOW DAILY SEPTEMBER 27, 2021

TUESDAY, SEPTEMBER 28, 2021 (CONT’D) throughput with uninterrupted operation. Todd Alford Dir, Product Management nVenia

THE POWER OF A SYSTEMATIC APPROACH TO PROCESS IMPROVEMENT

2:30–3:00 PM Processing Innovation Stage | N-24020

The typical “isolated but related” approach to improvement projects is that it’s either time consuming for processing companies handling everything in-house or expensive for those subbing out the work to engineering or consulting companies. Learn how equipment manufacturers can serve the food industry by implementing a systematic approach to the projects they address instead of handling requests for proposals (RFPs) as projects isolated from the broader system. Then explore how food processors substantially reduce costs by partnering with equipment and software suppliers to handle their RFPs as an extension of their team through a holistic and systematic approach to process improvement. Step into a case study for a look at Deville’s Systematic Project Development Process. Nehemiah White Mkt Mgr Deville Technologies

DIGITAL TRANSFORMATION

3:00–3:30 PM Innovation Stage 2 | C-2058

The fourth industrial revolution is changing our world. The foundation for networked, smart process automation during this revolution is paved with intelligent sensors. Intelligent sensors not only collect data but also prepare and process it to provide information. Sensors therefore no longer just “sense.” With the beginnings of digitization, sensors are starting to “think.” The transmission of information produced in this way is becoming a key technology. The success of networked value creation chains depends on the successful integration of sensors in the overall architecture of an application. Divya Prakash Dir, Business Consulting Industry 4.0 SICK

REQUIREMENTS TO CONSIDER FOR CODE VERIFICATION

3:00–3:30 PM Innovation Stage 3 | C-2151

Product-specific codes—alphanumeric, 1D or 2D barcodes—serve a variety of functions on product packaging, for example, inventory purposes, supply chain security and facilitation of product recalls. It is critical that these codes are present and correct to avoid unnecessary rework and product returns, the potential for fines or even lawsuits and brand damage. Cover the four Cs of reliable code verification and

hear a detailed explanation of code contrast, character spacing, character size and consistency of print and background. Robert Rogers Sr Advisor, Food Safety & Regulation METTLER TOLEDO

MANUFACTURING INNOVATION AWARDS

3:30–4:30 PM Processing Innovation Stage | N-24020

Manufacturing Innovation Awards featuring MWC, CTI Foods and Kraft Heinz. Meet the winners and learn about their state-of-the-art manufacturing technologies.

SUSTAINABLE BUNDLING FOR ECOMMERCE

4:00–4:30 PM Innovation Stage 1 | C-2051

As eCommerce continues to boom across all industries, every layer of the supply chain is being reevaluated. Common factors driving operational and packaging innovations within eCommerce, specifically related to direct-to-consumer packaging methods, include improving the unboxing experience, maintaining brand consistency through all channels, identifying how to fulfill orders faster and reduce freightcosts, all while providing sustainable packaging that protects the product in transit. Explore how ultrasonic banding addresses these key factors/pain points. Banding can reduce void fill, unitize shaped products prior to auto-box systems and eliminate corrugate damage associated with strapping, while utilizing various types of banding material (from paper and plastic to pre-printed and compostable). Gina Barrieau Banding Sales Mgr, eCommerce Felins

NOT BUSINESS AS USUAL AUTOMATION

4:00–4:30 PM Innovation Stage 2 | C-2058

Current industrial automation has done a good job of advancing industry, but to make step-change engineering and operational advancements, we need to make bold moves. It’s time for universal automation. Kaishi Zhang Global Dir, Product Management Schneider Electric

LIGHTWEIGHTING AND BEYOND

4:00–4:30 PM Innovation Stage 3 | C-2151

Explore technologies that enable and unlock a more sustainable bottle, finish to base. Dan Witham Dir, Product Development Amcor Rigid Packaging

WEDNESDAY, SEPTEMBER 29, 2021 USING QUANTITATIVE LEAK TEST DATA TO ENHANCE CERTAINTY OF SHELF LIFE

10:00–10:30 AM Innovation Stage 1 | C-2051

See how simple it is to leak-test packages (even compostable packages) nondestructively and create quantitative leak-rate data, which can be combined with a simple, fast, comprehensive quantitative gas concentration gas analysis to calculate real shelf-life projections. Bill Burnard Package Integrity Sales & Business Development Mgr, North America INFICON

ENABLING FREEDOM OF DESIGN BY LEVERAGING WIRELESS TECHNOLOGIES

10:00–10:30 AM Innovation Stage 2 | C-2058

Rethinking traditional design methods and constructs for unconstrained concepts that leverage effective machine design is challenging and can involve some risk. Learn how to overcome some of those challenges and mitigate risk with well-tried and proven non-traditional technologies like wireless IO and machine pneumatics. Nathan Eisel National Product Development Mgr SMC

HOW MARKET FORCES ARE RESHAPING THE CONTRACT PACKAGING/MANUFACTURING INDUSTRY AND THE BRANDS IT SERVES

10:00–10:30 AM Innovation Stage 3 | C-2151

Explore the rapidly evolving contract packaging (copack) and manufacturing (co-man) industries. According to the 2021 State of the Industry Report from CPA, The Association for Contract Packaging and Manufacturing, contract organizations are adding value as consumers and market-driven needs influence the packaged goods supply chain. Understand how labor trends have accelerated or altered views on automation. Discuss how consolidation, acquisition and internal investments are changing the nature of the industry. Gain a perspective on the evolving innovation needs of brands and how they are being fulfilled by co-man and co-pack services. See how supply chains and sourcing are morphing to meet new challenges with strategic co-man and co-pack partnerships. Ron Puvak Exec Dir CPA, The Association for Contract Packaging and Manufacturing

2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

WEDNESDAY, SEPTEMBER 29, 2021 (CONT’D) THE FUTURE OF SNACK PACKAGING

11:00–11:30 AM Innovation Stage 1 | C-2051

COVID-19 changed the way consumers shop for snacks, including shifts in package size preference and how they buy their snacks. Learn how changing demand has increased the need for further automation at the packaging end of the line and demonstrate how snack manufacturers can double current levels of performance with a single system. Teri Johnson VP, North America TNA North America

HOW OEMS CAN USE MACHINE DATA TO ADD SERVICES

11:00–11:30 AM Innovation Stage 2 | C-2058

See how data from any machine source is used in conjunction with a rules-based system to provide machine monitoring and predictive machine performance management for the machine builder/OEM. Adding intelligent maintenance and monitoring to an OEM’s smart machine initiative provides a platform for additional recurring revenue streams or Machine-as-a-Service revenue models. Ed Garibian CEO LLumin

INNOVATIVE PACKAGING SOLUTIONS FOR A SUSTAINABLE FUTURE

11:00–11:30 AM Innovation Stage 3 | C-2151

Discover the industry’s 2021 trends in flexible packaging and prepare now for the challenges of the packaging industry today. Stay at the forefront of the industry’s changing business landscape and one-step ahead of your competition by learning about the technological achievements that will take the lead in our future. Prepare for the challenges facing the industry, which are redefining business, without getting stressed from experiencing unknown and unexpected changes. Dimitris Gkinosatis Group Business Development Dir Flexopack

CURBSIDE-RECYCLABLE MAILER

12:00–12:30 PM Innovation Stage 2 | C-2058

Discuss the current sustainability landscape from the perspective of a diverse set of stakeholders (brands/retailers, NGOs, government/regulatory and consumers) and learn about a curbside-recyclable mailer. David Brabham Mgr, Sustainability Strategy Adam Ganz VP, Commercial Development Georgia-Pacific Corrugated

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PDC - the leading name in Shrink Sleeve Labeling and Tamper Evident Banding equipment. equipment

Brands worldwide rely on rugged PDC machinery for maximum productivity and efficiency, 24/7/365 operation, and unrivaled u longer lasting blade technology. Top consumer food, beverage and pharmaceutical brands rely on PDC’s smart tamper evident solutions as well as PDC’s “Total Sleeving Solution” for high performance, high volume and best overall value. Depend on the company that does more… and does it better: • PDC Machines – the toughest, most reliable workhorses on the market • Advanced Blade Technology – PDC Blades last months, not days • Full Vertical Integration from engineering to metal fabrication • State-of-the-Art Control Systems • The PDC Service Team – wherever and whenever needed • 50 Years of Innovation, Service and Reliability

PACKAGING AUTOMATION TAKES FLIGHT WITH FLYING MOTION TECHNOLOGY

12:00–12:30 PM Innovation Stage 3 | C-2151

This presentation will explore how controls engineers and plant managers in packaging can use new flying motion technologies to enable Lot-Size-1 production. Learn from real-world examples how these technologies transform packaging machines and lines with adaptive manufacturing concepts that deliver groundbreaking levels of flexibility and throughput in production. Jeff Johnson Mechatronics Product Mgr Beckhoff Automation SD

INNOVATION. SERVICE. PERFORMANCE.

ADVANCED BLADE

Technology

PDC BLADES LAST MONTHS, NOT DAYS! Rugged, resharpenable blades mean reduced downtime.

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2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

ProMach Pharma Solutions expands Four brands work under one umbrella to serve pharma needs.

roMach (Booth C-3220) continues to expand the number of brands collaborating under the banner of ProMach Pharma Solutions. All four members of the ProMach Pharma Solutions team—NJM (Booth C-3514), Pharmaworks (Booth C-3414), Serpa (Booth C-3418) and WLS (Booth C-3518)—are exhibiting together in the Central Hall adjacent to the other ProMach brands and businesses, as well as exhibiting together in the South Lower Hall (Booth SL-6501). The four brands represent nearly 200 years of combined expertise in pharmaceutical packaging with applications across the globe. “Our Pharma business line offers an incredibly wide portfolio of world-class solutions,” says Tom McDaniel, president of ProMach Pharma Solutions. “From standalone systems to fully integrated, turnkey lines, ProMach is positioned to give customers everything they need.” ProMach Pharma Solutions offers a wide range of equipment for a variety of package formats, including bottles, vials, syringes, blister packs and autoinjectors. Specifically, it supplies high-performance aseptic fill/finish, bottle unscrambling, tablet counting, filling, capping, blister packing, labeling, coding/serialization, label printing, conveying, cottoning and sealing systems, as well as complete pharmaceutical packaging lines for customers of all sizes and geographies. “ProMach has created a great balance between integrating their brands and cultivating their individual identities,” notes Adam Rosenthal, director of Pharma Marketing, who joined the organization early in 2021. “The brands work together while still maintaining their unique personalities,” he explains. Several machines are debuting this year, including the TF1 blister machine from Pharmaworks. Designed for low-volume production, this affordable, entry-level machine requires minimal training and is easy to operate. Delivering the same features as more complex machines, the TF1 unit offers straightforward cleanability, quick changeover and minimal maintenance requirements. As radio frequency identification (RFID) assumes a larger role in meeting serialization requirements, WLS has adapted its highspeed, pressure-sensitive label applicators and label printers to incorporate the latest RFID technology. Options include: RFID-ready labelers, which apply pressure-sensitive labels embedded with RFID inlays; RFID-enabled label-application systems, where dual label heads marry label and RFID tag just prior to application; and RFIDready print stands, which print on pressure-sensitive labels embedded with RFID inlays.

Four Brands, One Company, Total Pharma Solutions.

NJM is a single-source provider of automated packaging machinery for the pharmaceutical, nutraceutical, biopharmaceutical and personal-care industries. Established more than 100 years ago, NJM is both a manufacturer of select equipment and an integrator specialist for complete lines that require a high level of market niche expertise, assisting customers from the earliest stages of project planning and line design through implementation and production. Offerings include standalone solutions and turnkey integrated systems for liquid and solid dose products. Pharmaworks became part of ProMach in 2020, and manufactures blister packaging systems for the pharmaceutical, consumer goods and contract-packaging industries as well as feeders, cartoners and systems for online and bulk product vision inspection. Its robust and flexible lineup ranges from standalone machines to turnkey packaging lines. A specialist in robotics and end-of-line equipment, Serpa Packaging Solutions joined the ProMach family in February 2021. Founded in 1985, Serpa provides cartoners, case and tray

Capable of thermoforming many materials or with a cold-forming option, the compact TF1 machine can produce a blister up to 90 x 165mm with a maximum draw depth of 25mm.

packers, robotic palletizers, literature feeders, sleevers and robotic product-handling systems to Fortune 5000 companies across the globe. Additionally, Serpa provides line integration and validation services, designing turnkey integrated packaging systems from start to finish with single-source responsibility. WLS, formerly Weiler Labeling Systems, manufactures high-speed rotary and inline labeling machines along with serialization, coding and digital printer solutions that cater to products in the pharmaceutical, nutraceutical and medical-device industries as well as food, beverage and personal care. With equipment crafted to perform in controlled and safe environments, WLS ensures careful handling of delicate products without sacrificing speed and precision when applying labels and codes to containers such as bottles, vials, syringes and auto-injectors. ProMach is a family of best-in-class packaging solution brands. Its brands operate across the entire packaging spectrum: filling, bottling and capping, decorative labeling, flexibles and trays, pharma, handling and sterilizing, labeling and coding, robotics and end-of-line. ProMach also provides systems and integration including turnkey solutions, design/ build, engineering services and productivity software to optimize packaging line design and deliver maximum uptime. In addition to pharmaceutical and personal care, it serves the food, beverage, household and industrial goods industries. For more info, visit www.ProMachBuilt.com, www. NJMPackaging.com, www.Pharmaworks.com, www. serpapackaging.com, www.WeilerLS.com. SD

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2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

Vote now for People’s Choice Award Voting closes at noon tomorrow, winner announced at 3 p.m.

oting for the People’s Choice Award opens today. Attendees may vote for their favorite winner in this year’s AmeriStar Package Awards Competition, sponsored by the Institute of Packaging Professionals (IoPP) (Booth C-1253). The voting process involves scanning a QR code and takes place at the IoPP booth or the AmeriStar display in the Showcase of Packaging Innovations® (Booth N-9720), sponsored by WestRock (Booth C-2023). This year’s competition recognizes 24 AmeriStar and three Student AmeriStar winners, along with top awards for Sustainability, Design Excellence and Best in Show. This year, all three of the top winners come from the Health & Beauty Aids category.

Colgate’s category-changing toothpaste package won two out of three top honors in this year’s AmeriStar competition—Best In Show and Design Excellence.

The Colgate Elixir package by Colgate-Palmolive captured both the Best in Show Award and the Design Excellence Award. The reimagined toothpaste package marries a polyethylene terephthalate (PET) bottle with LiquiGlide technology, enabling the Colgate-Palmolive team to use PET with more viscous toothpastes. The cap opening was developed to dispense viscous toothpaste on a toothbrush while permitting air into the bottle to smooth the outflow of toothpaste. The package is designed for recyclability, including a thick-walled PET-E cap to provide a premium aesthetic while retaining compatibility with the PET recycling stream. The bottle is produced on a single-stage injection-stretch-blowmolding machine and assembled with an injection-molded polypropylene (PP) shoulder shroud and the PET-E cap. The label is a combination pressure-sensitive label, printed in four colors with dual matte and gloss varnishes, as well as two cold-foil applications and a reverse-printed back label. The Sustainable Packaging Award honors the most resourceful package in the competition. Judges consider how the packaging reduces its impact on the environment by evaluating efficient energy usage, recycling efforts and effective use of reusable, recyclable and eco-friendly packaging materials. This year’s winner, GlaxoSmithKline Consumer Healthcare (GSK), was honored for a 100% plastic-free, 100% recyclable toothbrush package. The toothbrush twin-pack consists of a color-matched, thermoformed PaperFoam tray that is compostable and recyclable in the paper waste stream. It is heat-

A plastic-free and recyclable toothbrush package earned GSK the Sustainable Packaging Award in this year’s AmeriStar competition.

sealed to a printed top card of NatraLock® UltraSeal solid bleached sulfate from WestRock (Booth C-2023), engineered to be used as a plastic clamshell replacement, while maximizing shelf appeal and enhancing sustainability. The top card has a die-cut window glued with clear, heat-sealable compostable cellulose film, allowing the consumer to see the product. Two plastic-free, paper-based labels on the back of the cellulose tray complete the package. The judges also recognized category winners.

BEVERAGES (ALCOHOLIC)

The Estrella Damm Rounded Corner Beer Cartons from Graphic Packaging International (Booth C-2442) provide a distinctive shelf presence. Developed with Estrella Damm, the Rounded Corner Pack is made from AquaKote™ solid unbleached sulfate using virgin fibers sourced from responsibly managed forests. The package is 100% recyclable, easily recycled and will replace 99 tons of shrink wrap annually.

BEVERAGES (NON-ALCOHOLIC)

The Liquipure™ Ultra mono-material flexible packaging from Liquibox (Booth SL-6131) reportedly is the first mono-material bag-in-box structure suitable for liquids requiring moderate- to high-barrier protection. Advanced resin technology delivers film that is recycle-ready, ultra-strong and boasts a higher barrier than alternative nylon structures. The MUD/WTR from TricorBraun reflects the brand’s ethos: simple, elegant and “less is more.” To showcase the products, a pair of reusable and recyclable custom tins were designed and topped with snuggly fitted pillow lids, evoking tea tins filled with loose tea leaves. Graphics are litho-printed, and a matte finish ensures no fingerprints mar the surface. The Dura-Lite® lightweight packaging from Altium Packaging for dairy, water and beverages reduces resin usage 5%–20%, moving bottle weight below the 62g threshold while maintaining or improving strength and performance. To date, this patented technology has saved more than 20 million lb. of virgin resin. The paper-based Boardio® “can” from AR Packaging Systems for modified-atmosphere-packed coffee provides gas-tight packaging for sensitive products. An ultrathin foil barrier layer protects freshness and achieves the same shelf life as the packaging it replaces. Minimized layers of PE seal tightly. The 80% fiber content makes the package recyclable in the beverage carton stream.

COSMETICS

Aveda Pyramid Holiday Carton from Graphic Packaging International relies on its unusual shape to be innovative for holiday gift-giving. The sideseamed, pyramid-shaped carton features a 1-2-3 style bottom to provide ease-of-use while offering a unique appearance. The cartons are produced from 18-pt. paperboard sourced from renewable resources and are 100% recyclable.

The patent-pending, easy-to-hold, easy-to-pour 2L carbonated soft drink bottle from PepsiCo redesigns the pinch grip to narrow the circumference from 13.4 to 10.4 in. The bottles use 24% less plastic label material than the old design.

ELECTRONICS

Liquipure™ Ultra mono-material film combines recyclability, strength and barrier properties.

A proprietary vacuum skin package, the winner in the Food (Refrigerated) category, shows off plant-based burgers.

The Medtronic Glass Component Automation Tote from Prent replaces a three-piece, injection-molded system, safely transports glass components and seamlessly integrates into the customer’s

2021 PACK EXPO Las Vegas

SHOW DAILY SEPTEMBER 27, 2021

automation process. A single, asymmetrical part functions as either the top or bottom of the tote. When interfaced with itself, it snaps into place to safely house 30 fragile glass components.

FOOD (REFRIGERATED)

A proprietary vacuum skin package consisting of a clear recycled PET tray and easy-open PE film shows how much the plant-based Impossible™ Burger from Impossible Foods resembles an animal-based burger. A wraparound oriented polypropylene band-label, adhered via ultrasonic technology, completes the two-patty package. The 100%-paper-based ThermoBox shipper from Smurfit Kappa North America delivers groceries at the right temperature. The 100% recyclable structure offers a smaller carbon footprint than the expanded polystyrene typically used for insulated shippers. The easy-open package offers convenience, protection and a consumer-pleasing unboxing experience.

FOOD (SHELF STABLE)

A print-enhanced, tapered hinged-lid confectionery carton from Graphic Packaging International, designed for Nestle’s Aero Bliss and KitKat Senses lines, conveys a memorable, premium image. The hinged-lid feature improves opening, reclosing and dispensing. The paperboard grade and caliper combine strength with a high-quality printing surface for superior graphics reproduction. The Boardio® recyclable paper bottle from AR Packaging Systems offers a sustainable option for gum, confectionery and other foods. The package can shrink carbon footprint up to 86%, reduce plastic consumption up to 83% and eliminate waste-tolandfill. Pack components are delivered flat to the point of filling, boosting transport efficiency at least 100% and saving warehouse space.

A thermoformed carrier from Nelipak Healthcare Packaging enables secure shipment of the Miltenyi CliniMACS Prodigy Set and enables clear, error-free installation of the blood management tubing set on the CliniMACS Prodigy Instrument. An integrated handle allows one person to remove the entire tubing set with one or two hands. Color coding ensures parts are handled in the proper sequence. The Deep Blue hernia mesh suture strand package from Merrill’s Packaging organizes the mesh suture strands and needles in a logical fashion, eliminating the need for doctors to thread several sutures through several needles for one surgery. Instead, the integrated package and device allow doctors to effortlessly extract the sutures and needles during the procedure.

OTHER

Smurfit Kappa North America’s 100% recyclable package for remanufactured toner cartridges replaces two expandable foam inserts with a corrugated insert. The package requires no glue or tape to assemble and is designed so the end user can remove the fresh cartridge from the box, take the empty cartridge from the printer and place it in the box for return to Clover Environmental Solutions.

MEDICAL DEVICE

A single card-hoop assembly from Medtronic for ClosureFast™ holds 60 or 100cm devices for the treatment of varicose veins and improves device protection. Design offers a 47% smaller footprint and an 80% reduction in weight. Additionally, a switch was made from PET to natural high-density PE.

Place was awarded for a redesign for Gold Medal flour. The goal was a repositioning to communicate high quality. The container, made from recycled, hard paperboard, effectively protects and preserves the flour and improves the user experience. The thicker paperboard prevents sifting, and the channeled corners act as a spout for easy pouring. A sliding top provides easy opening and retrieval of the flour.

PROMOTIONAL/DISPLAY

The Sharpie Spinner holiday design from Newell Brands combines an innovative structure in an existing footprint and is cost neutral. A simple three-piece design and outer box were developed after several rounds of ISTA-3A testing. The final design features a smooth-spinning tray, withstands shipping conditions and realizes a 50% reduction in rigid plastic components vs. the original concept.

HEALTH & BEAUTY AIDS

In this category, the judges honored the Colgate Elixir and GSK toothbrush packages, as well as the Pravana Pure Light container from Berlin Packaging–Studio One Eleven. A space-saving, taller, thinner, easier-to-grip bottle for hair color powder includes a pour cap with a built-in funnel for a mess-free, accurate pour. A second overcap acts as a dosing cup, and the bottle’s opening is wide enough for a scoop for stylists who prefer handling the powder in a traditional manner.

This upscale design by a student team from the University of Cincinnati features a transparent side panel, which aids measuring and provides product visibility.

The Terra–Nature Made Concept in a 100% biodegradable bottle is designed to appeal to a younger demographic than existing Nature Made products.

The Second Place prize recognized The Terra–Nature Made Concept. To appeal to a younger audience, the team designed Terra, a youthful line of multivitamins to support a vibrant, sustainable lifestyle with a health-supporting product and 100% biodegradable bottle. Third Place in the student competition was awarded to a team from Conestoga College for its redesign of a kraft/bubble wrap mailer. A perfed and glued design enables easy separation so the kraft can be recycled and the bubble wrap reused. The students believe current machinery could be retrofit easily to produce the design.

Belle Harvest sustainable cartons combine shelf impact with product protection, product visibility and a comfortable carrying handle.

SAVES FOOD (AGRICULTURE)

Belle Harvest sustainable cartons, made from 24-pt. AquaKote™ solid unbleached sulfate from Graphic Packaging International, are 100% recyclable and produced from renewable resources. The design provides a distinctive retail presentation while offering increased product protection, product visibility and a comfortable carrying handle.

STUDENT WINNERS

The University of Cincinnati captured First and Second Places in the student competition. First

Third Place in the student competition redesigns the kraft/bubble wrap mailer so the kraft can be recycled and the bubble wrap can be reused.

For more info, visit www.iopp.org, www.westrock. com, www.graphicpkg.com, www.liquibox.com. SD

2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

Encoder ensures cutting accuracy Overcomes surface variability caused by seams.

hile developing a machine to cut corrugated, testing by Hipsher Tool & Die, a custom fabricator in Wabash, Indiana, revealed that the finished sheet length was inconsistent. The encoder providing length data to the cut-

ting mechanism sometimes missed counts, which resulted in finished length variations that were outof-spec. The machine’s existing encoder and wheel system worked perfectly with other applications, but this particular material presented a challenge.

Your Global Automation Partner

With the Model TR3 Heavy Duty Tru-Trac encoder installed, Hipsher’s corrugated cutting machine reliably measures and cuts 100% of the time.

Optimize Your Packaging Machines and Lines Let Turck tackle whatever packaging automation challenges you are facing. Our wide range of reliable automation solutions – including sensors, industrial cordsets, distributed I/O products, and RFID stand up to the toughest packaging and processing environments. From improving highspeed cap and can detection to cost-effective machine control with a combined HMI/PLC, or more rugged washdown-rated cables, Turck has a solution. Can’t find what you are looking for? Choose from our wide range of custom options.

Visit us at Booth #SU-7629

SENSORS | CONNECTIVITY | FIELDBUS TECHNOLOGY

www.turck.us 1-800-544-7769

Further investigation revealed the cause. Seams in the corrugated passing under the encoder wheel would cause it to jump and lose contact with the surface. The right encoder would need to be heavy enough to provide increased down-pressure to maintain contact with the corrugated being fed through, yet constructed with a material that would not damage the corrugated it touched. The new encoder also needed to match the old encoder’s CPR and counts per inch. The encoder chosen had to meet the following requirements: • Quadrature output • Reliability • High resolution • Durability • Sealed bearings • Ultra heavy-duty housing • Wheels that would not damage material.

THE SOLUTION

Hipsher Tool & Die contacted C&E Advanced Technologies, an Ohio distributor for Encoder Products (Booth SL-6440). After consulting with Encoder Products, C&E’s Sales Engineer Jeff Ligon recommended the Model TR3 Heavy Duty Tru-Trac™ encoder, a compact, easy-touse unit that integrates the encoder with a spring-loaded, heavy-duty measuring Model TR3 Heavy Duty Tru-Trac encoder shown with dual-wheel option. wheel assembly.

2021 PACK EXPO Las Vegas

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SEPTEMBER 27, 2021

was spot-on and production was up and running. Starting as a one-man tool and die shop in 1946, Hipsher Tool & Die has expanded beyond tools, dies, jigs and molds to the design and fabrication

of custom machinery. Customers range from walkins with small requests, to companies needing larger manufacturing systems. For more info, visit www.encoder.com. SD

Partner With the Product Inspection Experts

Key features of the Model TR3 include: • Integrated heavy-duty, all-metal encoder and measuring wheel in one unit • Spring-loaded torsion arm for quick wheel pressure adjustments • Easily installed in a vertical, horizontal or upside-down orientation • Operates reliably on a variety of surfaces at speeds up to 3,000 ft./min. • Available in a single- or dual-wheel format • Three-year warranty. Available in a single- or optional dual-wheel format, the Model TR3 Heavy Duty Tru-Trac encoder is a versatile tool for tracking velocity, position or distance. Its spring-loaded torsion arm provides a simple-to-adjust torsion load, allowing the unit to be mounted in any orientation, even upside-down. The Model TR3 housing is an all-metal workhorse, specifically designed to withstand the toughest environments at operating speeds up to 3,000 ft./min. The Model TR3’s sturdy all-metal housing and integrated spring-loaded pivot arm were key features that appealed to Eric Flory, the Hipsher Tool engineering manager tasked with solving the problem. The heavier housing and stiff internal spring provided down-pressure that is more than adequate to offset the “jolt” caused by the corrugated seams passing beneath the wheel. To avoid any damage to the corrugated, 12-in. dual-urethane wheels were specified. The encoders also were configured with a line drive output and CPR resolution that matched the previous encoder counts per inch. After the Model TR3 was installed and testing completed, Hipsher’s customer reported that cut length

Metal Detection

Serialization Solutions

X-ray Inspection

Checkweighing

Customized Material Handling

Vision Inspection

Global Field-based Service

For ultimate brand protection, regulatory compliance, and an improved bottom line.

Visit us in booth C1814 See live demonstrations on new product inspection systems!

www.mt.com/pi PMMI_Tower_0821_kh.indd 1

8/18/2021 3:54:08 PM

2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

The Forum returns to Las Vegas ‘PMMI ProSource’ online directory debuts.

he Forum at PACK EXPO (Booth C-2158), a three-day program of interactive 45-min. sessions, combines educational presentations from industry experts with small group discussions and question-and-answer time. Some sessions offer a hands-on experience. This year’s schedule features the introduction of PMMI ProSource, an online directory and research tool that quickly matches an end-user application to the most relevant packaging and processing technology suppliers. The session shows end users how to use the directory and PMMI members how to place

MONDAY, SEPTEMBER 27, 2021 DRIVING PACKAGING LINE PERFORMANCE

10:30-11:15 AM

Today’s packaging lines are increasingly complex and expensive, so ensuring performance is more critical than ever. This hands-on session gives participants insight into getting the most out of existing lines by applying straightforward line-balancing techniques in combination with the information already available from the machines. Learn how to keep your bottleneck machine running, recognize starved and blocked conditions and manage machine speeds to ensure optimum performance. The session also demonstrates how the PackML standard makes this performance information readily available. Ronald MacDonald Sr Principal Eng, R&D Nestlé Product Technology Center, PetCare Chairman, OMAC - The Organization for Machine Automation and Control

WHERE ARE YOU ON THE AUTOMATION TIMELINE?

11:30-12:15 PM

NEW INNOVATION AND PARTNERSHIP MODELS PROPEL CONTRACT MANUFACTURING GROWTH IN A NEW DECADE

1:30-2:15 PM

Not even the shocks of 2020 could slow the continued growth of contract manufacturers. Turbocharged by seismic economic events and massive shifts in consumer behavior, contract manufacturers have pivoted to the new needs of their branded customers. Today the industry is in the midst of its next major growth phase. New demands from brands are being met with fresh tools and processes that tighten integration, foster transparency and create new value. In this interactive session, we look forward to the new decade based on the trends we see today. Carl Melville President The Melville Group

RISK ASSESSMENT OF LEGACY MACHINERY

2:30-3:15 PM

Review the risk assessment process and then dig into doing a risk assessment on an existing packaging machine. Questions of when, how, why and how much will be discussed so participants gain a better level of confidence in how to address legacy machinery. Bruce Main President Design Safety Engineering

KEY TRENDS IN ROBOTICS APPLICATIONS

3:30-4:15 PM

Robotics applications are advancing rapidly throughout the world. We’ll examine recent market trends as well as emerging uses of robots in a wide range of industries. Trends in key enabling technologies such as artificial intelligence and machine vision also will be discussed. Jeff Burnstein President A3-The Association for Advancing Automation

Session descriptions and times are listed on the following pages. Other educational opportunities on the show floor include the first PACK to the Future Stage (Booth N-9830) (see schedule, p. 22). In addition, the inaugural Processing Innovation Stage (Booth N-24020) joins the long-running Innovation Stage (Booth C-2051, C-2058, C-2151) program (see schedule, p. 26). Updated schedules may be found on the show website or via the PACK EXPO Las Vegas/ Healthcare Packaging EXPO App. For more info, visit www.PACKEXPOlasvegas.com, www.HCPElasvegas.com. SD

TUESDAY, SEPTEMBER 28, 2021 CYBERSECURITY: KNOW WHERE TO LOOK FOR VULNERABILITIES

10:30-11:15 AM

To confidently harness emerging technology in manufacturing, companies need to place renewed focus on operational technology and information technology cybersecurity. To properly address cybersecurity concerns, manufacturers first need to gain a comprehensive understanding of their operations, particularly those areas that are most vulnerable to cyberattack. In an interactive peer exchange workshop, industry professionals will gain knowledge about where to look for vulnerabilities in their operations, as well as learn what next steps should be considered to better safeguard those operations from a cyberattack. Donna Ritson President DDR Communications

RISK ASSESSMENT OF A 3D MODEL MACHINE

11:30-12:15 PM

Doing a risk assessment of a machine on the floor is one thing. Can it be done on a 3D model? We briefly review the risk assessment process and then start a risk assessment on a machine that does not yet exist. Discussion centers on methods of identifying potential safety issues when the design still can be modified easily. Participants will gain a better understanding of how to move their risk assessment efforts upstream during design. Bruce Main President Design Safety Engineering

THE WEAK LINK: WILL YOUR END USERS PREVENT OR CAUSE A CYBERATTACK?

1:30-2:15 PM

Time and time again, employees prove to be a weak

In the future, machines on the plant floor will talk to each other, take corrective action to maintain maximum uptime, schedule repairs and order inventory—all automatically and autonomously. The transformation to a digital platform is typically a gradual, step-by-step process that often requires companies to expand their level of IIoT connectivity and integration. In an interactive peer exchange, industry professionals explore the automation timeline, learn which technologies are most important in the short term and share some of the successes and challenges encountered during the journey toward a higher level of automation for smart manufacturing. Donna Ritson President DDR Communications

their listings. Other featured topics at The Forum include packaging line performance, risk assessment (physical and virtual), automation implementation, cybersecurity, food and beverage manufacturing, contract manufacturing, post-COVID food packaging trends and robotics. Session leaders represent the OpX Leadership Network (Central Lobby), CPA, The Association for Contract Packaging and Manufacturing (Booth C-1255), OMAC-The Organization for Machine Automation and Control (Booth C-1152) and PMMI Business Intelligence (Central Lobby).

Package and product changeovers on the fly: XTS

Mechanical flexibility The XTS advantage

NEXTSTEP

infinitely flexible dramatically reduces machine size faster time to market

Manufacturers around the world need to offer increasingly customized products – with machines that deliver reduced footprint and improved productivity. Available now in the U.S., the eXtended Transport System (XTS) from Beckhoff answers these machine design challenges and more. In combination with PC- and EtherCAT-based control technology, the XTS features a high level of design freedom for machine builders to develop game-changing concepts for product transport, handling and assembly. A stainless steel hygienic XTS version is ideal for use in the pharmaceutical and food industries. Take your next step in machine design with XTS: total freedom of installation position compact design integrates directly into machinery freely selectable track geometries few mechanical parts and system components

Scan to discover everything you need to know about the XTS linear transport system

embed XTS directly into machines configure for any track geometry install flat, vertical or at angles repeat or stack XTS tracks 30 –50% reduction in machine footprint

See XTS live! Booth SL-6149 Innovation Stage 3 | C2151 Tuesday, 9.28 | 10:00 AM

2021 PACK EXPO Las Vegas 44

SHOW DAILY SEPTEMBER 27, 2021

point in cybersecurity prevention plans. Are you prepared? Are your colleagues prepared? Find out as we dive into the keys for success for end-user security awareness. Ben Spencer IT Coordinator PMMI

GO BIG OR GO HOME– LEVERAGING RESOURCES IN TODAY’S WORLD OF CHALLENGING FOOD AND BEVERAGE MANUFACTURING

2:30-3:15 PM

Cash flow and resource constraints exist in every organization, from startups to established companies. Creating a culture within your company that engages team members across traditional functions drives better decisions. Leveraging knowledge, people and information within your company, the OpX network and PMMI members provide strength in numbers. Jill Costelow Co-CEO & Co-Founder Cultivate Group

GETTING THE MOST OUT OF THE NEW PMMI PROSOURCE ONLINE DIRECTORY

3:30-4:15 PM

Whether you are a packaging end user or PMMI member, you’ll want to learn about PMMI ProSource, a groundbreaking online directory and research tool. End users will learn how the tool is optimized to quickly zero in on packaging and processing technology suppliers relevant to specific application needs. The session also covers how and why this directory is different and far more accurate than any other online resource. PMMI members will learn how to easily submit their listing and ensure that it will be found under relevant categories and keywords. David Newcorn Exec VP PMMI Media Group SD

E-PAK celebrates 20th anniversary

-PAK Machinery (Booth C-4629a) celebrates 20 years as a supplier of versatile liquid packaging solutions to a variety of industries. The privately held company continues to be led by its founding executives. “We started out with a philosophy of listening to our customers, delivering a quality product and providing attentive customer service before and after the sale,” recalls Tony Swedersky, president of E-PAK Machinery. “Our founding beliefs remain our top priority today 20 years later. Because of that, our company remains viable, strong and growing. No one could have predicted the dramatic events that have taken place in the world over the last 20 years; we’ve seen it all and it’s been an incredible journey. A big thank you to the hundreds of valued customers and strategic partners, but especially to those who had faith in E-PAK Machinery from the very beginning.” For more info, visit www.epakmachinery.com. SD

NEVER OBSOLETE INSPECTION SYSTEMS

Combin Combination Sy System

888-220-8737 sales@fortresstechnology.com www.FortressTechnology.com

VISIT US AT BOOTH C-5404

2021 PACK EXPO Las Vegas

SHOW DAILY SEPTEMBER 27, 2021

3D-printed parts cut changeover time Fast format changes allow line to handle wide range of products.

or more than 30 years, Laverana Naturkosmetik has been fulfilling the beauty aspirations of customers worldwide with its lavera brand high-quality natural cosmetic products. Known for the highest standards in the quality of its all-natural ingredients, packaging and production processes, the company constantly redefines the world of cosmetics and follows visionary paths. This is exactly what happened with the latest joint project with Gerhard Schubert, parent company of Schubert North America (Booth SU-7651). “Today, our industry demands great agility and the shortest possible time-to-market. However, our existing systems were not designed for this and previously required a complicated and time-consuming retooling of the machines for every product or format change,” reports Thomas Haase, managing partner at Laverana. Therefore, in collaboration with the team led by Daniel Traub, group manager at Schubert-Cosmetics, Haase developed an entirely new type of fully automatic filling and packaging line suitable for today’s greater variety of products and smaller batch sizes. Attributes include a compact monobloc layout, speeds of up to 60 products/min., format changeover in 12–25 min., ability to handle 10 formats and shorter time-to-market thanks to 3D-printed format parts.

EVERY GRIP A BULL’S-EYE The agile vision system is based on Schubert’s proven TLM system components. All individual packaging elements such as bottles, caps, brushes and pumps are fed via a conveyor with no need for format parts. By using Schubert’s 3D camera system, it was possible to fully dispense with conventional feeding systems such as centrifuges with their long set-up times and enormous size. The 3D camera system detects the unsorted and partially overlapping objects three-dimensionally. A pick-and-place robot picks up these components with pinpoint accuracy (“gripping into chaos”) and places them onto the Transmodul. This takes the components to one of the two versatile programmable filling stations, each with six filling points.

A 3D camera system records the unsorted bottles, caps, brushes and pumps in three dimensions so the pick-and-place robots can precisely “grip into chaos.”

PATENTED, SUSTAINABLE PACKAGING

The labeling station applies front and back labels or a 360-degree label.

FLEXIBLE, PRECISE FILLING With two filling stations, cleaning times are shorter and two-phase products may be filled. Each filling station is connected via its respective filling needle to an F3 robot, which is 100% freely programmable and therefore allows maximum flexibility. Traub explains, “Depending on the filling medium, it is also possible to fill above or below the predefined level at any time. Also, to cover the widest possible viscosity range and achieve high filling accuracies, we rely on a volumetric filling process using eccentric screw pumps.” The eccentric pumps are easy to handle and can be combined with clean-in-place (CIP) technology without requiring any tedious disassembly. A corresponding CIP system with two heatable deionized water tanks, which allow up to five cleaning agents to be added, was considered and integrated by Schubert during the development of the agile packaging machine. If required, the filling system can be sanitized (cleaning and disinfection process to significantly reduce germ counts) and then dried. The Schubert system stands out with many functionalities for precise product inspection. After filling, for example, the system checks for proper weight. If there is an unacceptable deviation, the item is immediately rejected. The affected filling point can be readjusted fully automatically via a shift register in the scale control. The products are then sealed. When capping bottles with screw caps, the system precisely monitors whether the set torque is reached too soon or not at all. If the torque level is not appropriate, the bottle is rejected directly during this step. The labeling station, which is fully integrated into the packaging machine, then applies a front and back label or a 360-degree label. For this purpose, Schubert combined the common linear system with a rotary system. “This combination makes the vision system even more flexible and agile,” Traub says. “Essentially, six products are always inserted into the linear system during labeling. Depending on the requirements, each product can also be rotated individually by a servo drive. At the same time, the products are centered during insertion, which also eliminates the tolerances for glass bottles.”

Another special feature is the patented carton erecting and loading process for the subsequent ready-for-sale packaging. The outer carton is erected and loaded with the products in a single operation. For this purpose, the erecting die produced in the 3D printing process picks up the pre-grouped products. In parallel, a flat blank is placed onto the folding frame. Subsequently, the flat carton blank is pressed through the folding frame with the help of the erecting mandrel, which has the products contained within it. The mandrel then retracts, leaving the products inside the newly formed carton, which is then closed, labeled and palletized. “The main advantage is that tighter packaging is possible as transport protection,” says Traub. In addition, he says, “. . . the process step of separate loading can be dispensed with, which in turn saves Laverana costs and space. As an alternative to the carton, products can . . . be packed into plastic crates. These can then in turn be used for special packaging or for manual packaging for test markets.”

On the line, 3D-printed quick-change format parts impart agility and flexibility to the vision system.

FASTER WITH 3D PRINTING In addition to the short format changeover times, another reason for the high agility of the vision system is 3D printing. With the exception of the magazine plate, all interchangeable parts are 3D-printed parts. In the future, Laverana will print its own spare parts or completely new format parts—quickly, costeffectively and flexibly. The print quality is ensured by the Certified Print Jobs created at Schubert Additive Solutions. Haase is visibly delighted with the result of the renewed collaboration with Schubert: “The cosmetics industry has been waiting a long time for this machine. Thanks to Schubert, it has finally become a reality.” For more info, visit www.schubert.group. SD

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Sustainability award winners speak

Afternoon session features B&G Foods, Smithfield, Conagra.

epresentatives of B&G Foods, Smithfield and Conagra Brands discuss the green projects that earned 2020 Sustainability Excellence in Manufacturing Awards at 3:30 p.m. today at the Processing Zone Innovation Stage (Booth N-24020). Given annually by ProFood World, the awards recognize one-time projects as well as ongoing programs, which go beyond environmental compliance. In 2020, a Processor/Supplier Partnership category was added to recognize the importance of collaboration between processors and industry suppliers in protecting the planet. Entries are judged by a team of food industry peers.

The facility invested in equipment to delaminate the materials and now recycles 80,000 lb. of plastic each month instead of sending it to a landfill. Cutting water usage for its cherry fresh pack product earned Conagra a Third Place in the Program category. In 2020, an intern at its plant in Fennville, Michigan, was tasked with reducing water consumption. Resulting projects cut annual water usage 5.2% (2.5 million gal.).

PROJECT CATEGORY

In the Project category, Smithfield Foods in Sioux City, Iowa, took First Place with a switch from corrugated to reusable plastic totes for in-plant workin-process and inter-plant shipments. The plant saves nearly 200 tons/yr. of corrugated, reduces the amount of the material sent to landfill or recycled and eliminates recycling shipping costs. Five-year savings are expected to exceed $1 million. There was a tie for Second Place in the Project category. One prize went to Conagra in Maple Grove, Minnesota. The other recognizes Smithfield Foods in Kinston, North Carolina. At Conagra’s Maple Grove plant, measurement lasers installed on

two presses supporting the Orville Redenbacher and Act II microwave popcorn businesses, automatically trigger the paper splicer when it’s time to splice to a new roll. The automatic trigger allows the splice to be made closer to the end of the roll, eliminating 35 tons of waste per year and saving about $40,000 in material and recycling costs. At the Smithfield operation, two packaging lines rely on air knives to remove moisture before coding. The units operated continuously until photoeyes and timers were installed to turn off air if no product is detected within 3 sec. The change from continuous air flow cuts the system’s energy consumption 6.5% and is forecast to save 11,351.04 kWh of power annually. Another project at Smithfield’s Kinston plant took Third Place in the Project category. To cut costs and waste related to the continuous netting used in the ham smoking process, Smithfield and the netting supplier increased the length of netting shipped in film-lined boxes from 1,300 to 2,050 ft. The change reduced the number of incoming boxes by 2,541 and saved about 2.54 tons of corrugated and film.

An ultrasonic imager helps identify and eliminate air leaks at Conagra Brands in Menomonie, Wisconsin.

PROGRAM CATEGORY

B&G Foods was recognized with a First Place in the Program category. With a goal to minimize its environmental impact, B&G Foods’ Cincinnati Crisco facility has been on a journey to reduce water usage for 10 years. In 2020, the plant implemented several water-reduction projects, which cut water usage 19.5% vs. 2019, despite a 38% increase in production. During the past 10 years, the program has decreased water consumption more than 75% (250 million gal.). Conagra Brands took home two Second Place awards and one Third Place. One Second Place award-winning initiative involved its facility in Menomonie, Wisconsin, where a Fluke FLK119000 ultrasonic imager detects compressed air/ steam leaks, shows leak rate and estimates associated energy savings. In five months, the facility saved 152,829 kWh of electricity, lowered its power bill by about $17,000 and eliminated more than 95MT of Scope 2 (indirect) greenhouse gas emissions. Conagra’s other Second Place winner involves waste reduction at its Waterloo, Iowa, facility, where “stars and bars” of plastic remain when formed cups are cut and separated. This posed a recycling challenge because foil lidstock is attached to the plastic.

The first prize given in the Processor/Supplier Partnership category honors the collaboration between Liffey Meat and Graphic Packaging International to adopt a barrier-lined paperboard tray for homegrown beef.

PROCESSOR/SUPPLIER PARTNERSHIP A switch to reusable totes and baskets at Smithfield’s Sioux City plant not only saves money, but also reduces corrugated sent to landfill.

Photoeyes and timers activate the air to the air knife only when needed, reduce compressed air consumption and save energy at Smithfield’s Kinston facility.

A partnership between Liffey Meats and Graphic Packaging International (Booth C-2442) will supply Lidl, a grocery store chain based in Germany, with 2 million PaperSeal tray units annually. The barrier-lined paperboard alternative to traditional plastic vacuum skin packaging will be used for dryaged Angus steaks sold in the Irish market. The PaperSeal tray features 85% less plastic than traditional trays and offers good seal integrity and the potential for up to 28 days of shelf life. Post-use, the liner and tray separate easily, making the tray 100% recyclable. For more info, visit www.PACKEXPOlasvegas.com, www.profoodworld.com, www.graphicpkg.com. SD Editor’s Note: For details about this year’s award winners, see “Eye on Sustainability” published in August 2021 by ProFood World.

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Emerson launches smart pneumatics

ntegrated air preparation units and flow sensors from Emerson (Booth SL-6307) provide a clearer picture of air consumption in pneumatic systems to significantly improve packaging line efficiency and overall equipment effectiveness.

of leaks and enables preventative maintenance to be performed before issues arise. The compact Series 652/653 air preparation unit with integrated AF2 sensor is easy to assemble and install. It comes in an in-line piped version as well a modular filter version with both British Standard Pipe Parallel (G) thread and American Standard Pipe Tapered (NTP) thread. Online configuration

makes it simple to connect and operate, and its open interface works with existing protocols. The integrated system retrofits on machines with few changes and is compatible with many different controllers. An integrated data logger records and stores data up to seven days. For more info, visit www.emerson.com/en-us/catalog/aventics-652. SD

Avure’s High Pressure Processing Machines FOOD SAFETY, EXTENDED SHELF LIFE AND CLEAN LABELS WITHOUT HEAT OR PRESERVATIVES

The Aventics Series 652/653 airflow sensor, available with filter (left) or piped version (right), provides clear, actionable insights.

Guacamole and Salsa Thanks to Avure HPP, avocado has a shelf life of up to 45 days.

Beverages & Juices Avure HPP machines process most of the world’s HPP treated juice!

WHY AVURE: • Most Experienced • Highest Productivity

On their own, AVENTICS™ Series 652/653 air preparation units provide clean air and pressure control to downstream pneumatic devices. Now when integrated with the AVENTICS Series AF2 flow sensors, end users benefit from the versatility and variety of options this range of filters, regulators and lubricators offers. Operators can monitor air consumption, including flow, pressure and temperature, to detect leaks and optimize energy use. An integrated analysis option provides early warning

Ready-To-Eat Meals HPP offers the great taste and fast preparation times that consumers demand.

Wet Salads & Dips Boost shelf life. Ditch additives. And dip into new markets with HPP.

Vegetables Fresh-picked taste and long shelf life. No chemicals or

Meat Safe and great shelf life.

preservatives. Seafood Our seafood machine boosts yield and reduces costs.

Pet Food HPP offers health benefits for pets.

Baby Food Convenient, all natural with no additives or preservatives for little ones.

Dairy Extend shelf life for cheese, sauce, dips, and milk and other beverages.

• Robust Engineering • Application Expertise • 24/7 Support

WHY HPP: • GREATER PROFITABILITY: Than Conventional Processing • FRESH TASTE: Not Altered by Heat, Chemical or Irradiation • CLEAN LABEL: Aligns with Consumer Trends • LONGER SHELF LIFE: Drastically Reduces Spoilage • FOOD SAFETY: Extreme Pressure Inactivates Pathogens

EXTEND SHELF LIFE High Pressure Processing is a natural method of food pasteurization that uses pure cold water, and up to 87,000 psi (6,000 bar) to inactivate pathogens, and dramatically extend shelf life. No chemicals. No heat. No additives. Learn more about how high-pressure processing works.

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Booth WestRock (Booth C-2023) for sponsoring the PACK EXPO Las Vegas Hand Sanitizer Stations.

5244 Sept. 27-29, 2021 - LAS VEGAS

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The beat of a different drum motor Drum motor houses all drive components inside drum.

DG (Van Der Graaf ) (Booth SU-7462) manufactures drum motors to power belt conveyors for a wide array of industries, including food processing. In 1985, Alexander Kanaris, president of VDG, established a drum motor manufacturing facility in Brampton, Ontario, Canada. In 2009, an expanded manufacturing facility opened in Michigan. Today, more than 200,000-sq.-ft. of manufacturing space in the U.S. and Canada employs automated robotic production equipment to produce drum motors. All of the components used in VDG drum motors are manufactured in-house, using American materials and labor. Implementing sanitation processes to battle bacteria has become increasingly challenging in food manufacturing. The VDG sanitary series SSV drum motor features an all-316-stainless-steel construction and IP69K sealing that can withstand washdown pressure up to 3,000 psi. The enclosed drum motor design has no external moving parts compared to conventional exposed conveyor drives, eliminating areas for bacterial harborage and reducing washdown time and water consumption, while increasing sanitation, efficiency and worker safety. It also eliminates the maintenance required on external components of a conventional conveyor drive, such as the motor, gear reducer, sprockets and chain. Kanaris has become one of North America’s leading experts on drum motor technology and shares his expertise with ProFood World.

PFW: What are the most important benefits and functions of drum motor technology? Kanaris: Drum motor belt drive design entered the conveyor drive industry in the early 1950s as a unique drive for belt conveyor applications. Drum motor belt drive design is different from a conventional conveyor drive in that the drum motor has all drive components—electric motor, gear reducer, bearings—housed inside the drum. Without exposed drive components and with no other drive parts rotating outside the conveyor frame, it presents a unique belt drive design. The drum motor also maximizes space utilization and worker safety, as components—such as external electric motor, gear reducer, bearings, chain and chain guards, all traditionally mounted outside the conveyor frame—are not needed. Those components can be hazardous to staff required to work near conventional conveyor drives and render the conveyor line susceptible to bacterial contamination. Most standard conventional conveyor drives use a 90-degree gear reducer mounted directly on the drive shaft or use sprockets and chain to drive the head conveyor drive drum. Using a 90-degree gear reducer, especially a worm gear reducer, impedes the efficiency of the drive, resulting in mechanical losses. PFW: How can drum motor technology improve plant floor efficiency and sanitation? Kanaris: Due to its self-contained design, the VDG drum motor is space-optimized, allowing

more floor or overhead space for conveyor systems, and improves safety since there are no external drive components that can pose hazards. In addition, the VDG sanitary series SSV drum motor allows the belt profile to be machined directly onto the 316-stainless-steel drum, eliminating the need for plastic sprockets that can contribute to foreign material contamination and removing areas prone to bacterial harborage. This sprocketless SSV drum motor is a unique and attractive alternative to a conventional drive for food-processing applications by eliminating gaps and crevices where food byproducts can accumulate, increasing sanitation and reducing the amount of time and water required for washdown. Drum motors are both spatially and mechanically more efficient than conventional conveyor drives as well. Compared to the 90-degree arrangement of most conventional drives, in a drum motor, the electric motor is connected inline with the gear reducer, resulting in a 20%–40% increase in mechanical efficiency, depending on the type of gear reducer it is compared with. This leads to lower energy consumption without any sacrifice in torque or performance. The streamlined design of the drum motor also eliminates the need for chains and sprockets, promoting workplace safety and taking up a much smaller footprint than conventional conveyor drives, which require all components that rotate the drive drum to be mounted externally. Lastly, the amount of time required to install a drum motor into the conveyor frame is significantly less than the time required to install an external conveyor drive. PFW: How are drum motors maintained? Kanaris: All VDG drum motors are designed for 80,000 hr. of continuous operation before scheduled maintenance is required, drastically reducing the amount of maintenance-related downtime a plant experiences. An oil change is the only required maintenance.

The SSV Sanitary Series drum motor is designed for sanitary food production and is installed at major vegetable processing facilities. Photo: Courtesy of VDG.

PFW: Please describe the drum motor design. Kanaris: A drum motor is a cylinder with two square shafts on either side. An electrical connection box protruding on one side of the drum motor houses the electrical connections. The shafts are square and do not rotate. The shafts are fixed and mounted on the conveyor frame, eliminating the need for pillow block bearings. The electric motor that is housed inside the cylinder (drive drum) is an AC squirrel cage design motor. The stator does not rotate; therefore, there is no need for rotating brushes or slip rings delivering power to the stator windings. The rotor shaft is the input pinion driving either a two- or three-stage gear reducer. The last stage of the gear reducer is driving a gear ring that is bolted

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directly to the end-flange, and the end-flange is bolted directly to the rotating drive drum. All internal components, motor, gears and bearings work in an oil bath. The drum motor is hermetically sealed and filled one-third with oil. The oil inside the drum motor is used as a lubricant and also provides cooling. When the drum motor is running, the oil transfers the heat generated from the electric motor and gear reducer to the rotating drum and dissipates it to the conveyor belt. As the temperature inside the drum motor rises, the internal pressure can increase up to 1 atm [atmosphere] or 14.6 psi. Because of the internal pressure, it is necessary for the drum motor to be hermetically sealed to prevent oil leakage. PFW: What is the range of drum motor belt speed, horsepower (hp) and drum diameter? Kanaris: Depending on the manufacturer, drum motors are available in different drum diameters, belt speeds and horsepower. The diameter of the drum motor is dictated by the required horsepower and belt speed. Since all mechanical and electrical components must fit inside the cylinder, the drum motor rating is geometrically restricted. In order to achieve the required belt speed, drum motors offer a range of fixed gear ratios. When a different belt speed is required, it can be accomplished by changing the ratio of the gear reducer or by using a frequency inverter. The SSV sanitary drum motor is available in diameters from 3.1 to 8.5 in.,

Earlier this year, a panel of industry Ƶɮ Ƶ Ƶ ƵƧ ƵƮ ˛ȁƊ Ǟ ǏȌ ǘƵǞ ɐ Ƶ ǞȌ innovations in the categories below. NOW ITS YOUR TURN TO VOTE FOR THE WINNERS IN: Food / Beverage General Packaging General Processing Personal Care / Pharma

YOUR VOTE COUNTS. ACT SOON! Vote by Tuesday, September 28 at noon on the mobile app or at packexpolasvegas.com/vote.

WINNERS WILL BE ANNOUNCED ON TUESDAY AFTERNOON!

Additional info: packexpolasvegas.com/tea

In a drum motor, the electric motor is connected inline with the gear reducer, boosting mechanical efficiency. Eliminating chains and sprockets enhances workplace safety and saves space compared to conventional conveyor drives. Image: Courtesy of VDG.

with a horsepower range from 0.25 to 7.5 hp. The total range of all VDG drum motor designs is from 3.1 to 42-in. diameter, and hp range from 0.25 to 500 hp. PFW: What is the history of drum motor use in North America? Kanaris: Drum motors represent approximately 7% of the overall conveyor drive applications in North America. With all the benefits they offer, it would be reasonable to ask why they have low market penetration. When drum motors first appeared on the market, the overall selection of belt speeds, horsepower, drum diameters and drum lengths was limited, with belt speed selection being the larger issue. For these reasons, the majority of conveyor drives using chains and sprockets to power the head roller were more popular. Changing belt speeds on conventional drives can be achieved by simply changing the drive sprockets, resulting in different drive ratios. Changing the belt speed of the drum motor requires removing the drum motor from the conveyor frame and changing the gear ratio of the gear reducer. This problem has been largely eliminated with the introduction of variable-frequency inverters. Adjusting the belt speed with a frequency inverter contributed to a relatively small increase in market penetration of the drum motor. Market study indicated that conveyor manufacturers and end users implement the drum motor only when there are space constraints. Market feedback also showed issues with oil leakage and premature bearing, gear and electric motor failure. These issues had to be addressed in order to increase drum motor market share. PFW: How has VDG changed drum motor design practices? Kanaris: Most drum motor manufacturers produce drum motors as a sideline to other industrial products. Combined with low market penetration, these companies have little incentive to allocate funds and resources into research and development to improve the design and thus to increase market share.

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SEPTEMBER 27, 2021 In 2010, VDG began a two-year study of testing and analysis, which revealed that lack of heat dissipation was a major issue impacting overall product reliability. The basic principle of electric motor design is the method of cooling. The majority of electric motors used as conveyor drives are fan-cooled, which is a very effective method, albeit not ideal for sanitary applications due to bacterial movement in the air. Since all drive components of the drum motor are housed internally, fan cooling is not possible. Instead, the drum motor uses oil to transmit the heat from the electric motor to the drum shell and dissipates it to the belt. Cooling of the drum motor through oil submersion is not as effective as fan cooling a standard conveyor motor. Operating conditions can negatively impact the heat transfer from the motor to the belt. If, for example, an application requires the drum motor to have rubber lagging for belt traction, the rubber lagging will resist heat from exiting the drum motor. Stainless-steel drum motors for sanitary and food-processing applications are particularly sensitive to temperature elevations because stainless steel has poor heat-transfer properties. Without sufficient heat dissipation, oil temperature rises and oil viscosity decreases and may not provide adequate lubrication, resulting in premature mechanical component failure. In addition, the elevated oil temperature increases the internal pressure, which can affect the sealing system of the drum motor. This creates the potential for oil leaks. In 2012, as a result of this study, VDG developed a new generation of drum motor design. PFW: How does drum motor technology help food and beverage manufacturers improve sustainability? Kanaris: In the past, all of the issues mentioned above were mainly an inconvenience to end users but not a major detriment, since belt conveyor engineers over-designed and were liberal in selecting motor horsepower. More often, the specified horsepower of a drive would have been twice or more the required horsepower needed to drive the belt conveyor. Due to this over-design, conveyor drives, including drum motors, were not subjected to continuous full-load conditions. Today, energy conservation is more important than ever. Conveyor equipment needs to operate longer hours, at full load and close to the rated drive performance. In an electromechanical device, such as a drum motor, there are two sources generating heat: the electric motor and the gearbox. The gear reducer accounts for about 15% of the heat generation, while the majority of the heat is produced by the electric motor. The electric motor also has two sources of heat generation: the current density of the stator winding and the magnetic density of the laminated core. By increasing these densities, the temperature generated by the electric motor will increase, and by reducing them, the temperature will decrease. However, reducing the current and magnetic densities in the electric motor to achieve lower temperature also will reduce the amount of work the motor will produce, resulting in a reduction of torque and horsepower. Therefore, the standard method of calculating electric motor windings is no longer valid and cannot be used to design the electric motor for drum motor applications. The research I mentioned earlier resulted in a mandate for a new motor design that generates less heat inside the drum motor. This new design uses a new method of calculating the electric motor windings combined with different lamination sizes and materials with different metallurgic composition and has substantially reduced the drum motor temperature. Today’s new drum motor design offers an unmatched option for powering belt conveyors. VDG’s ongoing investment into R&D and in-house design has resulted in an innovative drum motor that fulfills all the critical needs of a sanitary food-processing plant, while contributing to a more efficient use of energy, water and space. Simultaneously, we have developed a new intelligent drum motor design, capable of communicating with central plant control or other plant equipment with data feedback for a more efficient production throughput. For more info, visit www.vandergraaf.com. SD Editor’s Note: The original version of this article was published in December 2020 by ProFood World.

Spiral conveying. Straight up! As the market leader in spiral conveyors in the packaging industry we think of solutions for elevating and accumulating packed items. It’s what we do. At AmbaFlex it’s not just about building the right equipment, it’s about developing a special solution for you. Here’s to spiral conveying. Spiral Elevators & Accumulators for primary and secondary packaging handling.

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Future Innovators SHOWCASE THE ‘BOTS ARE TAKING OVER PACK EXPO Las Vegas and Healthcare Packaging EXPO! Come see high school students showcase their “bot skills”. You can: • Ask about their robot design

Shrink wrap cocoons windows

Also can surround interior, exterior or storm doors with protective shrink film.

indows are easily damaged and can be tricky to ship safely through the supply chain. A large-format shrink wrapper, known as a panel wrapper or window wrapper, protects each manufactured window, regardless of size, by enclosing it in 2.5-mil low-density polyethylene (LDPE) shrink film. Big box and do-it-yourself (DIY) stores typically prefer to store and sell windows wrapped this way to ensure they are protected from incidental damage during shipping and handling, all the way to the consumer. Shrink wrapping, as opposed to complete corrugated packaging, plastic bags or stretch film wrapping, also offers complete protection while allowing the consumer to easily view the window in the retail setting. In April 2021, EDL Packaging Engineers (Booth C-2400), a Massman Company, shipped a window wrapper to a nationally recognized window manufacturer. With this new wrapper, the customer’s operations gain efficiency while enhancing product protection by preventing scuffing throughout the distribution process. The customer already operates several EDL Packaging window wrappers. And each new wrapper evolves to include the latest features and benefits. In a window production environment, the window wrapper typically is placed in a central packaging area, and finished windows are transported to it from multiple assembly lines. To enable it to adjust to varying input dimensions, the wrapper has features that automatically measure and adjust to random-sized windows.

• Inquire about the competition • Check out their innovations Located in the PACK to the Future exhibit, meet these talented teens and see their creations in action. Booth: N-9820 Monday & Tuesday 9:00 - 5:00 Wednesday 9:00 - 1:00

Sponsored by:

The Confectionery Pavilion Uncover specialized equipment and integrated systems for your candy, confectionery and gum production lines. Sponsored by:

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Co-pack/co-man industry thrives

Revenues reach $75.1 billion in 2020, poised for 10% CAGR.

o-packers (co-pack) and co-manufacturers (co-man) thrived in 2020, generating an estimated $75.1 billion in revenue, according to the 2021 State of the Industry Report, published by CPA, The Association for Contract Packaging and Manufacturing (Booth C-1255). Published quadrennially and now in its fifth edition, the report

defines the co-pack/co-man industry, updates statistics and includes new sections about mergers and acquisitions and the short- and long-term impacts of the COVID-19 pandemic. Brand owners hire co-pack/co-man firms for four reasons: speed-to-market; innovation; efficiency (cost advantages); and capacity. These needs

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drove business to co-pack/co-man firms during the COVID-19 pandemic and are expected to continue to spur growth, with 70% of co-pack/co-man leaders predicting they will emerge stronger post-COVID. The report’s five-year forecast concurs, projecting a 10.2% compound annual growth rate to reach annual revenue of $121 billion in 2025. The report also foresees favorable trends for capital expenditures. Almost every co-pack/co-man firm (93%) is planning to increase 2021 investments and spend 20% more on average. A substantial portion of this money will go toward higher levels of automation. Factors driving interest in automation include: acute labor shortages in most markets; significant wage pressures and cost increases; and growing backlogs and lead times. In addition, the cost of automation is declining while the flexibility, programmability and ease of use of hardware and software are increasing. The 180-page report, which delves into every aspect of the co-pack/co-man industry, is based on interviews with more than 150 industry leaders, including contract packagers, contract manufacturers, brand customers and suppliers. Purchase price is $1,995. For more info, visit www.contractpackagingreport.com. SD

PACK EXPO East set for March ’22

he fifth edition of PACK EXPO East (Central Lobby) returns to the Pennsylvania Convention Center in Philadelphia on March 21–23, 2022. The show draws several thousand attendees, primarily senior managers from consumer packaged goods companies situated throughout the midAtlantic corridor. The 2020 edition of the show broke records with more than 7,100 attendees and a 5% larger show floor than in 2018. Showgoers enjoy many popular PACK EXPO features including a networking breakfast hosted by the Packaging & Processing Women’s Leadership Network, the Future Innovators - Robotics Showcase and educational sessions on the Innovation Stage and at The Forum. For more info, visit www.PACKEXPOeast.com. SD

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Marchesini opens Beauty Division

Latest acquisition, Cosmatic, joins Dumek, Axomatic and V2.

he Marchesini Group, parent company of Marchesini Group USA (Booth SL-6535), has launched a Beauty Division. The designer and producer of packaging machines and lines for the pharmaceutical industry added 5,000-sq. m. to its Pianoro, Italy, headquarters, to house the offices and production department for all of the Group’s cosmetic operations. Lorenzo Gatti serves as the director of the Beauty Division’s facilities. In addition to the Marchesini Group Beauty machines and the Dumek, Axomatic and V2 engineering technologies—Italian brands acquired in the last three years with the aim of extending the Group’s range of systems for packaging cosmetics—the Beauty Division integrates the latest acquired company: Cosmatic, a business specializing in technologies for the production of lipstick and fill-in cosmetic

ic; from the expansion of the beauty routine to the closer focus on green and sustainable cosmetics and through to the greater awareness of safety issues.” reports Renato Ancorotti, chairman of Cosmetica Italia, the association of Italian cosmetics businesses. He adds, “According to the provisional figures, the Italian cosmetics market was worth €9.6 billion

in 2020, down 9.3% compared with 2019. We think that 2021 will be a year of transition before a complete recovery in 2022.” For more info, visit marchesini.com. SD Editor’s Note: This article was originally published in February 2021 by Healthcare Packaging.

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powders. Cosmatic was formed and developed in the Lombard cosmetics district: 500 businesses, concentrated in the quadrilateral between Crema, Bergamo, Milan and Brianza, which produce more than half of the makeup used by women across the world. The acquisition of Cosmatic expands Marchesini’s expertise in a segment that uses some of the most complex technologies in the cosmetics world, such as those that process lipstick paste. The waxy gel, which is formed from waxes jellified with oil, fat and resin, colored with pigments and supplemented with aromas, antioxidants and a series of active ingredients, is poured into cool silicone molds of different shapes and sizes. Though the use of face coverings has reduced purchases of lipsticks and other makeup products, the company says that, once the pandemic begins to subside, sales of fast-moving consumer goods, such as makeup products, will pick up again. “Despite the strong growth pre-COVID, the cosmetic products business has also undergone substantial changes since the start of the pandem-

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2021 PACK EXPO Las Vegas

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SEPTEMBER 27, 2021

Duravant launches nVenia

New operating company combines familiar names.

uravant (Booth C-4230) launches nVenia, A Duravant Company (Booth C-4425). The new operating company within Duravant’s Packaging Solutions Segment combines ARPAC (Booth C-4425), Hamer-Fischbein (Booth C-4425) and Ohlson (Booth C-4425) into a single entity and under one roof. “nVenia’s name comes from the Latin word invenio, meaning innovation,” reports Thurman Melson, president of nVenia. “That word will be the driving force behind everything nVenia does,” he explains. The ARPAC, Hamer, Fischbein and Ohlson brand names continue as product brands within the nVenia portfolio and will be prominently featured on nVenia equipment. The nVenia booth features a fully integrated packaging line with a robotic palletizer, which manages three distinct product infeeds simultaneously. The system palletizes shrink-bundled product from an ARPAC brand Brandpac tray wrapper, as well as large-format industrial bags and corrugated cases from nVenia’s fit-for-purpose eCommerce solution. That system, featuring an ARPAC brand DPM machine and bags suitable for a Hamer brand 2090 horizontal/form/fill/seal (h/f/f/s) machine, is designed to provide industrial customers with a single system to manage the increasing bag-in-the-box demands of today’s eCommerce giants. Also on display are select models of Fischbein brand hot-air, band and tape sew sealing equipment, as well as an Ohlson brand vertical f/f/s machine and an Ohlson ROFS model premade-pouch-filling machine. ARPAC equipment includes shrink wrappers, tunnels and bundlers, tray and case formers and packers, and robotic and conventional palletizers. Machines serve in a variety of industries including food, beverage, pharmaceutical, health and beauty,

nVenia, A Duravant Company, brings ARPAC, Hamer-Fischbein and Ohlson under one roof in a new 256,000-sq.-ft. facility in Wood Dale, Illinois.

consumer goods, construction products, automotive and printing/publishing/mailing. The Hamer and Fischbein brands offer almost 200 years of industrial bag closing and automated packaging experience. The comprehensive portfolio under the Hamer, Fischbein and Hamer-Fischbein names offers products for weighing, forming, filling, sewing, sealing and complete bag management with Fischbein focused on open-mouth bag sewing and sealing systems. Ohlson equipment for primary packaging lines weighs, counts and fills all types of packages, from flexible pouches to jars to rigid containers. Applications include handling delicate produce like hydroponic lettuce. “The union of these four equipment brands reflects a new era, further strengthening Duravant’s leadership position in the North American packaging industry,” says Mike Kachmer, president and CEO of Duravant. “By bringing these brands together under one roof and one name, we are creating next-level packaging equipment, integration and innovation solutions for our customers.”

nVenia operates from a newly constructed, 256,000-sq.-ft. facility in Wood Dale, Illinois, which opened in April 2021. Located just minutes from Chicago’s O’Hare International Airport, it’s convenient for visiting customers and partners. The building includes a 2,900-sq.-ft. Customer Care Center, outfitted for demos, testing and training. The relocation of nVenia’s existing manufacturing sites is expected to be completed by the end of the year. “Having worked in this industry for over 22 years, I can say that this is a truly exciting move for the entire Duravant family of operating companies,” says Rick Allegretti, senior vice president of Sales at nVenia. “nVenia is a powerhouse in the market now, with the strength, recognition and longevity of ARPAC, Hamer-Fischbein and Ohlson. We are positioned for incredible growth and look forward to better serving our customers with the same quality, service and relationship focus [they] have always counted on.” For more info, visit www.arpac.com, www.duravant. com, www.hamer-fischbein.com, www.nvenia.com, www.ohlsonpack.com. SD

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2021 PACK EXPO Las Vegas

STAND OUT FROM THE CROWD

SHOW DAILY SEPTEMBER 27, 2021

Virtual support cuts downtime

Program expedites troubleshooting and training.

Join a network of packaging and processing professionals dedicated to advancing the industry through its next generation of leaders.

Programs include:

eal-time virtual support from machine specialists decreases equipment downtime while enhancing line personnel skills. That’s why MG America (Booth SL-6614), the U.S. subsidiary of MG2 of Bologna, Italy, has launched its Remote Technical Assist (RTA) program. The comprehensive equipment assistance initiative consists of emergency support, line integration and training sessions with the goal of reducing machine downtime and operator error. With the program, line personnel can see and interact with technician specialists for real-time equipment troubleshooting and training. It’s akin to having a specialist working shoulder-to-shoulder with line personnel. Performed via secure Wi-Fi, 3G/4G or Ethernet connection, the RTA program allows line Performed via secure Wi-Fi, 3G/4G or personnel to hear, speak with and see technicians Ethernet connection, the RTA program trained on specific MG America packaging and enables line personnel and technicians to hear, speak with and see each other. processing equipment. Sessions also can include live streaming, instant messaging, file sharing, pics/screenshots and annotations. The program should be able to incorporate sophisticated virtual diagnostic tools that allow line operators to share issues with offsite technicians. Footage from endoscopes, microscopes, ultraviolet/infrared cameras, earscopes and iriscopes can be transmitted to technicians in real time, resulting in quick fixes that make it possible to restart production with minimal downtime.

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The RTA program is designed to simplify complex tasks via step-by-step guidance that should diminish production delays and maximize overall line efficiency.

MG America’s RTA program also is meant to be used as a training tool. A virtual “do-what-I-do” approach allows line personnel to quickly become proficient in machine operation. Skills upgrade sessions, meant to bridge the knowledge gap between new employees and veterans, also are available. These on-demand virtual primers improve retention and optimize worker performance, according to MG America. “In addition to the obvious advantages of virtual troubleshooting and training, including decreased downtime and enhanced line personnel machine proficiency, the RTA program also diminishes the time and cost involved with in-person maintenance, repair and training,” concludes Nick DeSantis, service manager for MG America. For more info, visit www.mgamerica.com. SD Editor’s Note: This article was originally published in April 2020 by Healthcare Packaging.

2021 PACK EXPO Las Vegas

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Robot loads cartoner

Unit offers dual pick-and-place of tall or oddly shaped products.

robotic loader for the Boxxer™ Kartnr automatic vertical cartoning machine from EndFlex (Booth C-1823) can pick up two products at a time, providing speeds up to 40 cycles/min. With the robotic system, the compact Kartnr machine easily adapts to transfer products of different sizes and odd shapes into the standard loading station, especially tall products that are more difficult to load on a standard cartoner.

synchronization between the robot and the rotation table can be regulated precisely, and machine torque, speed and acceleration can be controlled for many applications. Robotic programming is done using the standard touchscreen display. Engineered to vertically form a chipboard carton, insert the container and then close the carton, the Kartnr machine can be equipped to tuck or glue

the top lid of the carton after product insertion and seamlessly integrates with other machines in the EndFlex family, including the Traypacker™ topload case packer and Z.Zag™ robotic palletizer. An optional infeed is available to automatically convey product prior to carton insertion, eliminating the need for human interaction. For more info, visit www.endflex.com. SD

Robotic pick-and-place unit feeds tall or oddly shaped products to the Boxxer™ Kartnr automatic vertical cartoning machine.

“The pairing of this new robotic option into our flexible Kartnr allows our customers to not only reduce the risk and expense associated with manual cartoning . . ., but it also reduces the need for change parts,” reports Jorge Perez, vice president of Operations at EndFlex. “And that reduces client changeover time to only a few minutes, increasing efficiency and maximizing revenue,” he explains. The loader can be programmed to grab and release products ranging from 4.5–7.5 in. tall. The

Cognex (Booth SL-6156) and ORBIS (Booth SU-8001) for sponsoring the PACK EXPO Las Vegas lanyards.

2021 PACK EXPO Las Vegas

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Metal detector protects sausage

One portable system works online, the other works offline.

onghini Sausage, a maker of Italian sausages and other specialty meat products, takes pride in maintaining the high standards set forth by its founder almost 70 years ago. That dedication to excellence is paying off— the company has grown 80% this year. To help protect product quality and support its growing customer base, Longhini installed two Profile Advantage metal detectors from Mettler-Toledo Safeline (Booth C-1814). “We decided to automate inspection back in 2015 after seeing other companies experience metal contamination issues that were completely preventable,” recalls David Kemp, CEO of Longhini. “While we’ve never had problems with metal, we aren’t willing to take any chances when it comes to protecting consumers, customers and our brand.” “Our application is difficult for most metal detectors,” explains Rich Longhini, president of Longhini. “Meat products have natural variations in temperature and moisture, plus our wide range of case sizes presents a variation in product density. Products with variable characteristics are hard to accurately inspect. To overcome these challenges, we had to find an unusually advanced metal detector. “After considering multiple suppliers and speaking with our sales rep, Mark Stewart of Flo-Dynamics, we decided to go with Mettler-Toledo because they have great equipment as well as fantastic service and support,” notes Longhini. “We wanted to go beyond standard baseline inspection and find metal fragments far smaller than the industry requirement. The sensitivity and reliability of our Profile Advantage systems are amazing. If you’re going to get a metal detector, it makes sense to get the best.”

A semi-automated Profile Advantage metal detector inspects cases filled with products not already inspected with the inline system.

Longhini purchased its first Profile Advantage in 2015. To maximize versatility, they selected a semi-automated, standalone system on wheels that can be moved around the facility to inspect products in cases offline. Then, to increase throughput, they purchased a second Profile Advantage on wheels in 2019, but this one is rolled around and integrated with various lines throughout the facility to fully automate inspection. This new inline metal detector inspects thermoformed packages that range from 6 oz. to 1 lb. and tray packs that range from 5 to 10 lb. The offline system now exclusively inspects cases between 5 and 40 lb. in size, filled with either bulk sausages or tray packs not already inspected on the inline system. The top-of-the-line Profile Advantage identifies and rejects every type of metal in the most difficult applications. Compared to traditional single-frequency systems, the Profile Advantage detector is better able to discern changes due to the presence of metal vs. natural variations within the product by using multi-simultaneous frequencies to create a reference point. This advanced operation maximizes sensitivity while virtually eliminating false rejects when inspecting all kinds of products. “One of our favorite Profile Advantage features is the ‘product clustering’ capability, which allows us to run many similar products under the exact same setting,” adds Longhini. “We can almost always lump new products together under existing product settings. We also like the auto-setup routine. With it, our operators can easily add totally new products or recalibrate in less than 5 min. “Overall, the dependability of our Profile Advantage systems is awesome. They haven’t had any unplanned downtime at all and have been entirely maintenance-free. We test them a few times a day, which is why we know they’re consistently sensitive across our different products and packages. Mettler-Toledo’s customer service is always there for us if we have a question about our metal detectors. To be frank, if a supplier doesn’t have great service, it doesn’t matter if they have the best equipment in the world—Mettler-Toledo has both.” “These metal detectors give us hard evidence that no metal is in our products,” concludes Kemp. “Longhini is known for producing the highest-quality meat products on the market. Our Mettler-Toledo metal detectors are essential for protecting our reputation.” For more info, visit www.mt.com/pi. SD

THE LIGHTLINE CARTONPACKER

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LAS VEGAS

SEPTEMBER 27 – 29, 2021 UPPER SOUTH HALL

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The lightline machines from Schubert can be delivered quickly and are exceptionally attractive in terms of price. With the preconfigured machines, customers can adapt more flexibly to market trends and significantly shorten their time-to-market. The LIGHTLINE CARTONPACKER consists of a single compact machine frame, and packs boxes, cans, bags or bottles into cartons and trays with or without a lid, wrap-around cartons and RSC cartons. It offers an affordable and space-saving possibility to automate packaging processes with the most efficient technology on the market while ensuring the highest availability and packaging quality.

WHAT WOULD YOU LIKE TO PACK?

WHAT TYPE OF CARTON SHOULD IT BE?

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2021 PACK EXPO Las Vegas

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SEPTEMBER 27, 2021

Combo scale slashes labor needs

System doubles throughput, improves accuracy, cuts giveway.

rotein is the center of the production bulls-eye for Sugar Creek Packing, a Cincinnati-based co-man/co-pack that serves both retail and foodservice industries, mostly for brands or in-store private label. Bacon was the core competency upon

which the company was founded, but in the last five years, it has expanded to include a range of meats, mostly ready-to-eat, including a line of meatballs. Sugar Creek now operates six manufacturing and packaging facilities (four in Ohio, one in Indiana,

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The scales integrated seamlessly with existing thermoforming equipment from Multivac and quality control units from Anritsu Product Inspection.

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and another in Kansas). It stands to reason that in the thin-workforce era, these past five years of expansion must have relied heavily on automation. But Alex Hauck, vice president Engineering at Sugar Creek, says that shift has been slow, largely due to the artisan culture and variability inherent in proteins. He says, “I would say in the last three to four years, we’ve become more automated. Our industry traditionally didn’t lend itself to a lot of automation, but there definitely have been advances in the last several years and we’ve strategically taken advantage of those opportunities. It’s just with the way the labor force is these days, you really have to get into more automation. Investment in automation definitely is worthwhile, the ROI is there for sure.” Demonstrating this shift away from hand labor and toward capital investment in machinery, Sugar Creek’s Indiana plant features a pair of packaging lines specializing in vacuum-packed frozen meatballs that are destined for big brand distribution.

DECISION FACTORS IN UPGRADE

When the company first relocated meatball production to the Indiana plant, Hauck says Sugar Creek dabbled at automating for some time, but with marginal success. Originally, the Indiana line scaled and loaded meatballs into thermoformed trays (or pockets) which were then vacuum sealed. The setup included two mirrored lines, each including a legacy scale, a legacy depositor and a thermoforming system from Multivac (Booth SL-6349).

2021 PACK EXPO Las Vegas

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did solicit bids from various scale manufacturers, but confidence in Yamato certainly weighed heavily.

RESULTS

Labor reduction was the first noticeable benefit after installation, but throughput improvements also made an impression. Prior, Sugar Creek’s meatball lines were over-staffing the packaging machine, and they achieved only half the rated throughput of the packaging machine.

“Since we added the scales, our staffing is much more in line with how we are supposed to be,” Hauck says. “There is one person to replenish film. I’d say across two Yamato and Multivac systems, now we have one operator and we’re achieving the rated throughput of the packaging machine.” In an unintended benefit, the tolerance of the scales was so improved over existing equipment or hand labor that Sugar Creek also achieved a yield increase. The scales are able to select the precisely correct

Combination scales from Yamato have cut labor needs and giveway on frozen meatball packaging lines at Sugar Creek Packing.

“And when I say dabbled at automating, I mean we did scale the product automatically, but it was rather inefficient,” recalls Hauck. “We often had to supplement the automation with operators who, in some cases, would literally hand weigh the product and hand feed it into each thermoformed pocket before it was sealed,” he adds. Tim McDermott, packaging engineer at Sugar Creek, began looking for new combination scales to replace the legacy scaling and depositing and eventually landed on a combination scale from Yamato (Booth SL-5949) that would seamlessly integrate with the thermoforming machinery. Using this new scale, Hauck says they had an opportunity to rightsize the scales, take advantage of some newer technology, and also use the scales’ automatic depositors to automatically fill the thermoformed Multivac pockets under the depositor and scale. “That depositing system was a big factor in our decision,” he says. “Two [Yamato] reps came out and talked to us about the depositor, how it worked and its sanitary design, which is very important in a meat facility. These particular scales are in a ready-to-eat food production room, which for us has the highest level of scrutiny as far as sanitary design. We liked Yamato’s methodology around correctly sizing a scale, selecting the depositor that would best fit, showing us how they would fit together and demonstrating how they can be removed for cleaning and maintenance. A lot of those factors went into our decision. The price was competitive—I wouldn’t say it was the lowest price, but it was certainly competitive.” Hauck also mentions that prior to this installation, Sugar Creek had one Yamato scale at the Kansas facility, operating in a different packaging capacity. But it was working well enough to get noticed. Sugar Creek

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combination of meatballs in every pocket, meaning giveaway has gone down to within a 0.5% threshold. Previously, that number was in the 7% range. Hauck says, “I wouldn’t say we were running up immediately, but within two weeks we were hitting full cycle, which for an automation project is doing very well. We’ve had other instances where that has taken months to fully dial in and in this case, Yamato was great working with us; their service was there.”

CURRENT LINES AND WHAT’S NEXT

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To feed each of the combination scale systems, an incline conveyor carries the flash-frozen meatballs from upstream processing to a mezzanine level. There, a vibratory conveyor, programmed to work in conjunction with the Yamato combination scales, feeds them both and provides product only as each scale calls for it. After primary packaging, the sealed meatball trays pass through an x-ray detection and checkweigher system from Anritsu Product Inspection (Booth SL-6319). After that, depending on the product, trays are either case packed for an HPP (high-pressure processing) step, which is done at a separate facility, or a sleeve is applied to the tray in a semi-automated process. As is usually the case with automation, increased throughput upstream invites—often demands— improvements downstream. Sugar Creek is close to installing semi-automatic case erectors that will make it simpler for operators to hand-load primary packages as each case passes from the erector down a conveyor. The company also plans to automate the full facility with a common palletizing area. “It’s probably worth noting that with this facility, we really have a goal to package directly,” Hauck says. “This particular oven line is capable of producing 6,200 lb. of product/hr. It’s really important for our packaging to keep up so that we can package directly online and not have to produce work-in-process and then go back and repackage. With this installation, we are in fact able to maintain the speeds that we can pack directly online.” For more info, visit www.anritsu.com/infivis.com, www.multivac.com, www.yamatoamericas.com. SD Editor’s Note: The original version of this article was published in May 2020 by Packaging World.

Lenze Americas sponsors lounges

nce again, Lenze Americas (Booth C-1602) is sponsoring lounges for exhibitors and PMMI members at PACK EXPO Las Vegas and the co-located Healthcare Packaging EXPO. The lounges provide seating, coffee and a chance to take a break away from the show floor. “Lenze recognizes how important it is for members and exhibitors to have a space to recharge between networking with attendees in their booths, and we are proud that we are able to sponsor these lounges again this year,” says Susan Duval, senior marketing communications manager, Lenze Americas. Exhibitor Lounges are located in rooms N-114 and S-222, and PMMI Member Lounges may be found in rooms N-101 and S-221. The lounges are open today and tomorrow from 8 a.m. until 5 p.m. and on Wednesday from 8 a.m. until 3 p.m. For more info, visit www.lenze.com, www.PACKEXPOlasvegas.com, www.HCPElasvegas.com. SD

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2021 PACK EXPO Las Vegas

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Fanuc, Rockwell create coalition

Group works to solve labor shortage with apprenticeships.

ockwell Automation (Booth C-4742) and FANUC America (Booth C-1441) have formed a coalition to kick off accelerated work-and-learn apprenticeship programs designed to upskill current and future workers for jobs in advanced manufacturing, robotics and automation. The coalition includes APT, a FANUC and Rockwell Automation systems integrator, and NOCTI Business Solutions, which provides independent assessments of occupational standards and validation using recognized International Organization for Standardization

(ISO) process validation methods. Another key partner, Franklin Apprenticeships, provides apprenticeship program support for employers and apprentices. The coalition has developed new apprenticeship programs offering people opportunities to gain credentials that include fundamental robotics (Robot Operator) and automation (programmable logic controller (PLC) Operator). The program offers a second level of credentials for Robot and PLC Technicians. A third credentialing level, called Integration Specialist, builds on the fundamental and technical skills

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www.morrison-chs.com

8/24/2021 3:16:26 PM

that teach people to operate and troubleshoot integrated FANUC-Rockwell Automation technologies. All of the new apprenticeship offerings will provide more people with fulfilling careers and help companies bridge the demand for skilled workers. “Our number one goal is to help create a worker pipeline that will not only help people increase their skills and future earning potential, but to help manufacturers achieve their production goals and maintain a thriving economy,” says Paul Aiello, director of Education, FANUC America. “In most cases, current and future workers can complete the apprenticeship skills training and achieve their industry-recognized certifications in less than one year. It’s also important to note that these programs support all types of apprenticeship and certification models, including pre-apprenticeships.” “As industry adopts new technologies, it is vital to be able to quickly adapt with a well-trained workforce,” explains Michael Cook, director, Global Academic Organization, Rockwell Automation. “Having the most current standards will drive manufacturing competitiveness and simultaneously grow new talent to these new occupations, upskill current employees and allow companies to be more agile in their workforce planning.” The apprenticeship programs aim to help companies rapidly upskill employees at every level from Operator to Technician to Integration System Specialist. In addition to improving the skills of current production workers, these programs will be extremely valuable for engineers who are working to implement new automation systems and processes that require new employees trained in the latest automation technologies. “As technology advances at a fast pace, it is important that companies play a bigger role in education to ensure a safe, productive and sustainable work environment,” says Aiello. “FANUC and our coalition look forward to helping as many people as possible take advantage of these accelerated work and apprenticeship programs.” More than 40 leading companies, including Dana, Magna, Tyson Foods and Flex-N-Gate, have agreed to support and participate in apprenticeships for automation technologies, ensuring that their employees receive adequate training and are qualified to succeed. FANUC and Rockwell Automation have worked together over the past decade developing training, certifications and an education and training delivery network. FANUC’s network of educational partners includes more than 1,200 high school and post-secondary FANUC-certified training organizations, and more than 150 university and career technical training partners. FANUC’s network of schools, coupled with Rockwell Automation’s education partners, represent nearly 1,600 schools, the largest nationwide collaboration of industry and education working to narrow the skills gap. For more info, visit www.fanucamerica.com, www.rockwellautomation.com. SD

2021 PACK EXPO Las Vegas

SHOW DAILY SEPTEMBER 27, 2021

Yamato prepares to relocate HQ

n the heels of its 100-year anniversary, Yamato (Booth SL-5949) has acquired a new building in Grafton, Wisconsin. The U.S. subsidiary of Yamato Scale will be leaving the Mequon, Wisconsin, office it has occupied since 1998 for a 96,500-sq.-ft. facility. This new office in southeastern Wisconsin will feature a world-class demo room to host customers

Secondary packaging evolves New designs meet needs of omnichannel marketplace.

s the consumer experience becomes increasingly complex with the advent of omnichannel models, secondary packaging is being reimagined beyond the stereotypical plain corrugated box, reports the Secondary Packaging Trends: Retail, E-Commerce, Direct-to-Consumer white paper from PMMI, The Association for Packaging and Processing Technologies (Central Lobby). From expanding stock keeping units (SKUs) to changing consumer desires, manufacturers need to be ready to address industry drivers with secondary packaging strategies that fit the times. The white paper outlines key drivers impacting changes in the secondary packaging market, including growth in the number of SKUs, the importance of sustainability and an overall expansion of the retail market. Each factor increases reliance on supplier expertise and encourages a shift to more contract services. Expanding SKUs require flexible manufacturing. As consumers expect broader choices and greater product diversity, manufacturers need secondary packaging machines able to handle a wide variety of formats and shapes while maximizing uptime. Sustainability continues to drive secondary packaging as manufacturers seek out new and innovative materials, work to reduce material usage and replace non-sustainable materials with sustainable alternatives. The expansion of SKUs in the food, beverage and personal-care markets has necessitated the use of new resources to fill gaps in production and packaging capabilities. Currently, 65% of white paper participants use contract services to outsource at least a portion of their production and secondary packaging operations. In addition, 75% report collaborating on new secondary packaging designs and strategies with suppliers more often to help guide them through the process. For more info, visit www.PMMI.org. SD

and complete factory acceptance tests. The move also allows for the growth and expansion of production capacity. This location will serve as Yamato’s main headquarters and support customers in North, Central and South America. Yamato also has offices in Lake Forest, California, and Queretaro, Mexico. For more info, visit www.yamatoamericas.com. SD

Yamato’s new headquarters in Grafton, Wisconsin, will include a demo room and expanded production space.

2021 PACK EXPO Las Vegas

SHOW DAILY

SEPTEMBER 27, 2021

Processing Zone returns

Zone in North Hall hosts exhibitors, Innovation Stage sessions.

he Processing Zone returns to PACK EXPO Las Vegas and Healthcare Packaging EXPO to showcase front-of-line solutions from food processing/systems, food safety, engineering, design and construction services. “Many of the technologies in packaging and processing work in unison, and PMMI learned from attendees at previous shows that the ability to find complete solutions from the beginning through the endof-line was a priority,” says Laura Thompson, vice president, Trade Shows at PMMI, The Association for Packaging and Processing Technologies (Central Lobby). The Processing Zone displays technologies for baking and snack, beverage, meat and poultry, dairy and produce applications. It also offers targeted education via its dedicated Processing Innovation Stage (Booth N-24020). Session topics include high-pressure processing, process improvement, spiral immersion processing and the Manufacturing With more than 10 technologies onboard, this color sorter from Anysort handles virtually any sorting task.

NEW TO THE SHOW? YOU’RE INVITED TO THE

If your badge says, “First-Time Attendee” visit this exclusive resource center where you can: i Ask questions from show staff and industry experts

i Access tools to find products and exhibitors i Attend special sessions

Mon. 8:30 a.m. PACK EXPO 101: Navigate the Show Like a Pro 1:00 p.m.

How To Make Your Product’s Packaging Environmentally Friendly

Tues. 8:30 a.m. PACK EXPO 101: Navigate the Show Like a Pro 1:00 p.m.

Automation and Robots for Beginners

Wed. 8:30 a.m. PACK EXPO 101: Navigate the Show Like a Pro

SOUTH UPPER HALL ROOM S-224 Lounge Hours Sept. 27 – 28: 8:00 am – 5:00 pm Sept. 29: 8:00 am – 3:00 pm