Aluminium International Today Packaging Supplement April 2017 by Quartz

INDUSTRY NEWS

ALUMINIUM PACKAGING

ASSOCIATION UPDATES

RECYCLING

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THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

Packaging supplement

1 CONTENTS

Digital Edition No.5 – Packaging supplement Editorial Editor: Nadine Bloxsome Tel: +44 (0) 1737 855115 nadinebloxsome@quartzltd.com

COVER INDUSTRY NEWS

ALUMINIUM PACKAGING

ASSOCIATION UPDATES

THE EDITOR’S COMMENT

NEWS

RECYCLING

Production Editor: Annie Baker www.aluminiumtoday.com

Sales

THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING

Sales Manager: Anne Considine anneconsidine@quartzltd.com Tel: +44 (0)1737 855139

PACKAGING

Sales Director: Ken Clark kenclark@quartzltd.com Tel: +44 (0)1737 855117

Advertisement Production

Signiﬁcant to aluminium value chain

Packaging supplement

Production Executive: Martin Lawrence

Packaging: ASI

Association Update: AEROBAL answers

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MPMA The UK’s voice of metal packaging 13 Association Update: CiAl

Supporters of Aluminium International Today

Investing in growth

Aluminium closures: An open and shut case!

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Digital Edition - April 2017

Aluminium packaging... What else? The world’s lightest aluminium seafood can

New Trend: Light aluminium drink bottles

Earing Control in CBS from a single stand hot reversing mill

Aluminium foil takes ﬂexible packaging in Europe further

Flatness control technology

Importance of packaging recycling

C0MMENT

ALUMINIUM: WRAPPED UP

Welcome to this special digital issue of Aluminium International Today, which focuses on the production and processing of aluminium packaging. With the return of Interpack 2017 in May this year, it seemed that every other press release flying into my inbox had a focus on packaging, so I thought it only fair to dedicate some pages (albeit digital ones) to this growing market. The can usually hogs the limelight when it comes to appreciating aluminium as a packaging material, but the possibilities for other applications are endless and we are seeing more and more manufacturers experimenting with aluminium thanks to its lightweight and flexible properties. Bottles, caps, closures, tubes, trays, aerosols, pouches, sachets and cartons make up some of the ways that aluminium enters your home. But, while we in the industry know of it’s infinite recyclability and have the quote: “75% of the world’s aluminium is still in use today,” etched on our brain, there is still a way to go when it comes to helping the consumer understand the sustainability benefits of this ‘miracle’ metal. Hopefully, with the likes of the Aluminium Stewardship Initiative (ASI) becoming involved in this area, we will start to see more being done to maximise the collection and recycling of aluminium, with the help of the entire value chain. You can read more about how the ASI is working across the board to promote sustainable standards on page 5. This special issue is packed (no pun intended) full of news and interesting articles from across the aluminium packaging industry. Thanks to everyone who has contributed and if you missed out this time, don’t hesitate to get in touch to find out how you can be involved and get your company in front of the industry. Nadine Bloxsome Editor, Aluminium International Today E: nadinebloxsome@quartzltd.com W: www.aluminiumtoday.com Aluminium International Today

Digital Edition - April 2017

3 NEWS

IN BRIEF i2r acquires South Korean distributor Aluminium foil tray manufacturer, i2r Packaging Solutions, has acquired its former South Korean distributor. Established in 2015 and based in Seoul, i2r Korea supplies a variety of packaging products for food manufacturers and retailers across the region. Peter Reay, i2r’s CEO said: “We believe this is a great opportunity to join forces with an entrepreneurial led Asian business and provides the Group with new exciting market opportunities, whilst further strengthening the vertical integration of its European parent. We look forward to further investing in this geographic region in the future and enhancing the Group’s operations.”

Siemens exhibits digital value chain at interpack

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Aerosol cans growth at record levels

The International Organisation of Aluminium Aerosol Container Manufacturers (AEROBAL) has announced its sales report of 2016 stating an increase in YoY growth

of three per cent and production about 5.5 billion aluminium cans globally. The Asian market has achieved the highest growth while North, Central and South America are above-average growth in aerosol cans, as reported. AEROBAL’s Secretary General Gregor Spengler hopes for further growth of aluminium aerosol cans above all in the Asian markets. The region’s per capita consumption of aerosol cans is still well below the global average. In 2016, deodorants and perfumes were the major parts of

application of aluminium aerosol cans produced with more than 50 per cent while the other applications areas are in the cosmetics sector, to sum it up the personal care sector minted for about 80 per cent of all aerosol cans produced. Gregor added: “I see clear opportunities for further gains in the pharma sector. Here it is primarily the outstanding functional properties of aluminium aerosol cans that will ensure growth. I am thinking primarily of excellent product protection and best possible safety where aluminium scores over other materials.” “On top of its [aluminium] abundance of functional benefits, this is a further important argument in favour of the aluminium aerosol can, which thus makes a valuable and resource-efficient contribution to the future of our planet,” he concluded.

Ball’s latest craft beer offering Siemens is presenting innovative automation solutions for packaging machines, such as the Multi-Carrier System, as well as new machine concepts to meet the requirements for speed, efficiency, individuality, and flexibility. Visitors to the booth will also get to know what MindSphere, the cloud-based, open IoT operating system from Siemens, can offer them in the field of digital services.

Direct to shape digital printing at interpack 2017 Tonejet, a manufacturer of advanced electro-static drop-ondemand digital print engines, has announced a collaboration with Rockwell Automation. The collaboration will see a demonstration 2-piece direct to shape Can Decorator at interpack 2017.

Digital Edition - April 2017

As craft beer in a can continues to surge in popularity, Ball has now collaborated with Croatian craft brewer Garden Brewery to produce distinctive packaging for its craft beer range. The partnership is the latest addition to Ball’s craft brewery portfolio. Garden Brewery will also be the first of Ball’s Croatian customers to include the Metal Recycles Forever logo on the packaging, championing the strong sustainability credentials of the can as a packaging format. Produced in Ball’s Belgrade plant, Serbia and using their 330ml standard aluminium can, the beer comes in a range of five flavours consisting of Citrus IPA, Session Ale, Pale Ale, India Pale Ale and Stout. The can design focuses on strong single colours, geometric shapes and illustrations depicting Croatian landscapes, with a matte finish to maintain an authentic, craft feel. David Plant, Director at Garden Brewery, comments; “Right from the beginning, Ball showed

initiative, flexibility and support for our new company. Aimed at a young, urban and outgoing population, we’ve taken the concept of canned craft beer made popular in the US and UK and introduced it to a Croatian audience with a focus on design and innovation. We also recognise the environmental credentials of the can over other forms of packaging, with

our ‘We Love Cans’ sustainability campaign at the forefront of all brand communication”. Jovan Jovanovic, Sales Coordinator for South East Europe at Ball, says; “The 360° branding potential of the beverage can provides a great platform for craft brewers to communicate their story and passion to customers, whilst also differentiating them-

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NEWS 4

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GLAFRI Alufoil Trophy Winners 2017 joins ASI The Global Foil Roller Initiative (GLAFRI) has become a member of the Aluminium Stewardship Initiative (ASI) to further strengthen its position as a global voice for responsible and sustainable aluminium foil market growth, worldwide. GLAFRI will join 42 other members of ASI, including several national Aluminium Associations, Foil Converters as well as Industrial Users and International Civil Society Organisations. Oliver Hommel, president of GLAFRI confirmed the decision to join had been reached following strategic discussions at the 2016 Global Foil Roller Conference in Shanghai and its annual webinar early this year, “We are very glad to join ASI as one of the key objectives of GLAFRI is to promote sustainable growth for our sector.”

selves from competitors. The can is also the perfect packaging format for craft beer; protecting the product during transit, sealing in freshness and taste whilst also being extremely lightweight and chilling the cans faster than other packaging formats such as glass”. Matthew Rowland-Jones, Environmental Manager at Ball Beverage Packaging Europe, adds; “Ball is proud to work with environmentally conscious customers such as Garden Brewery. A champion of the 100% infinitely recyclable beverage can, Garden Brewery is the first customer in Croatia to adopt the Metal Recycles Forever logo on their packaging”. The cans are sold at various outlets in Croatia and are exported to a growing number of countries including Slovenia, Germany and the UK.

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A strong set of entries for the Alufoil Trophy 2017, the sector’s leading awards competition, showed, once again, the strength of product development programs and creative thinking in the aluminium foil industry. There were nine winners across five specific categories, plus a Trophy given for Innovation in Application for the first time. Leading the judges this year was Guido Schmitz, Director of Packaging Design in Consumer Health, Bayer, itself a previous winner of a Trophy for its Shamrock aspirin pack. He was full of praise for both the standard and ingenuity of entries, “We can only recognise the very best of the products entered and the judging proved very close in several categories.” “We were impressed with packs which showed real technical advances to create better sustainability, improved quality, more

convenient or flexible solutions. Particularly, one or two winners offer the aluminium foil sector a real opportunity to jump into new market segments or enable customers to put their products in places they could not reach before. That marked them out as very special and it fully justified their award,” he added. Organised each year by the European Aluminium Foil Association (EAFA) the Alufoil Trophy 2017 competition winners will be on display at the Association’s booth during interpack 2017, in Düsseldorf. The association’s Executive Director Guido Aufdemkamp commented on this year’s winners, “The different competition categories allow aluminium foil products made for a variety of industry sectors to demonstrate a wide range of innovations. It confirms

The Alufoil Trophy is organised by the European Aluminium Foil Association (EAFA). There are ﬁve categories – Consumer Convenience, Marketing + Design, Product Protection, Resource Efﬁciency and Technical Innovation. Judges also gave an award for Application Innovation. For 2017 there were 10 winners.

the ‘strength in depth’ of the industry that so many excellent products were recognised again this year.” The competition is open to products which are either made from aluminium foil or contain aluminium foil as part of a laminate, structure or packaging system, as well as aluminium closures. Categories cover every aspect of aluminium foil usage across many diverse markets, particularly those for packaging and technical applications. The classifications are Consumer Convenience; Marketing + Design; Product Protection; Resource Efficiency; and Technical Innovation. The judges also have discretion to award an Alufoil Trophy for products displaying excellence across a number of categories, or for an outstanding or clever application.

THE WINNERS Consumer Convenience closurelogic: OLIO Premium Constantia Flexibles: CONSTANTIA Unshredded Wrap Marketing + Design Constantia Flexibles: Bone-Shape Container with high-end printing Guala Closures Group: Siena for Stolichnaya Product Protection Constantia Flexibles: Cakees – Ready-to-eat cakes Resource Efficiency Contital: Happy Day Huhtamaki: Straight’n’Easy Technical Innovation Amcor Flexibles and Rohrer Leading Solutions: Frangible Formpack® Blister Guala Closures Group: 3D Embossing for Salute Application Innovation Constantia Flexibles and ABInBev: Capsule for beer flavour dispenser Digital Edition - April 2017

5 PACKAGING

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Packaging: Significant to aluminium value chain

Aluminium packaging value chain leaders actively contribute to ASI governance and program Under its membership-based participation structure, the ASI has attracted and is working with many aluminium packaging sector leaders, as well as relevant civil society organisations and associations. Member representatives participate on the ASI Board (governance), on the Standards Committee (standards development) and in Working Groups (research and

development). The 46 current ASI members are grouped into six membership classes (Production & Transformation, Industrial Users, Downstream Supporters, General Supporters, Civil Society, Associations), and one-third of members have direct ties to the packaging sector currently, including: � Production & Transformation:

Alcoa^, Ball Corporation^, Constantia Flexibles, Norsk Hydro^, RUSAL^, Constellium^, Aleris, Novelis, Tetra Pak* � Industrial Users: Coca-Cola Enterprises, lavit, Nespresso* ^ º � Civil Society: Keep America Beautiful^ � Associations: Can Manufacturers Institute, IGORA

*participates on the ASI Board ^participates on the Standards Committee º see related article from Nespresso in this issue

Open street map contributors

The Aluminium Stewardship Initiative (ASI) is a global standards setting and certification organisation. ASI’s core focus is the establishment of an independent third-party certification program for the aluminium value chain. Two standards will form the core of the ASI’s certification program once operational: 1) ASI Performance Standards and 2) ASI Chain of Custody Standard. ASI intends to launch its certification program in 2017. An increasingly important part of the aluminium value chain is the production and recycling of aluminium packaging. Numerous forms of aluminium packaging, such as cans, caps, capsules, trays, foils, pouches, sachets and cartons are now ubiquitous, particularly in the global food and beverage sector. Aluminium packaging has numerous benefits. It gives foodstuffs and beverages complete protection against oxygen, light, moisture and bacteria, conserving product taste and quality while extending storage periods1. More product can be transported with less energy2. New packaging types and applications that take advantage of the thermal, form, weight and other beneficial aspects of aluminium in packaging are continually under development and will further broaden its use. At the end of its use phase, aluminium is the most recyclable of all packaging materials and is more valuable than any other item in the recycling bin3.

Highly recyclable and highly recycled: Overall, 70% of all beverage cans in Europe are recycled and therefore remain in the European Circular Economy4. ASI’s approach to materials stewardship encompasses maximising collection and recycling of products containing aluminium at their end-of-life, and engaging with relevant stakeholders to increase recycling rates. Consult the ASI Performance Standard for more info.

1. www.aluminiumleader.com/application/packaging/ 2. www.packaging.world-aluminium.org/home/ 3. www.aluminum.org/industries/production/recycling 4. European Aluminium. www.european-aluminium.eu/data/packaging-data/recycling-rate-of-aluminium-beverage-cans/ Digital Edition - April 2017

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PACKAGING 6

The ASI has also entered into a collaboration agreement with the International Aluminium Institute (IAI) to support continuous improvement in the performance of the global aluminium industry and the sustainable use and recycling of its products. ASI Standards aim to encourage material stewardship and recycling Material stewardship in its broadest sense encompasses both process and product stewardship. Process stewardship refers to minimising environmental impacts and health and safety risks in processes to explore, extract and refine metals such as aluminium. Product stewardship seeks to minimise environmental, health and safety risks and enable recovery, reuse or recycling (as appropriate) of the metals utilised in product systems. Ultimately these approaches are defined and implemented through the actions of various players in the life cycle or value chain of specific minerals and metals (ICMM, 2006). ASI’s approach to materials stewardship is embedded in the ASI Performance Standard and encompasses: � Understanding the life cycle impacts of aluminium from mining to use and through to end-of-life. � Developing collaborative relationships with value chain partners and external stakeholders. � Enhancing sustainability and environmental life cycle performance in product design. � Minimising generation of aluminium process scrap, and where generated, maximising recycling and/or re-use. � Maximising collection and recycling of products containing aluminium at their end-of-life, and engaging with relevant stakeholders to increase recycling rates. Current state and next steps in the ASI standards development process The initial ASI Performance Standard (Version 1) was published in December 2014. An updated draft of the ASI Performance Standard (Version 2) is now being developed with the ASI Standards Committee, incorporating minor revisions so as to enhance clarity and auditability, and integrate the Performance Standard into the broader ASI certification program being developed. ASI’s Chain of Custody Standard aims to support implementation of the Performance Standard. A public comment period for the Chain of Custody (CoC) Standard Draft 3 was open from October to December 2016. The Standards Committee is addressing the feedback and comments received and will publish a CoC Standard Draft 4 in May 2017. ASI plans to hold 60-day consultation periods simultaneously for both the Performance Standard and CoC Standard to enable an integrated review by stakeholders, in advance of a planned pilot program. Key upcoming dates are: � ASI Standards – public consultation on latest drafts of the Performance Standard and CoC Standard – May-June 2017 � Pilot program – July-September 2017 � Review of all feedback by the ASI Standards Committee – September-October 2017 � Adoption of final standards – target November/December 2017. � More information on ASI, the Performance Standard, the Chain of Custody Standard and the entire certification program can be sourced from the ASI website: www.aluminium-stewardship.org Digital Edition - April 2017

Materials handling solutions for your industry

• Improved storage utilisation • Safer product handling • Increased productivity • Indoor / Outdoor

7 ASSOCIATION UPDATE

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AEROBAL answers Nadine Bloxsome* spoke to Eric Frantz, AEROBAL President, about the history and work of the association. 1. How did the formation of AEROBAL come about? AEROBAL was originally founded in 1976 as a European Association of Aluminium Aerosol Container Manufacturers. In 2006 AEROBAL was transformed from a European into an international organisation of aluminium aerosol container manufacturers. The main motivation for the internationalisation was the increasing globalisation of brand owners and the can industry. AEROBAL is run under the umbrella of DĂźsseldorf-based German Aluminium Association (GDA) which offers a great deal of synergies for members. 2. What is AEROBAL's purpose/vision? AEROBALâ&#x20AC;&#x2122;s purpose is to promote aluminium aerosol cans worldwide as the packaging of choice in an increasingly competitive environment in the packaging industry. We promote the sharing of information about global markets, regulatory and environmental developments as well as communication activities about cans so that the aluminium aerosol can industry stays innovative, competitive, sustainable and visible. 3. What is the current state of the aluminium can market? Since 2008 the aluminium aerosol can industry has recorded an average annual growth of slightly over 5% reaching a record production of 7.7 billion units in 2015. We are quite confident that our industry has broken this record again in 2016. 4. Is the reported growth expected to continue into the short and long term? AEROBAL members are rather confident that the market growth will continue in the years to come. True, competition between packaging materials and formats in the main end-use markets is likely to further increase in the short and long term, but the aluminium aerosol can industry is well positioned to successfully pick up this challenge.

5. What is the reason for this current growth? There are many reasons for the success of the aluminium aerosol can. First of all, it offers consumers a very hygienic, precise, safe and convenient use of the product. Second, aluminium is a permanent material which is infinitely recyclable without any losses. Did you know that about 75% of all aluminium produced up to now is still in use? This is sustainability at its best and a performance which no other material can claim. Thirdly, aluminium provides an absolute barrier for an unparalleled protection of the product.

Eric Frantz, AEROBAL President

6. Is there a particular area of growth across the industry? Personal care products have paved the way for the sustained success of aluminium aerosol cans. This market, particularly deodorants and perfumes, have been dynamically growing since decades all around the globe. And there is more growth in the pipeline because the per capita consumption of aerosols in countries such as China, India, Indonesia, Brazil and Russia is still lagging far behind that in Western European or North American countries. Besides the personal care sector also the health and pharmaceutical segment heralds promising growth because the aerosol system is really tailor-made for a hygienic, safe and precise application of products. 7. What market areas do AEROBAL members focus on? AEROBAL members focus on offering convincing packaging solutions in all market areas such as personal care, pharmaceuticals, household, chemical and food products. In close cooperation with current and potential customers the industry is always looking for new applications and business opportunities. 8. How does AEROBAL work with its member companies? AEROBAL has a very lean structure. The organisation is run by a permanent AEROBAL Secretariat and the President, who changes every two years. Twice a year AEROBAL members meet in the General

*Editor, Aluminium International Today Digital Edition - April 2017

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Assembly which is normally combined with international industrial fairs which are relevant for AEROBAL members. Special topics or burning issues are treated in dedicated Task Forces which are convoked on an ad-hoc basis.

Aluminium aerosol cans are accounting for slightly more than 50% of all aerosols produced worldwide. Aluminium cans have constantly increased their market share over the years, and we are confident that this trend is going to continue.

9. How important is aluminium in can packaging?

10. Does AEROBAL work to promote aluminium to the consumer? Consumers who are interested in aluminium aerosols should visit the AEROBAL website www.aerobal.org where a host of information about the convincing advantages of this packaging and many examples of innovative cans can be found. Indirectly we also reach the consumer via our regular press releases about the market situation, innovations and our annual World Aluminium Aerosol Can Award which are published in packaging and special interest magazines worldwide. In addition, AEROBAL is represented at interpack, the most important packaging fair worldwide, with a joint booth together with the German Aluminium Association (GDA) in order to promote aluminium as the packaging material of choice. 11. Is AEROBAL working with the aluminium can industry on any projects/R&D? In 2015 AEROBAL and GDA commissioned a renowned research institute to make LCA calculations on the environmental performance of aluminium compared to plastic containers in order to generate scientifically sound data for AEROBAL members which can be used in discussions with customers and other stakeholders. Moreover, we are currently running a project together with other partners in the supply chain, i.e. coating producers and fillers/brand owners, on an “ideal” process approach to develop and launch new or modified lacquers on the market. This effort is made to come to a well structured approach along the value chain which explains the responsibilities at the different production stages and to avoid time-consuming and costly failures in the development process. 12. What does the future hold for aluminium cans? AEROBAL members are looking into the future with great confidence. It goes without saying that they will face increasing competition from materials such as plastic. But aluminium provides many striking advantages such as no material ageing, a proven safety record, the compatibility with all propellants, excellent shapeability, perfect recyclability and sustainability which are of utmost importance for brand owners and consumers alike. This will tip the balance

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in favour of the aluminium solution. Innovation in the aluminium aerosol can industry will take place through the use of new alloys and further can downgauging as well as through less use of chemicals in the entire can production process, for example the coating and washing of cans. 13. Does AEROBAL work to promote aluminium’s sustainability benefits? As already mentioned, AEROBAL and GDA commissioned a renowned research institute to conduct LCA calculations on the environmental performance of aluminium cans compared to plastic containers. The scenarios showed that one cannot make sweeping statements as to whether one aerosol can system is better or worse than the other from an environmental point of view. The environmental impacts depend critically on the country-specific recycling routes or waste management systems and the material recycling rates achieved. Sweeping environmental statements on PET aerosol cans that claim, for example, that PET has a fundamentally better carbon footprint – in other words a more favourable global warming potential – are questionable technically, are not transparent and not comprehensible, and thus inappropriate. 14. Are there any ways AEROBAL is working with its members to increase recycling efforts/rates? National waste management schemes are greatly differing worldwide so that an internationally harmonised approach can hardly be successful. Appropriate measures at national level (e.g. by national aerosol associations and their member companies) have to be made in order to improve the collection, sorting and recycling of aluminium aerosols in the different countries. In this context aluminium has a decisive advantage compared to other materials because it is a valuable material which is also economically worthwhile to collect, sort and recycle. In order to reach this aim, investments in modern collection, sorting and recycling technologies are of key importance to increase the quantity and quality of the sorted and recycled aluminium packaging. 15. What is next for AEROBAL? AEROBAL is aiming at further expanding its membership. Currently the organisation is representing about 70% of total aluminium aerosol can production worldwide. In 2017 there will be a new member from Indonesia joining AEROBAL which is another step towards the final goal of achieving a global representation of 100%. � www.aerobal.org Digital Edition - April 2017

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MPMA - The UK’S voice o

Legislation, new and ongoing directives, pressure group activity and the competing business agendas of rival materials are just some of the issues that can makers face. But chief executive and director of the UK Metal Packaging Manufacturers Association (MPMA), William (Bill) Boyd (pictured above), is no stranger to such challenges. A former managing director of Swanseabased Afon Tinplate Company, Bill also spent seven years in the US as general manager of Tata Steel Plating USA and CEO of Thomas Steel Strip Corp and Apollo Metals, before taking the helm at the UK trade association in January 2016. Here, he explains how the Association works to achieve the best possible environment in which its members can thrive and grow, following what is now widely recognised as one of the most tumultuous years for decades.

Digital Edition - April 2017

The MPMA represents some forty UK can makers and associates which collectively employ more than 4000 people. Members have direct links into a European market producing over 70 billion containers each year; and in the UK alone produce over 18 billion units annually generating retail sales of around £25 billion. So it is perhaps not surprising that the MPMA is most active and best known for its input into industry matters related to operational, regulatory and environmental affairs. However, the association is also very active in promoting the benefits and the sustainable attributes of metal packaging through its support for consumer facing education programmes and campaigns, industry awards and wider communications activities presenting the sustainability attributes of metal to retailers and brand owners.

by Brexit and will create a real opportunity for the metal sector as set out in the current MPE position: “Metal Packaging Europe supports the ambitious plans of the European Commission to increase resource efficiency by turning waste into a resource. Aluminium and steel - due to their unique characteristics as permanent materials - can make a decisive contribution in helping to close the material loop and

Making a case for business Engaging with European regulators and administrations ensuring that the attributes of metal packaging are clearly understood and recognised has long been an essential part of the MPMA’s remit and, with the short and long-term implications of Brexit uppermost in people’s minds at present, this will undoubtedly remain a priority. For now, the UK government has indicated that business will continue as normal up until the point that the UK actually leaves the EU. As such, the UK will continue to take a full and active role in relevant negotiations including those underpinning the Circular Economy Directive, for example, where final EU recycling targets are committed up until 2025. And while the longer term may appear less clear-cut at present, it’s fair to say that a degree of unpredictability is really nothing new and it is unlikely that any especially divergent paths will emerge given our long and combined efforts with our European metal packaging partners over the years. As ever there will continue to be channels to influence and here the UK’s undoubted expertise is valued and welcomed. Our current links with other EU trade bodies, such as Metal Packaging Europe (MPE) will, I suggest, become stronger and even more important during and post Brexit. I am, however, wholly confident that we will all seek to build on our decades’ long established relationships and continue to deliver mutually beneficial progress. The move towards circular economic activity will continue apace, unimpeded Aluminium International Today

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of metal packaging support the development of a circular economy, providing the right policy framework is set in place.” Together we will continue to encourage EU and national governments to introduce new thinking into future resource planning, including the drive to distinguish beyond just ‘renewable’ and ‘non-renewable’ resources to include ‘permanent materials’ such as metal. Co-ordinating activity under the auspices of MPE, MPMA will continue to support a process that will produce a more level playing field for different material targets alongside a harmonised recycling rate calculation.

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Food contact is an ongoing challenge Food contact is clearly central to packaging legislation and the food supply chain has consistently and collectively argued for clear, science-based, EU regulation in relation to materials in contact with food, and specifically against a growing concern of political intervention as evidenced by the banning of BPA in France. The draft EU Commission Directive on BPA will, I believe, restore cross-EU implementation of the recommendations of the European Standards Agency regarding specific migration limits. For our part, the MPMA will continue to make

representation at UK and EU levels with the aim of having this draft directive implemented as soon as possible. Another emerging and potentially inflammatory regulatory issue is the deposit return scheme (DRS) currently being explored in some detail in Scotland. The packaging industry’s response is that such schemes do not help the environment, don’t prevent litter, don’t change litterers’ behaviours and actually

Digital Edition - April 2017

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increase transport pollution. The MPMA will continue to support this stance. Championing innovation, creativity and technical expertise Regulatory affairs aside, the MPMA adds influence and support on behalf of its members to numerous campaigns and bodies that further the sector’s business interests through more marketing orientated channels. Take innovation, creativity and technical expertise: Through our sponsorship of the metals’ category of the UK Packaging Awards, and by driving support for the Awards through our membership, we keep the latest and best in metal packing in front of key packaging industry stakeholders – not just those who attend at the awards ceremony itself, but also the retailers, designers and media commentators, who contribute through judging and talk about it in the press and on social media. In 2016, our outright winner in the metals’ category was CROWN Bevcan for its distinctive range of full aperture cans for Aegir Bryggeri craft beer. The aluminium cans feature Crown’s 360 End, the world first full aperture for two-piece beverage cans which releases the full beer aroma, a particularly important feature of enjoying craft beers, and enables the can to be used as a fully open-ended drinking vessel. These cans also won the MPMA’s coveted ‘Best in Metal’ Award 2016. Aegir Bryggeri claimed that it moved from bottles to cans in recognition of metal’s superb functionality, its suitability for craft beers, the design potential offered by metal, and the material’s superb sustainability credentials including its recyclability and ‘permanently available material’ status. Aluminium beverage cans were also to the fore in the UK through the Indie Beer Can Festival sponsored by the Can Makers and the Society of Independent Brewers (SIBA). Uprising Treason by Windsor & Eton won ‘Best in Show’ at the event which saw UK and Eire’s leading indie brewers gather together to champion the hottest trend in the independent beer market: cans. The market has grown from four brands in can two years ago to over 100 and based on the success of the event, this growth looks set to continue.

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towards a circular economy have become central to sustainable development and MPMA works closely with and supports other bodies in meeting these challenges. Metal’s superb recycling messages are reinforced with ground-breaking programmes such as MetalMatters, which encourages local authorities to support the kerbside collection of cans; while Every Can Counts encourages the collection of cans for recycling in the workplace and at public events such as festivals. Both campaigns are expertly managed by The Aluminium Packaging Recycling Organisation (Alupro) and have been highly commended in parliamentary and policy circles. The MPMA has also sought to help increase understanding and appreciation of metals many attributes by producing a series of animated videos for presentation across social media channels. First up was a depiction of metal’s permanently available status - Metal - the most recycled material. With food waste rapidly climbing up national and international agendas we are beginning to see a subtle but substantial change in the political awareness of the role of packaging in helping prevent such waste. Metal has a unique and outstanding position in responding to both of these targets with long ambient shelf life and a material that can be recycled forever - Shelf life of cans. Continuing the education theme, MPMA has this year sponsored the Student Starpack Awards, recognising, encouraging and rewarding clever use of metal designs for specialty packs. The sponsorship targets higher

education design and final years school students. MPMA also supports Canned Food UK, a consumer-facing website which promotes the benefits of canned food to consumers through recipes and recipe videos using canned food; plus useful information about health and nutrition. Current activity includes work with UK Master Chef finalists duo, Billy and Jack, who are developing ‘fine dining’ recipes using canned food. This activity is intended to highlight the versatility and convenience of canned food to a younger audience perhaps less familiar with the benefits of food in cans. As producers of packaging we face regulation, standards and politics at both manufacturing and product levels. It is a key responsibility to manage these external impacts collectively, and this requires commitment and engagement by the operating companies. In the UK we are grateful for continuing strong support from member companies who recognise that with ever evolving business structures and a dramatically changing political arena, the role of trade associations is more relevant than ever in ensuring that its industry voice is heard in the right place, at the right time, and with the right message. �

Lending support to sector campaigns In a world focused on resources for future generations, making waste a resource and building Digital Edition - April 2017

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Association update: CiAl CiAl is a non-profit Consortium representing the commitment of Italian manufacturers and users of aluminium packaging to research into new ways of reducing and reusing packaging, which reconcile the demands of the market with the need to protect the environment. The Consortium, the aims of which include guaranteeing collection and recycle of post-consumer aluminium wastes collected by municipalities in Italy, was established in 1997 and has increased the amount of aluminium packaging collected in recent years to meet and even exceed the requirements of European legislation. The results achieved so far in terms of separate collection, recycling and recovery of aluminium wastes have been very

positive, making Italy an example for the rest of Europe. But important new goals are already on the horizon, and in order to achieve them CiAl aims to achieve a larger and more conscientious citizens’ involvement, particularly younger citizens, to reinforce today’s awareness of the importance of separate collection and recycling. Today and in the future, communication will play an essential role in producing

positive changes in citizens’ behaviour. For this purpose CiAl has promoted in recent years a number of projects and campaigns providing in-depth information on aluminium and its countless uses. Trends confirm that Italy leads the way in Europe, with over 895,000 tonnes of recycled scrap (taking into account not just packaging). Visit: www.cial.it/english-posts/

2015 Facts & Figures for CiAL � 203 member companies � Quantity of aluminium packaging placed on the Italian market: 66,500 tonnes. � 6,607 Italian municipalities undertaking the recovery of aluminium packaging, with the involvement of over 52 million people. � 455 members, 224 platforms and 11 smelting works that guarantee the collection, treatment, recycling and recovery of aluminium across the entire country.

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2015 Results for CiAl � Total recovery of aluminium packaging in Italy (share of recycling + share of packaging sent for energy recovery): 50,200 tonnes, equal to 75.5% of the total quantity placed on the market. � Recycling: 46,500 tonnes of aluminium packaging, equal to 69.9% of the market. � Energy Recovery: 3,700 tonnes (share of thin packaging that goes to a waste-to-energy plant) � The recycling of 46,500 tonnes of aluminium packaging has resulted in: � the avoided production of greenhouse gases equal to 345,000 tonnes of CO2. � an energy saving equal to over 148,000 tonnes of petroleum. The entire quantity of aluminium produced in Italy comes from recycling. Aluminium International Today

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Investing in growth Further expansion plans of Assan Alüminyum in the aluminium and aluminium packaging industries

Assan Alüminyum, a subsidiary of Kibar Holding, is planning to grow over the short and medium term through new investments. Important investment projects, as a part of the planned expansion of Assan Alüminyum, include the casting and foil rolling capacity increases. The company plans to start production on its two new casting lines and a universal foil mill, by the end of this year. Göksal Güngör, the General Manager of Assan Alüminyum, notes: “With its excellent barrier properties, formability and lightness, aluminium is a very resourceefficient material for packaging. Therefore, we firmly believe that aluminium will hold a special place among packaging materials in the future of the industry. Ultimately we are very determined to grow further in this sector. Our technological know-how and pioneering position in the aluminium foil market, will allow us to focus more on high-value-added flexible packaging products. With our new investments in our existing facilities, we are targeting to reach an installed annual aluminium foil production capacity of more than 110 thousand tons within a few years. As our core brand values are flexibility, innovativeness and reliability, we feel that our business approach is a perfect fit to provide customised solutions for our business partners in the packaging industry.” Assan Alüminyum, founded in 1988, currently has an annual installed production capacity of 280,000 t/a of flat-rolled aluminium and 60,000 t/a of aluminium coil pre-painting. It produces out of two facilities: Istanbul Tuzla and Kocaeli Dilovası. In 2016 Assan Alüminyum acquired a hydroelectric power plant to ensure that all necessary electricity is supplied from renewables. The company has become one of the worldwide pioneers of continuous casting technology, both in terms of production capacity and technical knowhow, with a strong focus on sustainability. With this perspective, the company has acquired an aluminium recycling facility a few years ago and continues to implement several energy-saving measures with new projects every year, in order to reduce the Digital Edition - April 2017

overall carbon footprint. The company’s focus on R&D is also a significant contributing factor to the consistently high customer satisfaction and continuing growth trend. The highly qualified R&D Team, working as a part of the officially certified R&D Center of Assan Alüminyum, is dedicated to making continuous progress through process innovations, which sheds light on the industry through many papers and proceedings published and presented at specialised global conferences throughout the years. With a customer-oriented approach, the R&D projects are aiming to develop tailor-made products geared towards the specific requirements of each customer, ultimately contributing to the performance of the final product within the whole value chain. Another important project, which has started to bear fruit as of the year 2017, is the new ERP Integration Project. Assan Alüminyum aims to maximise customer satisfaction and corporate performance with its new fully integrated ERP system, which would provide the company with an important advantage in terms of Industry 4.0. In order to further increase process

efficiency, stakeholder satisfaction and to add value, other large-scale projects are being carried out in the year 2017, such as the Supply Chain Optimisation Project. Assan Alüminyum has further, largerscale investment plans as well. The most important one is the establishment of the first modern and high-width aluminium hot rolling facility in Turkey. This facility would aim to produce semi-finished goods for a wide range of industries, such as flexible packaging, aerospace, defense, aviation and transportation. The company is targeting to gain significantly improve its competitiveness by producing more high-value-added products and to play a key role in the advancement of the targeted strategic industries. � Aluminium International Today

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Aluminium closures: An open and shut case! Improved technology and decorating capabilities have increased the potential for aluminium closures to develop in both traditional and new markets. The representative body for the sector, the European Aluminium Foil Association (EAFA), explains how and why the aluminium closure has become such a success and is challenging the old order in the wine sector. By CĂŠdric Rauhaus*

ALUMINIUM BEVERAGE CL

*Manager, Communications www.alufoil.org Digital Edition - April 2017

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The aluminium closure is now a familiar sight on wine bottles and has been used as the closure of choice for spirits, olive oils and a lot of bottled waters for many years. But this familiar packaging component has undergone a revolution in both looks and capabilities in recent years, to meet new market demands and to challenge other traditional closure methods. This has enabled it to expand its market share very rapidly, in the wine sector particularly. Thanks to improved embossing, etching and printing methods, and the introduction of security, tamper evidence and easy pour features, the aluminium closure can now offer a range of options to Brand Owners and consumers which greatly enhance its value proposition to both. Just as important is the re-enforcement of its advantages as a convenient, secure and sustainable option to the cork. Several studies have given clear evidence that the aluminium closure out-performs its traditional rival in many ways and contributes to the better preservation of wine, reduces waste and can be easily recycled.

LOSURES

Expansion Growth in the aluminium closure market has been strong for some years, driven largely by a rapid expansion in the number of wineries adopting the format, particularly those from the ‘new world’ (Australia, New Zealand, South Africa, USA and South America). This has coincided with a big increase in consumption for these products. Predictions from Euromonitor International for 2016 put global metal screw closure consumption for beverages at almost 69 billion units, 75% of this in the retail sector. This number includes the spirits sector, where the developing markets in Asia have led to increased volumes in this area. Well established markets, such as food, account for nearly four billion units, while other sectors, such as personal care and hygiene, beauty, home care and tobacco are forecast to reach almost 450 million units in 2016. Technology Several advances in technology have enabled aluminium closures to meet new requirements for better security, such as tamper evidence and non-refillable features. In the wine and spirits sector, particularly, counterfeiting has become a very serious issue, not only in terms of loss of revenue, but potential damage to the Brand caused by a toxic fluid being put into an original bottle. Aluminium closures are one of the most efficient and cost effective weapons in the fight against forgeries, as some components, such as a tamper evident

Aluminium International Today

band (either discreet or overt) can be incorporated into existing designs and, importantly, existing ROPP lines. So there is no loss of production speeds or efficiencies. Several companies produce tamper evident closures with varying styles and functions, all of which give a clear indication if the product has been opened. But this is only one aspect of the problem, as refilling original bottles is the number one route taken by many counterfeiters. So the closure manufacturers, working in tandem with plastics component suppliers have devised inserts which mean refilling is impossible and the closure cannot be removed without damaging the bottle. Often the problem is not one of stopping crime but improving performance. Here again the aluminium closure sector has come up with new combinations of materials and components to eliminate, for example, external dripping down the surface of olive oil bottles, or erratic pouring rates. A further area of technical advance has been the creation of aluminium closures which offer varying oxygen transmission rates for aged wines. This is leading them to compete with corks in their traditional stronghold of Europe, where cork has been king for centuries. The advantage for these winemakers is that adoption of aluminium closures immediately eliminates the problem of cork taint, which is a major and very costly issue in this sector of the market. Design & decoration One of the drawbacks for smaller wineries using closures was the difficulty of decorating them with an effective Brand image cost effectively. Until recently minimum runs for printing could be as high as 50-100,000 pieces, making it an expensive option. The alternative was to use a blank closure with a ‘house’ colour. Today all this has changed. Thanks to new digital printing techniques, bespoke designs and print runs of only 1000 can be offered. This gives smaller wineries the chance to do special anniversary editions of a particular vintage, add a season flourish at Christmas, or even for a special event. So the closure can be part of the marketing, not simply a part of the packaging. Further up this chain new embossing, knurling and coating technologies (as well as the printing) have enabled major drinks Brands to create very high impact closures which really add to the premium quality message they wish to convey. Several recent re-designs for established drinks Brands have used the aluminium closure to full effect as part of a complete makeover of the packaging. Digital Edition - April 2017

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Convenience Perhaps the place where aluminium closures have made the biggest impression is with the wine consumer. The reassuring ‘click’ of a closure being opened is accepted just as readily, if not more so, than the ‘pop’ of a cork. But what the consumer really likes is that there is no fiddling about with knives and openers, just a twist and the happy drinking experience can begin. And if he or she only wants a glass or two and the rest later? No problem. Simply screw on the top and the contents are sealed and safe until the next occasion. This has serious implications, not only in terms of ease of opening and convenience, but the avoidance of waste. The wine can be kept in a bottle with an aluminium closure for some time. When a cork is released the contents are in far greater danger of spoiling. Firstly, it is often difficult to reinsert and second, runs the risk of tainting the contents or exposing it to the air which spoils wine very quickly. Recent developments also include screwcap devices for sparkling wines, keeping the gas in, so the bubbles stay in the drink and the fizz does not go flat. For the catering and food service sector, which often sells drinks by the glass, aluminium closures offer a highly effective tool to speed up service, minimise waste and maximise profit. While, for outdoor events, or even family picnics, carrying a bottle with an aluminium closure provides a much more convenient pack for transportation and, if necessary, the return journey – screw back the cap and off you go! Sustainable Last year in Europe more than 50% of all aluminium closures were recovered and put back into the recycling stream. As aluminium is infinitely recyclable this makes it a highly desirable material to use on high volume products. The eddy current technique of recovery enables the metal to be separated from the glass fraction easily. In addition aluminium’s lightweight makes it energy efficient to transport from the manufacturer to the bottling plant. With the EU taking a more holistic view of environmental impacts, which encompass the entire lifecycle of both the product and the pack, the aluminium closure has made a very strong case for being a highly effective element of sustainable packaging. And, like all good packaging (and the first screwcaps appeared more than 50 years ago) it has stood the test of time, but is adapting and successfully transforming itself to meet the challenges of the 21st Century. � Digital Edition - April 2017

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Aluminium packaging…What else? Nespresso’s push towards a circular economy Necessity is the mother of invention, and for the Swiss engineer who developed the Nespresso model, the challenge was this: How to recreate a perfect coffee at home that would satisfy the refined tastes of his Italian wife? His solution was to package premium coffee in individual aluminium pods which could then be extracted in a high-pressure machine, creating a consistently perfect coffee every time. Aluminium, he discovered, was the perfect material to protect the flavours and aromas of freshly roast and ground coffee. Today Nespresso has grown into a global brand and has revolutionised the way we drink coffee, with some 250 copycat-capsule rivals following in its wake. Much has changed in the 30 years since its launch, except for the iconic capsule: Nespresso maintains that aluminium remains the best material to preserve its coffee. The company has bet on aluminium big-time: 25 years ago it founded its first recycling scheme in Switzerland. Today it has dedicated schemes in 35 countries, and has worked with governments in Germany, Sweden and Finland to have capsules included in the national collective recycling schemes. Nespresso estimates that 86% of its customers have an ‘easy’ recycling option on their doorstep; this means being able to return used capsules to one of its stores, taking them to a drop-off point near their home or office, or have them collected from their doorstep when they take delivery of a new order. Their ambition is to increase this to 100% by 2020 – a challenge when considering that many of the countries on Nespresso’s recent expansion list do not even have a recycling infrastructure. Progress has a price – Nespresso’s recycling bill costs the company some €25 million each year. It is also a founding member of the Aluminium Stewardship Initiative (ASI). The ASI brought together industry users with supply chain partners and civilsociety representatives to create the first ever set of standards for the sustainablysourced aluminium. The standards cover all aspects of aluminium sourcing, at every step of the supply chain – from low-carbon production to the protection of biodiversity and indigenous peoples’ rights. Although it is a relatively small customer of aluminium, Nespresso is using its brand visibility to drive change across the industry. Despite its efforts on recycling and sustainable sourcing, Nespresso has been the target of much criticism over its Digital Edition - April 2017

environmental credentials. Whether due to its status as the pioneer of portioned coffee or the company’s high-profile ambassador George Clooney, as the brand grows in visibility, so too do the attacks over its choice of aluminium. Ironic, given the company’s commitment to sustainability. Its inhouse certification scheme, the Nespresso AAA Sustainable Quality Programme, takes the Rainforest Alliance standards as its starting point and adds several more layers. Last year it secured a grant from the World Bank’s BioCarbon Fund to scale-up its farmer training programme in Ethiopia. And in 2015, Nespresso’s SULUJA-ti South Sudan became the country’s first non-oil export, a remarkable indication of progress in the company’s attempt to revive South Sudan’s forgotten coffee industry and bring some financial stability to farmers in the war-torn region. Responsible management of aluminium is part of this commitment, but despite its efforts, the criticism seems to stick. “We do a lot to make it easy for our customers to recycle,” says Christophe Boussemart, Sustainability Manager at Nespresso (pictured right). “We committed a long time ago to making it as simple and convenient as possible for them to recycle their Nespresso capsules, and there are many examples of how we do this – for example, our recycle@home service, where we collect used capsules for recycling from a customer’s doorstep when we make a delivery. But we knew we had to do more: Until customers could put their capsules into their collective recycling system, there would always be a barrier.”

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Boussemart had been told that capsules could not be recycled in the collective system but he could not understand why. He drove to a sorting centre on the outskirts of Paris to investigate for himself. “I learned that day that the first stage in the recycling process is to sort the material by size. Everything goes in to – what looked like to me – the drum of a giant washing machine. Objects smaller than a yoghurt pot were sifted out and rejected at the first stage in the process – and our capsules were among them. But I could also

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Aluminium International Today

see many other metal items and I thought, this can’t be right. We can’t be sending all of that metal to landfill.” His proposed solution was simple: To use the same eddy current technology used to sort large aluminium items, such as soda cans, on this stream of smaller material. A feasibility experiment delivered interesting results: “We saw that not only were Nespresso capsules recovered, but many other lighter aluminium items – pouches of baby food, small foil cheese wrappers, Ikea tea-light candle holders, foil medicine blister packs. Altogether, it represented a lot of aluminium.” What’s more, the process of sorting the aluminium meant that steel was also separated from the stream. The pilot was a success: Nespresso had stumbled on a solution that had the potential to significantly increase recycling of all metal items. Rolling out this solution across France has required sorting centre operators to make a significant upgrade in their infrastructure, adding an over-band and Eddy current separator on the stream of rejected material. To help convincing authorities to make this investment, Nespresso brought together various stakeholders to form CELAA – the Club de l’Emballage Léger en Aluminium et en Acier (Light Steel and Aluminium Packaging Club). They had a simple goal: Sort more to recycle better. The project has been successful: The 18 centres that have so far made this upgrade recover on average 57% more aluminium than before. Nespresso is now looking to replicate this solution around the world. The company is already talking to MRFs and recycling operators in several countries to see how the collective recycling system could be adapted to include its capsules. The European Union’s Circular Economy Package represents an opportunity to formally increase aluminium recycling targets, and in doing so, build momentum towards better and more efficient recycling – creating a good opportunity for Nespresso and its partners to upscale the success of CELAA. “We are at a point now where the targets for recycling aluminium are increasing, and many member states are unsure yet how they will meet them. I think we have found a good solution, and we’re eager to share it. Also, having

higher targets adds to the incentive of recycling operators to make an investment in upgraded technology and processes.” Despite the high-visibility of its colourful pods, Nespresso is a relatively small user of aluminium (each of its capsules weighs just 1g, compared to 13g of alu in a soda can). The support of other stakeholders, Boussemart claims, has been essential and will be much-needed in future if the CELAA model is to truly gain momentum in the EU and beyond. Critics of Nespresso’s use of aluminium often highlight bioplastics as an alternative. Indeed, several companies are already producing generic Nespresso capsules in biodegradable or compostable materials. Bioplastic is controversial, with confusion rife among consumers about how to dispose of such materials in a responsible way. ‘Biodegradable’ does not necessarily mean that such materials will decompose on a garden compostheap: often, such materials will only degrade in an industrial composter, where the temperature and humidity levels are carefully defined. Processes and capabilities for managing bioplastics’ end-of-life vary greatly around the world; many waste operators lack the facilities to treat them and those that do are often reluctant to accept packaging materials into organic waste collections because of contamination fears. Compostable materials are equally disputed - estimates suggest that as few as 3% of people compost waste at home. Questions remain over consumers’ confidence in this area, with many assuming that ‘biodegradable’ or ‘compostable’ materials will degrade naturally if buried in the ground. This is perhaps one of the reasons why so much organic waste ends up in landfill – the Environmental Protection Agency estimates that Americans throw away some 30 million tons of food waste each year. However, organic waste in landfill becomes starved of oxygen, resulting in it breaking down in a process called anaerobic digestion. The by-product of this process is methane, a greenhouse gas 25 times more environmentally damaging than CO2. Christophe Boussemart continues: “Of course we have looked at other materials, but there is really nothing as good as aluminium for protecting coffee. Coffee is a very delicate, and contact with oxygen completely destroys the flavour and aroma. Aluminium is also infinitely recyclable” “We know that aluminium is the best option for our coffee, we also know that aluminium is the most sustainable choice. That’s why we will continue to invest in recycling and responsible sourcing.” � Digital Edition - April 2017

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The worldâ&#x20AC;&#x2122;s lightest aluminium s

Can making is a high-speed and highly efficient production process, and during the past years, metal packaging has become lighter and thinner due to cost saving and environmental convictions. In fact, nowadays, metal packaging is up to 40% lighter than 30 years ago. It offers numerous advantages throughout the supply chain. Due to their inherent strength, filled cans can be stacked to make maximum use of storage. They are filled at high speeds with virtually no product loss, increasing overall efficiency, including energy and CO2. Because they are unbreakable, cans reduce the risk of leaking or tearing during transportation. Aluminum packaging is a perfect fit in a circular economy. Made from monomaterial it can easily be separated from Digital Edition - April 2017

the municipal waste streams, enabling high recovery rates. Aluminium packaging is easily and efficiently separated through Eddy Current Technologies. Once sorted, it is re-melted into new virgin material. Due to its unique characteristics, metal can be recycled again and again and will always be available for our future generations. Once melted down, metal can be used for any new product. Thanks to its endless recyclability, 75% of all aluminium ever produced is still in use today. Aluminium is truly versatile, supporting the branding of the product by presenting it in any desirable shape, offering a premium branding surface and opening convenience: whether it be fruit or vegetables, meat, beverages, whipped

cream, baby food or seafood. Canned food has an equivalent or sometimes even higher vitamin content then freshly prepared food. The canning process locks in nutrients at their peak of freshness, and due to the lack of oxygen during the storing period, canned fruits and vegetables remain stable up until the time they are consumed. The material provides the perfect barrier against oxygen, without the need for chilling or freezing during transport or storage. Particularly in the case of seafood, which mostly canned close to the location where it is caught, it allows for safe transportation over long distances, even in the most severe climates and harshest of conditions. With a new generation of consumers discovering quality canned fish, it is becoming a hip Aluminium International Today

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seafood can

and fashionable gourmet food. Many trendy restaurants worldwide have canned seafood on the menu with some designs becoming true collector’s items. Pioneering development work at Ardagh Group’s aluminium can plant in Cuxhaven, north Germany recently resulted in the production of the world’s lightest aluminium seafood can. The patented oblong shaped seafood can, referred to in the industry as a “dingley”, has been designed with a wall thickness of only 0.17mm, a significant advance over its nearest competitor at 0.215mm. This impressive innovation was achieved by technicians at the Cuxhaven plant involving particular beads – the ridges, which come in many shapes and sizes, built into the can to give its body Aluminium International Today

strength and stability. The development involved detailed testing, which established the most suitable shape and size of the beads as well as ensuring the correct distance between the beads to achieve the same optimum stability as cans with standard thickness. The Cuxhaven Technical Service Team also developed a modified sealing technique for the new can. Working closely with Larsen Danish Seafood in Germany – the first customer to use the new lightweight can – they overcame the challenge of securing optimised seaming on a lightweight can with a much thinner body and Easy Open ring pull lid. Patrick Savouré, Commercial Director, Seafood at Ardagh Group’s metal division

commented: “Our innovative ultra-thin seafood can is a continuation of the pioneering work that we carry out to achieve higher standards of performance with reduced material input and weight. “As is a feature of many of our important developments, the cooperation with our customer, Larsen, was a crucial part of the process, and I am delighted that the new can has been well received by their customers.” Innovation and sustainability continue to play an important role in packaging. Consumers increasingly want to engage with and participate in the circular economy and will expect brands to play their part. � www.ardaghgroup.com Digital Edition - April 2017

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New Trend: Light aluminium drink bottles Aluminium drink bottles are predicted rapid growth: Leading bottlers are increasingly using “DWI Bottle Cans” as premium packaging, which allows for improved freedom of design. As Drawing and Wall Ironing (DWI) is used in production of bottle cans, they require significantly less raw materials than traditional extruded bottles. Experts are going so far as to say that, in the future, more of these aluminium bottles will be produced every year than aerosol cans. The trend has spread from Japan to the USA and also to China. It is in this context that Schuler has partnered up with Japanese specialists in DWI Bottle Cans, TMC. TMC is a market leader in machinery for the production of aluminium bottles and has developed a machine to form bottle necks (“Bottle Necker”) with ambitious tool technology. They are defining the individual design of metal packaging with this. The TMC-neckers are available with 40 to 56 forming stations. Independently of this, the maximum diameter of the bottles is 59mm or 66mm, with a maximum bottle length of up to 245mm. The rate of production is up to 150 bottles per minute. TMC Bottle Neckers are in use all over the world. The company has further locations such as in Hong Kong and in the USA.

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Due to the increasing demand for “DWI Bottle Cans” Schuler is partnering up with systems provider TMC Experts are going so far as to say that in the future, more of these aluminium bottles will be produced every year than aerosol cans.

Pictures courtesy of Schuler TMC, Schuler’s new collaboration partner, is a leading provider of Bottle Neckers for light aluminium bottles among other things

Bottle Cans production lines generally consist of a cupping press, a “Bodymaker”, a “Light Tester”, and a Bottle Necker, as well as cleaning, decorating and inspection equipment. Schuler is offering high-performance Cuppers and highly flexible ServoCupFormers as well as Bodymakers with complete mass balancing (BodyFormer) from its own production. Schuler is taking over commercial representation for TMC Bottle Neckers in Europe, Latin America, the Middle East and Africa. Interested parties are thereby gaining a competent contact for the machinery and processes necessary for the production of drink bottles in these regions. “TMC is bringing its know-how of tools and processes to the collaboration and we are bringing our experience of building metal packaging presses, as well as our global customer service,” says Schuler director Johannes Linden, who manages the Systems division. “Thus we are creating the ideal environment for our customers to successfully profit from the success of bottle cans in South America, Europe, the Middle East and Africa.” Digital Edition - April 2017

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Earing Control in CBS from a single sta By Dr Gary Mahon, Director and Senior Metallurgist, Innoval Technology

Many companies are interested in establishing if single stand hot reversing mills are capable of producing Can Body Stock (CBS). This is for potential supply to either can-making plants in that country or, if the product can reach worldclass standards, for export. Significantly more expensive multi-stand tandem rolling mills currently produce almost all CBS. This is because these mills are capable of producing the required earing characteristics in the final product. What is earing? Earing is the non-uniform height of a can sidewall. It appears after any deep drawing operation, such as that used in beverage can manufacture. Fig 1 shows a very simple example of severe earing after a laboratory drawing test. This is something we can do in our material testing labs at Innoval. Earing from a multi-stand mill The good earing that comes from a multistand mill is due to the strip acquiring high levels of hot deformation as it passes through a hot tandem mill. However, there is insufficient time to allow any inter-pass recrystallisation. This results in suitably high levels of the desirable crystallographic cube texture when the material finally has time to recrystallise in the hot rolled coil. The cold rolling reduction to achieve the required strength levels in the final gauge

Digital Edition - April 2017

Fig 1. Example of severe earing in CBS after an earing test

sheet also results in a nicely balanced crystallographic texture. This generates low earing after drawing the can. Fig 2 gives an example of an earing profile test result from world-class CBS produced via a hot tandem mill. It shows the desirable 6 ears at 45° and 0°/180° to the rolling direction. Earing from a single stand hot reversing mill There have been trials through hot reversing mills that simply replicate the ~3mm hot band gauge used in a hot tandem mill. These confirm that AA3104 CBS is not able to meet the strength and earing requirements specified by the canmakers. Making CBS on a single stand hot reversing mill Innoval Technology has considered

three separate approaches to modifying the production schedule when using a single stand hot reversing mill to make CBS. These are outlined below. Each approach requires a detailed experimental investigation to assess the effect on all of the product requirements. � Change the alloy content of the aluminium outside that allowed within the AA3X04 (3004, 3104, 3204) alloys. This would mean that the property development during cold rolling is significantly modified. Clearly this approach would require the can-maker to agree to a compositional modification outside the accepted range of current CBS alloys. However, there can be commercial benefits of doing this especially for local markets. � Take advantage of the detailed knowledge of how crystallographic texture develops in aluminium alloys by carrying

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and hot reversing mill out an anneal in the production route. This would de-activate the un-desirable Particle Stimulated Nucleation (PSN) recrystallisation sites that compete with the desirable cube texture sites. � Carry out near-isothermal rolling in the last hot rolling passes on a coil-to-coil mill, as described in published patents. It is not easy to evaluate this on an industrial rolling mill. However, the Innoval Rolling Model can investigate the feasibility of controlling the rolling temperatures within the desired temperature range. This would be a precursor to more detailed hot deformation studies. The risks For each of these three options there are technical risks which we could easily explain. We can also offer an assessment of the likely commercial success, together with a detailed calculation of any additional Opex costs you might incur. In addition, it is likely that any rolling plant would need to make a Capex investment specific to each solution. Again, this is something we can estimate. In addition to these specific options for achieving the required balance of strength and earing in the final product, there are other Capex items that may be required at a plant that is not currently making CBS. These might include the correct molten metal filtration, and an electrostatic coating with post-lube on the final gauge product. For an existing rolling plant, we’d usually make a site visit to evaluate other requirements. This is because it is important to assess the capability of existing hot and cold rolling equipment to control profile and gauge, since these affect other key attributes of the product. I have worked on the metallurgy of beverage can materials for over 20 years. So, if anything in this blog has sparked your interest, please get in touch. You may also be interested in our Beverage Cans training course. � Fig 3. A selection of beverage cans (from www.canmakers.co.uk/photobank)

16.30 Revised cup height (mm)

16.10 15.90 15.70 15.50

Fig 2. Example of an earing test result from world-class CBS

15.30

180 90 Cut rotation (degress)

270

360

Consultancy and technical support to the aluminium industry • Build long-term partnerships with our aluminium experts • Solve your current aluminium production problems • Prepare a downstream business case • Detailed investigation and testing • Product and process training courses • Aluminium industry expertise

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Aluminium foil takes flexible packa In Europe, aluminium foil is a core packaging material and has been so for over a century. While many of the formats using it continue to function very much as they have always done – barrier wraps for chocolates are a good example – changing preferences mean foil is also at the cutting edge of innovation. Flexible packaging demand is driving many of these advances, as requirements for more convenient and lighter packs are made possible through technological and materials developments. In addition, the excellent sustainable performance of flexible packaging, both with and without foil content, is leading the industry, converters, consumers and legislators to re-assess the whole issue of what is meant by environmentally friendly packaging. Today it is the Circular Economy which holds sway in Europe – looking at the whole lifecycle of the product and the pack – and here the new formats using flexible materials score heavily. Facts and figures Several studies of both the global and European flexible packaging markets all indicate a very strong growth pattern until the mid 2020s. According to Global Market Insights the world market, which, in 2015, stood at $150 billion, will increase at more than 5% CAGR from 2016 to 2024 to reach $250 billion, with Europe holding about a 27% share, or $65 billion. Other studies offer a similar prediction. Of course flexible films containing aluminium foil make up only a part of this picture. But certainly in healthcare and segments such as confectionery, tobacco, coffee and dairy, there is a high use of foil, either as a mono-material or as part of a laminate. Additionally, food and beverages account for 70% of the flexible packaging market and, as many contain foil as part of the laminate, this accounts for the greatest volume of use. What is driving this growth? Improved barrier properties, technological advancement in thin elastic material, along with reduced wastage are key trending factors. Superior sealing, heat insulation

and barrier against moisture and light makes these packs more attractive for end user industries. Flexible packaging shares a major portion of the shift in consumer preference towards convenient packaging and easy to store and transport properties. And cost is a factor too. In terms of the market for packaging incorporating flexible foil, Western Europe is the largest regional market for flexible aluminium foil packaging film, followed by Asia Pacific and North America, according to a recent study by SmithersPira. Progress in pharmaceuticals The blister pack has been in use for more than 50 years and aluminium is the main component of this format, either as a top and bottom web or as a ‘lidding’ membrane attached to a thermoformed plastic. With the advent of more complex pharmaceutical formulations, so too the materials have had to become more elaborate to meet the challenges of more volatile ingredients and more hostile environments during transportation and storage. A good example is bio-meds, which are often highly moisture sensitive and can require a mixing solution when no sterile water is available. The aluminium foil sector has developed some highly effective solutions for retaining an almost zero ingress moisture barrier with the introduction of a desiccant layer into a top web of a fully foil blister. It enables the shelf life of the contents to extend up to four years, even in humid conditions. Another solution offers a blister with integrated liquid and dry chambers, enabling the medical staff to mix at the point of use and dispense direct from the pack, thus avoiding possible contamination. The contents can be kept in stable conditions, even in tropical or very hot and dry atmospheres, enabling it to be used in remote or difficult access areas. Of course more traditional blisters also utilise combination of paper, plastics and foil to achieve required results, such as puncture resistance as well as

*Manager, Communications, European Aluminium Foil Association e.V. (EAFA) www.alufoil.org Digital Edition - April 2017

Today’s flexible packaging soluti required performance. Aluminiu By Cédric Rauhaus*

aging in Europe further

ions utilise a combination of materials to achieve um foil is a vital component in many of these innovations.

31 PACKAGING

improved sealability and peelability. The foil has also been used creatively to come up with new shapes for traditional OTC products to both re-invigorate the brand image or to offer more convenient formats than the traditional strip or ‘tray’ styles used commonly. Yes, even nonprescription pharmaceuticals need to look at the marketing aspects of packaging sometimes! Pouch explosion The explosion in the pouch market can probably be traced to the advent of retortable formats (thanks mostly to the foil element), which opened up the juice and prepared food markets (soups being a good example) and the introduction of reseal and reclose features which make them highly convenient for on-the-go pack styles. Not only do these packs offer a modern solution for food and beverage suppliers, they still retain the characteristics which made aluminium foil a material of choice originally. Chiefly, the barrier properties, offering both protection and potential for extending shelf life, are still as important as they always have been. But lamination with plastics often enhances that performance while, at the same time, offering improved puncture resistance, ease of opening and better printability. Leverage for lids Flexible packaging comes in many forms and one of the major uses of it are in the dairy and dessert sectors for lidding foils and laminates. Like every other material format these have undergone major changes to meet demands for lighter weights, better peeling/sealing characteristics and improved decoration possibilities. While the barrier performance, particularly for dairy, remains paramount. These days all the major converters in this sector have made great strides to reduce the thickness of lids without any loss, and sometimes a marked improvement, in performance. Working with the adhesives and sealing equipment companies has also resulted in better peelability as well as improved sealing onto every container material. New printing and embossing technologies have also greatly enhanced what can be done on lids to create better branding and more impact. These advances not only help in the supply chain and retail environment, but also contribute to better convenience as much of these formats are used for snacking or in ‘on-the-go’ situations by consumers. Convenience rules Portion packs are ideally suited for flexible materials, so wraps, sachets, stickpacks Digital Edition - April 2017

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as well as different pouch sizes have proliferated in the last two decades. Once again the aluminium foil content can offer advantages for both wet and dry products, particularly the latter. Recent studies are showing food waste can be reduced significantly using single portion formats – contrary to some opinions the other way. Other technical advances, such as elastic coatings, have made foil flexible wrapping more user friendly. These coatings can help to avoid the packaging coming off in small pieces – a common problem with some chocolate confectionery. Shelf appeal The on-shelf impact of flexible packs can be very high, thanks to the excellent printability of modern materials and improving print technologies. Thanks to the use of combinations of materials, using aluminium foil with a plastics film, the natural finish – shine or matt – can add significantly to the look of a pack. When combined with high quality printing across the entire pack, so not restricted to a label, this offers brand owners and retailers the maximum opportunity to make their product stand out. Recently some interesting formats have come on the market, for example drinks pouches in fun shapes and striking colours; packs that reflect the contents, like animal shapes, or packs that mirror the origin of what is inside. Or the material is used creatively to mould around the product, such as chocolate figures, to enhance and emphasise the contents. High sustainable score The environmental implications of flexible packs, in both food and other markets, are significant. They are smaller and thinner than glass, paper and metal packaging and on average will use 60% less plastic and be 23% lighter, compared to traditional rigid packaging. Both the stand-up and flat variety of a pouch generally has a higher product-topackage ratio than rigid packaging and require about half of the energy required to produce the alternative rigid packs. This cuts down on the CO2 emissions generated during production and transportation. Less space means fewer trucks are needed, reducing fuel consumption, both before and after filling, and enabling further savings of CO2 emissions. Holistic Effective disposal has become a critical factor for any form of packaging. High recycling rates are seen as good, while low rates are a big negative, which has been an issue for flexible packaging. Even allowing for the fact aluminium foil is

100% recyclable, separating it from other materials can be costly and difficult. But now, thanks to a more holistic view of environmental impacts, initiated by the European Union’s policy of establishing a Circular Economy, flexible packaging hopes to become recognised as a truly sustainable product. The European Aluminium Foil Association (EAFA), which represents European foil rollers and rewinders, works closely with its sister association Flexible Packaging Europe (FPE), and has initiated Lifecycle Analyses (LCAs) which prove the flexible pack has less environmental impact than its rigid equivalent. In one, rigid packs weighing 50g were replaced by a 5g flexible equivalent for the same volume of product. After use, 80% of the rigid packs were recycled, compared with 0% for the flexible packs. But, in the waste stream, this meant the rigid pack generated 10g of waste compared with only 5g for the flexible pack. This does not mean, however, that the flexible sector is complacent about the recycling issue. It is actively engaged in developing better ways to recover and recycle higher volumes of flexible materials. EAFA and FPE are taking a lead role and some companies within the sector have also taken the initiative, through the instigation of sponsored recycled programs for their packaged products, to solve this packaging problem. One difficulty, for example, is that pouches can feature handles, zippers, easy-tear and resealable openings, spouts, straws, spoons and caps to name just a few closures and fitments that make consumer food products easier to transport and use with high functionality, but make them more difficult to recycle due to their component parts. At the very least flexible packs reduce landfill waste because they are lighter, less bulky and take up less volume than conventional packaging. And burning to generate energy is also an effective option. Flexible future Flexible packs, many with aluminium foil as an integral and vital component, offer innovative, sustainable solutions for packaging consumer products. Their future success lies in inventing the most efficient, environmentally sound ways to accommodate Europe and the world’s changing lifestyles. Convenient, efficient and smaller in carbon foot print than most rigid packaging, flexible packaging, of all material compositions and shapes, addresses consumer trends while moving in the right direction for waste reduction. They continue to offer enhanced functionality and convenience in exciting new ways. � Aluminium International Today

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Flatness control technology

World class quality, food-grade aluminium foil 1/6th the thickness of a human hair at PG Foils Ltd with ABB’s a

ABB recently commissioned India’s first flatness control system for manufacturing aluminium foils at PG Foils Ltd that ensures consistent thickness and flatness. These parameters are extremely crucial for high quality aluminium foils required for food-grade packaging to preserve product quality and freshness while adhering to high standards of hygiene. PG Foils chose ABB’s flatness control technology for its manufacturing unit

Digital Edition - April 2017

in Pipalia Kalan, Rajasthan, where the company manufactures plain and printed aluminium foils, foil laminates and flexible packaging material for various products. A foil rolling mill reduces the thickness of cold-rolled aluminium coils from 300 microns, the average diameter of a strand of human hair, to 6 microns. ABB’s Automatic Flatness Control (AFC) technology engineers consistent flatness at 1/6th the thickness of a human hair,

suitable to be used in packaging. The high-accuracy technology allows for better flatness control with consistent flatness quality, lower material wastage, better yield, lesser breaks and lower downtime. The scope of supply included an upgraded automation system with ABB’s powerful control platform AC 800 PEC with XF 801 fast I/O based system, critical to ensure precise thickness control while addressing challenges associated with

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automatic flatness control

extremely thin gauges and high speed rolling that can lead to poor quality foil. A DCS 800 drive system for the mill, coiler and uncoiler ensures excellent control performance for high dynamic applications. It also includes a flatness control system on third-party Vidimon flatness measurement roll. ABB designed and engineered a highly responsive automation system capable of excellent control performance for dynamic

Aluminium International Today

applications, ensuring production of highgrade aluminium foils with extremely thin gauge at high rolling speeds. It reduces differences between the userdefined profile and system limitations by dynamically varying mill operational parameters. The system is based on two methods of control - mechanical (bending and tilting) and thermal (nozzle). A larger part of the error is addressed by mechanical control

while thermal control corrects the residual flatness error. Automatic gauge control keeps thickness deviations to a few microns ensuring higher quality of metals strips. Speed-tension optimisation, a technique used for thickness control in foil mills, helps achieve desired thickness reduction at higher mill speeds and optimisation of the throughput. ďż˝ www.new.abb.com/metals

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Importance of packaging recycling The aluminium industry’s national schools design competition – the Alu D&T Challenge: Inspiring the next generation of consumers, designers, engineers and recyclers How does the aluminium industry engage the next generation? To help them appreciate the benefits of our material and inspire them to want to work within the businesses that produce, convert and consume this most versatile of metals? How do we get young people to understand the material properties of aluminium, so they can make informed decisions about purchasing and recycling products? It’s not a problem that’s unique to our material; but in the UK the aluminium industry has joined forces and developed a programme that is reaching out to young adults and helping them to appreciate the wonders of aluminium: by challenging them to use it in the design sustainable products. In the last four years over 50,000 11-14 year olds from schools across the UK have been taught about aluminium via the Alu D&T Challenge; a free teaching resource for

Digital Edition - April 2017

secondary schools linked to the curriculum for Design and Technology (DT) and the national Science, Technology, Engineering and Maths (STEM) programme. The online resources include lesson plans, presentations and films which teachers can use to teach pupils about the material properties and sustainability potential of aluminium. The Challenge element is in the form of three design briefs, which students can attempt individually or as part of a team, to create a sustainable product for the future using aluminium. The Alu D&T Challenge has been developed by the Aluminium Packaging Recycling Organisation, and developed from a shared piece of research conducted with the Aluminium Federation to explore opportunities for linking aluminium to the school curriculum. Project manager, and Alupro Marketing Director, Diana Caldwell explains: “Our research found

that while there are plenty of activities from industry to support lessons on recycling and sustainability and specific scientific processes, there was nothing to draw all the topics together in one single resource. The subject that gives students the opportunity to work on a project and pull all of these topics together, Design & Technology, was suffering from a real lack of ‘real world’ resources to help students develop an understanding of how a product is designed and made, and why particular materials and processes are used to create these products.” The design challenges are based on reallife briefs faced by designers, engineers and manufacturers in three categories transport, building and packaging. They have been developed in partnership with industry sponsors including packaging container manufacturer i2r Packaging Solutions, Jaguar Land Rover and Novelis.

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Students must research their product and explain why it meets the 6R’s of sustainable design. Every academic year schools can enter their designs in a competition, with the finalists being judged by a panel of industry experts. The winning team and individual designers in each category receive a 3D printer for their school, plus a cash prize. Winners are also invited to a celebration event in Birmingham where they meet the judges and sponsors. Other opportunities that have arisen from the competition are factory tours, school visits and work experience placements. The winners of the 2016 competition were presented with their prizes in March. Every year the judges comment on the quality of the ideas and the standard of the entries. This year it was no different, with the pupils’ creative ideas, understanding of processes and design impressing the judges; who all have decades of experience in their chosen field. But the value of the Alu D&T Challenge

goes beyond celebrating the winning designs. There is a ripple effect that the industry needs to capitalise on: This is an initiative that is reaching thousands of young people and giving them an opportunity to develop ideas and work on projects, often for the first time. Among the 25,000 children who used the resources for the 2016 competition are future architects, engineers and designers. The many businesses that use aluminium rely on this future talent and must appreciate that nurturing it from an early age is a shared responsibility. The D&T Challenge is a positive way to engage with schools in their area, and is an extremely cost-effective way to build relationships with future employees and customers. �

The 6Rs of Sustainability FEWER RESOURCES, LONGER LIFE, LESS IMPACT. By thinking about the 6Rs at every stage of the product life cycle, designers can radically reduce a product’s impact on the environment.

A design & technology challenge using aluminium for students aged 11-14

REFUSE Don’t use materials that

RETHINK Is this really necessary?

harm the environment.

It should meet a definite need with real and lasting benefits. What real need can this product satisfy? What benefits do we need to deliver?

2015 / 2016

What materials are usually used in products like this? Do these materials harm the environment?

REDUCE Make your product as

simple as you can, using as little as possible. How can the design be simpler than existing products? How can it use fewer materials, while still being safe and fit for purpose? What features don’t people need?

RECYCLE Used recycled and recyclable materials.

Which parts or materials can be recycled at the end of the product’s life? How would these products be recovered?

REPAIR Make your product

REUSE Make it easy to take

apart, to reuse its parts. Which parts could be reused at the end of the product’s life? How will the product be taken apart? How might someone reuse each part?

easy to repair.

What parts of our design might break or wear out? How could these parts be repaired or replaced easily? Who might do this, and where?

Visit learningaluminium.co.uk/6rs to find out how companies are addressing the 6Rs of sustainability.

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