FPT 3:2020

Bhojraj Industries leads the way in gravure printing in Nigeria with large invest And how increased recycling will cut oil demand

From crushed smoke to boiler plate!

“We are at full capacity, and expect more than 30% growth over the next years�

Comexi on the no longer relevant pandemic of plastic, Covid19 & the1 flex pack industry

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The demand for high barrier packaging in recent years has been driven by consumer need for convenience and product safety. For example, high barrier films have been developed to extend the shelf life of microwave ready meals, as well as barrier packaging being used to further protect products when using alternative outer-shell packaging

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We’ve all had our ‘Blue Planet’ plastic moments. My latest was on a remote Hebridean island in a rare heatwave last month, swimming on a pristine, deserted beach with only a basking shark for company. Pristine, save for the plastic ropes, twine, broken creels, bottles, containers, floats, nets, six-pack rings and indeterminate shapes of polystyrene littering the shoreline.

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Family owned blown film extrusion line manufacturer Macchi is on a growth course. Currently they are planning the expansion of their production capacity, and hired new staff. We met with the new Sales and Marketing Manager Matteo Spinola to understand better the plans for the coming years.

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Just prior to the Covid-19 lockdown I was invited to visit the Martin Automatic headquarters in Rockford, IL and given a personal guided tour by Roger Cederholm, Company Director since 1992 and President and CEO since taking over from founder John Martin in 2002.

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It seems we are facing once-in-a-generation situation. How are these circumstances really affecting the flexible packaging market and consequently, how is this ultimately shaping the Fast-moving consumer goods sector?

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The online sale of products is one of the segments that has rapidly grown in the last five years. In the United States, this market earned US$304.9 billion in 2014, according to the U.S. Department of Commerce reports, and according to Packaging World, by 2017 sales reached US$453.5 billion.

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Lagos-based Bhojraj Industries Ltd supplies flexible packaging to the food industry, printed on a top of the range MASTER RS 6003 gravure press from BOBST. The Nigerian company is now adding a BOBST NOVA RS 5003 to the lineup, as it looks to extend capacity and continue its successful expansion in high-quality printed packaging.

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Innovative solutions integrate prepress and print into client facilities

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The virtualization of events The corona virus pandemic has changed a lot of things for us within a very short amount of time. Many companies have been forced to realise that having their employees work from home or wherever they fancy too is not only viable but actually has some advantages to it. Another noticeable trend is that all industry events are now virtual, if not postponed.

While I know from many of you that the event calendar was too full as it is, and many consider it actually a relief, I find the lack of actual networking possibilities is nothing I want to get used to.

Show organisers and associations have reported successful virtual events, and personally I have attended some myself. The technical possibilities are there, and its working fine. In my opinion this is a good way for the future in order to replace some smaller local events in order to free up time and resources. But I cant wrap my head around the idea to completely ditch face to face meetings.

For all of you feeling the same way, 2021 is the year. Interpack will take place in February/March, ICE Europe in March, and drupa in April. Few exhibitors have cancelled their participation, but I am optimistic that all mentioned shows will be a big success as that’s what has been missing in 2020.

I am eagerly looking forward to see you again next year in Dusseldorf and Munich!

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Considerations for optimal barrier packaging The demand for high barrier packaging in recent years has been driven by consumer need for convenience and product safety. For example, high barrier films have been developed to extend the shelf life of microwave ready meals, as well as barrier packaging being used to further protect products when using alternative outer-shell packaging. Find out more about four ways in which you can optimize your barrier packaging to ensure safety and customer satisfaction below.

Does it provide suffi- their value, form and cient protection? quality during transit, in retail environments and The main aim of packfor the expected shelf aging is to protect the life of the product contents inside. Barrier packaging needs to pre- Is it easy for convent foreign objects sumer to use/open? from entering the pack, Usability and functionalas well as ensure that ity are crucial to ensure nothing escapes, such repeat custom and user as air or moisture. An satisfaction. There is a optimal barrier will be fine balance between part of a 'just right' too tough to open and pack, where the contoo easy - both of which tents do not break, and provide poor outcomes. the barrier elements This is where laboratory ensure that the packanalysis can help definiaged goods will retain

tively measure the optimal strength required to open the barrier packaging for the specific circumstance.

Is it safe for food contact?

If your packaging is for food use, the barrier materials used should be food-safe, with no chemicals which could leach into food and be harmful to human health. Considerations need to be made for packs that endure vari-

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able temperatures, from ice-cold transit to heat applied through cooking or containing hot liquids as this increases the chances of chemicals leaching out.

Packaging functionality testing Food contact analytical testing

How will it perform on the packing line?

Hold ups, delays and unexpected costs.

These are all things which poorly implemented barrier packaging can result in. In order to understand its characteristics, it is recommended you contact a trusted expert to explore how your barrier packaging performs in all situations - from production through to transport and in the consumers' hands.

Testing checklist To ensure the safety and performance of your barrier packaging throughout its expected lifespan, our experts recommend the following testing and analysis services: Physical packaging materials testing

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Stemming the tide of plastic waste We’ve all had our ‘Blue Planet’ plastic moments. My latest was on a remote Hebridean island in a rare heatwave last month, swimming on a pristine, deserted beach with only a basking shark for company. Pristine, save for the plastic ropes, twine, broken creels, bottles, containers, floats, nets, six-pack rings and indeterminate shapes of polystyrene littering the shoreline.

Alongside climate change, the rising tide of environmental waste, plastic included, is society’s other sustainability challenge. I asked Guy Bailey and his Petrochemicals Research team how we can get on top of the problem.

By Simon Flowers, Wood Mackenzie Why is plastic waste plastic or packaged in so out of control? it. The majority of plastic today is single-use The litter on your beach and once it’s served its is just one symptom of purpose, it’s dumped in the explosive growth in landfill or just discardconsumption of materied. als in the last 50 years, fuelled by a rising popu- Will plastic consumplation, growing incomes tion continue to and new technology. grow?

People want to buy Yes. Intensity of use is more and more stuff, actually falling in richer much of it made of

service-based economies – in the US, plastic consumed per unit of GDP began to decline in 2015, after a brief bounce following the 2008/09 recession. But absolute volumes will continue to increase in the developing and developed world because of rising GDP and population, and modern life’s

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dependence on plastics.

The tide of waste threatening our ecosystems isn’t going to subside without determined action.

Can the materials industry learn from the energy transition?

Definitely. The energy transition started gaining traction once society recognised that climate change is a problem.

That led to new policies (the Paris Agreement, as well as others at the national, state and even city levels); investment in technology and innovation (such as EVs and green hydrogen); and energy companies shifting strategic direction to embrace decarbonisation.

Belatedly, the dropped that

penny plastic

waste is a problem.

There’s now policy (plastic bag bans, the EU’s 2019 Single-Use Plastic (SUP) Directive, among others) and technology advances (light-weighting cars and packaging, chemical recycling); while companies have begun to source recycled feedstock. But there’s not enough action across all fronts. Policy makers and the industry need to push harder to catch up with their peers in energy.

ing the business model with the three ‘R’s: reduce (using less plastic in soft drinks bottles, for example); re-use (multiple-use packaging) and recycle.

Plastic can trump glass or aluminium on environmental grounds because manufacturing it emits less CO2 and uses less water. But the successful company of the future will work out how to collect and process the waste plastic to recycle it back into the value chain. There’s What can companies a cost, but it’s now hapdo to instigate pening. Nestlé has earchange? marked US$2 billion to pay for the higher cost Packaging presents a of recycled inputs. major problem for the plastics industry in How much plastic is terms of environmental recycled today? and reputational damIt’s pretty modest – age. Packaging compaacross the board, nies need to start align-

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around 10% to 12%. If we focus on the three main polymers used in packaging – polyethylene, polypropylene and polyethylene terephthalate (together, 85% of plastic packaging) – about 17% of feedstock is recycled plastic.

Assuming a gradual increase in waste collection rates consistent with today’s trends, we’d expect recycling to rise to about 40% by 2040.

What could make harder-to-recycle applithings move faster? cations. We think recycling rates could reach There are two essential as high as 67% by drivers in our more ag2040, keeping 53 milgressive ‘sustainable fulion tonnes of packagture’ scenario. First, ing materials from binding global regulatowaste, whether landfill ry targets using the or the oceans. But we EU’s SUP Directive as a need to see action soon model. Second, new to make this happen. policy sparks investment into technologies, What are the implicasuch as chemical recy- tions for oil demand? cling, as well as new Potentially significant. capacity post-2030 to The petrochemicals inenable the recycling of dustry already accounts a much wider range of for 13 million b/d of

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global oil demand and is the main driver of demand growth for the next two decades. The 83% of plastics production that doesn’t come from recycled feedstock is made from naphtha or natural gas liquids. If plastic recycling reaches 67% under our sustainable future scenario, it would take 1.5 million b/d a year from global oil demand by 2040.

Doubling the rate of plastic recycling would reduce 2040 oil demand by 1.5 million b/d

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“We are at full capacity, and expect more than 30% growth over the next years�

Family owned blown film extrusion line manufacturer Macchi is on a growth course. Currently they are planning the expansion of their production capacity, and hired new staff. We met with the new Sales and Marketing Manager Matteo Spinola to understand better the plans for the coming years.

Interviewer: How long been shifting to 5, 7, 9 I: Will the technology have you been here? layers. center be there?

Matteo Spinola: I’ve MACCHI made a lot of been here since 2018 investments in this perias the Sales and Mar- od. We have empowketing Director. ered our production division. We have been I: What have you installing a huge tooling changed or implementmachine to produce big ed to improve sales and dyes for Agrifilm marmarketing? kets.

M: 2018 was a record We have plans to exyear for MACCHI. We pand the facility where grew in terms of emwe pre-assemble comployees, turnover, and ponents for extruders complexity of and winding systems, projects because the and test the lines. We market has recently will be installing a complete Agrifilm line there.

M: We already have a technology center, but we have a height limitation of 20 meters. In the new one, we will possibly extend 35 to 38 meters upwards to install and test the Agrifilm line.

I: In square meters, how big will the expansion be?

M: It depends. Right now, there are two different possibilities.

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I: When will you make of another 20, 30, 35 The general concept of percent. the decision by? the line we will be presenting is not only the M: It's a matter of the We are investing in evolution of the POD local municipality’s ap- products this year. We line, which we want to proval. So the plan is to will be testing 2 big transfer to the 5 and 7 start building at the end lines – a 1.8 meter and layer, but the flexibility of this year and finish 2 metre dye. We’re of the line. It’s becomat the end of next year. working on developing more common for ments on our 5, 7 and 9 us to receive inquiries I: A building is one layer lines to reduce the for lines capable of dothing, but you have to downtime when you ing short runs, and hire staff too. switch whatever is conchanging the type of M: Yeah, of course. The nected to the job reci- jobs and resins to be goal, this year, is to pe. We’re working with processed. our partners on the grow, very quickly. gravimetric system and We have started emA reason for the new on the cooling ring and powering our sales building is to increase we will have new solu- force. Last year we production’s capacity tions which will be pre- have started the coopbecause we are fully sented this year. We will eration with Riekbooked. When you in- also present the evolu- ermann for China and crease space, you need tion of our fast winding the Far East, which will people. We'll see, in the system, and introduce give us a huge boost in next 2, 3 years, growth the MDO units. that area.

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I: Will there be a tech- M: It's not as important nology center in Asia? as what we want it to be. That's why we want M: We have started to finalize the cooperawith the sales organization with Rieckermann tion. We are now trainbecause we have the ing the Rieckermann opportunity to increase technical engineers beour total turnover by up cause they will be on to 25 percent, which is the frontlines with our our plan for the next 2, people.

3 years.

I: What significance I: Where are you now? does the market have in terms of sales and mar- M: Right now we are in keting for MACCHI? the range of, I would say, a little less than 10

percent. We have to double it. It’s substantial growth.

I: Are China and the Far East where you expect the biggest growth to be?

M: We think we’ll have big growth in that area.

But our biggest markets are Europe and North America. In the last 2, 3 years, we have started cooperations with very big groups there.

And we are investing in these partnerships because when you enter a cooperation with big groups, and do the job properly, you can plan continuous partnerships with those customers.

I: Those machines will also be produced there?

M: NO. Everything’s produced at our headquarter in Italy. It’s the key to MACCHI’s success. And if customers have problems with key components of the line, we can service them quickly.

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I: So if I order a blow film line today, when will I receive the line?

What’s the delivery time right now?

line, it could require a longer time. If we are talking about the standard lines and we aren’t requested to test the line, the delivery time is M: We offer to test the reduced by a few line before the delivery. months.

This affects the delivery time because if we as- I: Do you think with the semble and test the line new plant that you’re with different formulas building, the delivery for 5 days, we have to times will be reduced? give the customer beM: From the end of this tween 8 and 10 year, we will have one months. If it’s a special or two lines that will be-

come our lab lines at our new plant – 5 or 7 layer lines dedicated to customer trials. That will shorten the delivery time because the customer can come test our lines, and then we can work on standard delivery terms for the line to be completely assembled and tested before the deal.

I: You mentioned trends towards shorter runs. In

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terms of kilograms, lines. But it's more what does that mean? common for us to receive inquiries for lines M: Customers that buy to run 5, 6, 7 different real POD lines go for kiformulas.

Customers los, and we have may no longer ask for demonstrated that we only a huge amount of can access 1000 kilos kilos, but for a versatile an hour on our standard line capable of changing 5 layer POD MACCHI

different jobs with almost zero waste, granting always perfect quality films.

I: Do you have any plans to add technology to your portfolio by acquiring competitors to offer a bigger package to customers?

M: Right now, we are going through substantial growth which must be organized properly.

That is where we want to invest now. We have technology which has to be considered the best on the market. The level and knowhow in terms of processing every single material is extremely high.

I: How can you make your lines better?

M: MACCHI was the first to introduce the concept of the POD lines. MACCHI will be the first to introduce another POD concept.

There is a market for the fast winding system because it's connected

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to the MDO units, which develops. And every we are investing in. single time we work with our resin partners, And we have to face the we see developments. market trends so we’re going to completely I: Let’s say I’m a film change the resins. producer, I have offers Some producers are from two competitors moving towards the and from MACCHI. Why production of new res- should I choose MACins in compliance with CHI? legislation. And this will M: MACCHI has almost affect the technology.

60 years of experience.

So we must research The family has the and develop those comsame passion to continponents of the line. ue pursuing the quality I: What kind of resins of the products that we do you mean? produce.

M: The big problem is the barrier films, and the future is to find something reusable for them. So I think there will be a specific evolution of the resins there.

I: What trends, other than automation and versatility, do you see in terms of extrusion technology?

M: A lot depends on the resins. The evolution of the screw, barrel, die heads is always connected to how the resin

the components inhouse to test the lines.

And then the concept of the flexibility of some specific lines that are capable of doing different jobs. These are the main selling points.

We produce everything here. We have been investing time in testing our lines with different materials. We test all lines before shipment, with the formulas indicated by the customer.

This isn’t common. Not every single formula is standard. And then you have to produce extruders according to their specific formulas. And having a factory to produce those is a huge advantage.

So does possibly producing all

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From crushed smoke to boiler plate!

Just prior to the Covid-19 lockdown I was invited to visit the Martin Automatic headquarters in Rockford, IL and given a personal guided tour by Roger Cederholm, Company Director since 1992 and President and CEO since taking over from founder John Martin in 2002. For more than five decades Martin Automatic has helped packaging converters to improve their process and productivity with tailor-made, state-of-the-art solutions.

But the scope of the company’s technology has taken it into a variety of markets that range from non-wovens to metals – in fact it’s fair to say that most products that are manufactured on a reel have been processed

by Martin equipment at some stage.

As Roger Cederholm stated: “There are companies that make some equipment similar to Martin Automatic, but we manufacture the most diverse line of products for more markets.” He went on to explain the way the business operates: “John Martin founded the company and put good principles in place, and I have been fortunate to be able to build on this foundation. We were green before it was in vogue, and multicultural and employee-centric before it was mandated. Our guiding principles have always put us ahead of the curve because we still believe work should be enjoyable when possible.”

A history of technolo- know Martin for its gy for diverse appli- range of narrow-web cations automatic butt splicers and transfer rewinders, Although many in the the company is equally label converting field

well respected for its significant presence in roll-fed processes across a number of diverse industries.

For

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example, high-speed, low-tension roll changers utilizing tape and heatseal technology in wide-web (up to 4.2m) coating and laminating of nonwovens, tissues and films. These products are then fed into continuous processing lines by other Martin splicing unwind platforms to produce, for example, disposable di-

apers, feminine care products, absorbent pads, sanitizing wipes and facial masks. Other markets where one can find Martin unwinds and rewinds include: paperboard products, including folding cartons, beverage carriers, and disposable cups and plates; roofing, industrial and construction goods; medical and

diagnostic products; and specialty converting and manufacturing.

Today, under the guidance of John Martin’s son, Jordan, Martin Automatic occupies a 190,000 square feet (17,650 square meters) complex where 175 employees address both company operations as well as its manufactur-

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ing processes. Martin Automatic’s reputation today is one defined by the quality and clarity of the technology it designs and manufactures, such as the inertia compensated dancer roller and, in more recent years, the Airnertia™ idler rollers, which is gaining renown for its high-speed, low-tension processes. More importantly, Martin Automatic has leveraged its extensive understanding of automation to develop solutions that improve efficiencies, reduce waste, and enhance profitability for a long list of companies.

Martin Automatic currently deploys its technology and solutions to manufacturers in more than 55 countries around the world and maintains multiple patents while continuing to explore new ways to innovate for web-fed industries through automation. Given this success, it’s no surprise

that the enterprise enjoys one of the lowest staff turnover rates in the US, with averag job tenure being 22 years.

Indeed, Cederholm himself has been with the company since the early 1970s.

Many companies send these to either recycling or the landfill, generating waste and reducing profits. In response, Martin’s technology allows converters to incorporate partially used rolls efficiently into their production runs as well It’s all about automaas to function in addition tional contexts, such as Mrtin Automatic’s pa- cleanups and maketented technology and readies. innovative solutions enUsers of automatic able continuous producsplicers typically experition that results in enence an increase in net hanced productivity and production speed of 15 profits for partner compercent or more, due panies. Integrating auboth to the fact that tomatic butt splicers straight line production and rewinders into their involves fewer starts production lines proand stops, as well as vides Martin’s customthe greater confidence ers with significant cost such automation gives savings and waste rean operator to run a duction. Consider just press at a faster speed. one aspect of material Automatic splicing often waste in label convertresults in improvements ing: partially used rolls. to process quality, In the past, there has thanks to the fact that been a large amount of this technique allows waste related to the presses to run at a condisposal of partially sistent speed, avoiding used rolls that contain fluctuations in, for exless than 600 feet (180 ample, UV power output meters) of material.

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and associated curing intensity.

Eliminating manual changes also allows web tension to remain constant, helping to ensure that color matches stay consistent across a run.

Martin Automatic solutions can also transform actual physical operations on the floor for company employees.

With a manual setup, operators typically have to handle large shafts or operate complex lifting systems. Automation via a roll changer with an integrated lift and load system allows operators to execute this task with the simple push of a button.

Companies using this approach can reduce the risk of workplace injuries while also reducing the risk of damage to shafts during roll changes.

The specific act of changing rolls automatically, without stopping or slowing a process, is just one aspect of auto-

mation.

Increasingly, Martin’s customers are looking to use personnel resources more efficiently, leading to technological innovations that optimise efficiency in the use of their splicers and rewinders. As an example, an automation package available on the MCBWW Automatic Butt Splicer, typically used on high speed wide web paperboard presses

The above gives an overview of the company’s range of capabilities and says much about its innovative prowess. As Cederholm commented: “There are two plaques in my office that characterize this perfectly. The first one states Innovation - ‘The best way to predict the future is to create it.’

The second, and equally as important is: ‘You can’t build a reputation on what you are going runs material off the to do!’ core at full speed for maximum roll usage The company’s innovative skills combined removes spent cores with its pastoral attiautomatically and tude are perhaps best transports them for use exhibited in its corpoat the rewinder rate center on the leverages an integrated banks of the Rock River. conveyor system to Initially a vision of the late founder John Martransport rolls tin, this steel and glass loads rolls onto spindles complex is the largest automatically and, structure designed and facilitates accurate and built by Martin AutoFormerly Marfast splice preparation matic. with automatic align- tin’s personal residence, the architectural showment of a new roll. piece, fondly referred to A culture of creativity as the tongue-twisting

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‘inverted hyperbolic parabola’, is used for company meetings and functions, including receptions and the annual Independence Day picnic.

It continues to serve as housing, nowadays for university students serving internships in Martin’s engineering department.

each person maximum creativity within their sphere of influence and to encourage active, versus passive, participation in spending the company’s money as if it were their own. We believe the result is faster more creative responses to customer needs and more fun and satisfaction within An entrepreneurial spirit the four walls.” permeates throughout the company and is en- In summary demic in its culture – a It’s clear from all this kind of DNA. Referring that automation brings back to his earlier comwith it a wide range of ment about being emadvantages across an ployee-centric, enterprise. From inCederholm spoke about creased efficiency to rethe way the company duced waste, compaempowers each memnies leveraging Martin ber of staff. “We beAutomatic solutions get lieve that each person a serious return on their is the owner of a cominvestment. These adpany of one and has a vantages extend to single large customer, their customers as well, Martin Automatic. And allowing companies to each person has multiprovide more efficient ple smaller customers, service and delivery, his or her colleagues and generating a higher who take ownership of quality product. This is their decisions and roles sure to give Martinwithin the company. partnered companies a The goal is to allow competitive advantage

too, as they compete for orders in an increasingly crowded space.

One final comment on the Martin culture and the freedom and trust given to its employees is the fact that, unusually for the US, there is a keg of beer on tap in the staff break area. It started out as a way to bring employees together at the end of the day, keep open the internal lines of communication, and brainstorm new ideas and approaches.

But as Roger Cederholm concluded: “I’ve sat down with customers and actually begun to design machines here, and we often joke that there are vending machines for those who want a soda – at Martin Automatic the beer is cold and free - the soda is just cold!”

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Comexi on the no longer relevant pandemic of plastic, Covid19 & the flexible packaging industry It seems we are facing once-in-a-generation situation. How are these circumstances really affecting the flexible packaging market and consequently, how is this ultimately shaping the Fast-moving consumer goods sector?

Let’s go through the challenges the industry has been facing lately and what might have in store for the next few months. Let’s not forget though, that the industry is between those considered indispensable during this terrible pandemic and that -thanks to its exceptionality- it is a perfect occasion to dive into the ongoing plastic dilemma through a different perspective.

By Eduard Boja, Comexi Until not so long ago the main concern of the biggest FMCG companies in the world was getting rid -whenever possible- of the plastic used to package their products and substitute it for potentially less polluting alternatives.

Plastic contamination has been labelled during the 21st century as

one of the biggest threats to ever be faced, spreading like a virus through our freshwater streams and oceans.

tionality when approaching the plastic casuistry. This has led us to a scenario in which, out of our own biased perception, we have -relentlessly- been blaming plastic for our own lack of strategy in the handling of our very own waste.

During this unequal clash between hyperbolic turtle-choking images and scientific studies supporting the use of plastic, we have been The below diagram stripped out of our ra- aims to illustrate how a

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proper evaluation should take place (in red) in comparison to what happens with plastic (in orange) which is dangerously - happening in the opposite direction.

We have already made up our minds that plastic is a bad alternative and we are trying to figure out our way backwards.

This happens -to a great extend- due to the amount of unaccredited sources from which we receive spamming on a daily basis on

how much plastic is damaging the environment. The expansion of Covid-19 though, has shaped the environment in a completely different way and has also shifted the balance of priorities in this all-out war against plastic that has been ongoing for the last few years.

ago. People are more even more concerned for the protection of the products they consume, paying special attention to how the products they pick are packaged and protected.

Also, the consumption of single-use masks and gloves has skyrocketed since proIronically, tection of Brands and human welConverters fare is are now obviouslyhaving the utmost more workpriority. load than ever and Let’s not the chal- forget lenges they though how are facing all this are way dif- started, ferent from since the those only a major susfew www.packagingnewsletter.com months pect of the 25

virus outbreak has been the Pangolin, one of the many animals that are smuggled everyday into continental China to be later processed into -of course- food or medicine. The safety and cleanliness conditions under which these endangered animals are trafficked adds up to their -already dangerous- very nature.

This may seem as something that has very little to do with flexible packaging, right? Well in fact it does. Can you imagine what would happen if we stopped using plastic to protect all the products we consume daily? This will of course not happen, but in case it did it would be an absolute catastrophe.

It is now -more than ever- time to carry out an exhaust analysis as a society on how we should be handling our waste and encourage and empower initiatives -like Ceflex and many others- that are aiming to create a more sustainable economy by improving the recyclability of the materials we use for packaging while ensuring there are reliable recycling methods downstream of the whole process. This is the only way materials will -in fact- be reused.

It will also be a big challenge for all the Brands to move out of the comfort zone in which they are with the current structures to move into more sustainable alternatives.

This will be an act of responsibility and commitment towards the society and the environment, trying to stay away from alternatives like paper that -even they are suitable for

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some low barrier applications- are not the panacea or the Holy Grail that will solve the problem. Can you imagine we substituted all the packaging we use on a daily basis for paper? How many trees would we need to chop off?

flexible packaging and also how we can improve it so that it brings along even bigger benefits for the society!

Once we have all the pieces of this chess match in place we will be in position to deliver the checkmate to the ongoing- problem of plastic pollution! Nevertheless, this unprecedented situation has put us in perfect conditions to really put into perspective the benefits of

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E-commerce, the key is in packaging The online sale of products is one of the segments that has rapidly grown in the last five years. In the United States, this market earned US$304.9 billion in 2014, according to the U.S. Department of Commerce reports, and according to Packaging World, by 2017 sales reached US$453.5 billion. The "The Impact of E-Commerce on Packaging: Long-Term Forecasts for 2029" a market report from Smithers Pira, a market forecasting and assessing expert company, says e-commerce has an average growth up to 20% in the last few years driven by market leaders such as Amazon, JD.com and Alibaba.

This e-commerce boom, Among the challenges need for converters to as well as demanding a that this new market create high-quality high improvement level channel has opened, we graphic designs for the in the packaging role, found the packaging shipments”, Smithers opened a new market design. In other words, Pira says. According to niche with its opportu- e-commerce poses the the Packaging World, nities and challenges need for packaging to some companies are that include corrugated, attract consumers, no implementing cuttingflexible, protective, and longer from supermar- edge solutions to make in transit packaging, ket shelves, but from customers feel attracted and is mainly based on websites and apps. to their products. A usefulness, transparen- “Many brands require good example of this is cy, and cost. nowadays that the sec- Boxed.com which creatondary packaging bring ed an augmented realiE-commerce is detheir image to the hous- ty tool to allow consummanding “perfect” es, not only to the re- ers to see the products packages tailer. This increases the and Walmart that has

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invested in drones with commerce channel”, live streaming cameras. said Brent Lindberg, Founder & Director of In terms of structural Fuseneo, a packaging design, the challenge is design firm located in to produce 100% funcSt. Charles, Illinois, tional packaging, that USA. “We cannot askeeps the content insume something that side save and brings as was designed for the much protection as posretail market will meet sible to the product, the needs of a very difthat does not allow ferent supply chain”. leaking and that lower steps and items in- To use the words of the volved in logistics and market consulting firm, shipping processes. e-commerce takes packaging to a new levAccording to the Smithel, where the most imers Pira report, there is portant are lightweight an average of 30% redesigns that save powturn rate on online orer, protect content, ders and packaging save space, and are must survive to the eeasy to recycle. Therecommerce supply chain, fore, it is critical that which includes many the packaging is creatmore handling points. ed with e-commerce in Besides, they must be mind from the beginpractical because prodning as technical, legal ucts are not always and business changes shipped separately, and are happening at the “friendly”, as the unsame time. packing process is part of the customer experi- Flexible packaging: ence. the best option for ecommerce and mar“Brands need to design ket sustainability products and packaging to survive the e-

Sustainability is another callenge packaging converters for the ecommerce channel are facing, and it is being addressed from the packaging size, ensuring that it is the correct one, and avoiding air shipment. Major packaging suppliers are introducing flexible and versatile packaging to address this problem.

Moreover, reusable packaging is also a growing item in the sustainable packaging strategy. And, as for plastic material, especially single-use packaging, these are being analyzed and will be replaced in the future.

Amazon, for instance, is changing to more flexible plastics. Besides, new materials are being developed to replace less sustainable options and we may use more bioplastic and EPS alternatives in the future At the same time, today 80% of the packages ecommerce demands are

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made with corrugated cardboard, thanks to the high flexibility provided by this material, especially in secondary and tertiary packaging.

Corrugated cardboard boxes can be made with a heavier material to support more than 30 touches it may suffer during its delivery.

According to Packaging World information, the design firm Fuseneo Inc. has worked on packaging design for some Amazon products and is helping to let know the company’s ecommerce certification program to potential partners. Brent Lindberg said that Amazon will continue to evolve and drive packaging design and reduction, especially by 2020. According to him, companies that want to deliver their products through this platform should complete a certification test based on the new ISTA tests (International Safe Transit Association), ISTA 6-Amazon.com.

Independent laboratories must test and certify each package set-up.

According to Daniel Demerutis, Communication Coordinator at Smurfit Kappa Mexico, the Irish cardboard box manufacturing company is very clear about the opportunity ecommerce offers in that regard, and that is why they are betting on this market through investments in redesigning their facilities, expanding their production capacity and the acquisition of some companies that already are in this Amazon has three certimarket. fication levels: unprepared packaging, shipAmazon is committed ping in its containers, to improving packagand frustration-free ing packages. These Certifications are designed to

ensure that products will survive a journey to the consumer's place and that will not require any additional preparation or packaging.

During the Sustainability in Packaging conference, some brands reported that Amazon often charges them for this training. As a result, together with companies such as Fuseneo, they are designing packages that meet Amazon's criteria in order to obtain company certification and thus eliminate those extra fees.

"We want to help brands go through the certification process and redesign their packaging to make a sustainable transition from retail to e-commerce," Lindberg explained.

For more information about this report "The Impact of E-Commerce on Packaging: Long-Term Forecasts for 2029" download the brochure here.

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Bhojraj Industries leads the way in gravure printing in Nigeria with large investment in BOBST technology Lagos-based Bhojraj Industries Ltd supplies flexible packaging to the food industry, printed on a top of the range MASTER RS 6003 gravure press from BOBST. The Nigerian company is now adding a BOBST NOVA RS 5003 to the lineup, as it looks to extend capacity and continue its successful expansion in high-quality printed packaging.

As a full-service provider, Bhojraj Industries offers film extrusion lamination, gravure printing, slitting and converting. A recent increase in demand for flexible packaging coincided with the need to upgrade its older printing equipment and improve on output.

First established in the 1960’s (as Bhojsons Industries Ltd) the food packaging specialist is part of Bhojraj Chanrai Group (formerly Bho-

jsons Group of Compa- leading manufacturer nies) with other interest with the best kit, gear in West Africa. and practices. Gravure printing in particular is To facilitate the transiset for significant tion, the company growth over the next chose to partner with few years, so we are inBOBST and invest in its vesting in the best posgravure technology to sible printing presses to produce added value, help us take advantage top quality packaging of this opportunity and for big brands. serve our customers highest quality “Packaging printing in with explained Nigeria, which is Afri- products,” Sadhwani ca’s largest market, is Mahesh developing rapidly and Chairman of Bhojraj Group. we are determined to Chanrai retain our position as a

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High speed and high conditioning, Electroquality static Print Assist (ESA) system, detection and control of solvent conThe first step in the centration levels, exprocess of upgrading tended double dryer, production came in the web viewer with 100% form of a nine-colour inspection and in-line BOBST MASTER RS heat seal capabil6003 press, which was ity. The extended high installed in 2019 and is duty dryers of this mathe first machine of this chine drastically result specification to be inin substantial reduction stalled in West Africa. of retained solvents up As the first of its kind in to <5mg/mtr2. This the country, it is an inhelps in production of vestment that has given solvent taint free lamiBhojraj Industries a nate which will be food unique proposition in safe for the industry to Nigeria. The advanced the highest specificafeatures have enabled tions. the company to produce food-grade packaging No other machines can for a wide variety of match the capabilities products, catering to of the MASTER RS food, pharma, beverag- 6003.

Furthermore, es and agricultural printing thin unsupportproducts industries in ed LDPE film at high Nigeria speeds of 400 m/min on a rotogravure press Running at speeds up to is a completely unique 500 m/min, the RS feature, which means 6003 offers superior that the company does web handling of films, require flexo press laminates, paper and technology to print such aluminium substrates, substrates. including delicate materials such as very thin â&#x20AC;&#x153;BOBSTâ&#x20AC;&#x2122;s gravure LDPE. The press config- presses produce the uration at Bhojraj In- best print in the mardustries has also been ket, while the fast runspecified with www.packagingnewsletter.com pre- ning speed and mini33

mum waste keep the unit cost on long runs low, which helps us compete on both quality and price,” said Managing Director Nikos Gkanetsos. “And with these new machines, we can make the most out of gravure print and color sharpness in terms of quality, consistency and repeatability across all substrates, something that the brands we work with demand. It is a real game-changer for us.”

The MASTER RS 6003 is soon to be joined by a NOVA RS 5003, another highly productive press that delivers superior performance on a variety of flexible materials, including new ecofriendly packaging substrates. Both machines will be housed in a brand-new production hall that has been built specifically for this purpose.

Vice President Operations Mustafa Khokhawala said, “I can’t believe how easy it is to work on the RS 6003 press. We have cut down to the time it takes to make a job ready and only need two operators to get it up and running, plus the production environment is so much safer and nicer for all our staff.” He added, “And the high efficiency of Speaking about the exthe twin flow dryers perience with the first means that we experiBOBST press so far, ence much lower sol-

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vent smell in the production area, as well as low solvent retention on the final product, so our working staff as well as our customers are happy too.”

we know we are in good hands as we face the future of food packaging printing. I’m very pleased to welcome in this new era for Bhojraj Industries,” concluded Mr Sadhwani.

Partnering for transformation “There is a huge amount of satisfaction in seeing the transforThrough its future vimation at Bhojraj Insion for the packaging dustries and we are industry, BOBST drives very proud to have innovation in technoloplayed our part this gy to enable customers massive step change, to maximise their packwhich will certainly see aging production and the company flourish,” gain more market said Angelo Cavallo, share. The experience Product Sales Manager, gained in developing Bobst Italia “This is a gravure printing techperfect example of a nology over more than partnership that beneeight decades is the fits both parties and we foundation of its market look forward to continu-leading position today. ing our support for this packaging “Choosing BOBST as innovative our supplier was an leader.” easy decision. Their commitment to innovation and excellent reputation in the industry is second to none, and they have a global presence that includes local service and support, so

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Asahi Photoproducts Supports Comexi, In A Breakthrough Turnkey Project Asahi Photoproducts reported it is participating in an important project with Comexi and other industry partners. As part of this Turnkey Project, Asahi will place an Asahi AWP 4835 P water wash processor and Asahi AWP water-washable plates with CleanPrint at Comexi’s Manel Xifra Boada Technology Center in Girona, Spain. The project is designed to educate flexible packaging companies about the value of bringing flexo platemaking in-house and demonstrating how easy that is to do with today’s technology.

“We are proud to be participating in this very important project together with our partner Comexi,” says Philip Mattelaer, Asahi Photoproducts’ Head of Sales.

“There is an increasing trend for flexographic printers to bring platemaking in-house, both to drive efficiency and improve quality. This project will demonstrate to the flexo market how easy it is to produce

plates in-house, strengthening the value chain at the point of print production. In addition to improved efficiency and quality, this project also demonstrates how print providers can drive increased sustainability by incorporating Asahi CleanPrint technology on-site.”

specifically engineered

by Asahi’s chemical engineers to transfer all remaining ink to the printed substrate, reducing makeready time and press cleaning stops in comparison to other platemaking systems while delivering exceptional quality.

Asahi CleanPrint flexographic plates are also ideal for fixed colour CleanPrint flexographic palette printing, a plates from Asahi Phomethod that is increastoproducts have been

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ingly being adopted to save time and money while still delivering the quality brands expect.

This is made possible by the precise register of Asahi water wash CleanPrint plates. Its AWP family of plates and processors bring flexo platemaking into harmony with the environment, minimizing the use of water, eliminating noxious chemicals, and that way creating a cleaner direction for the flexographic industry.

of plates, resulting in improved OEE. This is one factor driving the move to bring platemaking in-house – the same trend the offset printing industry underwent many years ago.

Comexi’s Turnkey Project will host regular customer events demonstrating the power of “everything under one roof”.

“Visitors to the project will be pleasantly surprised to see how quickly and cleanly Asahi AWP water-washable Making flexographic plates with CleanPrint plates in-house also are produced, and they means faster availability will have access to ex-

perts who can help set them on their own CleanPrint path toward a cleaner flexo printing future,” Mattelaer adds.

“The key to controlling quality and service levels in flexographic printing is to control prepress, and the Comexi Turnkey Project shows visitors just how easily they can do that. It combines hardware, software, installation, optimization, training and production support to ensure a seamless transition to a clean future for flexographic printers of all sizes.”

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