M
ar
ke
tT
re
nd
t Corrugated Marke
s
el
b La
s
s
nd
Tre
Flexible Packaging
Packaging Asia News, August 2018
Acknowledged by:
Table of Contents
Plastic Phase Out: Who Will be Most Affected?....................................................6 Switch from Glass to Plastic.....................................................................................9 Plastic Packaging...................................................................................................10 100th WPO Board Meeting-AIP...............................................................................12 Folding Carton Packaging....................................................................................14 Know How to Perfect Die Cutting ........................................................................20 System Tolerance Flexo Printing............................................................................23 True Hybrid Changing the Perception of Digital.................................................30 Inline Flexo Key to Added Value Packaging Retail Market...............................34 “Plastic Free”-Packaging Supermarket................................................................40 Small Pack Euromonitor..........................................................................................45 ACCA’s Meeting April 2018...................................................................................48 DS Smith-Packaging Pizza.....................................................................................55 DS Smith Launches Made2fit to Reduce E-commerce Packaging Size..........58 Digital Corrugated..................................................................................................60 Proper Plan for Corrugated Direct Printing..........................................................68
Dear Readers... In this edition we see the contradiction of Plastic Packaging one side we love it. It light, economic and very usefull while another side it not environment friendly the waste populate our world. But according to Mr Fajar of Inaplas we can manage the waste as long as we work together and back to the source of the waste. Early June I join World Packaging Organization (WPO) yearly even in Gold Coast. I am so happy to meet all the fellow Packaging from around the world and join the very interesting symposium, get inspired with the young man who manage to be succed in his new venture with Health Drink. Also tasted three session of the Certified Packaging Expert (from the Packaging Book by WPO). Digital is the primadona in the printing industry as present it started with the commercial printing, but now has come to the packaging as well especially in Label Printing. To fit the market well now the new trend having Hybrid machine which can cater for traditional print as well as for Digital. We all know that e-commerce is getting more and more. We see some closure of traditional store, while online is getting more and more, therefore we should think how to use this opportunity to grab the grow of e-commerce with the right packaging. DS Smith has seriously launch Made2Fit (patent pending) ecommerce package with just S, M, L size to cater 32 boxes sizes. What a “smart move�. To be more competitive now everything has to be efficient, fast and less waste, therefore inline machine for printing as well as automation packaging in the FMCG is more and more. We cover herewith the inline printing machine and also concentrate on the Diecutting as the most important finishing that will effect the productivity of the automatic package of the FMCG. On the next issue we will cover the new trend of special folder gluer which needed for a specific boxes types. For the corrugated industry we cover Asia Corrugated meeting last April as well as an article about how to print flexo in corrugated rightly. This article will contine with theright plate,ink and material on the next issue. We cover the system tolerance in Flexo printing on this issue and will continue with Flexo Printing Problems on the next issue. Last but not least we will attend the All Print China 2018 next October and will cover it on the next issue. Happy Reading Tuti Buntaran Chief Editor
Shanghai New International Expo Center (SNIEC), Hall N1-N5, E4-E7 2345 Longyang Road, Pudong, Shanghai, P.R.China 24-27 October 9:00 - 4:30PM 28 October 9:00 - 4:00PM
All in Print China will be held this year again for the Seventh time in di Shanghai New International Expo Center. This year they will have 8 pavilion/zone. Each zone will give us the latest technology trend in the packaging printing industy.
DIGITAL PRE-PRESS PAVILION In 2015, the global market value of the digital printing accounts for 13.9% of that of the printing and packaging industry, and the figure is expected to reach 17.4% in 2020. A digital work-flow featuring computer integration has come into being, CTP technology has been widely used, and the digitalized revolution has penetrated into the traditional printing industry. In the Digital Pre-press Pavilion, visitors will acquaint themselves with the new trend of digital printing, try its new application, explore new opportunities and grasp new digital technology for pre-press. COMPREHENSIVE PRINTING PAVILION Due to rising human cost for printing services, printing enterprises have tried to benefit from the equipment, so it is inevitable that more intelligent, automated equipment will be employed in transformation and upgrading of enterprises. Printing equipment manufacturers, through more research and innovative technology materials and improved automation, have seen noticeable progress in technical level. The Comprehensive Printing Pavilion will showcase the latest findings on the offset printer and related technologies and solutions. POST-PRESS CONVERTING PAVILION The development of science and technology and the fierce competition of the market call for development of printing in a faster, better and cheaper direction. Therefore, the automated and intelligent post-press converting is of great significance for the entire printing industry. Now the digital technology has revolutionized the post press toward automation and intelligent operation: automatic connection for higher quality and efficiency; the surface finishing and diversified processes (cutting, polishing, stamping, embossing) for higher value. In this pavilion, you will have a close contact with the era of post-press converting 4.0. PACKAGING EQUIPMENT PAVILION With the development of food, cosmetic and other packaging applications, the global packaging market is growing. The data show that in 2016, the output of global packaging industry increased to about $820 billion. Among them, the paper packaging will continue to lead the global packaging market, with the total output value nearly reaching $250 billion, while the rigid plastic package output value was over $200 billion, and that of soft packaging rose to $163 billion. This Pavilion will showcase the sophisticated
domestic and international packaging equipment. At the same time, there will be an area specifically for corrugated equipment, focusing on technical solutions of advanced corrugated packaging. INK & INNOVATIVE MATERIALS PAVILION Green materials have become a consensus in the industry, but the use of green materials is just at a primitive stage of the green application. In the future more attention should be paid to innovating the new green auxiliary materials, thus making the green concept penetrate deeper in the production. In this pavilion, visitors will find all kinds of innovative and environmentally friendly printing supplies, such as paper, plates, ink, etc. LABEL INDUSTRY PAVILION Statistics show that, in 2015, China’s total output value of the label printing industry surpassed 35 billion Yuan, up 7.8% in contrast to 2014, while the total output of self-adhesive materials surpassed 4.6 billion m2, up 5.6% over the previous year. From a global perspective, the growth rate of label market in the Asia Pacific region is by far over the global average, being the fastest growing market as well. It is expected that by 2019, the global label market value will increase from $32.7 billion in 2014 to $41.6 billion. Asia, the world’s largest label printing market, will account for 41% of the global label market share. The Label Industry Pavilion will be an epitome of Asian label printing industry. FLEXO TECHNOLOGY PAVILION Flexo printing technology has developed for over 30 years in China. Today, flexo printing technology has been able to compete with offset printing, gravure printing, embossing and digital printing technology in many areas, and China’s flexo market will usher in a new era of development. Flexo Technology Pavilion will familiarize you with the best practice and application of the flexo printing technology. INNOVATION FACTORY “Innovation Factory” made its debut in the 6th All in Print China in 2016, enchanting visitors with 30 printing and packaging solutions, 24 sharing speeches, frontier application scheme and exquisite booth design in an exhibition area of 1,500m2. The Innovation Factory will continue to delve into such topics the cultural creativity of printing, green environment, future technology, 3D fab + print, intelligent manufacturing and Internet Plus, focusing on the latest technology, application and future of the printing industry.
5
PLASTIC Phase Out: WHO Will be MOST AFFECTED?
M
aterial or redesigning or reducing packaging. A long list of companies have already announced plans to change their approaches to packaging use. For instance, Costa Coffee owner Whitbread has launched a nationwide recycling scheme. Coca cola has committed to collect and recycle the equivalent of all its packaging in Western Europe by 2030 and McDonald’s plans to
6
make all of its packaging renewable or recyclable by 2025. There will be costs to retooling equipment, reconfiguring supply chains and in some cases higher materials costs. However, our analysis shows that companies already adapting to these trends may benefit. Cost savings achieved by lower packaging use, improved consumer perceptions and reduce regulatory risks could contribute to higher margins for food producers and
household and personal product companies. We find that soft drinks companies carrying on with business as usual face the biggest downside risks. Packaging companies face bigger challenges. Currently, 37% of consumer packaging is plastic, the outlook for which is clearly challenged. On the other hand, leaders that are able to develop sustainable alternatives like bio plastic or improved recyclability will emerge from these challenges stronger. They should be able to establish distinctive products for which they have pricing leverage, replacing their current reliance on traditional commodity plastics categories. While some major players are already their innovation efforts to developing more sustainable packaging, we believe that
innovation is too slow to allow the industry as a whole to pivot away from traditional plastics undamaged. Our analysis of the operating profit exposures of individual packaging companies highlights the value of leadership, with well-placed companies suffering little impact and laggard seeing up to one third of earnings at risk. Chemical companies are starting to develop compostable, bio based plastics as well as different types of polymers that can achieve reductions in material use. Bio plastics and compostable materials are starting to gain traction. The bio plastic market is set to grow at 30% compound annual growth annual growth rate to 2030 (form 2013), compared to an average of 3% growth for fossil based plastic. They have their flaws: they can be hard to recycle more expensive to make and not yet available in 7
large quantities but improvements in cellulose conversion technology are expected to enhance the quality, quantity and cost. As manufacturers face pressure from their customers, the more innovative companies should gain market share. Most of those beneficiaries appear likely to emerge from the current industry leaders. Waste utility and recycling companies are likely to benefit from growing demand for end of life recycling and reuse. Recent Chinese waste import restrictions, couple with increased political and regulatory pressure on plastic waste, create a potential springboard for the recycling industry. New geographies, new applications and new products could lead to market growth of 7% to 9%. Picking out winners from a fragmented, highly competitive industry is
8
challenging and we think localized solutions will be key. Oil is the main raw material used in plastics production. However, 4% to 8% of global oil production is used to make plastic of which an estimated half is used for packaging. As a result, the impact on that market is likely to be modest, although the issue unhelpfully compounds the wider challenges facing the energy sector. Single use plastics have become ubiquitous in today’s consumer product industries and value chains. We expect pressures to spread from the specific niches on which attention has focused so far, to the wider range of products contributing to a global environmental challenge that had begun to move from ecological concern to economic driver. by www.pressreader.com
Switch from GLASS to PLASTIC
V
entura Foods has partnered with Ring Container Technologies on a glassto-plastic conversion for its Marie’s refrigerated salad dressing. According to Ring, consumer insights, safety, and packaging optimization were integral to Ventura Foods’ decision to switch the product packaging. “It was a collaborative design and development process throughout, which involved engaging teams from various departments at both Ring and Ventura Foods,” says Tom Kerstetter, Senior Director of Food Service Sales at Ring Container Technologies. “Once the final designs were selected, both our local and product development teams worked closely to ensure a seamless qualification and transition to PET.” Discussions for Marie’s glass-toplastic conversion began years ago, when Ventura Foods first expressed their desire to investigate a packaging change. As more data was collected and timing properly aligned, momentum picked up over the last 18 months. What followed were several interactive engineering
sessions, along with ideation and real-time design consultations, where Ring produced 3D models of the new Marie’s bottle. For Ventura Foods, it was essential that the conversion from glass to plastic honor the company’s commitment to corporate social responsibility. Today, Marie’s product packaging is 100% recyclable and BPA-free. Additionally, it is lighter in weight, making it easier to stack and ship, and more efficient to transport. Consumers also appreciate that the product is easier to hold and carry. Marie’s can be found in the refrigerated produce section of retailers nationwide. “Marie’s consumers are passionate about this brand and demand quality ingredients and premium packaging,” says Revay Ripp, Director of Marketing at Ventura Foods. “Backed by market research and supported by Ring’s high-touch partnership that kept our strategic business goals top of mind, together we created a product that we are proud to share with our customers.”
A new PET container for Marie’s refrigerated salad dressing is 100% recyclable, BPA-free, and lighter in weight, making it easier to stack and ship, and more efficient to transport. 9
W
PLASTIC PACKAGING
hen I read two article “Plastic will Phase Out” and “ Supermarket without Plastic Packaging” I decided to interview Mr Fajar from Inaplas (Indonesian Plastic Association) about Plastic in Indonesia. Start to dial my phone and asked for an appointment. As usual Mr Fajar is very friendly and open during the interview, He brief me with the program they have. The main program call MASARO (Manajemen Sampah Sero or Management of Zero Waste). MASARO target to eliminate Temporary Garbage station by 2025.
In accordance with the President Jokowi program to reduce sea garbage 70% by 2025, we all must work together to achieve it. We must support each others. Inaplas with their Masaro Program while others has different program. As long as all has similar target to manage waste. To reduce waste.
Director General of Tekstile and Other Indusrty (IKTA) Ministry of Industry, Ahmad Sigit Dqi Wahyono with Head of Environment Aep Surahman and President Director of PT Polytama Propindo Didik Susilo inaugurate Masaro Program 25/1/2018
One of the factor causing the failure of waste program is the complexity of waste compilation. Therefore Inaplas started with the easiest way started with one village. Their program as follows : Non-recyclable (23% of all waste in the United States), Recyclables (44%) and Compostable waste (33%).
10
MASARO similar to each name, try to manage waste from its own resoures : • Each Household have to manage their garbage • Each Market have to manage their garbage
•
COMPOSTABLE WASTE Mainly from the food waste will be process as follows : 1. The rough one become fertilizer 2. Soft ones will be fermented by equipment from ITB (Institute Technology Bandung) 3. Liquid food for animal 4. Liquid fertilizer
Industry, Mininstry of Economic and Navy. We expected that this initiative program will be follow by others and can be spread all over Indonesia. Mr Zaenal Abidin, the Head of LTPM-ITB explain that this first initiative program will used the garbade from Tinumpuk Village. By educative the village about this program and it will be done by their community.
•
UNCOMPOSTABLE WASTE This waste wil be separated according to the economic value. 1. Waste with economic value will be recycle (cooperation with garbage collector) such as paper, glass, steel, plastic. Garbage collector only collect garbage with value more than Rp 1.000/kg.
Beside education, they also will arrange a kind of competition in school and between villages about waste management. Once this program work well the amount of transportation waste to Temporaty Waste Station (TPS) and Permanent Waste Station (TPA) will become less and less and will be positif for the economic and health of the society.
2. Waste with NO economic value such as small plastic wrap of candy, etc will be process become fuel where the baking process also using this waste.
If society can manage their own waste especially if they educate since they young the waste problem will be diminished by itsel.
The first project sponsor by PT Polytama Propindo in cooperation with Istitute Technology Bandung (Laboratory of Polymer Membrane). This program launch in Tinumpuk Village last 25 January 2018. The program supported by The Ministriy of
love
•
DANGEROUS WASTE WILL BE MANAGED BY THE GOVERNMENT (PEMDA)
Mr Fajar suggested “Do not disturb the existing business” instead we have to accelerate the related industry – while we all have to participate to rescue our plate in general and our industry specifically.
hate
11
100TH WPO BOARD MEETING
Held alongside the 2018 AIP National Conference
I
t was only apt that I attended my first World Packaging Board Meeting as the newly-elected ANZ representative in Queensland. The Board Meeting was extra special as it was Pierre Pienaar’s first as the newly-elected President of the WPO and also the 100th Board Meeting for the organisation. I had the opportunity to meet the heads of packaging associations from many countries including Korea, Lebanon, Finland, Sweden, US, UK, Singapore, Indonesia, Japan, Argentina, Brazil, South Africa, India, Sri Lanka, Turkey and many more.
12
It was wonderful to be able to learn more about the WPO and the other countries programs and initiatives. I soon realised that there are many amazing like-minded associations across the glove who are all keen to learn and network. The AIP is committed to ensuring that we contribute to all initiatives of the WPO and to work together to create a global packaging community without barriers or borders. Nerida Kelton MAIP, Executive Institute of Packaging (AIP).
membership
professional networking packaging community
education sharing
WHO WE ARE First Packaging Asia will facilitate the process of education and training for the packaging industry. Primary goal is to provide a platform for players in the indonesian packaging industry to network, learn and exchange ideas. We arrange monthly seminar for flexible packaging, label, folding carton as well as corrugated industry. General training such as : - Packaging Fundamentals - Packaging Design - Food & Beverage Packaging - Cosmetic & Personal Care Packaging Basic Printing Package : - Design - Prepress Printing (enhance for packaging printing) - Intro to Flexo - Advanced Flexography
WHAT WE DO FOR YOU Your membership generates a solid return on investment, paying for itself many times over through the benefits you receive. You’ll find unmatched resources, education, information, and networking opportunities.
The necessity of memberships for packaging professionals Packaging has evolved into a strategic tool that can be leveraged into a competitive advantage. New technologies, new materials, new markets, new regulations - today’s professional needs to scan those and other horizons to stay apace. Who should join : • New to packaging and need a broad introduction • A manager who needs a wider view of packaging • A sales rep who wants to expand your technical background • A packaging professional changing your focus who needs to come "up to speed" in a new area of packaging • A purchasing professional who needs more technical depth Market segments represented : - Flexible Packaging -
Corrugated Folding Carton / Boxmaking Tag & Label DIgital Printing Envelopes Prepress
FPA Member will get value in our offering that include : 1. Conference, Seminar and Networking 2. Free subscriptioin to FPA Publication 3. Attend Seminar for free (1 x a year) 4. Special price on all Training Course 5. Support on expertise
just click www.firstpackagingasia.com
Guest arrival Argha Karya Prima
Mr Jimmy-PGGI and Mr Untung-Royal Standard
13
Folding Folding Carton Carton Packaging Packaging
W
orth more than $75 billion dollars worldwide, the folding carton industry is a vitally important part of the packaging sector. By working with materials that range from paper, carton board and cardboard, through to heavy solid board, microflute litho-laminates and light corrugated board, folding carton makers create recyclable products that both protect and promote. The production of folding carton packaging can process the following categories of materials: • Paper
14
• • • • •
Corrugated board (up to ,, mm thickness) Carton board Heavy solid board Semi-rigid plastics Laminate
Folding carton packaging applications, serving end-user industries such as: • Food • Wine & spirits • Liquids & beverages • Pharma • Healthcare • Detergents & houseld cleaning • Toys / Games / Playing Cards
Flat Bed Die-Cutting Process
storage
pile
die cutting
waste
separating
pile
storage
Stripping The Blanks Chart 1
Die-cutting is a process in which materials are cut in a specific pattern. Flat bed die-cutting is a process used for the cutting, creasing, embossing, waste stripping, and blank separation of a range of sheet materials, from light papers and carton board, through heavy solid board, plastics and in-mold labels (IML), to micro-flutes and most types of corrugated board. The process is used in a wide variety of sectors from packaging, label, and display manufacture to commercial printing. The sheets are separated in conventional vertical pile feeders and transported through the machine by means of a gripper chain. The sheets are cut one by one using vertical platen die-cutters; the
waste is removed and the individual blank delivered. The working principle is shown Chart 1. The platen die-cutter is based on the knife cut principle. The die is fixed to the chase of the cutting bar (also called “fundament�). The cutting table moves towards the fundament. The table is driven by a camshaft and toggle lever. The sheet is stationary during the cutting operation. After the cut, blanks and waste are still sticking together. This facilitates the conveying of the products through the machine and the disposal of waste. In a waste-stripping station, tools push the waste into a container. The individual blanks are still connected by attachment points.
15
The final process section is the separation of the blanks in the delivery. In this process, the gripper edge (if there is one) needs to be removed from the blanks and the blanks themselves need to be separated. Simple vertical die-cutters are not equipped with a separating unit of this type. This operation must then take place manually outside the machine. The platen die-cutter is equipped with steel-rule dies. With both types of tools, productive make ready of the machine for a job is possible since all cutting knives are arranged in one tool in accordance with the pattern to be cut out on the sheet. Steel-rule dies include a plywood base (multi-layer, 16 to 18 mm thick), in which the steel rules are inserted. Tracks are cut into the plywood base in accordance with the cutting pattern and the imposition pattern of the blanks on the substrate. The steel rules are inserted into these tracks To stop the inner plywood sections from falling out, the track is interrupted by crosspieces. The steel rule has recesses at these places To cut the contours into the base, computer-controlled
16
laser cutters are used. The data that is used to control the laser is the same as was produced for the development of the die-cutting products and for the sheet imposition. Release material, made of rubber, presses the sheet down on the cutting table when the die is opened. In this way the sheet is transported smoothly into the stripping station. With steel rule dies it is also possible to score and crease the products at the same time. For scoring, shorter steel rules are used than is the case with cutting. Steel rules for creasing are rounded off at the top. Two plastic rails serve as counter tools; the creasing tool sinks in between these two rails.
AUTOMATIC DIECUTTING MACHINE WITH STRIPPING ALTERNATIVE
BRAUSSE 1050SE
SHANGHAI ETERNAL MACHINERY CO., LTD.
Indonesia Partner:
Shanghai Plant: No. 1125 Taishun Road, Anting Town, Jiading District, Shanghai, 201814 China Tel: + 86-21-59502451 59502481~2487 Fax: + 86-21-59502477 E-mail: sales@eterna-shanghai.com International Sales Dept: T1/13AB,Gateway Plaza, No. 2601 Xietu Road, Shanghai, 200030, China Tel: + 86-21-64262538 Fax: + 86-21-64262153 E-mail: export@eterna-shanghai.com Website: www.eterna-group.com
www.tosijasindo.com info@tosijasindo.com +62 21 75902726
17
Specially equipped platen diecutters are able to do embossing or relief embossing operations. For hot-foil stamping • the base must be heatable (regulated heating up of the stamp), and • the machine must have an unwinding and rewinding unit for the foils. A flat bed die-cutting press may be an offline, stand-alone machine, or may be inline with a printing press and/or other units. Having been fed into the press and held by a gripper bar, the sheet of substrate is transported through a
1. FEEDER OR LOADER Using suction heads or a push system, this unit transports sheets from the pile to the machine in-feed. Can be equipped with preloading systm with either preloading cart or with pallet jack tto reduce down time. It will have four pick up and four suction heads with angle adjustment. The turbo spiral air blower will smoothen the sheet transport. 2. IN-FEED Takes control of each individual sheet and registers it to the cutting tools using mechanical or dynamic registration. Slented Feed Table to obtain stable and accurate registration especially for light weight paper at high speed. Side lays on both left and right hand sides push and pull convertible. Sheet will slow down device of feeding belts with selective o/ off switch to ensure accurate registration of the sheet at the front lays.
18
number of stations which carry out sequential processes. The exact configuration of a flat bed diecutter will vary depending on the application but, in broad terms, the elements that may be present are:
3. PLATEN SECTION This is the heart of the machine, bringing the cutting die and cutting plate together under pressure. Held between them, the sheet of substrate may be die-cut, creased or embossed, depending on the application and substrate. With pneumatic push botton die chase locking mechanism to ensure safe and operator friendly during job change. The gripper bar will drive chain tension display with maximum pressure limit protection. Seven high precision alloy griper bars. State of the art 3 cam index gripper bar driving system to ensure smooth and precise gripper bar intermittent movement. The air blasting nozzle bar will stretch light weight paper. 4. STRIPPING SECTION Internal waste, and sometimes side and rear trim, is removed using an upper stripping tool, central stripping board, and, in some tooling arrangements, lower stripping pins. Triple action movement of the upper and lower stripping frames with lower spring loadset stripping pins. The upper and lower stripping toll mounting frame can be pulled out for job set up. The motorized upper frame suspending hoister. 5. BLANK SEPARATION SECTION (this unit is good for a very very long job only). Using universal or dedicated blanking tools this unit pushes individual cartons from the sheet, creating a pile of flat blanks ready for further processing or for transfer to the customer. A blank separation unit incorporates its own delivery unit 6. DELIVERY On machines with no blank separation section, the delivery creates either a pile of full sheets or of blanks attached to each other by nicks. The front trim of the sheet may be removed at this stage. Nonstop delivery with automatic slow down, designed with safety device should be choosen. The sheet stretching air blower and sheet tail pressing down brush bar. Rear and side joggers with easy position adjustment would be good. Counter with Tape inserter also possible. 19
Know How to Perfect
“DIE CUTTING” cutting die
press plywood substrate
cover sheet carbon paper
creasing channel
patch paper
W
sheet material
ejection rubber
press
thin plate
ithout Die Cutting, there will be no Corrugated Boxes as well as Folding Carton. To make a good and attractive Corrugated Boxes and Folding Carton we need the perfect Die Cutting as well, therefore we held one day seminar “How to Perfect Your Die Cutting” last 26th April 2018 at our Packaging Centre PT First Packaging Asia, Cikarang. This seminar presented by Mr. Markus Stegmann, CEO Marbach Asia Pacific, the pioneer and the best Die maker in the WORLD. He presented how to choose the right Cutting, Creasing and Rubbering for each of our box production to assure the perfect quality we aim for.
20
steel rule die
creasing rule die
It turn out each material may need a certain type of cutting, creasing and rubbering to assure the high and smooth production. For example we need to determine the job will be laminated or not. The cutting and creasing for job with and without laminated would be a different kind. Mr. Stegmann also give us guidance how to set up the die cut machine properly as well as the use of canal, counter dies and counter plate. While Mr. Erfin Prasetyawan from PT First Packaging Asia give us guidance how to make the right layout with its step and repeat to get an efficient box production to
run the machine on its full speed production capabilities. Then Mr. Erfin explain how to design the right knife and board to support high speed and perfect quality box production. How to make a prefect knife to assure there will not so many narrow channel which might make problem on the stripping process. Rubbering also one of the most important things to support high productivity. Some people tend to underestimate the necessary of rubbering and would like to get a simple and very low price rubber. This is a wrong perception. Rubber is also very important. We have to determine the right hardness (shore) of the rubber necessary for each job function. If we use the wrong one, we might not get a clean cut and stripping of the boxes – resulting we have to do some manual cleaning as well as might increase the waste. The width of the canal also has to be determined perfectly to assure that we can fold the box rightly and not affecting cracking. We have to
calculate well the width of the canal not just making estimation. Last but not least we also need to make the necessary Patching. Patching will increase pressure in some uncut point. By using the right Patching we can increase the speed of the knife on the counter plate as well as prolong the life time of the counter plate. The seminar participants come from various industries and they were very keen with the seminar subject and request us to arrange more advance knowledge of the Die Cutting, which we will arrange it by this year as well. by Mr. Erfin Prasetyawan
21
Die Maker Equipments Die Board Cutting Stripping Tools Sample Making FIRST CUT merupakan produk diecut dan berbagai tooling untuk produksi corrugated (flatbed die cuter), folding carton, flexible circuit ataupun greeting card. Tim kami telah berpengalaman untuk memproduksi diecut dari berbagai macam folding boxes dan corrugated boxes. Pengalaman dari tim kami akan memastikan pembuatan produk yang berkualitas, biaya yang ekonomis dan efisien. Setiap proyek akan diteliti oleh tim berpengalaman kami dengan memperhatikan secara detail apa saja yang dibutuhkan agar produksi Anda menjadi lebih produktif dan lancar. Kami bersedia memberikan saran ataupun internal training di perusahaan anda jika dibutuhkan. Pengalaman dan skill tim kami dilengkapi dengan teknologi terbaru
dilengkapi dengan peralatan yang memadai: • Software khusus untuk kemasan • Laser cutting machines • Automated rule processing cutting • Automated bending machines • Sample Plotter Kami memiliki data base yang lengkap untuk memenuhi kebutuhan customer kami, baik corrugated (FEFCO) maupun folding carton/ECMA dan display boxes, Software khusus kami untuk kemasan dapat mempersiapkan gambar detail yang tepat dan efisiensi untuk memenuhi kebutuhan customer kami (sesuai dengan permintaan dari Brand Owner). Kami dapat membuat layout dengan otomatis baik untuk single atau multiple nesting yang memastikan efisiensi pada produksi dengan minimum
website: www.firstpackagingasia.com
waste. Software kami akan mengikuti kriteria dari material yang digunakan arah dari flute atau grain dari kertas dengan secara otomatis memilih arah yang dibutuhkan untuk produksi. Membuat design male, female, dan front edge strippers dengan tingkat keakuratan yang tepat. Stripping sistem yang didesain dengan menggunakan dynamic stripping system. Kami juga menyediakan jasa pembuatan Sample atau contoh untuk : Cartons Corrugated boxes Display boxes Labels Bags Flow wraps Peralatan Penunjang : • CAD system for cutting out cartons • Die cutting and creasing
email: fc.dies@gmail.com
System Tolerances in Flexo Printing
Which tolerances are of most concern in flexo printing? Which tolerances are holding back the process’s fitness for the future and further development? What therefore do we need to work on hardest? PROF MARTIN DREHER All printing processes have one thing in common: substrates come into contact with the most diverse array of materials on the press and through the laying down of inks and varnishes, the application of coatings as well as lamination and other converting technologies they are combined to form a new product exhibiting defined properties. The correct interaction of the components determines the final print quality that can be achieved. For print shops, the primary concern is the quality of the visual impression made by the printed image. However, a whole series of physical and chemical requirements must also be fulfilled, whether it be, for example, the adequate adhesion of the ink to the substrate or its resistance to heat during sealing or sterilization. 23
A
printing press brings together very different materials and the success of such a “combining process” is always dependent upon the properties of the particular components involved. These usually exhibit specific tolerances. Just as the viscosity of the ink may vary slightly over the course of a print run, so too can the ink acceptance behavior of the substrate. Of course, the variations that arise may cancel each other out but this tends to be the exception. It is no surprise therefore that the final printed product is also subject to variations and in extreme cases, these can be significantly greater in total than the tolerances of the ink and the substrate. There are two fundamentally important requirements for the production run. Firstly, the printed image must reproduce the customer’s copy to within very narrow tolerances and secondly the printed ink film must exhibit certain levels of chemical and physical resistance. This means that press settings need to be constantly adjusted to compensate for material tolerances and furthermore, the
24
press itself and its elements (anilox roller, flexo plate, and blade) also exhibit tolerances. What could be more obvious than to minimize the amplitude of the variation that is “tolerated?” Which tolerances really matter? First of all, it is possible to divide these variations into various categories. One such category consists of the topological tolerances of the various elements in the press: mechanically determined height differences due to cylinders with concentric running errors, differences in the thicknesses of plates and adhesive tapes down to substrate thickness tolerances. Taking a more detailed view, a distinction can be drawn between concentric running and thickness errors, which are generally measured in tens or hundreds of micrometers, as opposed to the roughnesses of plate and substrate surfaces, which are also subject to variation but in the single digit micrometer range. Here, these parameters are grouped together and referred to as “Z deviations.” During ink transfer in the roller nips these Z deviations lead to dynamically changing printing
Eight-color central cylinder flexo machine at the DFTA Technology Center
ratios, which can influence the local distribution of the ink. In flexo printing this can affect both the XY dimensions (squeezing, pushing the ink sideways) and the Z dimension (ink film thickness or homogeneity of the ink layer). In addition, the roughness of the plate surface and the substrate can result in major qualitative differences in the transferred ink layer. Deviations in the XY directions are detectable in the printed image as register errors. The dimensional stability of printing plates is subject to tolerances and is a decisive factor here. Unlike cylindrical formers, flexo plates have to be mounted on a carrier and deviations from the ideal are possible. Plate mounting can, however also be used as a corrective mechanism. For example, it is possible to at least partially eliminate register errors resulting from plate sections that are slightly out of position. If the web is printed with each separated color as it passes through the press then its weight increases from one printing unit to the next. This is a complex process and clearly it can lead to deviations. On the one hand, in many cases the individual inks can affect the stability of the web tension as they are printed whilst, on the other hand, it limits the rotational accuracy (angular positioning) of the printing forms on even the best presses. A distinction can also be drawn between systematic errors (e.g. through the relative displacement of forms and substrate or deviations due to mounting) and dynamic errors (the positioning errors referred to above). All can lead to register errors during printing.
The deviations described so far can be quantified by means of linear measurements, which in some cases require precision of the order of a nanometer. Another category of tolerances relates to the physical properties of the substrate’s surface. Anyone who has ever printed plastic films with water based inks will have clear idea of just how important surface physics is. However its impact is not confined to substrates and inks. It also comes into play with other surfaces that are involved in the process, such as those of the anilox roller and the forme. Although there have long been theories about surface energy levels, too little is still known about this subject. There is no robust measurable value that will reliably predict the printability of any substrate with any ink. The DFTA technology center is currently undertaking research into this. Ranking the tolerances In order to better understand flexo printing, tolerances, some of which have already been mentioned, need to be ranked in terms of their significance for the printing process. The following list arranges the factors that affect flexo printing in order of how difficult it is to quantify them. What is surprising is that it matches how significant they are for print quality. In 8th place: Flexo plate thickness variations Thickness variations in flexo plates as a cause of poor print quality have faded into the background in recent years because the interaction between relatively hard formed materials and the substructures 25
used with them compensates more effectively for errors that arise. When measuring thicknesses the elastic photopolymer material deforms slightly in response to the usual thickness gauge feeler but this can be effectively dealt with through the area of the gauge’s feeler, allowing definitive measurements to be obtained. Currently, plate thickness variations are the least significant factor affecting flexo print quality. In 7th place: Cylinder and roller concentric running errors It is relatively simple to quantify cylinder and roller (formes, anilox rollers impression rollers on flexo press units or impression cylinders on CI flexo presses) concentric running errors. Obviously, modern presses with unworn bearings peform significantly better in this respect than older ones. By using modern materials and tools good results, although probably not the very highest quality, can be achieved even with older presses. In 6th place: Mounting tape thickness tolerances It is more difficult to measure the thickness or soft mounting tapes than flexo plates. However, since in combination with modern plates, it is possible to achieve good print 26
quality even with differences of more than 12 micrometers in the thickness of the mounting tape, such variations are ranked in the lower half of the list of factors affecting print quality. In 5th place: Surface structuring of flexo plates The currently available options for structuring plate surfaces have improved flexo print quality. This factor is ranked above thickness and concentric running tolerance because it has a greater impact on the printed result. However, it is unclear how these structures and especially their structures and especially their depths, should be measured or checked in practice. It is not for nothing that the DFTA technology work group is also looking at this question. In 4th place: Printability The printability of a substrate cannot be determined by measuring its surface energy, even if this can be broken down into polar and dispersion components. Experience has shown that there must be at least one further and as yet unknown factor that exerts a substantial influence on printability. However, the relevant understanding is still lacking, which explains its high position.
Source: DFTA Micrograph of a register error
In 3rd place: Register accuracy of the mounted plates It is desirable to measure the register accuracy of mounted plates but the underlying fundamental question is how good could the register of this job actually be if all the other parameters on the press were right? In other words, was the plate mounting precise enough? There are now automated systems for mounting flexo plates. These are capable of a high throughput but are expensive to purchase and so relatively high volumes of plates are required to make their use economically viable. Furthermore, these systems only takes the XY dimensions into account, height tolerances are ignored. In 2nd place: Ink surface energy As relatively low viscosity liquids, inks elude a quantitative examination on the press. Here it needs to be realized that to a much greater degree than with substrates there is a lack of understanding as to which factors and if applicable measurements result in what impact on print quality.
28
In 1st place: Anilox roller cell volumes It is the yet to be satisfactorily resolved measurement of anilox roller volumes that has the greatest influence on print quality. Uncertainty continues to prevail over the precise determination of the actual ink transfer volume of an anilox roller. How much ink does an anilox roller actually transfer? All one knows for certain is that it is definitely not be stated theoretical cell volume, because no cells are completely emptied during ink transfer. This factor becomes less important if inks no longer need to be constantly changes, as has to be done with spot colors. The production process can be adjusted more effectively if anilox rollers remain on the same press unit and always print the same ink. The uncertainly over the quantity of ink that is actually transferred no longer presents much of a problem. This in turn is one reason in favor of printing with a fixed color palette. Possible steps and improvements In some areas there is scarcely anything left to improve. These include the thickness tolerances of plates and adhesive tapes, as well as the concentric running precision of cylinders and rollers. In the case of the surface structuring of flexo forms there really is hope that one day it will be possible to reliably check and measure their patterning and formation. A plausible working hypothesis could be available within the next few years that would allow the phenomenon of higher ink transfer due to these surface structures to be predicted quantitatively (and not just qualitatively) and therefore to be controlled.
It is not currently possible to numerically quantify the printability of any substrate. Some of the research activities at the DFTA Technology Center in Stuttgart are already focusing on this but, as already mentioned, at least one important parameter is missing. However, if this printing process is to be industrialized then it is vitally important to have reliable foreknowledge of substrate printability. Only then will it be possible to set the press up in advance with the minimum of effort, instead of the current situation where one feels one’s way towards the desired printed result by a process of trial an error. Accurate flexo form register benefits from automation but automated flexo plate mounting systems are too expensive. Furthermore, they are tailored to a set format size and therefore to a limited market segment. However, the need for automation is so pressing that further developments in equipment and improvements may be expected. Quantifying the printability of substrates is only useful if one is able to successfully describe its counterpart, the ink, in the same way. This means that it needs to be possible to perfectly characterize flexo inks by mean of a number of easy to use quantitative values. It is not currently possible to satisfactorily determine the actual volume of ink transferred by an anilox roller. The same is true for the measurement method, which ultimately, attempts to quantify the amount of ink transferred on the basis of the volume of air in the cells. However, real advances in its
development have been made. At present, only one technology, the DFTA Technology Center’s anilox roller measurement technology, is able to partially quantity the amount of ink transferred, but even this technology cannot be used with real inks. Here there continues to be a great deal of uncertainty. Printing with a fixed color palette without large numbers of spot colors might be a solution in future, because it is these color that are particularly affected by imprecise information about the actual volume of ink transferred by anilox rollers.
Source: Zecher Lengthened cells should improve the emptying of ink from an anilox roller
Summary The team at the DFTA Technology Center has investigated the tolerances of certain flexo printing parameters and the influence that they exert on print quality. Some of the result may perhaps be a surprise to the industry and might stimulate discussion. The staff of the DFTA Technology Center would be happy to engage in a lively exchange of views on these technical questions. Flexo & Gravure Global 1-2018 29
TRUE HYBRID Changing the Perception of Digital Digital printing has been a popular topic of discussion for labels and packaging over the last decade. Historically an industry dominated by offset and flexography, the narrow web label market is realizing a shift toward new production methods, those being digital and digital hybrid workflows.
“
Data shows true hybrid brings two shift of flexo work down to one, and reduces ink and substrate costs by up to 20% by Chandler Davis
30
“
A
ccording to a study by LPC Inc., 50% of label presses sold in 2016 were digital devices and it is predicted that by 2020, three out of every four units sold will be digital. One of the main drivers of digital growth is new requirements by converters’ customers the brand owners. Brands are investing more time and energy into their labels and packaging in hopes of connecting with product consumers on a deeper level. As shelves become more crowded, standing out is critical to maintain sales revenue. In fact, the Food Marketing Institute reports SKU growth is more rapid than ever before, with an average of 39,500 SKU’s in the typical North America grocery store. This equates to a 400% increase in the number of goods available for purchase in the last 30 years. SKU proliferation is everywhere, which in turn reduce run length or units per job. Seasonal goods and sophisticated customization, such as variable data printing (VDP) and versioned graphics, are also preferred by the end user, pushing low volume label orders and an even bigger need for digital technology. WHERE DOES HYBRID FIT? The need for shorter runs also comes with the need to differentiate. That’s where hybrid comes into play versus conventional digital process. Digital hybrid is a printing method that leverages the advantages of digital printing with the proven capabilities of flexo in a single pass. A hybrid production unit combines traditional flexo embellishment, inline
converting and digital printing into a single solution. In the past, all of these necessary label production steps would need to be done using several processes and pieces of equipment. Offering a profitable solution for label converters, hybrid technologies maximize the long lasting success achieved with flexographic capabilities while providing printers with the opportunity to stay current with market trends and meet the straining demands from their customers. THE MANY FACES OF HYBRID In recent years, many OEMs have brought hybrid digital solutions to market. That said, hybrid comes in many forms: Semi, Modular and True. Semi Hybrid devices use near line finishing methods and consist of multi company integrations. For these types of presses, two or more companies buddy up to support digital printing and finishing components of the label production process. Modular Hybrid solutions are digital retrofits for flexographic equipment. Offered through programs like Mark Andy’s Digital plus program, solutions of this nature aim to allow converters to enhance existing
Digital Hybrid presses combine flexography with Digital Print. Photos, including FLEXO iQ cover, courtesy of Mark Andy Inc
31
assets with the benefit of digital without having to invest in a new, standalone piece of equipment. This type of solution is well suited for the converter with a specific application need, such as VDP or marking. Additionally, Modular Hybrid solutions are great for companies facing capital constraints of those wishing to make better use of an underutilized legacy press. The last and arguably most efficient classification of Hybrid is true. True Hybrid provide single source production platforms with web handling, digital print, converting and finishing in one pass. As of early 2018, there were more than 80 pieces of true hybrid equipment in production, ranging from approachable entry level units to high output devices. Data shows trues hybrid brings two shifts of flexo work down to one and reduces ink and substrate costs by up 20%.
“
According to a study by LPC Inc., 50% of label presses sold in 2016 were digital devices and it is predicted that by 2020, three out of every four units sold will be digital
“
THE POWER OF THE PLATFORM Many converters are making the shift to true hybrid due to the advantages of the process. Inline converting is the standout differentiator. Blank rolls of material put on the press are transformed into expertly crafted labels and packaging ready to be sent to customers, all in a single pass of production. Substantial time and waste savings are achieved; Mark Andy digital hybrid customers are reporting 50% and 20% savings, respectively. True hybrid also reigns king when evaluating the ability to differentiate through decoration. This is especially important in craft industries, 32
True Hybrid Presses support Inline cold foil, among many other decorative features.
where highly embellished output is the standard. True hybrid presses enable the same degree of customization flexo provides. A printer can utilize cold foil, varnishes, laminates, digital special effects and intricate die cuts in a single pass. With semi hybrid solutions, this is only achievable with ancillary equipment or secondary decoration processes, leading to more downtime. The same concept rings true when addressing upgradability of true hybrid. Unlike semi or modular solutions. true hybrid enables a clear upgrade path with a longstanding partner.
Another clear advantage of true hybrid solutions is the single source nature of the product. Adopters of true hybrid are clear who to reach out to with any questions, as opposed to with semi or modular hybrid solutions. If there are questions about new application development or substrate compatibility, the OEM is always available and knowledgeable. One company stands behind your business, your equipment and your success. The same concept rings true when addressing upgradability of true hybrid. Unlike semi or modular solutions, true hybrid enables a clear upgrade path with a longstanding partner. WHERE HYBRID IS HEADE There is no denying flexography has a stable place in package printing, but the future of flexo isn’t the humble tape press from the industry’s infancy; rather, the intuitive digital hybrids engineered in the last few years. Hybrid comes in many shapes and sizes, and every converter’s need is different. With inline converting and decoration, a clear upgrade path and rock solid support, true hybrid provides a future proof platform with the flexibility to change as individual business needs and the market require. Source: Flexo Magazine, March 2018 www.digital.realviewtechnologies.com
33
INLINE FLEXO THE KEY TO ADDED VALUE PACKAGING FOR RETAIL MARKETS ALLAN SANDER “With stable printing and coating running at speeds up to 800 m/min (2625 fpm), the ability to include many processes in a single pass with a high level of versatility through modularity is important. The latest inline flexo presses provide a competitive solution for delivering retail packaging solutions that add value through a variety of means, not just for consumers, but for the supply chain as a whole.” A COMPLEX COMBINATION OF DEMAND Arguably, the packaging has to work harder nowadays to generate sales. At the same time, supply chain partners face greater cost and time pressures. Converters are expected to deliver smaller volumes, at very short notice and to reduce logistics and warehousing costs. These trend are having a disruptive influence on the supply chain, particularly for converters. This complex combination of demands makes it essential for converters to invest in a press that offers the right mix of versatility, quality, efficiency and speed capabilities to suit customer’s needs. 34
Inline flexo has clear advantages for many package printing situations, as it offers both the high standards of quality and flexibility. MODULAR INLINE FLEXO While offset provides a fast, economical workflow, the same can also be said for flexo, thanks to advances in printing plates and digital imaging systems that enable a definition of 70 l/cm (180 lpi) to be achieved. For the consumer, this level of quality is indistinguishable from either offset or gravure. However, the thicker ink coverage of flexo makes it possible to achieve richer solid colors, andan array of contrasting varnish effects in a single
pass, and quality reproduction on economical substrates such as Kraft paper. Inline flexo offers modularity, so that presses can be configured with any desired number of color and coating stations and complementary processes. These can include reverse printing, coating, the inclusion of digital and rotogravure processes and a combination of different ink sets, in a single pass. It is the role of the press manufacturer to look carefully at the converter’s job mix so that the optimum press configuration can be devised. The right choice offers a return on investment that should continue for 20 years or more. Another important advantage of inline presses is the ability to add additional units as needs change. A gap in the middle of the line can be created to retrofit UV curing, inkjet modules, or not yet invented enhancement techniques. For liquid packaging applications, it is possible to integrate cutting and creasing units between the printing stations and rewinder. ADVANCED DRYING AND CURING Line configurations also allow a greater web distance between printing stations for better control and faster speeds during drying
and curing. This enables hybrid flexo printing combining several water based stations with one or two UV curable and solvent ink printing stations to be used. Inline flexo is beneficial for fast water based printing because a longer web path between printing stations is possible, resulting in cleaner color printing. High performance drying depends on air flow and velocity rather than temperature, especially when water based inks are involved. Tresu has optimized drying efficiency by situating the fan that supplied the air and pressure inside the drying hood, thereby shortening the distance from the fan to the air nozzle. This enables heat and noise to be contained within the head and provide better insulation: up to 80% of the air inside the dryer and 60% of the exhaust energy can be recycled, through an overhead exchanger. Additional UV flexo units for adding a high gloss or matte varnish effect are specified for high end packaging, not only to provide reflectivity, but to create a velvet soft touch effect. Using both varnish types in combination provides a contrast to make a logo or icon stand out. UV curing in these situations is a productive alternative to water based inks that may require excessive ink coverage. 35
The Tresu Flexo Innovator is a mid-web flexo printing and multi-process finishing line for folding carton, laminates, metallic substrates and paper applications
Solvent flexo inks are in decline, but still chosen for specific applications, like adhesion and abrasion resistance. Incorporating solvent Inline with UV or water based stations has not impact on the web path or press footprint. However, because of the ink’s flammability, the unit must be sealed and grounded to meet ATEX regulations, meaning more covering of the press. To comply with environmental regulations, exhaust drying air for solvent inks must pass through an incinerator before being evacuated from the factory, and 36
must not be mixed with air used to dry water based inks. INLINE FEATURES SHOWING A GROWING DEMAND Double sided coating capability is a growth area, for printing and coating on the inside of the carton. This is used to give grease and water proof qualities to fast food containers and provide decorative images. With flexo, this process is integrated into the line with ease, with the addition of a turner bar.
Digital inkjet printing modules are increasingly requested not only for coding and numbering for track and trace data, but for consumer promotions with the inclusion of QR codes that link to a website to enhance relationships with a brand. These units are normally integrated in the final printing position, mounted on a platform above the press. Metallic, high lustre and scratch and sniff effects can also be applied and cured by the standard flexo process, thanks to the development of inks together with specially designed ink supply systems and chambers to apply the ink at carefully controlled viscosity levels to protect the particles. For cold foil lamination, a UV curable adhesive is applied to the board, then the metallic foil is laminated, cured and the waste is split away and rewound. The extra processing requirements limit speeds but following extensive tests at Tresu we have achieved speeds of 160 m/min (525 fpm) when incorporating this process. AUTOMATION FOR A LEAN WORKFLOW Automated ink supply systems regulate viscosity, flow rate and pressure at precise levels. Chamber doctor blades, available in lightweight, corrosion resistant carbon fiber as well as ceramic and aluminum varieties, ensure even coverage, consistent ink density and contamination free printing at the highest speeds. Their seal systems prevent leakage and safe exchange of doctor blades is possible within two minutes.
Automated ink supply systems enable fast, simultaneous cleaning of the chambers at all print stations after the job is finished within a few minutes and the return of ink or coating media to the bucket after printing. This feature significantly cuts make ready times and delivers significant long-term ink savings. Thanks to automatic controls and supply systems, manual intervention is minimized. Inline flexo offers potential for ergonomic design because all parts of the press are easily and safely accessible without the need for ladder. STABLE PRODUCTION AT MAXIMUM SPEEDS One of the strongest advantages of inline flexo is speed, which is significantly faster than sheet-fed offset. Speed optimization depends on a controlled and enclosed ink supply, servo drives, sleeve systems that eliminate bouncing, automated register controls, tightly regulated web tension and drying system design. These features can be included in the latest presses, ensuring stability and quality consistency at up to 600 m/min (1969fpm) in many cases and sometimes, even 800 m/min (2625 fpm). Web tension can be measured at all units with relatively little intervention as it is controlled centrally through a single human machine interface.
by Magazine “Flexo & Gravure Global 1-2018�.
37
FIRST PLATE
Membantu Anda untuk pembuatan plate Flexo, Baik untuk narrow maupun wide web applikasi Flexible Packaging Tag & Label Pre-Print Corrugated
Finger Print Elements
-
Process Control Solid Color Patches - Proses dan Spot Color Overprint/Trap Patches Gray Balance Patches Tone Scales Vignettes Barcodes Line danType elements Mechanical Control Registration Targets Impression & Blur targets Solid Ink Color Patches Printer Control Target Prepress Control Target Pencatatan Data Catat semua proses dan kondisi pada waktu dilakukan Fingerprint. Ukur beberapa sample untuk memperkirakan hasil yang dapat dicapai dan apa saja kendala-kendalanya website: www.firstpackagingasia.com
email: fp.plates@gmail.com
Food and beverage industry
EKOPLAZA Supermarket in the Netherlands Invites You to Shop “PLASTIC FREE”
40
O
ver the past several decades, the world’s population has been credited with believing. “We can not live happily ... if the food industry on the planet does not have plastic,” but that would be just a lie. The latest Dutch supermarket chain Ekoplaza has come up with the opportunity to launch a new 100%. At the new store opening of the godfather Ekoplaza Supermarket in central Amsterdam, over 700 items have been presented to consumers in a new, non-plastic packaging format. Including materials. On sale floor is made from all other alternative materials. The challenge for this mainstream consumer market is the collaboration between the Ekoplaza retail brand and the A Plastic Planet environmental campaigners who want to motivate the global population to change their attitudes. About Food Packaging And turn to help reduce the amount of plastic waste that is. ‘Ocean overflow’ in today. Erik Does, the chief executive of Ekoplaza, told the media. “The plastic-free shelves offered by Ekoplaza are an important step in revolutionizing the food and drink industry in the mainstream. Customers can buy almost anything from this shelf. Beef, rice, seasoning, yogurt, cow’s milk, cereal, chocolate, and seasonal fruits and vegetables. The kind that you will not feel different from going shopping for ordinary goods. “
And another interesting point is that Ekoplaza is the first mass-market ‘super’ commercial supermarket to come out of plastic. The 2018 plan is to open the shelves. This plastic product is available in 74 supermarkets nationwide. “The food display in this plastic zone shelf is made up of only glass, metal, carton and plastic substitute materials that are biodegradable in nature. And although some packaging looks very plastic. But it is actually a substitute material made from plants and plants. They can be disintegrated in the waste bins at home within 12 weeks, “said Erik. Sian Sutherland, the co-founder of the A Plastic Planet campaign, added, “It sounds unreasonable, but first we think of a short life span. The food in the packaging is hard to destroy as plastic ... This plastic has only a few days to function. But back to floating in the sea, polluting the world for hundreds of years. “ Of course, the idea of a live shop against the excess is not something new in contemporary society. (According to many alternative markets, it encourages customers to bring their own bags or boxes from home.) But the issue that makes Ekoplaza’s plastics free zone is that it offers a shopping experience. In the same mood To the consumer. We can also pick up items that have been packed from the shelves and put them into a cart. Do not bother with changing behavior. Or worry that the food bought will be in the
41
bag. Or boxes of items taken from home will not fit the purchase of food, etc. “ However, making the change to sustainable packaging isn’t quite as simple as it sounds. The problem with plastics isn’t a new realisation in the materials industry, so there are various alternatives available. From chicken feather plastics to liquid wood, there are numerous experimental biodegradable alternatives to plastic, but which are we most likely to see in wide usage in the next few years? Glass Glass has been a staple of the bottling industry for years, but plastic bottles have risen in popularity in the past few decades. While the price difference was initially the main driver for many manufacturers considering switching to plastics, it’s likely we’ll see industry shift back to glass in the coming years. Glass is advantageous because it is endlessly recyclable, meaning that it can be used, recycled and recovered repeatedly without a loss in quality or purity. This is in stark contrast to plastics, where the material fibres shorten with repeated recycling and become ineffective and unusable. Aluminium According to the labour force survey, one-third of European households only have a single occupant. This isn’t specific to European nations either; the US has experienced an increase in single 42
person households since the 1920s. That’s why single-serve portions and ready meals have grown in popularity, bringing with them a rise in microwaveable plastic packaging. As a replacement for these plastic trays, food manufacturers can instead turn to aluminium. Like glass, aluminium is endlessly recyclable and its sustainability means it has a low cost of legislative compliance. Effectively, swapping to aluminium allows food manufacturers to remain as competitive as they were with plastics. While aluminium and glass are effective alternatives, some manufacturers will still require the malleability of plastics for their packaging. That’s why materials scientists have been actively developing biopolymer alternatives to serve as sustainable and safely biodegradable plastics. Most of these originate in byproducts of other industries. Liquid wood is derived from lignin, a waste product created in paper processing, while other bioplastics are known to use casein from dairy production or keratin derived from chicken feathers from poultry farms. But by far the most popular are plant-based polymers, typically from sugarcane or potato starch. The launch of a plastic-free aisle reflects a wider consumer appetite to reduce the footprint and environmental impact of their food. To remain competitive in the future, food and beverage manufacturers should consider the same things.
AIP 2018: BEVERAGE ENTREPRENEUR RISES FROM THE ASHES
S
teve Chapman, who co-founded “smart drinks” company Shine + with Zambrero food chain entreprenuer Sam Prince, says his road to success has been Ilned with thorns. Sharing his “hero’s Journey” at the AIP Conference in Queensland last week, he described using his ego as armour throughout high school. “You need to wear your ego comfortablyotherwise you will be found out,”he said. Always the “start-up kid”, Chapman sold his car wash services from his back-yard and carved out an inevitable path towards investment banking. However, realising he was “more entreprenuer than accountant”, he came up with an idea to sell an app, called faceBuy, for a billion dollars. The next thing he knew, facebook’s legal team sent him a cease and desist letter for trademark violations and deleted the 8000 follower facebook page Chapman had built. “The toughest thing was spending my dad’s $100K savings which were meant for his retirement,”he said. His biggest insights came in this dark season and he was able to rise above his circumstances and slowly pay his father back. It was a humbling time, with Chapman taking on a job
working as a PA for Zambrero food chain founder Sam Prince for three years, taking notes and making burritos. “The road back was tough and I had to shed my old skin,” Chapman said. Even the Shine + launch was met with challenges. The natural nootropic drink sold out straight away, finding its away into 2000 stores in 18 months. But 90% of the bottles they shipped broke which led Chapman and Prince to a packaging team which helped them qith a custom display holder which would ensure it wouldn’t happen again. They went on to devise a new 400ml range to roll out nationally but it too was met with challenges, with the matt black painted bottle chipping and flaking during delivery from China. “We then had to create shrink wraps and depalletise and apply new shrink wrap over the label,”he says. “We’re always on the journey of reinvention and we know we will continue to feel the chaos of the unknown. But we will continue to believe that anything is possible.” This article was reproduced with permission from PKN packaging news https://www/ packagingnews.com.au/ news/aip-2018-beverageentreprenuer-rises-fromthe-ashes 43
AIP 2018: COMBATING THE “PACKAGING IS BAD” MINDSET
S
ealed Air’s food scientist Karl Deily believes the industry can do more to combat the belief that packaging is bad. President of the packaging company’s $2.7 billion food care division, Deily has worked hard on designs which contribute to a more sustainable food industry, proving that packaging can, indeed, be very good. As a keynote speaker at the AIP National Conference, held from 2-3 May in Queensland, he talked about top trends in food waste, food security and food safety. “Packaging can have a significant role in reducing waste as well as driving towards a more sustainable solution.” he said. “Highly engineered suspension packaging for products such as TVs can reduce damage and offer a sustainable alternative. There is also packaging which can mask brand names on e-commerce parcels and prevent thieves prowling front door-steps.” One of Sealed Air’s developments is the Darfresh On Tray system, which enables denser packaging in shippers and a doubling of product shelf life. The retail tray lid and tray skin program have resulted in zero skeletal waste.
44
He believes suppliers should also be thinking about using statements such as “this packaging uses fewer trucks” to draw attention to the value of sustainable packaging. He cited Plantic as a company which uses use bio-derived, renewable resin for its meat packaging, showing examples fro Coles. “Innovating the package as well as components to put on the package is vital.”Deily says. Here are some other strategies for reducing food waste, according to Deily: • Repurposing “ugly” fruit and veg in meal kits • Better temperatute control and sustainability of meal kits by using wool as insulation • Working to get more food per truck, driving better shipping economics • Better communication of best-before and use-by dates to avoid waste • Industry consortiums getting the message out about technology and innovations around the materials they use for packaging.
This article was reproduced with permission from PKN packaging news http://www.packagingnews.com.au/news/ aip-2018-combating-the-packaging-is-badmindset
Small Pack Euromonitor
GLOBAL FOOD PACKAGING TRENDS SIZE RIGHT AND PROVIDE PORTABILITY Rosemarie Downey, Global Head of Packaging Research, Euromonitor International Total demand for retail packaging amounted to 3.4 trillion packs in 2016, according to Euromonitor International. Food is the primary industry end-use, and is growing in line with demand for packaged and smaller sizes – the latter alone underpinned by a number of drivers, with affordability, health and premium product development being the key three cross-industry. RIGHTSIZING AS A KEY BRAND PACKAGING STRATEGY: GO SMALLER FOR HEALTH Rightsizing is a key packaging strategy being used by brands, with diversification rather than standardisation as the new order of the day. This is intrinsically translated into a shift toward smaller sizes and a wider range of pack sizes, enabling
brands to be more customised in addressing consumers’ healthier consumption requirements across food and soft drinks. SMALLER PACKS AS REMEDY FOR CONCERNS OVER SALT AND SUGAR INTAKE Portion control through smaller pack sizes is increasingly apparent across confectionery and snacks. In chocolate confectionery, the strongest global onward growth to 2020 in consumer purchases of tablets is set to be in the 0-50g size band. This smaller size trend is accelerating volume growth for flexible packaging; also true of countlines, in which Nestlé launched KitKat in a 17g flexible plastic pack in Vietnam in 2016. In biscuits, single-serve options further provide consumers with a biscuit alternative to the classic chocolate bar for impulse purchase. In 2016, Mondelez in Malaysia launched Mini 45
Oreo sweet biscuits in a 38g pack, whilst Swiss retailer Migros introduced Blévita Biscuits Müesli Mini sweet biscuits in 38g flexible plastic.
convenience for grazers is also gaining traction.
The move toward smaller sizes extends to ice cream, where the miniaturisation trend continues. In impulse ice cream, whilst 80ml is the most common pack size, globally the 0-50ml size band is forecast the most dynamic growth, of a 7% CAGR over 2016-2020, according to Euromonitor International, helping consumers to exercise restraint when it comes to indulging in their favourite ice cream.
OFFER PORTABILITY: BABY FOOD AND THE SUCCESS OF POUCHES OVER JARS Portability for busy on-the-go consumers is widely evidenced by the strong rise in purchases of single-serve beverages (soft drinks, dairy drinks and alcoholic drinks), where PET bottles, beverage cans and liquid cartons fare especially well. The need for portability extends across food, beverages, beauty and home care.
GRAZING AND ON-THE-GO TRENDS ALSO FAVOUR SMALLER PACKS Food packaging is influenced by on-the-go lifestyles, which lead to snacking throughout the day over formal meal times; added-value snack pack sales are on the rise to meet need, primarily the foray of the flexibles industry. Recloseability
According to Euromonitor International, in food packaging, portability applies even to prepared baby food, where the classic glass jar, accounting for 54% of global pack demand in 2016, down from 64% in 2011, is being usurped by lighter, more portable packaging solutions, such as pouches. © Euromonitor International 2017
46
Source: Euromonitor International
Corrugated INDUSTRY
53
ACCA’S MEETING
HELD ON 9TH APRIL 2018 AT THE HJ INTERNATIONAL HOTEL, DONGGUAN, CHINA MR. XU XIAOGUANG (Hexing/CPF) as President, ACCA expressed his thanks to all participants. On this meeting we have new mem ber Henkel and the representative of Henkel made a brief introduction Henkel organization and their respective products. Country Report on Their Local Corrugated Industry Activities and Services CHINA China Paper Packaging Industry In china at present paper only has 32% of the total packaging industry while in Europe has reached 41%. While the consumption per capita only 10% of the develop country therefore the opportunity to grow 48
is still very promising. We can see from the grow of the China National Paper Product output 68.088 million tons, an increase of 1.55% over the same period of last year. Among them, the output of corrugated cartons was 36,995,500 tons, an increase of 1.67% yearon-year. And the profit grow even much higher. In 2017, the national paper and paperboard container manufacturing industry realized a profit of 1,859.96 billion yuan, a year-on-year increase of 12.60%, an increase of 10.88 percentage points over the same period of 2016, and creating a new normal for the development of China’s paper packaging industry. Characteristics of the development of China’s paper packaging industry First, the industry scale achieved sustained and
steady growth (asset scale, output, output value, total profit, and total import and export volume). The second is the gradual optimization of the industrial structure. Pearl River Delta, Yangtze River Delta, Bohai Economic Zone, Central Plains Economic Zone, and Yangtze River Economic Belt - the five major paper packaging industry regions, accounted for more than 60% of the country’s paper packaging industry. Third, the ability to adapt to changes in the market continues to increase. Fourth, diversification of business development approaches and models. Fifth, the industry has taken a new step towards transformation and development. Intelligent manufacturing and “Internet Plus” have started, automated production lines and the plan to reduce emplyees from 1.000 person become only 100 persons. HONG KONG GBA Facts: • Total Population: 68M • Area: 56000 square KM • Total GPD: USD1.4Trillion • GDP 12% of China
GBA Aims to: • Facilitate development advanced manufacturing, innovation, shipping trade and finance, • Catalyst to the Belt and Road initiative • 12% of China GDP Corrugated Industry in the GBA • Usage in Guangdong: -- Y2017: 21,770,000T of container board produced -- Increase of 3.1% year on year -- Production volume the largest in China (17.3%) • Over 700 corrugators (over 1.8m) in GBA Analysis • Domestic OCC continues to be at a high level • Rising of pulp prices • Government enforcement of environmental policies • Limited New Domestic Supply • Limited Import Supply still limited => Kraft and Medium Prices continues to be high; depending on market may have drastic increase in 3rd or 4th quarter 2018
49
Challenges • Uncertain Market • Interest Rate Increase in US and Hong Kong • Trade War between China and US • RMB Appreciation INDONESIA Indonesia Economic Performance in 2017 is quite good with yearly growth increase from 2015 (4.88%), 2016 (5.03%) and 2017 (5.07%) and Indonesia also No 3 in G20 & Brics (China 9%, India 7,4% and Indonesia 5.6%).
1. Industry News / Trends Jan – March 2018, Demand of corrugated boards in Indonesia has been dropped about 1015% average. But in April, the demand is expected to increase again due to the coming big Moslem festival in mid of June 2. Price of imported OCC to Indonesia is low about USD 150 compared to domestic OCC price of USD 200 3. Few paper mills start to export to China again due to more attractive price than domestic price
PRICES TREND OF DOMESTIC MEDIUM LINER & TEST LINER
Note : 1. Prices per MT in USD 2. Prices based on exchange rate 1 USD = IDR 13.300
MALAYSIA Malaysia GDP Growth Slows to 5.9% in Q4. The Malaysian economy advanced 5.9 percent year-on-year in the December quarter of 2017, compared to a 6.2 percent growth in the previous three months and beating market consensus of a 5.7 percent expansion. Private consumption, investment, and exports increased at softer paces while government spending accelerated. For full 2017, the economy grew 5.9 percent, the most in three years. 50
Malaysia Inflation Rate at 16-Month Low of 1.4% Consumer prices in Malaysia increased 1.4 percent year-onyear in February of 2018, after a 2.7 percent rise in the prior month while market estimated a 1.9 percent gain. It was the lowest inflation rate since October 2016, mainly due to a slowdown in cost of food & nonalcoholic beverages and housing while prices of transport fell sharply. Malaysia Average Monthly Wages in Manufacturing 2012-2018 Wages in Manufacturing in Malaysia decreased to 3494 MYR/Month
Malaysia Corrugated Supply Vs Demand (’000MT)
in January from 3568 MYR/Month in December of 2017. Wages in Manufacturing in Malaysia averaged 2896.86 MYR/Month from 2012 until 2018, reaching an all time high of 3568 MYR/Month in December of 2017 and a record low of 2391 MYR/ Month in August of 2012. Corrugated Case Trend • E-commerce retail market in Malaysia continues to remain robust and growing at an encouraging rate which augurs well for packaging. • Advancement in digital printing technology posing a challenge to flexographic printing. • Slower demand for local paper amidst stronger Malaysian Ringgit resulting in local prices partially down in March 2018 after having stabilized in the last quarter of 2017 through February 2018. • Manpower shortage and high cost of levy forcing industry players to opt for automation. • New and upgrading of machineries increasing production capacity.
SINGAPORE S’pore Economy Outlook Positive • Singapore excellent infrastructure will continue to attract/retain high value manufacturing to ride on recovery in USA economy. • MIT helps to promote Food Industry (ready meal) for export. • The 2 IR continue to boost good demand in F& B industry. • Political stable Negative • Government tightens the foreign worker supply further with more increase in foreign worker levy and reduce the number. These will have impact to local SME. • Singapore open economy will suffer if trade war erupts between USA and China Manufacturing remained resilient (+8.9%) in Feb-18, dispelling concerns after non-oil domestic exports contracted (-5.9%) in Feb. Electronics (+17%) remains the key driver despite our expectations of a moderation due to the high base, boosted by 51
semiconductors (+27%). All clusters recorded gains in Feb except general manufacturing. THAILAND Corrugated Carton Industry Thailand H2/2017 & Outlook H1/2018 Economic situation • H1/2018: Thai economy in H1/2018 remained strong, supported by expanding in export sector .Thailand’s private consumption also improved due to an increase in consumer confidence. Government projects has fueled positive growth in tourism and private investment. • H2/2018: GDP 2018 is forecasted to grow by 3.6-4.6%: Driven mainly by the export due to the acceleration of the world economic growth. A global trade war from US and China may affect Thai exports. Private investment is expected to rapidly increase by growth in export. Thailand: Industry Situation H1/2018 and Outlook H2/20 Food and Beverages H1/ 2018 Organic growth in domestic demand. Most producers stimulated market by new products launch and marketing campaigns. Meanwhile,
52
export continued to grow especially from frozen chicken and canned food due to higher raw mat. supply. Domestic consumption could increase from improved consumer confidence (+) Food: High growth in poultry exports from secured food safety standards with expected +7% export growth y-o-y. (O) Beverage: Seasonal low demand during rainy season / new products and sizing strategy play key roles in stimulating sales. Challenges: New excise tax adjustment both Alcoholic bev. and Sugar tax Electrical Appliance Overall production picked up from 2017 , followed by innovative product launched and early summer season. At the same time, export orders remained strong from world economic growth. Positive outlook for export market (+) Air conditioner : higher demand both domestic and export. (+) Washing m/c: Higher production for export markets. (+) Multifunction copy m/c : Continued high production to serve export demand. Challenges: Indirect effect from US trade policy Consumer Products Aggressive promotional campaigns and E-Commerce sales channel help boost domestic demand. Growth of diaper products is forecasted to be at 10-15% per year. Export situation slightly improved. MNC producers continue to expand capacity in Thailand
(+) Skin / Hair care: Improve buying activities in export countries esp. Japan, Philippines. (+) Diapers and Convenience products: Sales expansion to rural areas and online channel. Challenges: Household indebtedness and consumer confidence. Corrugated Industry situation and trend in THAILAND • Labor shortage • Retail Ready Packaging is growing • Changing corrugated specifications from RSC to Diecut • Changing board construction to micro flute • Sustainability; reduce, reuse and recycled • Automation • Environmental Issue (Waste water treatment …) Retail Ready Packaging is growing Shelf-ready packaging (SRP) is delivered to a retailer in a readyto-sell merchandised unit. Products which come in SRP can be easily placed on the shelf without the need for unpacking or repacking Automation Investment Automation investment in order to increase productivity , improve product quality and serve E commerce market
• • • •
Increase productivity Increase running speed Short set up time Minimal man power (lack of Thai worker in Packaging industry). As usual after the meeting, we have dinner and exchange gift with each country. The next day we all invitd for the Hong Kong Association Anniversay Dinner which is amazing for me. The place ... the ceremony. During this event we also amaze by PackCon - The exhibition Hall for corrugated and other China
RSC W/A → Die cut Double wall Single wall converter plants display their products. Some innovation and good marketing strategy (will be covered in the Sino Corrugated Dongguan 2018 article on next page).
53
ACCA’S DINNER
54
DS SMITH PROVIDES A SECOND LIFE TO PIZZA HUT PACKAGING
“
The packaging specialists at DS Smith worked in partnership with Pizza Hut to extract the maximum benefit from its 100% recyclable
cardboard packaging, giving it a new purpose and functionality, and avoiding its disposal immediately after
“
its primary use was fulfilled.
55
U
nder the scope of the World Cup, DS Smith worked in close collaboration with Pizza Hut in Portugal, to provide a second life to pizza packages during this period.
the concept also aimed to offer a moment of relaxation while assembling the puzzle, especially after such a stressful situation as a football match!
The new, special edition pizza boxes (medium, large and extra-large), had a built-in puzzle/ball, allowing those who bought two pizzas to construct a ball with the two detachable covers from these new boxes.
The solution provided by DS Smith combined innovation and sustainability, with a genuine understanding of the client’s business needs. The packaging specialists at DS Smith worked in partnership with Pizza Hut to extract the maximum benefit from its 100% recyclable cardboard packaging, giving it a new purpose and functionality, and avoiding its disposal immediately after its primary use was fulfilled.
Based on the fact that these pizza boxes could do more than just deliver pizzas, DS Smith actively developed this innovative solution, which allowed Pizza Hut to communicate a brand message and stand out in an active and differentiating way within this specific time frame. This special edition of new boxes provided customers with an experience which was both fun and educational, engaging them on an emotional level. In addition to the fun that a puzzle provides, bringing friends and family together, 56
Recognised for its ability to innovate and the quality of the products it develops and produces, DS Smith employed a strategic approach which considered all aspects of its client’s economic, environmental and social needs. DS Smith not only helped Ibersol conceive new packaging to generate more sales, it also offered sustainable value to all stakeholders by providing completely recyclable packaging.
Packaging Solution
VALCO CORRCHECK
Cockling and Honeycomb effect due to excessive moisture
www.tosijasindo.com info@tosijasindo.com +62 21 75902725/26
The CORRCHECK enables you to measure your board directly as it comes off of the corrugator. There is no need to prepare samples for measurement. Simply place the device onto the surface and start to measure. If the resulting WBE is higher than allowed corrective actions can be taken immediately. Preliminary testing in real world applications are showing an excellent correlation with the visual appearance of the board. Depending on the application and the corrugated composition, different tager WBE numbers are typically used. An objective measurement tool for the washboard effect will allow you to define your quality parameters upfront, as it done for most other production parameters. The CORRCHECK offers new parameters for the corrugated industry. It is now possible to offer consistent, high quality products to packaging buyers. As in any other production environment, there is but one simple truth-quality means measure, measure and measure.
Relationship between amount of starch and washboard effect
CORRCHECK-the ideal measurement tool for corrugated board
SMS C300 is a modified tapioca starch product, applied in a corrugated board adhesive formulations. SMS C300 is suitable for use on single facer and double backer for all types of corrugated board and glue kitchen
High end application: WBE>0.007 is visible
Easily Dissolved character as peak viscosity during dissolution is low Stable Viscosity gives a more consistent operate on the machine and a better board quality Good Water Retention which leads to better bonding strength Less Consumption Less Consumption of glue due to better distribution allowing good bond strength with less glue
Packaging Solution
www.tosijasindo.com info@tosijasindo.com +62 21 75902725/26
57
INNOVATION – key to be profitable
DS SMITH LAUNCHES MADE2FIT TO HELP REDUCE E-COMMERCE PACKAGING SIZE DS Smith has launched a customisable packaging solution to enable e-tailers to reduce packaging size and associated costs, including void fill, storage, shipping and administration.
58
A
nnouncing the launch at the Deliver e-logistics event, Made2fit, is based on three available sizes of cardboard sheet (mini, small and medium), from which 33 different box sizes can be manually created in a quick and easy way. With built in crease lines and a tool for custom perforation, DS Smith says the product is the first ever 3D adaptable packaging in that it can be modified in three directions. Made2fit is estimated to reduce void fill by 80% on average, and achieve a potential cost saving of 3% on inbound and outbound shipping. Isabel Rocher, head of e-commerce solutions at DS Smith, said: “Made2fit has been developed to make a large difference to our small and medium sized business customers. We’ve taken our knowledge from working with large, global e-commerce firms, to help smaller companies reduce costs and streamline processes and administration. The aim is that this will allow these retailers to focus on what’s important developing and marketing great products. “At the same time, the product is aimed at delivering a great end user experience which enhances their impression of the retailer’s brand. Right sized packaging shows that a brand has a focus on sustainability and avoiding waste, and means retail customers don’t need to dispose of void fill. The boxes are also easy to open, and simple to return if the products consumers have purchased aren’t suitable.” DS SMITH RECORDS REVENUE AND PROFIT GROWTH ON WAVE OF ECOMMERCE BOOM DS Smith has recorded 21% revenue and profit growth along with strong organic box volume growth in its full year results. Revenue reached £5.76bn, while adjusted profit before tax was up 21% at £473m and profit before tax rose 11% to £292m. The positive results were boosted by strong organic box volume growth, which reached 5.2%, a rise of 5.2%. Additionally, a booming ecommerce market helped sales, along with a successful year for the corrugated giant’s North American business, which delivering ahead of initial expectations and registered strong returns with its cost of capital in initial period of
ownership. Moorgate Capital M&A expert Nicholas Mockett, said while organic growth looks convincing, DS Smith is really seeing benefit from its bold acquisition programme which is delivering higher growth in revenue with associated growth in earnings. “This is a key driver for mergers & acquisitions in the packaging industry, particularly where, like DS Smith, the acquire can beat its own expectations in integration or realising synergies.” “We are gaining market share and showing strong margin performance, offsetting significant input cost headwinds,” said Miles Roberts, group chief executive. “Our box volume growth continues to be impressive at just over 5%, demonstrating the continuing demand for our sustainable, high quality products.” Roberts said the company was confident its proposed acquisition of Europac will successfully build on its recent acquisitions in Europe of EcoPack and EcoPaper and also in the US, where the integration of Interstate Resources had delivered ‘excellent performance’. “We’re seeing good momentum into 2018/19, feel that our model is more relevant than ever for our customers, and view the future with confidence. DS SMITH LOOKS TO RAISE £1BN THROUGH RIGHTS ISSUE On 4 June the corrugated giant announced the proposed acquisition of the Western European integrated packaging business for for £1.9bn. The amount targeted will be used to partly fund the deal, which still needs to be approved by its shareholders at an annual meeting on July 10 which is the date the rights issue is expected to open, closing on 24 July. It will represent 27.3% of DS Smith’s existing issued share capital and 21.4% of the enlarged issued share capital immediately following completion.
59
Digital Corrugated Packaging In 1993 Benny Landa said, “everything that can become digital will become digital. Printing is no exception.� Since then, a lot has become reality.
60
Within the packaging market, digital adoption remains below 1%, however, for labels, this is around 18% and the next sector to follow is corrugated. Why? Because trends point to a major industry transformation.
Between brands, converters and corrugated equipment manufacturers, something big is happening.
• • •
Firstly, take brands, who claim that point of sale (POS) and packaging are extremely important in consumers’ purchasing decisions; there are various studies claiming that between 60%-80% of purchase decisions are made instore. At the same time, brands drive a proliferation of products addressing a growing worldwide population one that is becoming richer and more educated. In addition, faster time-to-market, personalisation, versioning and simplified supply chains are key success factors for all brands – big or small.
•
Reduced turnaround time Increased planning complexity Increased inventory of plates, cylinders and related tooling Requirements to lower box costs
The same happened in the labelling market and the solution came from the equipment manufacturers who delivered digital solutions, which have now been adopted and help converters and brands to deal with the challenges effectively. For corrugated applications, there is a number of manufacturers who already have established corrugated platforms. EFI, Durst, HP, Barberan, Inca, Erajet and Fujifilm as well as others who will enter this space soon, are enabling print service providers and converters to print corrugated Lastly, and not to be ignored, the sheets and POS in a new way. Their solutions range Smithers Pira data shows paper from printing rolls of paper used as a top liner in the packaging value $270 billion corrugated production proin 2016, it is worth 31% of total cess to print directly on to packaging market and represents pre-cut corrugated boards.
next material to experience digital revolution. A value of $1.44 billion in 2016 for digitally printed corrugated and will accelerate to over $2.35 billion by 2020. development of e-commerce is consuming more corrugated boxes than ever and these boxes are not always brown. From a converter’s point of view, brands are increasingly asking for: • Growing number of print jobs • Decline in the run length
Yes, the solutions are new and it will take more than a new digital press in your factory to be successful, but without looking at digital printing for corrugated seriously, you are going to miss something. Digital printing provides a way to do things that were previously impossible and, today, there is more demand than ever. In short, brands see packaging as the most important customer touch point. POS is a strategic part of the 61
customer shopping experience. Online shopping is driving growth for a new type of box and converters need to optimise their production to handle a growing number of short runs. In corrugated, despite the size of many cases, digital can deliver significant improvements over the analogue means of production, either direct flexo or indirect litho lamination or simple inkjet coding. This applies across different parts of the corrugated market. In post corrugated print, where the board is already made, flatbed inkjet printing allows brands to call off short run boxes at tight notice to avoid waste. Print can save time and money for retailers as well as improving presentation for brand owners because the style of presentation on primary packaging can be carried across to the secondary packaging. With the growth of discount retailers this becomes even more important. The corrugated box becomes the presentation vehicle, carrying promotional messaging which can be altered at short notice using digital processes. The additional cost of inkjet printing is more than offset by the additional value that print like this conveys.
62
Sun Automation has developed the CorrStream as a single-pass machine for printing corrugated and Spanish company Barberan has the Jetmaster in a variety of widths originally for printing laminates, but in use by Smurfit Kappa in Spain for corrugated board. The press uses Seiko heads. Inca reckons that for post print corrugated a production speed of 1,000 m2/hr is the threshold for acceptable production speed. Its latest Onset X3 can achieve this, though there are no in the field examples to back this up. DS Smith has an Onset at its Belper plant complete with the handling systems that load and unload the corrugated sheets to the press. Fujifilm has also delivered the earlier version of the Onset to Model Group in Switzerland. There is a set of OL inks, optimised for printing on the absorbent corrugated surface to keep costs under control and to deliver the low odour and gloss finishes that post corrugated print requires. The company has been running a series of seminars at its Broadstairs site where it has a demonstration machine with full automated handling capability, where it has developed the sets of inks needed for printing
on these surfaces and where participants are introduced to the potential of the market. “We have been working on corrugated for more than three years,” says Steve Wood, marketing manager for corrugated at Fujifilm Speciality Ink Systems. “We have the dedicated ink and handling systems for corrugated board sheets so have been able to show people where the opportunity fits for their business. It has been very successful.” The move to shelf ready packaging is creating a demand for higher quality decoration that inkjet an meet he adds. Fujifilm is also working on inks that are food safe, even though they are UV cured and direct contact is unlikely. But regulations around any consumable that comes near food, and shelf ready is by definition close to food, make this necessary. Legislation will continue to change. Part of the Fujifilm presentation is about the flexibility of its approach. The commitment can begin with the X1 machine operated manually, building through stages to a full X3 specification with automated loading and unloading of materials. “It’s about price point and speed,” says Wood. “We provide a choice because we have so many variations we can offer.”
Swanline reckons that 30% of its £12 million turnover is attributable to digital production, but is hardly scratching packaging at present. Likewise Inspirepac has installed an HP Scitex 15000, the latest version of the press, at its Markham Vale premises alongside flexo, screen and the ability to litho laminate. The inkjet press is not for packaging, at least not at this time. It is also happening everywhere. In Europe VPK, which owns Rigid Containers in the UK, is including digital production to a €6.5 million investment in Belgium, while Model Group in Switzerland is the first beta site for the Bobst flat sheet press using
It is also happening everywhere. In Europe VPK, which owns Rigid Containers in the UK, is including digital production to a €6.5
63
Kodak Prosper inkjet heads. Bobst believes there are strong prospects for this technology, also in use on a web press for flexible packaging. In corrugated sheetfed is the focus. The press runs at 200m/min on sheets to 1.3x2.1m maximum. Model Group believes this will be suited to long runs as well as short and for packaging as well as point of sale. “It will transform the packaging market fundamentally,” says Dr Daniel Model, chairman and CEO of the business. It is something that Bobst CEO Jean-Pascal Bobst agrees with: “This press will start a revolution in the corrugated packaging industry because it opens up such a huge range of possibilities to box makers, and to their clients – the brand owners.”
64
The greater potential comes through expanding the market. Currently preprint represents 10% of the corrugated market, mostly because of the supply chain issues. For DS Smith, the issue of digital printing is of strategic significance in creating maximum value for its customers as well as enabling continued market growth in the future. Being a pilot customer of HP, DS Smith was the first enterprise from the packaging industry to produce digital corrugated board pre-print.
Stefan Kunzmann, Sales & Marketing Director at DS Smith, commented: “The digital printing process requires no printing plates, meaning we are able to make last-minute changes and quickly react to current promotional campaigns and events. This can be of particular advantage when implementing marketing campaigns. A significantly shorter time to market is another crucial advantage of digital print for our customers. DS Smith is investing a total of approximately 15 million euros in the printing press, which has dimensions of 40 x 5 m and is currently being installed at the DS Smith site in Fulda, Germany. Specifically for this purpose, a hall has been gutted and furnished with new foundations. The official unveiling of the new digital corrugated board pre-print machine is scheduled for the second quarter of 2018. Smurfit Kappa proceed with Nozomi C18000 single-pass LED inkjet corrugated packaging press. The new
press is scheduled to be installed this month at one of Smurfit Kappa’s plants in Iberia – a facility that currently manufactures a wide range of boxes and trays, including ready-tosell packaging requiring higher-quality, full-color imaging. The Nozomi press, with its high-end grayscale imaging capabilities and fast running speeds up to 246 linear feet (75 linear meters) per minute. The Smurfit Kappa plant installing the Nzomi press currently does six-color analog printing on single-channel B, C, E and double-channel B/C and C/E board. The new 71-inch (1.8 meter) wide Nozomi press prints in six colors plus white and can run same grades of single-and double-channel board the company already uses at full press-rated speeds. Output from the press is unique in having certification for OCC recyclability and repulpability from the Western Michigan University Recycling, Paper and Coating Pilot Plant – a leading certification organization for corrugated recycling.
65
You have the best machines and the best people ... ... now is the time to invest in the best software. w w w. k i w i p l a n . c o m O ffi c e s Wo r l d w i d e
The premier software solution provider to the corrugated industry
SIMPLY A BETTER SOLUTION
A PROPER PLAN ESTABLISHING PROCESS CONTROL WITH DIRECT PRINT CORRUGATED by Brad Gasque With customers demanding consistently higher quality print as well as tighter tolerances, the flexographic print industry has been challenged. However, we have accepted this challenge and stepped up the plate (no pun intended).
“
Direct print corrugated brings its own unique challenges, but with the proper training, wise use of control targets, habitual maintenance and consistent incoming materials, you can achieve great results.
68
“
N
ew developments and technologies with prepress, plates, inks, substrates and presses have all contributed to our successes. Even with the latest and greatest technologies, process control continues to be the make or break for flexography. A good process control system gives printers the opportunity to satisfy a customer’s demand for consistent products day after day. Direct print corrugated introduces its own unique challenges with harsh printing environments, inconsistent/ compressible board, large widths/ repeats and soft, thick plates, along with the numerous mechanical challenges that come with flexography. In order to keep this to an article and not a book, let’s break down process control into four categories: materials, maintenance, control targets and training. MATERIALS Before we look into anything else, we need to make sure we have consistent materials being used on press. There are three main materials that have the greatest impact on a print: Substrate, Ink and Plate. One of the biggest struggles for direct print corrugated is the appearance of fluting. Boxes need to be strong in order to protect the product inside, so the flutes are critical. Unfortunately, these flutes become an eyesore when printing halftone dots. Dot gain varies with the valleys and peaks of these flutes as the plate comes in contact with the board. This variation in dot gain gives us the fluting appearance that can take away from the intended communication of the graphics.
Precise impression and optimized flat top dot plates will help reduce fluting, but having a consistent and smooth board is paramount. Out of the three ink types, water based is the most difficult to work with, from my experience. It becomes even more difficult when the environment it is used in is constantly changing. The surfaces of corrugated board (clay coated, mottled white, #1 white, #3 white, Kraft, brown) are normally not the smoothest print surfaces and vary in absorption characteristics. Therefore, they require thicker ink films to cover absorbent substrates and thinner ink films to cover nonabsorbent substrates. Inks need to be formulated to achieve the desired strength required with the anilox roll used, while still drying at a rapid rate and achieving the customer’s end use requirements. Inks need to be color matched before hitting the press, so the only variables press operators are expected to adjust are pH and viscosity.
A bad fluting appearance can be distracing, especially in a continous tone image. Photo courtesy of DuPont Advanced Printing
69
Plates are another material component that need to be consistent by the time they hit the press. With most corrugated plates coming from their makers, it is important to verify you have the right example, with the correct prepress applied and mounted on the correct carrier. Using a bench top micrometer to measure the plate package caliper ensures the plate is correct for you press undercut and has the proper relief for your process. The plate supplier should be using plate making control targets to ensure the proper bump and press curve are applied to your file, as well as making sure its plate making process is in control. MAINTENANCE Now that we have consistent incoming materials needed to run the press, it is vital to determine the press itself is in a condition suitable for running consistent product. Maintenance schedules recommended by your OEM are always the best starting point. It is important to stay on top of maintenance even when you feel
This Anilox condition test with a solid plate shows an anilox that is in need of a deep clean, as you can see the pattern in the solid.
70
Another example of fluting
like the timing isn’t best. Downtime from broken equipment is always worse and longer than downtime for schedule upkeep maintenance that can prevent breakdowns. Both scheduled maintenance and autonomous upkeep habits are important expectations to instill in any printing culture. Since most direct print corrugated presses do not have a quick and easy method for removing anilox rollers, their cleaning and inspection are more difficult, but still need to be accomplished. An easy way to check for a damage anilox roll or metering issues is to run a 100% solid coverage plate that is large than the repeat of the anilox. Any damage to the anilox will be visible in the printed solid. Establishing a scheduled doctor blade change is also important for consistent ink metering, as well as preventing damage to the anilox. As with all printing methods, cleanliness is very important. Direct print corrugated is no exception to that fact, even though the environment can be more challenging. The key to keeping a printing press clean is quite simple: Develop good habits and schedule
time to clean. Treat cleanliness as a maintenance item and stay on top of it daily. Water based inks do not like to rewet without the use of harsh chemicals and force, so cleaning them while wet is much easier than after they have dried. Work with your ink, anilox and plate suppliers to find an appropriate press wash for your specific environment. CONTROL TARGETS As stated in Flexographic Image Reproduction Specifications & Tolerances (FIRST) 6.0, “it is impossible to control what is not measured.� In order to make sure the print is in control, you need to have a control target that gives the operator feedback. While some targets give visible feedback, others require measurement devices, such as a densitometer or spectrophotometer. Direct print corrugated printing requires a few additional targets that are not normal for other flexographic printing. Slur and impression targets that are necessary to gauge impression on press. Both the hexagon and flower targets are common, with the hexagon giving the most feedback. When the hourglass pattern appears, this tells the operator there is excessive plate to substrate impression. When the bow tie pattern appears, this tells the operator there is excessive anilox to plate impression. It is important to note that appearance changes in slur targets can also be the result of numerous issues, such as improper ink metering, high ink viscosities, a loose plate, etc. However, most corrugated printer use a stepped impression target since the hexagon slur target is best used for fine tuning impression.
Using liquid polymer to make thick plates gives the ability to create this stepped impression target slug. This target will have stepped print height in increments of 0.002-in to 0.005-in that will only print when over impressed that amount in both anilox to plate and plate to substrate. The step printing at perfect impression would read 0.0-in. where the step printing at 0.010-in over impressed would read 0.010-in. Ideally, you would want 0.0-in impression, but this is not practical in some direct print applications. It is imperative press operators are trained to not try to get the entire impression gauge to print when setting impression. This instantly equates to an over impressed plate and premature wear on the impression gauge, which then leads an untrained operator to impress even more to get the worn down target to print, thus over impressing the plate even more. Railroad Track Targets are commonly used for corrugated printing, since they give the operator the exact amount of misregister and an easy visual to correct. This reduces the amount of adjustment needed to get the print in register and also minimizes the need to constantly use
This out of register Railroad Track Target communicates the exact moves necessary to get into register.
71
a tape measure during a pressrun to maintain register. The scale and tolerance of these targets should be determined in the fingerprint press trial and will often need adjusting to get a scale properly built for your printing environment. Measuring tone scales used in process control targets for corrugated printing ideally requires larger patch sizes and devices with larger apertures. As mentioned earlier, the flutes cause inconsistent dot gain depending on whether the
“
I
Even with the latest and greatest technologies, process control continues to be the make or break for flexography.
nk trap targets are also very important to use in direct print corrugated. When using larger volume (bcm) anilox rollers or printing on nonabsorbent substrates with water based inks, the wet ink traps often behave poorly. The print sequence, drying rate of ink, ink pH/ viscosity, dryer settings and press speed can all have an effect on the wet ink trap. In order to produce the best quality print, you need to ensure the ink film is transferring to the substrate, laying down smoothly and drying even when printed on top of other inks. TRAINING Before knowing how to evaluate and measure control targets, the press first must be set up correctly to print the first sheets to pull. Every press variable and job component
72
dots find themselves on a flute tip or flute valley. Because of this periodic high and low, you need to capture a larger area to achieve more usable data. It is recommended to have solids and tone scales two to three flutes wide for the most accurate measurement. Densitometers and spectrophotometers will work best with either 0.157-in or 0.236-in aperture size on corrugated. The larger aperture allows the device to measure more surface area for a more accurate measurement across flutes.
“
needs to be clearly defined in the job recipe/ticket. This ensures the job is set up in a repeatable manner. Also included in this job recipe is that specific job’s targets and tolerances. Even after having the correct control targets printed for operators to use, if they do not understand how to measure or evaluate the targets, then it was a waste to print them. Thorough and consistent training for all operators is important, especially when it comes to how they will use control targets. For instance, there are many variables that can affect physical dot gain on press and the operator should be educated on these. The operator should be trained to work through a list of possible reasons why the 50% control target is measurement 82%, when the target was 72%.
Many times, there are time consuming press changes happening that are not necessary when all that is needed is to adjust ink viscosity into tolerance. Every manufacturing process has targets and tolerances. It is vital these targets and tolerances are specified and easily understandable. Most of the main components to the flexographic print process can have a measurable number applied to them, which needs to be communicated clearly. These numbers need to be included in each job recipe or ticket. Below is a basis list of these numbers for direct print corrugated: • Ink viscosity and pH • Measured dot area of specific tint • Solid ink density, color (L*a*b*, L*C*h0) • White opacity • Feeder setup • Impression starting points The blood of the flexographic print process is the ink. With water based ink used in corrugated print, the pH and viscosity is expected to be adjusted by the press operator. The pH and viscosity should be measured and recorded on a scheduled basis to ensure it stays in control throughout the pressrun. Foam or micro foam is common in direct print corrugated, so its cause and resolution need to be communicated to the operator.
Water based inks foam when air is pumped into them through the return. The most common way to reduce excessive foaming is to make sure the return line is submerged in the ink and not just dropping the ink from the top of the bucket. However, even when the pump and return are set up correctly, air can enter the ink system through the empty cells of the anilox as it rotates back to collect more ink. Defoamer is used to reduce foaming and should only be used in small amounts in a squirt bottle. Press operators should be trained on proper ink management and basic ink problem solving. YOU CAN DO IT As with any flexographic printing, process control is critical to produce repeatable and consistent products. Direct print corrugated brings its own unique challenges, but with the proper training, wise use of control targets, habitual maintenance and consistent incoming materials, you can achieve great results. Work with your suppliers to leverage their knowledge and resources to aid in establishing good process control. FTA also offers great resources through FIRST 6.0, and online training and certifications that will educate operators on how to establish and maintain process control through every step of your process. Flexo Magazine, April 2018 www. digital.reviewtechnologies.com
73
74
Pack & Print Event 2018 CCE SOUTH EAST ASIA 2018 5-7 Sept, 2018 BiTEC (Bangkok international Trade & Exhibition Centre) Bangkok, Thailand
TOKYO PACK 2018 02-05 Oct, 2018 Tokyo International Exhibition Center (Tokyo Big Sight), Tokyo, Japan
ASIA FRUIT LOGISTICA 05-07 Sept, 2018 Hongkong, China
PACK EXPO INTERNATIONAL 2018 14-17 Oct, 2018 McCormick Place, Chicago USA
INDOPLAS/INDOPACK/INDOPRINT 7-10 Sept, 2018 JIExpo Jakarta
SIAL INSPIRE FOOD BUSINESS 21-25 Oct, 2018 Paris Nord Villepinte, Paris
THE PRINT SHOW 18-20 Sept, 2018 NEC Birmingham Hall 9, UK
ALL IN PRINT CHINA 2018 - CHINA INT’L EXHIBITION FOR ALL PRINTING TECHNOLOGY & EQUIPMENT 2018 24-28 Oct, 2018 Shanghai New International Expo Centre (SNIEC)
E-PACK SUMMIT 2018 18-19 Sept, 2018 Chicago, IL. Smithers Pira PACKPRINT 18-21 Sept, 2018 BITEC, Bangkok Thailand THE INDONESIAN INTERNATIONAL PLASTICS, PROCESSING, PACKAGING AND PRINTING EXHIBITIONS 19-22 Sep, 2018 JI Expo Jakarta-Indonesia PROPAK ASIA 25-27 Sept, 2018 BITEC, Bangkok Thailand LABELEXPO AMERICA 2018 25-27 Sept, 2018 Donald E.Stephens Convention Center, Rosemont, Illinois GRAPH EXPO 30 Sept-03 Oct, 2018 Chicago, USA
SUSTAINABILITY IN PACKAGING EUROPE 30-31 Oct, 2018 Barcelona, Spain, Smithers Pira EURASIA PACKAGING 2018 31t Oct-3 Nov 2018 Istanbul-Turkey LABELEXPO INDIA 22- 25 Nov, 2018 Greater Noida, India ALL 4 PACK PACKAGING / PROCESSING / PRINTING / HANDLING 26-29 Nov, 2018 Paris Nord Villepinte, Paris PLAST EURASIA 2018 5-8 Dec, 2018 Istanbul-Turkey
th DIRGAHAYU RI 17 AGUSTUS 2018