ProPack Pro December 2020

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ProPack People Technology Business

www.propack.pro December 2020

A FOCUS ON:

Wagner nabs win Wagner Labels gets global recognition as it takes home one of Durst’s inaugural RSC Label Masters Awards

G2psd installs G2psd installs an iEcho PK+ in QLD and an Intec digital die cutter in WA, following a new deal with the supplier

Starleaton: Boost your productivity with ZĂźnd

Heidelberg Innovation Week Heidelberg has revealed the latest in its labels and packaging technology at its virtual event ALSO INSIDE...

AIP Conference

REASONS WHY HERO SHOULD BE YOUR TRADE PRINTER

AUSTRALIA’S BEST TRADE PRINTER

HUV PRINTING Hero Print is home to Australia’s only 10 colour HUV press.

This means we are able to print CMYK + Spot Colour or CMYK + Varnish on the instant dry B1 press.

6 iMAGS If you print an offset printed magazine or booklet with Hero Print, we send you an online version free of charge.

We are also able to link different pages to specific URLs - perfect for product catalogues.

2 FAST TURNAROUND We are super fast at what we do, and track the turnaround times on every product we offer to make sure you are getting your job on time, every time.

7 DAZZLING SPECIALTY FINISHES Make your job stand out with our specialty finishes.

Hot stamped silver or gold foil, plus 6 different raised foil colours available.

These foils plus Spot UV and Raised UV can be done on small digital qtys to give any job a lift!

3 HIGH QUALITY Even though we are quick, that is not at the expense of quality. Hero Print prides itself on making sure your job leaves our factory in perfect condition.

8 BLANK PACKAGING

Let us take a back seat while you take all the credit - everything that leaves our factory goes in blank boxes, and is shrink wrapped - ensuring you can send direct to your client with no fuss.

4 AUSTRALIA WIDE

With presses in four States, we are able to service the whole of Australia as quickly as possible.

9 CONSISTENT COLOURS Stringent monthly calibrations on all print output devices allow us to get consistent colours each time you order - whether it be 50 digital brochures or 5,000 books.

5 EASY TO USE WEBSITE We are constantly getting compliments on how easy our website is to use - it makes sense - we want the ordering process to be as streamlined as possible.

10 DEDICATED ACCOUNT MANAGERS Speak to the same person each time.

Tired of talking to a different person each time you pick up the phone? Hero Print assigns a dedicated account manager to you when you first sign up - easy.

EDITOR’S NOTE HAFIZAH OSMAN

A focus on creating value The need for creating value and productivity is on an upward curve, especially given the effects of COVID19 on businesses. Industry experts have voiced their concerns around the issue, and are creating solutions that enable their customers and businesses to be more productive.

Automation is a key part of this. In this issue, you’ll be able to read about Starleaton’s approach to value and productivity through Zünd’s line of automated equipment.

Within the labelling and converting area, Wagner Labels was recently recognised with a Durst RSC Label Masters Award, having improved its productivity and

processes with a Durst Tau installation last year and creating a Truce wine label that demonstrated quality work and value.

That same agenda is driving Heidelberg – the company recently took to its Innovation Week to reveal a spectrum of solutions in labels and packaging. With ‘Unfold Your Potential’ as the virtual event’s slogan, it focused on the optimisation of the entire process in offset and digital printing, all the way through to end-to-end production.

Productivity and creating value rings true to G2psd as well, as evidenced by its two installations in Australia – at Crystal Media in

Queensland and another installation in Western Australia. The company has also expanded its offerings with the introduction of Intec digital die cutters in Australia.

Within the ink and substrates space, value lies in the use of premium recycled paper, as told

by Mondi and Ball & Doggett.

This issue of ProPack.pro also covers the topic of recycling and what needs to be done for the creation of a better circular economy.

Locally and internationally, the issue of recycling has been of high importance and the time to deliver on these sustainable goals is now.

We hope you enjoy the read.

Hafizah Osman Editor hosman@intermedia.com.au Ph: +61 431 466 140

Stay informed… visit www.propack.pro and subscribe to receive the latest packaging industry news and views

ProPack Industry Supporters

Managing Director & Publisher: James Wells Editor: Hafizah Osman Design: Carrie Tong

Sales Manager: Brian Moore Production Manager: Jacqui Cooper

Pre-Press Manager: Tony Willson Printed by: Hero Print, Alexandria, NSW 2015 Mailed by: D&D Mailing Services

ProPack.pro is published by Printer Media Group, registered in Australia ABN 47 628 473 334. This publication may not be reproduced or transmitted in any form in whole or in part without the written permission of the publishers. While every care has been taken in the preparation of this magazine, it is a condition of distribution that the publisher does not assume any responsibility or liability for any loss or damage which may result from any inaccuracy or omission in the publication.

4 ProPack.pro December 2020

www.propack.pro

CONTENTS

IN THIS ISSUE...

Elof Hansson delivers innovative BillerudKorsnäs packaging solutions P28-29 Elof Hansson is encouraging converters as well as packaging technologists and designers to consider more sustainable solutions from BillerudKorsnäs

Jet Technologies celebrates 40 years of success P30

Wagner Labels wins prestigious Durst RSC global award P 16-18 Improving productivity with Zünd P6-8 Productivity needs to be top of mind for today’s printing and packaging businesses and having the right automated equipment is crucial to deliver on those needs

interpack will definitely proceed as planned in 2021: Thomas Dohse P10 interpack’s recently appointed head confirmed that the tradeshow will go on from 25 February to 3 March 2021 following its recent postponement

G2psd makes installations in WA and QLD P12 Company installs an iEcho PK+ for Crystal Media and moves into postpress space by bringing in Intec digital die cutter from the UK

Wagner Labels beat global competitors to take home the Durst award in the RSC Combination Print category

The impact of COVID-19 on packaging P20-21 Analysts assess the impact that COVID19 has had on the industry, with some sectors seeing growth while others see a slump in demand

The impact of COVID-19: Real lessons learnt and what is just a ‘pandemic’?

P22-23 The World Packaging Organisation recently met virtually to discuss COVID-19 and its implications on packaging

Use premium recycled paper if possible P32-33 The use of premium recycled paper worldwide is crucial in the conversation around recyclability and sustainability

Packaging: Fit for the future

P34-37

Industry experts provide an extensive array of educational and technical opportunities within packaging

A RED Recycled Road for soft plastics P38-39 Changes to procurement strategies are key to stimulate further investment in soft plastic recycling and reprocessing

Federal Govt introduces Recycling and Waste Reduction Bill P14

Recycling graduates to become Green Consumption P40-41

The Australian Government introduces landmark legislation to ensure Australia takes responsibility for waste

Joint venture sees $45m recycling plant build P15

Heidelberg unfolds the potential of labels and packaging P24-27

Asahi Beverages, Pact Group Holdings and Cleanway Waste Management have come together to build a new recycling plant on the NSW-VIC border

Heidelberg took to its innovation week to reveal its latest in labels and packaging as opportunities arise from these markets

www.propack.pro

Jet Technologies celebrates 40 years of service, innovation and expertise in the industry this year

Green consumption is all about integrity, trust, sustainability, responsibility, and accountability

Nekkorb adds automation to labels P42 MPS takes label converters to new levels with connectivity and automation December 2020 ProPack.pro 5

COVER STORY

Improving produc

1 Productivity needs to be top of mind for today’s printing and packaging businesses, and having the right automated equipment is crucial to deliver on those needs

W

ith a drive to guarantee productivity for its customers, Zünd has tailored its suite of digital flatbed cutters, including automation to cater to that need. Its local distributor, Starleaton, is ensuring that the message is delivered to Australian and New Zealand customers to reap the benefits from these systems.

Starleaton Senior Manager for Industrial Products Dale Hawkins said productivity is a necessity in today’s world as the marketplace is competitive and to win, businesses need to keep costs to a minimum.

“The key to cost minimisation is to remove or reduce production costs 6 ProPack.pro December 2020

including labour, mistakes, and waste,” Hawkins said.

“Maximising production time using 24/7 automation can extend production shifts, enable ‘lights out’ manufacturing which enables production with minimal or zero human intervention, as well as reduce the requirement for penalty labour rates for shift workers that contribute longer hours.

“Businesses need continuous automation and output times that they can rely on – manufacturing automation does not stop, unlike a manual human process.”

Hawkins added that automation is increasingly important as it removes any manual heavy lifting and associated risks.

Specifically, Zünd and Starleaton aim to help businesses double their productivity with the Zünd D3 series.

The cutting system has two beams that operate independently, meaning that depending on the job, this can double productivity.

The intelligent cutter controller allocates the work optimally to each of the two beams. The two beams can

each be equipped with up to three different modules, instantly doubling the throughput.

It has a cutter controller, which optimally allocates the jobs to each of the two beams, ensuring maximum productivity is achieved.

In addition, the setup of its knifecutting, routing, and creasing tools occurs fully automatically.

The integrated initialisation system makes the process quick and precise.

Hawkins said the series supports the packaging industry’s productivity needs as it utilises modern digital cutting systems instead of traditional die-cutting methods.

“If you look at a packaging business or the primary print business, the way that they would cut contour shapes is using die cutting processes. Die cutting processes can be costly and doesn’t offer as much flexibility,” he said.

“Digital cutting, such as the Zünd D3 series delivers the most flexibility around a device to finish cutting.

“The digital method also works well if there are multiple sizes required for each job.” www.propack.pro

COVER STORY

ctivity with Zünd A bigger boost to production For added productivity, the Zünd D3 series pairs with the Zünd Board Handling System BHS150 (the latter can also be paired with the Zünd G3 series).

As industrial-level manufacturing uses highly automated production lines, the BHS150 delivers on automation efficiency as it produces around the clock while keeping personnel requirements to a minimum.

The combination of 1.5m stack height, high production speeds, and extremely short set-up times leads to considerable increases in productivity and profitability.

As a result, even long runs can be finished efficiently and economically.

Finished stacks can be removed without interrupting production.

During the loading process, a scanner captures job information via printed QR codes. This enables reliable identification of different jobs within a stack for fully automated processing.

The BHS150 can also efficiently process materials up to 110 mm thick.

The off-load conveyor and stacking system deposits cut sheets in a perfect stack on a pallet.

Depending on the job, this stacking method eliminates the need for bridges to hold cut parts in place. This facilitates separating cut parts from waste, saving both time and money.

Hawkins said combined with the Zünd D3 series, the Zünd Board Handling System BHS150 extends the market reach of any printing or packaging business.

“With this combination, a printer or a packaging company can extend the products that they make,” he said.

“It diversifies a company’s offerings beyond point-of-sale, promotional or signage and allows them to take their capabilities into supplying other markets like interior design, furniture manufacturing, or even COVID applications beyond floor stickers and standard signage, such as divisional partitions and screens.”

Success with the BHS150 In Switzerland and beyond, B. Heer, a company that designs and develops custom packaging solutions, has used Zünd towards reaching maximum efficiency. At the company’s six locations, everything revolves around the development, production, and www.propack.pro

2 1. Zünd D3 paired with the BHS150 Board Handling System 2. Starleaton Senior Manager for Industrial Products Dale Hawkins

logistics of packaging, primarily for industrial customers.

Heer packaging protects coffee machines, sensitive measuring instruments, or laboratory analysis equipment during transport and usually consists of a combination of corrugated cardboard, foam, and wood.

The foam ensures a secure fit in the cardboard box and at the same time provides protection against impact.

Ultimately, maximum transport safety is what system packaging is all about.

This is what is being manufactured at its Felben-Wellhausen location, where the company’s Center for Corrugated Board and System Packaging has been housed since 2015.

This is also where two Zünd G3 cutters are in continuous operation.

With the investment in a highlyautomated cutting system consisting of a Zünd D3 cutter with BHS150 board handling, a third production line was added not long ago.

For Joachim Basler, head of the Corrugated Center, the high-level automation and superior performance of Zünd production equipment are the two most important factors in meeting the requirements of the business’ increasingly demanding customer base as customers are placing orders in eversmaller quantities and continue to shrink their packaging inventory to keep stock altogether.

As a result, replacement cycles are becoming ever shorter and packaging is becoming more customised to ensure perfect protection of packaged goods.

Basler said for Heer to be able to meet these demands, it was looking

to optimise process efficiencies by minimising set-up and changeover times, automating production, and expanding to lights-out manufacturing.

“How this works can be seen in the sprawling production hall, where three Zünd cutting systems are in continuous operation, processing corrugated cardboard and packaging foams nonstop,” he said.

“Thanks to the Zünd BHS150’s 1.5m stack height, we can now drive entire pallets of raw material into the loading unit from which the boards are fed automatically. This means there is little effort into the handling of raw materials and do not have to re-stack at any point.

“In addition, we can now also produce medium and long runs completely automatically, either during the day or at night. This significantly extends machine run time and helps reduce our production costs.”

Basler also mentioned that the innovative off-load unit with conveyor belt of the Zünd BHS150 has allowed for bridge-free cutting of corrugated board, further increasing efficiency.

“Because of this feature, the time it takes to break out the cut pieces and separate them from the waste is much shorter. Without the need to add bridges, the cutting time itself is reduced, which in turn minimises overall production time. And finally, without those visible connection points, the quality of the end product is greater as well,” he said.

With the Zünd BHS150 Board Handling System, Heer aims to further exploit the true potential of fully automated production.

“The complete production line consists of a loading unit, a Zünd dualbeam D3 cutter, and an off-load system.

The 1.5m stack height allows for significantly longer operating time without interruption. As a result, even long runs can be finished economically and efficiently,” he said.

Doubling down on productivity in the UK

Another example is Durham Box, a well-established family-owned business operating in the packaging space in the UK since 1989. The business recently expanded its business capabilities by investing in a Zünd D3 digital cutter, Continued on page 8 December 2020 ProPack.pro 7

COVER STORY Continued from page 7

3 equipped with the fully-automated Board Handling System BHS150.

As part of its decision to grow business and keep up with increasing customer demand, the packaging solutions provider is Zünd’s first customer in the UK to have a Zünd D3 cutter with a BHS150 board handling system installed, offering the business 24/7, non-stop operation capabilities.

The purchase was part of an ongoing factory expansion and the recent acquisition of the property next door – the 929 square metre unit enabled the installation of the Zünd cutter.

“We saw the Zünd cutting edge automation first-hand during our visit to the Zünd Customer Experience Centre at Zünd HQ in Switzerland and knew straight away this was the right investment for us,” Durham Box joint managing director Dan Morris said.

“We saw other digital cutting manufacturers, but the Zünd D3 build quality and cutting speed impressed us, especially the dual beam configuration for maximum productivity alongside the board handling system.

“The Modular cutter concept the D3 has to offer was also a positive for us because it means we can adapt our Zünd cutter to new requirements at any time, making our investment future proof for upgrades and expansions.”

Durham Box predominantly manufactures corrugated packaging for both small SMEs and large multinational companies, and a key driver to its success is its ethos of supporting customers of all sizes regardless of their volume requirements. In recent years, the company has seen an increase in enquiries for digital printing and took a business decision to invest and expand its offering to also include large 8 ProPack.pro December 2020

format printing solutions for its customers. This led to the purchase of the Zünd D3 XL-3200 flatbed cutter with a working space of 3200mm by 2270mm, equipped with a BHS 150 board handling system that enables them to produce around the clock with minimal operator intervention or resources.

“Medium and large orders can now be processed by us unattended, even during lights-out operations,” Morris mentioned.

“We also liked the intuitive, modular functionality the D3 offers compared to a conventional die cutting machine, jobs can be set up extremely quickly which means we have the flexibility of having short run capabilities on the Zünd with minimal downtime.

“The Zünd D3 digital cutter complements our recent digital printer purchase, giving us a complete workflow process.

“Through our investment in Zünd, we have now become a one stop shop for corrugated packaging and highquality large format print finish.”

Starleaton delivers on further support for industry

Another key part of Starleaton’s ongoing support is its exclusive Zünd Tool and Module Rental Program, which provides the convenience of immediate, available, and additional capabilities to get jobs done.

The program allows customers to rent individual modules and tools for their Zünd cutter, and have a portion of the rental price deducted from the price of the tool if they decide to purchase. Hawkins said it gives customers a chance to try out work across different applications, or produce jobs for customers they would

3. The BHS150 is designed for operation with the Zünd G3 and D3 cutter series.

D3 dual-beam technology provides a significant increase in performance and thus, offers maximum productivity

have had to outsource otherwise.

By deducting a portion of the rental price from the tool or module purchase price, customers can then make a decision to invest once they’ve secured additional work from their customers, or gained the confidence to market work on that application to other potential print buyers.

“Zünd digital cutters have over 20 tools to take advantage of. Each tool has been designed and manufactured to meet specific cutting, creasing, perforating, scoring, routing, and punching needs,” he said.

“Initial investment in a Zünd system is usually focused on the tooling capabilities to meet current application needs. Inevitability, due to digital cutting capabilities other diverse work comes their way.

“To take advantage of this, the service provider needs to get instant access to Zünd tools to do the job or create the prototype.

“The Zünd tool and module rental program provides this facility and the cost is only a fraction of investing in the tool cost outright.

“With ‘Murphy’s Law’, a service provider can be in full production on a massive job, and only have one of a specific tool or module for that job only to experience a failure. Ordering a replacement tool generally needs a four-week lead time.

“So, the rental program provides immediate access to the tool (or tools) or modules needed to complete the job while they wait for a replacement, resulting in limited interruption to production.”

According to Hawkins, Zünd and Starleaton not only deliver on the productivity needs of today but both companies also keep ahead of trends to deliver in future.

“Zünd and Starleaton listen very closely to our customers and therefore, know very well where their pain points are,” Hawkins said.

“This gives us the opportunity and allows us to develop solutions that help our customers to make digital cutting even more efficient and economical.

“Starleaton has built its strong expertise in cutting applications across a wide variety of materials that extend past those traditionally viewed as printing media.

“Starleaton also employs a fullytrained team of Zünd technical specialists that are digital cutting experts and are now installing and consulting workflow automation of both software and hardware. We are one of Australia’s leading suppliers of both flexible and rigid materials in the market place, providing a knowledge that extends across the material and cutting profiles.” www.propack.pro

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FOCUS INTERPACK

interpack will definitely proceed as planned in 2021 interpack’s recently appointed head has mentioned that the tradeshow will go on from 25 February to 3 March 2021 following its postponement from May 2020

T

he new head of interpack, Thomas Dohse, has confirmed that the event will definitely proceed from 25 February to 3 March 2021 after being postponed from May 2020.

In correspondence with Dohse in the last week of November, he confirmed with ProPack.pro that the event will take place as planned “even if we have to expect low attendance from exhibitors and visitors”.

“Due to the ongoing COVID-19 pandemic and fears of a lower number of visitors, all participating companies will receive discounted participation conditions. In addition, there is a temporary special right of termination for all exhibitors who cannot or do not want to participate,” Dohse said.

“We fully understand the reservations and concerns of our exhibitors in the current situation. On the other hand, we have also received feedback on how important personal exchange is for our customers and what significance interpack has for the processing and packaging industry.

“In this respect, we believe that with our offer we can best protect the interests of all parties involved and would like to thank our partners for their constructive cooperation,” Dohse said in statement.

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1. interpack’s newly appointed head Thomas Dohse 2. interpack was initially scheduled for 7 to 13 May 2020, but due to COVID-19, has been postponed to 25 February to 3 March 2021

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10 ProPack.pro December 2020

Messe Düsseldorf has developed a strategy to hold interpack in conjunction with its industry and trade association partners, modelled on a successful field-tested hygiene and infection protection plan executed in 2020 during another trade fair for the Caravan industry called Caravan Salon – the first trade fair at the Düsseldorf trade fair centre after the coronavirus outbreak.

This ‘hygiene plan’ enabled exhibitors and trade visitors to meet safely in the exhibition halls and also included selling personalised tickets exclusively online before the trade fair, as well as extensive hygiene measures implementation on-site at the exhibition grounds.

According to Dohse, Messe Düsseldorf relies on a comprehensive hygiene concept in order to protect exhibitors and visitors. “interpack is the most important event in the international packaging industry and, especially in times of crisis, provides crucial stimuli in order to build a successful future for the companies involved. Therefore, we give our all in order to do justice to this

responsibility and simultaneously guarantee the best possible protection of the health of the people coming to our trade fair centre,” he said.

For more information about interpack and other Messe Düsseldorf events, contact Robert Laing – email: robert@messereps.com or mobile: +61 427 353 536.

Thomas Dohse was appointed in September as the new head of interpack following the appointment of his predecessor, Bernd Jablonowski, to the managing board of Messe Düsseldorf as an executive director. Dohse has woven an excellent web of connections within the global packaging industry and the related process industry. He has been part of the interpack team at Messe Düsseldorf since 2005 and led interpack 2017 on an operative level as deputy director. During this period, the father of three supported many formative themes for interpack, such as SAVE FOOD and the special shows under the innovationparc label. These are now also successful at the international events within the scope of the interpack alliance, which will also be led by Dohse in the future. www.propack.pro

For further information and assistance with travel and accommodation planning Robert Laing _ Messe Reps. Pty. Ltd Tel. +61 427 353536 robert@messereps.com _ www.messereps.com

FOCUS INSTALLATIONS

G2psd makes installations in WA and QLD Company installs an iEcho PK+ for Crystal Media and moves into post-press space by bringing in Intec digital die cutter from the UK

1. Crystal Media’s Luke Allen with the iEcho PK+ flatbed cutter 2. G2psd business development manager Terry Mays with the Intec Printing Solutions UK digital die cutter

1

B

risbane-based supplier G2psd has installed an iEcho PK+ flatbed cutter at Crystal Media in Brisbane and its first Intec Printing Solutions UK digital die cutter to a company in Western Australia.

G2psd business development manager Terry Mays said the installation of the iEcho PK+ flatbed cutter was done at Crystal Media in September as it was looking to beef up its portfolio with the latest in flatbed cutting technology.

“Crystal Media is a medium-sized business that has a digital arm and it also works in signage, lithographic offset and bindery. Effectively, the company can start a job, plate it, then send the job to digital or offset – offering an end-to-end solution,” Mays mentioned.

“The company has a flatbed that prints a lot of corflute, and given that the iEcho PK+ can cut through 6mm of corflute, the machine fit in well with its needs. The beauty about the iEcho PK+ is that it has an auto-feeder on it.

“So, rather than having to be put on manually, the corflute is picked up onto the table automatically and cuts and creases all in one hit without having added supervision required.”

Mays said since installation, the iEcho PK+ flatbed cutter has made Crystal Media more productive and in turn, it is getting more work.

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12 ProPack.pro December 2020

“The machine is named ‘the beast’ at Crystal Media because of its speed and its ability to get work done efficiently,” Mays said.

“It works seamlessly with other machines – it fits with any digital press.

It’s connected to a Ricoh press at Crystal Media and has improved the company’s processes.”

Even though the installation was done during COVID, Mays said the process went very smoothly.

“There were no delays of the machine shipping out of Asia. The machine itself was easy to install, which G2psd managed to set up with ease. We’ve even lined up two more units that are currently being shipped out to Australia,” Mays said.

As for the Intec Printing Solutions UK digital die cutter installation, it is for a version 2 FB8000 Pro automated cutting system.

Mays said offering the digital die cutter in Australia has enabled the business to extend its reach beyond offerings in pre-press to press to include post-press.

“The nucleus of G2psd is offset printers, consumables, software RIPs, colour management, CTP, and wide format printing – predominantly Mimaki, Epson and Mutoh – and mostly within the pre-press to press stage,” he said.

“Bringing in Intec has enabled us to ‘dip our toe in the water’ within the post-press space.”

G2psd became Intec Printing Solutions UK’s distributor earlier this year, giving G2psd the ability to distribute its digital printers, foiling and cutting equipment in Australia.

The deal was made after G2psd director Bernie Hockings returned from a one week familiarisation course in the UK, impressed by the technology being released by the manufacturer.

In conjunction with ColorCut Pro3 software, the FB8000’s firmware has been re-engineered with intelligent cutting algorithms to deliver performance that is up to 40 per cent faster than its predecessor.

Its auto sheet feeder enables users to stack up to 25kg – up to 2,000 of printed media – which is loaded on to the cutting mat using a pneumatic feed system with vacuum pick up suction pads and a sophisticated air blade system, to help streamline feeds.

“The version 2 FB8000 Pro automated cutting system is most suited for industry players within the digital space, especially those in shortrun, personalised packaging,” he said.

“This kit is not for major high volume production.

“It’s more for production volumes of up to about 250 pieces, which seems to be a niche market these days.

“The auto-feeder is the jewel in the crown in this machine. It’s set and leave, so you can attend to other duties instead of having to solely manage the machine. The press is also efficient, accurate and works speedily.”

According to Mays, a lot of thought and discussion went into the Intec distribution deal.

“With our other machines, we can sell the machine and the consumables around it. But with this press, it’s just the machine,” Mays said.

“So, when Bernie and I had the conversation about bringing it into Australia, we assessed the possibility of us going into a new area of play.

“We thought that it makes a good add-on for any business that is in digital. And the kit works seamlessly with other presses from other manufacturers; there is no commonality required.

“Doing this enables us to find our way into other businesses that we never had previously.

“Having this particular application might get us into more doors, hopefully, than we have ever done before.”

Mays also mentioned that since the press is made for sheet labels and packaging, it opens G2psd up to a plethora of businesses that work across multiple verticals.

“There are a lot of digital users out there and they might not even be in the printing industry,” he said.

“It has opened our business up to so many other avenues and businesses, like cosmetics packaging or pharmaceutical packaging.

“The list is endless in packaging as the industry is only booming in Australia and the time is now to capitalise on it,” he mentioned. www.propack.pro

$150K Instant Asset Write-Off may apply !

Scan to watch video

Fully Automatic Intelligent Cutting System The iEcho intelligent cutting system allows operators to die cut, perforate, kiss cut and crease all in the one unit. This unique digital cutting system has a vacuum bed, automatic conveyor load and unload for media, as well as the ability to change configuration from sheet to sheet. CCD media positioning recognition ensures accurate cutting every time.

A versatile cutting system with tools for through cut, kiss cut, perf cut, creasing on materials up to 2mm in thickness.

Add the optional oscillating cutting head and you can cut substrates up to 6mm in thickness.

Barcode recognition means you can mix cutting jobs on the one production run without operator intervention required.

Suitable for both production and sample creation of signs, packaging, digital print cutting and more, the iEcho system is a cost-effective cutting solution for all your creative needs.

G2psd

Print Supply Division

G2 Systems Pty Ltd Unit 6, 1368 Kingsford Smith Drive Pinkenba, Brisbane QLD 4008

Contact Terry Mays for more information T: 0408 458 307 E: terry@g2psd.com.au

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FOCUS RECYCLING

Fed Govt introduces Recycling and Waste Reduction Bill The Australian Government introduces landmark legislation to ensure Australia takes responsibility for its waste

T

he Federal Government has introduced landmark legislation that sees Australia take responsibility for its waste with a national industry framework for recycling.

The Recycling and Waste Reduction Bill 2020 is expected to significantly reduce the 645,000 tonnes of unprocessed plastic, paper, glass and tyres that Australia ships overseas each year.

At the same time, the reforms to the regulation of product stewardship incentivises companies to take greater environmental responsibility for the products that they manufacture and what happens to those products and materials at the end of their life.

Minister for the Environment Sussan Ley said the Bill will see the implementation of the export ban on waste plastic, paper, glass and tyres agreed by Commonwealth, State and Territory Governments in March 2020.

“This is about tackling a national environmental issue that has been buried in landfill or shipped offshore for far too long,” Ley said.

“That is why the government is the first Federal Government to place waste firmly on the national agenda.

“This is a once in a generation opportunity to remodel waste management, reduce pressure on our environment and create economic opportunity as we move to a circular economy with a strong market for recycled materials.

“Our $190 million Recycling Modernisation Fund and our actions under the National Waste Policy Action Plan will create 10,000 new jobs over the next 10 years – that is a 32 per cent increase in jobs in the Australian waste and recycling sector.

“We are introducing legislation; we are driving a billion-dollar transformation of Australia’s waste and recycling capacity and we are investing in new technologies and new ideas to transform recycling and reprocessing.”

Waste Reduction and Environmental Management assistant minister Trevor 14 ProPack.pro December 2020

The $190 million Recycling Modernisation Fund and actions under the National Waste Policy Action Plan will create 10,000 new jobs over the next 10 years

Evans said the legislation makes it easier for industry to set up and join in product stewardship schemes.

“Yet where voluntary product stewardship schemes are not effective, or where they are not created in priority areas, the government will have new tools to intervene and regulate,” Evans said.

“Our legislative changes will transform our waste industry, meaning increased recycling and remanufacturing of waste materials which will create new industry and generate more jobs.”

Australian Council of Recycling CEO Pete Shmigel said taken together with other reforms, this unprecedented legislation marks a new era of environmental and economic achievement in recycling through government leadership and industry partnership and innovation.

“Our industry is making unprecedented investments in collecting, sorting, cleaning, and manufacturing from recyclate from homes, businesses and construction sites. Having the law, policy and governments backing will unlock huge intergenerational value – whether it’s keeping stuff out of wasteful landfills or creating jobs in country towns,” Shmigel said.

“That’s a key shift we need to make the system even more successful, and we would welcome further measures in this area consistent with achieving the National Waste Policy’s objectives.

“Indeed, we acknowledge the Government’s strong focus on achieving the targets of the National

Waste Policy, including for plastics recycling. And, we are optimistic that Government – with industry partnership – will continue to rise to the challenge and opportunity, including through large-scale infrastructure investment, massively increasing demand for RCPs including through public procurement of recyclate for ‘lighthouse projects’, as well as the standardisation of operational and logistical aspects, alongside other incentives.”

Australian Food and Grocery Council acting CEO Dr Geoffrey Annison welcomed the Bill as a “significant leap in the right direction” to reduce waste and increase access to high-quality packaging, including high levels of recycled content for Australia’s manufacturers.

“The Bill balances the needs and responsibilities of all industry sectors to collaborate and improve their management of end-of-life material recovery and recycling,” Annison said.

“It also provides industry with greater certainty to underpin investment confidence for industry.

By all sectors of industry collaborating, packaging previously exported for processing and remanufacturing will soon be value-added onshore increasing the availability of high-quality recycled packaging that complies with stringent food safety regulations.

“Increasing the availability of local recycled packaging not only creates local jobs in many industry sectors, it also assists brand owners deliver the National Packaging Targets and creates a circular economy.” www.propack.pro

RECYCLING FOCUS

Joint venture sees $45m recycling plant build Asahi Beverages, Pact Group Holdings and Cleanaway Waste Management have come together to build a new recycling plant in Albury, on the NSW-VIC border

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apan’s Asahi Beverages has entered into a joint venture with Australia’s Pact Group Holdings and Cleanaway Waste Management in the build of a $45 million recycling plant in regional New South Wales. The facility will be located at the Nexus Precinct, 10km north of Albury/Wodonga’s CBD in NSW and will be among the first businesses located at the new industrial precinct.

It will recycle the equivalent of around 1 billion 600ml PET plastic bottles each year and the recycled material is expected to be used to produce new bottles and food and beverage packaging.

This will see the amount of locally sourced and recycled PET produced in Australia increase by two-thirds – from around 30,000 tonnes currently to over 50,000 tonnes per annum, according to Pact Group.

By closing the recycling loop, the facility aims to help reduce Australia’s reliance on virgin plastic, lower the amount of plastic waste sent overseas and the amount of imported recycled plastic. Solar energy will power part of the facility.

Asahi Beverages group CEO Robert Iervasi said, “We already have our beverage manufacturing plant in Albury. We are delighted to expand our presence there and create more local jobs. We are very pleased to be contributing to the creation of a truly circular economy and can’t wait to get this project started.

Iervasi also acknowledged Australia’s environment minister Sussan Ley for her commitment in transforming the country’s waste and recycling capacity, as well as New South Wales minister for energy and environment Matt Kean and the Albury Council for their considerable support.

The project was supported with nearly $5 million from the Environmental Trust as part of the www.propack.pro

Staked bales of plastic for recycling: The facility is expected to recycle the equivalent of around 1 billion 600ml PET plastic bottles each year

NSW Government’s Waste Less, Recycle More initiative. The Department of Regional NSW also provided support.

The recycling plant will draw on the expertise of each member of the joint venture, which will trade as Circular Plastics Australia (PET).

Cleanaway will provide the plastic to be recycled through its collection and sorting network, while Pact will provide technical and packaging expertise and Asahi Beverages and Pact will buy the recycled plastic from the facility to use in their packaging.

Pact Group managing director and CEO Sanjay Dayal said, “We are delighted to have formed this partnership. We would like to thank the NSW Government for their support enabling the acceleration of investment in local processing capacity.

“The arrangement is clearly aligned with our Vision to lead the circular economy and will support Pact in achieving our 2025 Sustainability Promise to offer 30 per cent recycled content across our packaging portfolio.”

According to Cleanaway CEO and managing director Vik Bansal, this partnership will create valuable raw materials from the recyclables collected and help make a sustainability-fuelled future possible.

“Being the joint operator with TOMRA of the NSW Container Deposit Scheme has provided Cleanaway with confidence in the market to invest in this facility. This partnership has been made possible by

the NSW Government and I’d like to thank minister Kean for his continual support. This is a natural extension of our value chain and expands our footprint of prized assets,” Bansal said.

The partnership is said to create dozens of direct jobs when construction starts in coming months. Over the course of the build, the project is expected to create more than 300 direct and indirect jobs, with tradespeople, engineers and technicians among the roles that need to be filled.

Construction will start towards the end of the year, pending approval from Albury Council, and is expected to be fully operational by December 2021.

Australian Packaging Covenant Organisation (APCO) CEO Brooke Donnelly congratulated Pact Group, Asahi Beverages and Cleanaway on reaching this important milestone for the project.

“This new partnership is a real testament to the powerful impact of collaboration,” she said.

“By bringing together key roles within the plastic packaging supply chain, the partnership will ensure more PET plastic is collected, recycled and used again in future packaging – all while reducing the strain on virgin materials and boosting a local economy with the creation of more jobs and greater opportunities.

“This industry-led, decisive leadership is fundamental to ensuring the successful delivery of Australia’s 2025 National Packaging Targets.”

December 2020 ProPack.pro 15

FOCUS DURST RSC LABEL MASTERS

Wagner Labels wins presti Wagner Labels nabbed the recent inaugural Durst RSC Label Masters Award in the RSC Combination Print category, beating global competitors to the win

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ydney-based Wagner Prestige Label has won the global Durst RSC Label Masters Award for the innovative Truce wine label using a combination of printing techniques.

The award was announced as part of Durst’s Label & Packaging first Virtual Digital Day held at the company’s Italian head office in Brixen that also provided unique insights on the new Tau RSC platform, its printing solutions, ink systems, software and important developments.

In an exclusive interview with ProPack.pro, Wagner Prestige Labels managing director, John Galea explained how the award-winning Truce wine label was produced.

“Originally the design for [the Truce project] came to us with the brief of ‘what can you do with this label’. From there it was a team effort showing our strengths with an end to end process starting with our graphics design and pre-press team. Wine labels are a

A brief history of Wagner Labels: 1938

1997

2000

2003

2005

2008

Established and built a reputation for quality embossing labels and seals

Expansion and relocation to new purpose-built factory premises in Wetherill Park

New slitting and inspection machine installed for increased capacity

Completion of full in-house pre-press, allowing the business to go from artwork to film to plates

Increasing capacity also meant the increase of inspection and finishing, with a new finishing line

A new inline inkjet was introduced to cater for demand on variable data

1989

1998

2001

2004

2007

New ownership, bringing multicoloured labelling.

Relocated to larger premises in Wetherill Park

The installation of the first six colour inline press with foil stamping, die cutting, and UV varnishing

Installation of the screen printing machine to cater for outdoor, and specialty labels

The introduction of new seven colour press with foil stamping, embossing, die cutting, and varnishing

For big production runs of 250,000+, it installed a new six colour and varnish machine

16 ProPack.pro December 2020

www.propack.pro

DURST RSC LABEL MASTERS FOCUS

tigious Durst global award 2

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particular passion of mine and we have recently completed work on a label for an Australian gin as well,” he said.

“We have only had the Durst Tau RSC for a little over 12 months and we are still discovering what we can achieve and where we can go. We bought the Durst after looking at toner machines as well as different avenues in inkjet – but we went with the Durst Tau RSC because of the quality and the speed. For the Truce label we used Avery Estate 8 label stock and then we

1. Wagner Prestige Labels managing director John Galea shows off his winning label design 2. Details of the winning Truce label 3. Wagner Labels always had a vision towards being creative

added black using a screen press and then satin varnish on top. This is one of four labels we developed in the Truce range and all of them featured different effects such as a simple foil using uncoated material. My favourite part of the label is the definition of the roses and that’s the Durst and its 1200 x 1200 dpi inkjet resolution which is where the RSC comes up trumps over other presses. We are proud to have won this award as it demonstrates what can be done digitally using the Durst machine.

“We have always flown under the radar and produced good quality work, but we have never entered things so for our team it was an impressive achievement,“ Galea said.

Durst Oceania managing director, Matt Ashman, said this award was a

great achievement for a local business and provided a potential business opportunity for printing companies looking to diversify their business.

“We are very proud to see a strong labelling business and amazing company like Wagners win this international award judged by industry peers,” Ashman said.

“Wagners have had the machine since PrintEx last year and they have grown by winning new business they may have otherwise have missed.

“For any other business looking to expand into the digital labelling sector, this is the perfect time to consider an investment with equipment like a Durst Tau with government incentives in relation to writedowns. The Durst Tau RSC platform is perfectly placed

2010

2013

2016

2018

2020

The introduction of the first four colour laser digital press for small print jobs

Larger footprint required and 33 Hallstrom Place, Wetherill Park was acquired

Installed a new six colour + white Epson inkjet press, complete with Esko software

Running at full capacity now meant upgrading the power supply to futureproof the business

Faced with a global pandemic, the belt was tightened to support staff, customers and families

2009

2011

2015

2017

2019

Wagner Labels acquires JV Labels/JV Group, branching out into general print and embroidery

Upgrade of the four colour screen press – now complete with foil stamping and die cutting

The 370 web eight colour digital flexo was completed with cold foil, multi-page, and flexible packaging

The introduction of Esko plate making, providing faster preparation and quality across all machines

The installation of the Durst four colour + white press and an ABG Digicon flexo press with inline sheeting

Continued on page 18 www.propack.pro

December 2020 ProPack.pro 17

FOCUS DURST RSC LABEL MASTERS Continued from page 17

to help printers step into the digital UV market and also enable the business to grow over time as it is upgradable.

“The other major benefit of the Durst Tau is the ability to have zero set-up time compared to traditional flexographic label printing.

“With the ability have zero waste – this also helps the environment and allows your business to be more agile while also offering customers a compelling and competitive worldbeating web width of up to 51cm and an unrivalled speed of 100 linear metres per minute.

“This is an interesting time for nonlabel printers looking to step into this growing category and Durst can provide the turnkey solution.

“Label converting has reached a digital turning point and resembles when screen print was superseded by digital direct to media inkjet.

“In the same way that several printers diversified into sectors such as wide format – they would be well advised to consider looking at this

5

18 ProPack.pro December 2020

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opportunity and diversifying their business into the latest value offering within the ink to substrate sector.”

Durst described the winners of the RSC Label Masters Awards program as “truly inspiring“ and selected entries will become an integral part of the Customer Experience Centre located

4. The labels were printed on a Durst Tau RSC press 5. A close-up view of the label which won a global Durst RSC Label Masters award

at the company’s Italian headquarters.

Throughout the Virtual Digital Day, partners and customers from all over the world joined experts from Durst’s Label & Flexible Packaging Segment for updates on latest developments and an experience of the new Tau RSC platform, its printing solutions and ink systems.

Topics covered progress on the Tau RSCi beta test, Durst RSC Low Migration Solutions and hybrid label production with the new OMET XJet – powered by Durst. The event also included Digital Embellishment and mid-web finishing – with an ABG solution – which is also going into operation in Durst’s Customer Experience Centre.

Durst label and flexible packaging segment manager Helmuth Munter said, “The Tau RSC is a true gamechanger for us as a company and for all our customers. With that in mind, we challenged them to take part in the Durst RSC Label Masters Awards. There were an impressive number of entries. They were all truly inspiring, making it a difficult task for the judges to choose the winners.

“Since the Durst Tau RSC platform was launched just over three years ago, we have achieved over 100 installations worldwide in less than three years.

“This demonstrates that our printing solutions have been very well received by the market.

“We are looking forward to the future despite these uncertain times for everybody.”

Australia’s R. Wagner Prestige Labels captured the RSC Combination Print category for its Truce Wine of Australia label, while China’s Shandong Golden Realm Industrial Company was runner-up and LabelPrint OÜ of Estonia, third. The 100 per cent RSC Print category was won by Shanghai Yingcai Printing Co Ltd of China, for its Qing Ping Yue entry. Runner-up was LabelPrint OÜ of Estonia, with Pyrotec of South Africa in third place. www.propack.pro

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WE KEEP YOU PRINTING durst-group.com/label

FOCUS COVID-19

The impact of COVID-19 on Analysts assess the impact that COVID-19 has had on the industry, with some sectors seeing growth while others see a slump in demand

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nalysts have determined the impact of COVID-19 on the packaging industry, with mixed growth predictions across the various packaging segments.

The demand for e-commerce packaging has increased exponentially in recent times as a result of more consumers purchasing things online during the COVID-19 pandemic, according to GlobalData.

The research firm’s practice head of consumer beverages Arvind Kaila said, “The online shopping market in the APAC has evolved drastically during the last decade.

“Moreover, the onset of COVID-19 is going to further drive the long-term growth of e-commerce as the unengaged consumer segments rely more on online shopping for day-to-day purchases during the isolation or quarantine period.

“This spurt within the e-commerce industry will enable packaging providers to venture into untapped packaging markets and gain from it in the process”.

According to the research firm, the e-commerce channel has been one of the largest disruptions to the traditional packaging industry.

It added that the increase in e-commerce in the APAC region has already been positioned as a trend as while the customer base for online shopping in India is growing exponentially, China is already a world leader in e-commerce, contributing a significant share to the APAC e-commerce transactions.

It credited the SARS outbreak in the early 2000s with giving Chinese e-commerce a large boost while consumers were staying at home, and said Alibaba used the crisis as an opportunity to build the Taobao online marketplace that was a cornerstone of their growth in the last 20 years.

20 ProPack.pro December 2020

Changing consumers’ lifestyles towards packaged food and ready-to-eat products is expected to further drive the growth of packaging in APAC. “For instance, food already accounts for 38 per cent of the flexible packaging market in India. With a rise in food deliveries, demand for packaging materials used by online retailers, and takeout joints such as boxes, tapes, labels, corrugated boxes and cartons, which are crucial for doorstep delivery, are likely to go up,” Kalia said.

“Packaging companies should take this opportunity to invest more in packaging research, design, innovation, and production practices adapted to e-commerce to optimise its assets for opportunities in growth segments within packaging industry.”

As for the packaged food market in the Asia Pacific region, GlobalData expects to see a short-term decline given the uncertainty in the consumption patterns owing to the COVID-19 pandemic.

The research firm found that major economies like China, Japan and South Korea contribute to about 25 per cent of the world’s food waste while other South and Southeast Asian regions together account for 22 per cent of the world’s food waste.

With Asia Pacific as the largest consumer of packaged food with a recorded volume of 372.03 billion kilograms in 2019, against this backdrop, the packaging and endproduct suppliers are planning to address these food losses and waste by using nano-technology to extend the shelf life of food products, according to GlobalData.

“Moving past the pandemic, resurgence is expected in the consumption of packaged food products in the region primarily owing to the increasing population, which is estimated to reach nearly 10 billion by 2050,” GlobalData senior consumer analyst Albin George said.

“Minimising food loss and waste, and economic utilisation of resources will be the major challenges that packaging and end-product suppliers will be tasked with. Nano-technology based packaging materials can extend the shelf life of food products further by acting as a more protective barrier against environmental factors.”

With consumers becoming highly concerned about the possibility of being exposed to COVID-19 and its impact on their health and lifestyle, customer behaviour, especially consumption

The demand for some segments of packaging skyrockets during COVID-19, while others decline as consumer patterns change

www.propack.pro

COVID-19 FOCUS

on packaging segments habits, is changing within Asia Pacific’s food service industry, GlobalData said.

The research company found that with customers shifting their consumption habits, it is now necessary for brands to follow growing business trends that are in sync with the consumer’s comfortability.

GlobalData consumer insights analyst Shagun Sachdeva identified some key trends and developing insights impacting the food service industry in the region as a result of the COVID-19 pandemic.

Sachdeva said COVID-19 has transformed the dynamics of the market, giving rise to automated and robotic led outlets.

“Automated systems will allow food service companies to defend themselves against these unexpected disasters while at the same time appealing to customers who are still wary of human-to-human contact, justifying the social distancing aptly,” Sachdeva said.

As per GlobalData’s 2019 Q4 survey, the concept of being served by robots instead of humans while eating outside the home is appealing for nearly 46 per cent of Asia Pacific consumers.

In the longer-term, automation of the kitchen and e-commerce may become important to keep labour costs low and potentially increase funds for delivering meals, GlobalData said.

According to Sachdeva, food service companies are now shifting from meal distribution to the sale of grocery and raw products.

“The scale of upheaval is staggering as most pubs, clubs and restaurants have been closed for business. Profit sector sales forecasts in the APAC for 2020 are 16.4 per cent lower as a result of the pandemic and reduced socialising,” he said.

“Hence, food service operators and third-party delivery companies are currently explicitly courting more ethical and community-focused models of business, even if this is simply to help out rather than to drive sustainable revenues.”

He suggested that operators and their suppliers seek to make maximum use of the new ways consumers are socialising, such as using online applications, to re-connect with their current consumers.

Sachdeva added that ‘contactless’ operations might also help to attract new and existing consumers who may still be concerned about human contact following the outbreak. www.propack.pro

“Many hotels and restaurants that previously did not offer a delivery service are joining the bandwagon to reach out to their customers and maintain their business,” he said.

On the other hand, in its Produce Packaging – Global Market Trajectory and Analysis report, ResearchAndMarkets.com found that amid the COVID-19 crisis, the global market for produce packaging estimated at US$29.4 billion in the year 2020, and is projected to reach a revised size of US$36.3 billion by 2027, growing at a CAGR of three per cent over the analysis period 2020-2027.

Corrugated boxes, one of the segments analysed in the report, is projected to grow at a 3.4 per cent CAGR to reach US$13.6 billion by the end of the analysis period.

After an early analysis of the business implications of the pandemic and its induced economic crisis, growth in the bags and liners segment was readjusted to a revised 2.6 per cent CAGR for the next seven-year period.

This segment currently accounts for a 27.7 per cent share of the global produce packaging market.

The produce packaging market in the US is estimated at US$8 billion in the year 2020.

The country currently accounts for a 27.01 per cent share in the global market. China, the world’s second largest economy, is forecast to reach an estimated market size of US$7.4 billion in the year 2027 trailing a CAGR of 5.6 per cent through 2027.

Among the other noteworthy global geographic markets are Japan and Canada, each forecast to grow at 0.8 per cent and 2.2 per cent respectively over the 2020-2027 period. Within Europe, Germany is forecast to grow at approximately 1.4 per cent CAGR while the rest of the European market will reach US$7.4 billion by the year 2027.

In the global plastic containers segment, the US, Canada, Japan, China and Europe will drive the three per cent CAGR estimated for this segment.

ResearchAndMarkets.com found that these regional markets accounting for a combined market size of US$5.3 billion in the year 2020 and will reach a projected size of US$6.6 billion by the close of the analysis period.

China will remain among the fastest growing in this cluster of regional markets and led by countries such as Australia, India, and South Korea, the market in Asia Pacific is forecast to reach US$5 billion by the year 2027.

December 2020 ProPack.pro 21

FOCUS WORLD PACKAGING ORGANISATION

The impact of COVID 19: Real lessons The World Packaging Organisation (WPO) recently met virtually to discuss COVID-19 and its implications on packaging here is what they had to say...

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OVID-19 has turned the packaging world on its head, changing up not only how things are being packaged but also the rate at which change is needed.

But sifting through what’s just pandemic and what could be the longterm effects of it is hard to do.

The World Packaging Organisation (WPO) and some of its global ambassadors came together in a webinar, moderated by WPO president Professor Pierre Pienaar, to discuss the topic at hand.

WPO global ambassador Dr. Carl Olsmats, who is based in Sweden, said we’re now in the middle of the crisis and that change within the packaging space is inevitable.

“I made a couple of predictions for 2020 a few years ago and never in my wildest dreams did I predict anything close to what we’re facing this year,” he said.

“Many societies are in lockdown, people are unable to travel, and we have GDPs that are on a decline. It’s such a different world as compared to just one year ago. Global supply chains have been disrupted and we have a new social pattern emerging.

“There’s no one clear answer to COVID-19 and its impact on packaging but there is a lot to learn from it.”

Dr. Olsmats also said that the biggest challenge for the packaging industry, following COVID-19, is for it to find a ‘new normal’.

“We’re facing problems with staffing, as well as imports and exports, and logistics. At the end of the day, we have to find a way of operating that brings us value in future. COVID-19 has emphasised social efforts so I feel that if we take sustainability into our agendas, we can do better with our packaging efforts and reduce waste,” he said.

He added that the pandemic has impacted recyclability as social measures implemented have resulted in a greater load on the environment.

“As a result, the use of one-way plastics has increased and been reported in several markets. Some markets that banned plastics have lifted those restrictions temporarily as well to 22 ProPack.pro December 2020

1 make way for these solutions,” Dr. Olsmats said.

“We have to come up with the best solutions with the most minimal load on the environment in the current environment. Conversations around sustainability have to be around safety but at the same time around the circular economy for the long-term.”

As such, Dr. Olsmats mentioned that the right materials need to be used for the right applications.

“We have to make some adjustments to ensure that we’re handling all recycling material in the safest way as a direct response of COVID-19,” he said.

“We have to make sure that materials are used for the right purpose and if the question of human safety comes to play, we have to be prepared for a more linear instead of circular economy as we don’t want to end up recycling contaminated materials. It needs to be properly managed.

“In terms of technology, COVID-19 has accelerated traceability and this trend will play a bigger role in future as tracking the origins and cleaning and safety of products and packaging materials become the new norm.”

WPO global ambassador Kishan Singh, who is based in Africa, said COVID-19 is a social issue that has impacted most countries in the world in a similar fashion.

“Packaging has been the reason that we have been able to develop a supply chain and move products around the world. Now, enter COVID-19, all of a sudden, the world has been brought to its knees and consumer demands have changed,” he said.

“Take this and multiply it by the 7.8 billion people that exist in the world.

What does that mean? It means a reduced demand in consumer products, reduced demands for manufacturing, and reduced demands on packaging.

“Because packaging is a barometer in GDP growth in every country, economies are dwindling and they are currently constrained. This is expected to be the case in the next three to five years, which will definitely suppress packaging demand.”

Singh mentioned that consumer trends have changed significantly given the restrictions and social distancing measures in place.

He said the concept of shopping has now become one of needs rather than wants, therefore resulting in consumer behaviour that now doesn’t include unnecessary expenditure.

“Most consumer expenditure is now turning to online, which enables safety for customers as they don’t have to physically be in a store and interact with other people,” he said.

“This also means that the whole idea of entertainment is gone, as is the idea of social gatherings.

“Now that consumers are purchasing more products online, packaging has to be redesigned to support that buying pattern, rather than the usual fashion that we see in supermarkets.”

Singh addressed the issue of what the future may look like and said he finds COVID-19 to just be a punctuation mark in the role of packaging.

“I think that the future is still going to be very supportive of a circular economy and what we’re going through is just a small punctuation mark in the grand scheme of things. Yes, it has derailed and delayed some things in packaging but I don’t think it is going to completely change the future direction or trajectory that we have been on in the last 20 to 30 years in any way,” Singh said.

“There will always be a role for printed material in packaging – the future belongs to value-add packaging, which needs to be both functional and user-friendly. www.propack.pro

WORLD PACKAGING ORGANISATION FOCUS

learnt and what is just ‘pandemic’?

2 “So, all of the packaging industry needs to adapt to these changes.”

According to WPO global ambassador Chakravarthi AVPS, who is based in India, addressed the importance of having a better quality of life through better packaging.

“This is proving to be true more and more, and time and again, especially during this pandemic. COVID-19 has left us in a great helpless situation and the industry today is experiencing a wave of disruption,” he said.

“It has changed the world and how it operates forever.

“For me, this pandemic is the mother of all disruptions for our generation.

The only industry that is surviving through this, even during lockdowns, is packaging.

“It is and has been serving essential goods, food, pharmaceutical medications and other necessary products. We can’t and could not have done anything through COVID-19 without packaging.”

AVPS said we’re no longer in a world driven by the survival of the fittest, but rather the survival of the quickest. www.propack.pro

“Entrepreneurship is important now more than ever. Whoever comes up with solutions the quickest will survive; it has become as simple as that.

Millions of jobs have ceased around the world because of COVID-19 and the silver lining of this is that these people now have the opportunity to be entrepreneurs,” he said.

“Adaptability is also key. Think about how you can adapt to the changing needs of the market and customers, and we can surge ahead.”

AVPS said the industry can use COVID-19 to promote the benefits of packaging, especially the function of plastics which has, until now, received much negative attention.

“It’s hard to see this pandemic through without the imprint of plastic.

It would be impossible to imagine the number of deaths and the affected without plastic,” he said.

“We are using it for PPEs and packaging hand sanitisers and other disinfecting products. Even for people who have passed as a result of COVID19, they have to be properly wrapped in plastic before they can be buried.

1. (l-r) WPO ambassadors Dr. Carl Olsmats, Chakravarthi AVPS, Kishan Singh, and Luciana Pellegrino 2. COVID-19 has changed the way packaging is thought of and designed

“But having said that, plastic doesn’t need to be supported as greatly.

Governments, NGOs and businesses have to be more vigilant in creating products having considered the disposal methods of people.”

With 90 per cent of purchases occurring online, AVPS said e-Commerce has seen a rise in uptake, resulting in packaging companies needing to cater to this need.

“The unboxing process is now very important to sustain the interest in a consumer, retain brand value, and focus on product promotion,” he mentioned.

“Just because you’re selling your products online doesn’t mean you should ignore your packaging.

“Packaging is about protecting the product and improving shelf-life, but you also need to create the emotional connection with a brand and that’s where packaging is important too.

“The world will adapt to a new normal soon, so players in packaging should remain optimistic and embrace new technologies. The future will then belong to us.”

December 2020 ProPack.pro 23

FOCUS HEIDELBERG INNOVATION WEEK

Heidelberg unfolds the potential of lab Heidelberg took to its innovation week to reveal its latest in labels and packaging as opportunities arise from these markets

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everal thousand registrations from more than 100 countries, several hundred one-toone discussions arranged with decision-makers, and around 100,000 hits on videos – that is the upshot of the five-day Innovation Week that Heidelberg recently had.

This online event, taking ‘Unfold Your Potential’ as its slogan, focused on transferring knowledge relating to the urgent issues in the sector.

With product presentations on its latest highlights, innovation talks, and personal discussions via video chat, Heidelberg provided a comprehensive overview of its offerings in the commercial, label, and packaging segments.

“The feedback we have received so far from participants and our partners has been truly overwhelming,” Heidelberg head of global sales and marketing Ludwig Allgoewer said.

“As a result, Heidelberg was able to register specialist customer contacts on a similar scale to an international trade show. We are confident that the numerous customer discussions will also generate business contracts in the near future.”

At the heart of all the presentations was the optimisation of the entire process in offset and digital printing, all the way through to end-to-end production. This is based on its enhanced Push to Stop technology with all its facets, including automatic optimisation of job sequences and navigated printing, accompanied by user-friendliness for operators as a result of easy-to-understand user interfaces, all of which – combined with ‘integrated intelligence’ – enables highly productive operations with fewer staff and skilled personnel.

Heidelberg also provided supplementary information about offerings in the fields of Prinect workflow, consumables, and contract business. This did not focus on presenting individual product functions, but rather looked into responding to the most urgent customer requirements in the respective market segments.

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“The priority is no longer simply achieving the highest possible printing speed – instead we aim to make the entire process as efficient as possible.

Boosting productivity offers the greatest earnings capacity for industrial print shops,” Heidelberg CEO Rainer Hundsdörfer said.

“Digitisation is key to this – and that is precisely what we demonstrated at Innovation Week.

“The response to our Innovation Week underlines how it is possible to use digital formats to successfully contact customers and get them excited about innovations, even in the middle of a global pandemic.”

New solutions for packaging With packaging providing the industry with more opportunities, Heidelberg is increasing its play in this space with new product launches.

It has unveiled a new Mastermatrix 106 CSB, a new flagship die-cutter in collaboration with MK Masterwork with a production speed of up to 9,000

sheets per hour. The machine is designed for high speed and fast make-ready times.

For example, a new quick-lock clamping system for the cutting plate shortens the setup time without affecting tool compatibility with existing plates.

The setup time is further minimised

by MasterRake: the non-stop swords in the delivery are locked pneumatically and can be disengaged at the push of a button and moved by the operator.

This shortens the setup time at the delivery by up to 70 per cent.

The Mastermatrix is integrated in the Prinect workflow. Job specific data is received at the die-cutter from Prinect. Data such as the sheet format is transferred and – after confirmation by the operator – the MasterFeeder sets itself automatically to the sheet format without further manual intervention.

During production, the MasterSet optical register system ensures perfect registration between the print image and cutting tool for each sheet www.propack.pro

HEIDELBERG INNOVATION WEEK FOCUS

bels and packaging at innovation week

individually with the utmost precision.

The camdrive of the Mastermatrix ensures a smooth and quiet production.

During production, the MasterSet optical register system ensures perfect registration between the print image and cutting tool for each sheet individually with the utmost precision.

The camdrive of the Mastermatrix ensures a smooth and quiet production.

Two other new die cutters were launched earlier this year to complete the portfolio – the Powermatrix 106 CSB and Promatrix 145 CSB. For short runs in packaging and commercial printing the Digimatrix line will be added in future: the Digimatrix 80 LR and the Digimatrix 106 LR. These digital die-cutters are integrated in the Prinect workflow and employ laser cutting technology; they are currently scheduled for launch sometime in 2021.

Both machines provide the option of an inline rotary creasing station and achieve speeds of up to 3,000 sheets per hour. www.propack.pro

1. The Heidelberg Innovation Week focused on optimising the entire process in offset and digital printing through to end-to-end production

Heidelberg has also taken the wraps off a new operating concept based on Heidelberg User Experience UX. For example, the Speedmaster CX 102 from the new 2020 generation combines flexibility with navigated printing. It starts with efficient production planning via the Prinect Scheduler where production is optimised for multiple print jobs with the same or similar spot colours, materials, or die-cutting tools, and placed in the Job Queue of the Speedmaster CX 102 fully automatically and in the correct order – without manual intervention.

The Wallscreen XL guides the operator through the individual processes. With Intellistart 3, up to 50 upcoming job changes can be prepared on the press while production is underway.

Intelliguide navigates the operator through the complete job change and always selects the fastest makeready process. Intelliline visualises the process phase at the individual printing and coating units and indicates when and where a manual intervention is required. Assistance systems like Color Assistant Pro and Wash Assistant use artificial intelligence for continuous improvement.

For highly industrialised folding carton printers, Heidelberg has expanded the capabilities for the Speedmaster XL 106.

The new presetable CodeStar at the feeder ensures full traceability throughout the production.

It marks each sheet with a unique number, barcode or batch number so it can be identified again at any time during production.

Another innovation is Hycolor Pro, the Speedmaster XL 106’s automated dampening system. The dampening solution is metered between pan roller and metering roller. The pressure/ squeeze required for this purpose can now, for the first time, be controlled from the Prinect Press Center.

The operator can now quickly confirm the correct settings in all units – that saves time and effort while also enabling targeted corrections during production as the printer can address dampening issues on either side of the sheet. This results in fewer waste sheets at start-up and a more stable production run.

Effects for point-of-sale Complex jobs for special effects often involve elaborate and time-consuming make-ready processes that must be planned and carried out meticulously.

To illustrate the capabilities of the new

user interface, a demanding job change was shown in less than five minutes on a Speedmaster XL 106-8+LYY-1+L (eight printing units, one coating unit, two dryer units, another printing unit, and a second coating unit) with FoilStar.

“Intellistart 3, Intelliguide, and Intelliline navigate the operator through the various make-ready processes for complex jobs. Even less experienced operators are guided through elaborate make ready tasks: complexity is mastered and can be managed,” Heidelberg said.

This 13-unit press can produce a wide variety of embellishments, offering economical flexibility coupled with high process reliability and short make-ready times. Automation features such as the Hycolor Multidrive intelligent inking unit drive allow the blankets and the inking units to be washed while the plates are being changed. If an inking unit is not required for the next job, the washup program can continue to run while the press resumes printing.

Heidelberg said eye-catching metallic effects can be achieved in one pass with the FoilStar cold foil module as it claims that the most economical way of applying cold foil is using indexing and multi-reel capability.

“Foil consumption can be reduced by up to 80 per cent. The cold foil can be partially overprinted to produce a wide range of metallic and colour effects. All in all, this is a more sustainable solution than foil-laminated cardboard, which also can have long lead times,” it said.

Depending on the desired effect, different inks, varnishes and coatings are required along with a press configuration that provides the flexibility for many applications.

The 13-unit Speedmaster XL 106 serves as an example for a press that can produce stunning effects for high impact folding cartons at the point of sale economically in a single pass.

Heidelberg said it installs 40 to 50 of these special presses with customised configurations per year.

“The growth market of packaging and especially folding carton manufacturing are part of our core business. Our product portfolio is leading the industry, and we are introducing innovations to further enhance it based on our customers’ needs and demands,” Heidelberg head of the folding carton segment Jörg Dähnhardt said.

Continued on page 26 December 2020 ProPack.pro 25

FOCUS HEIDELBERG INNOVATION WEEK Continued from page 25 2. The new Speedmaster XL 106-D die cutter makes it easier for customers to move into rotary die cutting

2

3. World premiere: the new Mastermatrix 106 CSB high-performance die cutter, which represents top performance in postpress with a production speed of up to 9,000 sheets per hour

“The optimisation of folding carton manufacturing for the benefit of our customers is an integral part of our company strategy.”

Heidelberg has also mentioned that from mid 2021, Prinect Business Manager Packaging will be launched specifically for packaging printing.

Together with the Prinect Production Manager and the tailored packaging add-ons, the result will be a fully integrated packaging workflow.

New suite of solutions for labels

Heidelberg has unveiled a suite of solutions for label printers – namely a new Speedmaster XL 106-D, new CutStar Gen. 4 Push to Stop solution

and new FoilStar Cure. Heidelberg has launched its new Speedmaster XL 106D, featuring just one die-cutting unit which aims to make it easier for printers to move into rotary die cutting.

The XL 106-D is able to process the thinnest of materials at a high speed of 12,000 sheets per hour.

It punches even the smallest injection holes, which are stripped and extracted immediately as a result of the high-precision magnetic cylinder with 1 µ pressure adjustment.

This high precision, resulting from the cylinder design and uniform cutting, die dispenses with the timeconsuming make-ready required when using the flat-bed process due to differences in level within the cutting

die. Heidelberg said this means far shorter setup times, tooling costs that are also up to 50 per cent lower than with a flat-bed die cutter, and three times higher production speeds.

According to Heideberg, the installation of over 60 Speedmaster XL 106-DD rotary die cutters has provided proof of the market success it has been enjoying with this machine since 2008.

It is now available in various configurations – from the new Speedmaster XL 106-D with just one die-cutting unit, to the XL 106-DD with magnetic cylinder and extraction system for added injection and decorative holes.

“The new Speedmaster XL 106-D with just one die-cutting unit makes it easier for label printers to move into rotary die cutting and complements the successful Speedmaster XL 106-DD with magnetic cylinder and extraction system, which has been available for a number of years,” Heidelberg head of product management label Markus Höfer said.

The company has also made other announcements in the labels sector, concentrating on end-to-end digitised solutions in sheetfed offset printing.

“With its digitised sheetfed offset printing solutions, Heidelberg will continue to play a leading role on the growing labels market in the future,” Höfer said.

3

26 ProPack.pro December 2020

www.propack.pro

HEIDELBERG INNOVATION WEEK FOCUS

“We remain a reliable partner and supplier for our customers in this segment, working with them to overcome the challenges of this demanding market.”

Heidelberg has also made available its new Push to Stop CutStar solution, based on a new platform, with the latest drive technology, control technology, a new blade geometry, and new peripherals.

“Customers’ growing demands in terms of print speed, stable sheet travel, level of automation, and ease of handling when processing thinner substrates on the CutStar sheeter prompted us to develop a new generation of this system,” Höfer said.

The new CutStar Gen. 4 features high-quality results on foils as thin as 50 grammages, combined with an impressive production output.

The fourth-generation sheeter is fully integrated into the Prinect workflow and also the Intellistart system on the press for production based on the Push to Stop principle.

Air/format settings and format changes take place fully automatically, which aims for shorter setup times.

The surface treatment integrated into the CutStar is another new feature, ensuring high end-to-end quality by improving ink adhesion.

Optimisation is also geared specifically to low grammages as paper

4. The enhanced fourth-generation Push to Stop CutStar enables label printers to process particularly thin materials

4

5. The new Promatrix 145 CSB die cutter features pallet logistics, the automatic non-stop feeder, MasterSet, and also a sample sheet delivery, a novelty in this format class

increases the production speed by up to 2,000 sheets per hour.

The company also unveiled its new FoilStar Cure, enabling label producers to meet challenging finishing requirements.

In conjunction with another Heidelberg innovation – the DryStar LED Pro dryer – high-gloss metallic effects can be produced.

In the FoilStar Cure, drying for the first time takes place right through the foil, which enhances gloss levels.

Heidelberg said cold foil is the perfect solution for a wide range of effects, combined with an impressive processing speed. It also has environmental benefits over aluminum-coated material because

it saves on aluminum and makes labels easier to recycle.

As a result of customised indexing lengths during production, and because only the specified parts of the label are foiled, up to 80 per cent less material is used, according to the company.

Heidelberg added that service agreements complementing Heidelberg equipment and software are also available for the labels sector, which ensures continuously high availability of all systems.

“Like all other Heidelberg customers, label producers benefit from the industry’s largest service network, with global availability of spare parts and access to the Heidelberg Assistant digital collaboration platform,” it said.

5

www.propack.pro

December 2020 ProPack.pro 27

FOCUS ELOF HANSSON & BILLERUDKORSNÄS

Elof Hansson delivers innovative Bil 1

2

3

4

Australian-based paper importer Elof Hansson is encouraging converters as well as packaging technologists and designers to consider more sustainable and environmentally-friendly solutions sourced from its partnership with Swedish-based pulp and paper manufacturer BillerudKorsnäs

B

illerudKorsnäs has recently transformed the confectionery packaging market with the announcement of a unique Recyclable Flow Wrap, enabling a shift from conventional plastic to renewable and recyclable materials.

The Recyclable Flow Wrap, created in conjunction with German-based intelligent and sustainable packaging specialist Syntegon Technology (formerly known as Bosch Packaging Technology), has been tested with its retrofit upgrade kit, paper-ON-form.

According to Elof Hansson Australia managing director Adam Bohatko, this paper-based flow wrap flexible packaging solution with a pending patent is ideal for confectionery, but could be used for many products in the fast-moving consumer goods (FMCG) sector.

“Today, plastic film flow wrap is standard for FMCG while 28 ProPack.pro December 2020

1. The Recyclable Flow Wrap was created in conjunction with Syntegon Technology 2. This paper-based flow wrap flexible packaging is ideal for FMCG products 3. The Recyclable Flow Wrap is based on primary fibres from well-managed forests 4. The solution enables companies such as confectionery manufacturers, to shift from conventional plastic to paper packaging

BillerudKorsnäs Recyclable Flow Wrap is an innovative paper packaging solution, based on primary fibres from well-managed forests and with high barrier performance that can be recycled as paper,” Bohatko said.

“As the agent for BillerudKorsnäs Cartonboard, Sack and Kraft paper products in Australia, we know this new packaging solution enables clever and innovative companies to shift from conventional plastic to paper and is suitable for medium to high barrier requirements such as those posed by chocolate bars and other confectionery, as well as bakery products.”

Bohatko said he believes this is a great opportunity for major confectionery and FMCG brands in Australia who are looking to develop a sustainable aspect to their business, this is an ideal solution.

“We know customers are actively seeking, and in some cases demanding, fully recyclable packaging across a number of product categories where this was not previously possible – and this solution from BillerudKorsnäs achieves this,” he said.

“Moreover it is an environmentallyfriendly solution for packaging technologists and designers for major brands that helps them address their triple bottom line reporting and the growing need to address needs and interests of shareholders, as well as consumers.”

Recyclable Flow Wrap project manager Peter Åström has confirmed the product is recyclable as paper and brand owners don’t have to

compromise either on product shelf life or on converting productivity in comparison to plastic packaging options. With the Syntegon upgrade kit paper-ON-form, it can be installed on existing horizontal flow wrapping machines and new flow wrappers from Syntegon Packaging Systems AG. The solution was engineered in Syntegon’s own development centre in Beringen, Switzerland, and consists of a flow-wrap forming unit and sealing tools or paper cold-sealing applications.

The kit is already being used on existing lines from international manufacturers for packaging chocolate bars in paper.

“To make flow wraps future-proof, we have to take a holistic approach.

In our test lab, we are concentrating on three elements – avoidance, recycling and recovery,” Syntegon Technology Sustainability Horizontal Packaging project manager Christoph Langohr said.

“Our retrofit kit allows customers to transition to paper packaging on their existing Syntegon Packaging Systems horizontal flow wrapping machine – without any restrictions regarding speed compared to the existing for cold-sealable paper.

“By introducing Recyclable Flow Wrap, BillerudKorsnäs brings to market technologically-forward innovation based on renewable and biodegradable materials meeting brand owners and legislators’ need to reduce littering and increase recycling without compromising on the barrier characteristics.” www.propack.pro

ELOF HANSSON & BILLERUDKORSNÄS FOCUS

illerudKorsnäs packaging solutions Melbourne-based films and food packaging specialist, Verix, has developed a unique product in the Australian market using material sourced from BillerudKorsnäs – supplied in Australia

by Elof Hansson.

According to Verix managing director, Jeremy Kavnoudias, its fully-recyclable FormFresh tray and blister packaging is unlike any other product available in the local market.

“Our goal was to develop a thermoformable paper-based solution for food packaging as an alternative to the existing products that Verix supplies to the market. One of the major considerations was to ensure this product would work on existing customer equipment with minimal machine upgrades. After extensive research, development, trials and discussions, FormFresh was born,” he said.

“To create FormFresh, we source the BillerudKorsnäs FibreForm product in rolls which comes to us from Elof Hansson in a white paper format.

“We then print directly on to the board in colours such as black, brown and wood grain or it can be white.

“We process further to add barrier performance for perishable foods that allows the packaging to still be accepted at kerbside.

“What is unique about this product is that it can be formed, filled and sealed on conventional thermoforming equipment as an ideal and more environmentally friendly alternative to what is currently available on the market.

“It is ideally suited as a replacement for PET/PE and PVC/PE trays utilising shallow depths such as skin packing for steak and Modified Atmosphere Packing for small goods products.

“There is currently no other formable paper-based product available like this that is also kerbside recyclable in Australia and New Zealand.

“Customers like the look and feel of the products, but the overwhelming reason why clients love our FormFresh packaging is because it is genuinely sustainable and it is a very unique and new product.

“We have been working with the FibreForm product from Elof Hansson and we have been slowly developing the barrier properties using the PREP tool as a guide to ensure the recycling specifications are within the correct parameters.

“We have also noticed that customers are choosing packaging materials that cost more per pack as they feel there is a communicable difference in terms of marketing messages which relates to sustainability and recyclability.” www.propack.pro

FormFresh can be formed, filled and sealed on conventional thermoforming equipment

FormFresh is ideally suited as a replacement for PET/PE and PVC/PE trays utilising shallow depths December 2020 ProPack.pro 29

FOCUS JET TECHNOLOGIES

Jet Technologies celebrates 40 years of family success Jet Technologies celebrates 40 years of service, innovation, and expertise in the Australian and global industrial printing and packaging industries this year

J

et Technologies is celebrating turning 40 this year, continuing its legacy of providing stellar service, innovation, and expertise in the Australian and global industrial printing and packaging industries. Now a renowned Australian family-owned and operated business, Jet Technologies commemorates its 40-year history as a leading specialist importer and distributor of printing and packaging products.

“Jet Technologies is proud to be celebrating its 40th anniversary as a leader in the industry, and to be showcasing the hard work of its industry expert staff who continue to deliver their customers in Australia and globally, the knowledge and practical knowhow to provide premium quality products and outstanding service,” Jet Technologies director Jack Malki said.

The story of Jet Technologies began when its managing director Albert Malki and his family made their journey from Italy to Australia back in 1980. When Albert and his family immigrated to Australia, hardly able to speak English, the landscape was vastly different, with difficulties faced in assimilating into the Australian culture. With this very obstacle in mind, Albert decided to start a company called Jet Overseas Trade to facilitate trade of a varied range of products between Australia and Europe. Industrial products were added over the years, including surfactants and aluminium.

By the late 1980s, Amcor requested the assistance of Jet Overseas Trade in working with the Cerutti Group, an Italian manufacturer of gravure printing presses, and from there grew the print division of the company.

“We pride ourselves on our strong family-based values, which we translate to our staff and our culture; investing in our staff to build long-lasting relationships with our customers, and 30 ProPack.pro December 2020

1. (l-r) Jack Malki, Albert Malki, and Daniel Malki run Jet Technologies today 2. (l-r) Albert Malki, Jack Malki (Albert’s father) and Elliot Malki (Albert’s older brother) are the pillars of Jet Technologies’ early days

1 striving to deliver genuine and expert service always,” Albert said.

Working originally from offices in Sydney’s Bondi Junction, the team quickly expanded, and in 2001 moved to a larger location in Alexandria and became Jet Technologies. With further growth, including the addition of new team members in South Australia, Victoria and New Zealand, Jet Technologies moved to even larger locations with warehouses in Mascot and then its current headquarters in Rosebery. The Rosebery site features a state-of-the-art demo centre and a

2

purpose-built ink management facility.

Jet Technologies now also has a state-ofthe-art office-warehouse in Melbourne.

“Today, we have grown and diversified significantly into the divisions of industrial, packaging, and printing – now employing over 70 staff and operating from locations across Australia, New Zealand, Indonesia, and Singapore, alongside a range of leading supplier partners including Screen GP, Kocher + Beck, ESKO, Flexo Wash, Crown, Goglio, ILPRA, and LG,” Jet Technologies general manager Daniel Malki said.

Albert continues to lead Jet Technologies and is supported by the second generation of the family business, with director Jack Malki and general manager Daniel Malki.

They say that the company’s core focus on family, expertise, partnership, reliability, and trust has really been the key for its success, alongside the company’s collective and constant push to find and materialise the latest industry innovations and technology to offer its customers. www.propack.pro

The Intermedia Group proudly publishes over 30 specialty print titles in Australia and New Zealand with a readership in excess of 800,000 people.

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FOCUS PREMIUM RECYCLED PAPER

Use premium recycled The rise and success of premium recycled paper around the world is crucial in the conversation around recyclability and sustainability

1

T

here’s no single route towards sustainability and as a manufacturer of paper and flexible plastic packaging, Mondi delivers using one ethos – paper where possible, plastic when useful.

It is now increasingly necessary to sustain the natural resources of the earth as a result of climate change. As climate change, forests and water are interlinked, it has become important to focus on all three elements together to bring about a positive impact.

International packaging and paper group, Mondi, finds its purpose in contributing to a better world by making sustainable and innovative packaging and paper solutions through sustainable forest management, responsible sourcing, and science-based climate targets.

Mondi Uncoated Fine Paper marketing and sales director Johannes Klumpp identified three ways to do so – shift to renewable resources, conserve natural ones, and recycle what we can.

“We cannot take one topic in isolation; climate change, forests and water are very much interlinked and we need to work to have a positive impact on them,” he said.

Paper ticks all of those boxes as 72 per cent of the fibre that the business uses are FSC or PEFC certified, and it is committed to zero deforestation and forest degradation.

The manufactured paper can then be recycled by consumers, which is then remade into paper.

According to Klumpp, when talking about sustainability, both virgin fibre and recycled paper is necessary to maintain a balance as without virgin fibre, there can be no recycled paper.

Earlier this year, Mondi launched three new members of the premium recycled paper NNAUTILUS family, the NAUTILUS ProCycle, NAUTILUS ProCycle high-speed inkjet and 32 ProPack.pro December 2020

1. Mondi Uncoated Fine Paper’s Johannes Klumpp is an advocate for the balanced use of virgin fibre and recycled paper

NAUTILUS SuperWhite for HP Indigo. The company, which produces uncoated fine paper and pulp in six mills across Austria, Slovakia, Russia and South Africa, released these solutions as it recognised a shortage of uncoated recycled fine paper in the marketplace even though there was a huge demand for such products. In response to this, Mondi’s recycled paper brand NAUTILUS was grown to include a full portfolio for professional print and office applications.

“At Mondi, we believe all our products should be sustainable by design. With our broad portfolio, strong supply and distribution partnerships as well as our considered approach to natural resource use which is reflected in our new Nautilus brand design, we want to ensure that our

customers find the right recycled paper for diverse applications, be it for industrial, office or personal purposes,” Klumpp said.

“But paper cannot be recycled indefinitely. At some point, the fibre will be too short, and usually that point comes after four to six lifecycles.

“So, even with the most thorough post-consumer collection of waste paper, we would run out of usable paper to recycle.

“You need fresh fibre to make recycled paper; so fresh fibre papers need to have sustainable and responsible processes so that we can extend the life cycle of recycled paper in a well-managed and certified way.”

Mondi was one of the first players within the industry to tap into the sustainability trend – the company www.propack.pro

PREMIUM RECYCLED PAPER FOCUS

d paper where possible has been delivering on sustainability since the late ‘80s, with its production mills being one of the early adopters of chlorine-free processes.

“Sustainability is an important message for us. It is not a short-term but a long-term development for us. We have noticed an increasing awareness of sustainability, partly driven by industry and partly driven by political bodies and our offerings now falls into the space of demand,” Klumpp said.

Mondi’s national distributor, Ball & Doggett, has been delivering on the sustainable message in Australia. It provides customers with premium recycled paper in Australia under the brand ecoStar+.

The take-up of ecoStar+ has been popular amongst Australia’s government circles and larger corporate businesses as these organisations have corporate and social responsibility charters that focus on recycle-grade paper.

Ball & Doggett national marketing manager Tony Bertrand said, “Our business is diverse and we’re dealing with customers that are increasingly seeking premium recycled paper solutions. Our partnership with Mondi addresses the increasing demand for such solutions”.

“Sustainability for the paper industry is a necessity and Australia, per capita, is one of the highest countries in the world when it comes to recycling.

“There’s an expectation from the community that what we do is sustainable. We’ve looked at sustainability over the years, not just as in environmental sustainability but also keeping in mind social and economic costs as well.

“For us, moving with expectations of the community and ensuring that we’ve got a sustainable supply chain is very important for our sustainability as a business. This has been a constant for Ball & Doggett over the years, even when we were known by other business names. It started about 20 years ago and still forms one of our key pillars moving forward.”

According to Bertrand, the percentage of recycled paper in Australia as compared to virgin fibre papers has maintained its percentage of the total market.

“It hasn’t necessarily grown to the point where it’s now the leading product by any stretch, because of the contracting demand of paper globally over the past eight years or so, but it certainly continues to maintain even www.propack.pro

when other products in the virgin fibre space have contracted in volume,” he said.

Both Klumpp and Bertrand agreed that moving forward, there is only going to be an increasing requirement for sustainable products, especially premium recycled paper, as more consumers understand the benefits of it and its impact on the environment.

They both also identified that printers are crucial frontiers in delivering this message to the market.

“Printers, by and large, want to have a good offering for their end customers.

I expect to see a growing request for this as they continue to increasingly take up premium recycled paper,” Klumpp said.

“If printers don’t respond to the needs of the end customers, it will be difficult for them to meet customer expectations.

“In Europe, we’ve seen a number of printers that have switched completely to a sustainable printing approach where they not only offer sustainable paper products such as premium recycled paper or certified to have fresh fibre papers, but also make sure that their energy consumption come from sustainable sources, that they use the right inks, and also offset any CO2 emissions that they might have with CO2 projects.”

Bertrand added that printers shouldn’t be looking at sustainability or recyclability as an important attribute.

“I’d like to see more printers take a position when offering the clients alternatives. We’ve seen some printers do that in Australia and they’ve done very well for a long period of time having taken on a position of sustainability,” Bertrand said.

“I was recently talking to a printer that manufactures standardised products and I said, “why don’t you give the customer an alternative, they can buy all of those standardised products but using 100 per cent recycled FSC carbon neutral paper”.

“Why not put it out there to the end user to say, “we’re an organisation that has a sustainability policy and we want to encourage you as an end user to take on the benefits of our sustainability position by using these products”?

Bertrand added that many years ago, recycled paper was difficult to use as it depended on what technology capabilities were at that time.

However, with paper technologies encompassing recyclability as part of its innovation, there is now no excuse.

2. Ball & Doggett’s Tony Bertrand calls for printers to lead the sustainability message to end customers

“There’s no excuse for a printer to say, “I can’t print on ecoStar+, because you don’t have the product that works on my equipment”. The paper is now suitable on all technologies when it comes to printing,” he said.

“There’s a great opportunity here for printers to grab onto this and be different to a printer friend down the road, who may not take that position.

“I hear a lot of doom and gloom out there, but it’s an entrepreneur’s world out there.

“The opportunity to innovate in this market, going into the future, is still very much there.

“We want to give printers, in this country, the platform to be successful.

“We want to do that through sustainability and giving them the confidence that we’ve done the work for them. The products we’re bringing to market are the best in class. The printers who come out the other side will have a bright future.”

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Packaging: Fit 2

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Experts in the industry provide an extensive array of educational and technical opportunities for stakeholders within packaging

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he Australian Institute of Packaging (AIP) recently held its digital packaging conference for 2020, bringing together industry experts that provided thought leadership and forward thinking around trends within packaging.

During the welcome address and conference opening, AIP president Jason Fields said COVID-19 has impacted not only packaging, but all other industries as well; but the industry should be prepared for the future of packaging.

“How do we prepare for the future when we can’t even see six months or six days ahead? Do we give up and say ‘it’s too hard?’ No. for the sake of our future generations, we need to be prepared. When the world recovers, or learns how to live with the 34 ProPack.pro December 2020

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pandemic, the focus will be back on sustainability, packaging, and packaging design for recovery,” he said.

“If you haven’t been working hard in the background, we won’t be ready when the spotlight is on us.”

World Packaging Organisation (WPO) president Professor Pierre Pienaar spoke about the global perspective on packaging during the first keynote session.

According to Professor Pienaar, packaging is necessary for food safety and quality, protecting food, extending its shelf-life and reducing food waste, but there needs to be solutions that reduce packaging volume and impact without compromising on protection.

“Within the WPO, we see a future without waste. And we see this by increasing plastic recycling and identifying alternatives like focusing on sustainability and increasing consumer awareness of packaging waste,” he said.

He said a lot can be learnt from the FMCG industry as these companies are promoting recyclability and recycled content.

“FMCG companies no longer take a passive approach – they are building infrastructure to manage increased

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recycling, employing more closed systems and are building recovery capability,” he said.

“As such, we require more intentional collaborations between FMCG manufacturers, retailers and packaging converters. Only with this approach will we see a reduction in the environmental impact of packaging and satisfaction of the consumer.”

As the first keynote session, Seabin Project CEO and co-founder Pete Ceglinski addressed the need to invest in cleaner oceans.

“Using clean-up, prevention and measurable impact is the path forward to cleaner oceans and a better value of life for everybody,” he said.

“Many councils and State Governments are committed with no commitment. The team and I are putting together a document to justify why they should get involved.

“There are also jurisdictional overlaps that occur, so we need to figure out how we’re not bouncing back and forth and solve the problem.

“We know that there’s plastic that needs to be reduced. We know that it’s branded litter but no one wants to see plastic in the water. So, we need to www.propack.pro

AIP CONFERENCE FOCUS

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work together collaboratively to find the best solutions. Everyone is accountable and the fastest way to deliver is through collaboration.”

New APCO program Keynote session two saw Helen Lewis Research principal Dr Helen Lewis join several representatives from the Collective Action Group – the senior advisory group overseeing the strategic direction of the 2025 National Packaging Targets – to explore how the 2025 Targets are progressing.

The session also explored the new monitoring program, which maps the critical success factors, milestones and key performance indicators that are in place to ensure Australia is on track to deliver the 2025 targets.

Lewis, who headed the session, said Australia needs 100 per cent circularity for all packaging in order to achieve the 2025 National Packaging Targets, and that the newly launched 2025 Monitoring Program will determine how it gets there.

“The Monitoring Program is designed to provide insight and a structured framework to regularly measure progress towards Target. www.propack.pro

1. AIP’s Jason Fields 2. WPO’s Prof Pierre Pienaar 3. Seabin Project’s Pete Ceglinski 4. Australian Govt’s Cameron Colebatch 5. Nestlé Oceania’s Margaret Stuart 6. Coca-Cola Amatil’s Jeff Maguire 7. Ernst & Young’s Terence Jeyaretnam 8. Planet Ark’s Paul Klymenko 9. CAG’s Phil Preston 10. Helen Lewis Research’s Dr Helen Lewis 11. AFGC’s Barry Cosier 12. Pact Group’s Siobhan McCrory 13. Tetra Pak Oceania’s Vikas Ahuja 14. TerraCycle A/NZ’s Jean Baillard

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We need to monitor our progress every year between now and 2025,” she said.

“It also provides an opportunity for all stakeholders to identify when progress isn’t sufficient, and where that occurs to look at what actions we need to take to make sure we achieve the right level of progress.”

Lewis identified the four critical areas of progress, which includes: • Design and production: For 100 per cent of packaging to be designed to be reusable, recyclable or compostable • Use of packaging: For problematic and unnecessary single-use plastic packaging to be phased out • Disposal and recovery of packaging: For 70 per cent of plastic packaging to be recycled • Market creation: For the creation of an average of 50 per cent of recycled content in packaging to ensure a sustainable and robust end-markets Across these critical areas of progress are seven strategic intervention points, which include: • Design in use of sustainable packaging guidelines • Production where single-use, unnecessary and problematic

plastics get phased out • Australasian recycling labels to be used • Material standards for proper packaging disposal • Reprocessing capacity for recovery of materials • Optimising the value of materials at end-of-life • Market creation through the use of recycled content Collective Action Group (CAG) facilitator Phil Preston said producing a better outcome for everyone, no matter where they sit in a value chain is important.

“There are many stakeholders in this process – all levels of government, all parts of industry, consumers and NGOs. So, measurement is a critical part of the process to tell us if we’re on track,” he said.

“What’s changed recently and quite rapidly is the conversation around creating value – it’s not one that is just about brand reputation but also about creating value for shareholders. What this means is that investors are starting to look at more sophisticated measures.

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FOCUS AIP CONFERENCE Continued from page 35

Companies at the forefront of this agenda are more highly valued in the market – so there’s a strong incentive to change.”

Planet Ark CEO Paul Klymenko said the role of the 2025 Monitoring Program is vital as packaging is a whole-of-systems problem and requires a whole-of-system solution.

“Everyone knowing their own particular roles – ranging from consumers to brand owners and reprocessors – is essential, and setting those milestone targets enable regular monitoring, making it open and transparent,” Klymenko said.

“Consumer confidence in recycling has taken a hit over the past few years over things such as war on waste.

“It is a double-edged sword as the awareness of recycling has increased tremendously, but there has been a decline in confidence on the system.

We need to restore that confidence and improve on it. If you want to get people involved in a behaviour change, they have to clearly know what actions are required of them.”

Ernst & Young climate change and sustainability partner Terence Jeyaretnam said only $25 million

worth of recyclable material is currently being captured from waste in curbsides in Australia and that there is a massive opportunity of about $274 million in recyclable material that could be attained from curbside recycling itself.

“Australia’s waste problem is also a behavioural problem. Reducing contamination in our recyclables requires a fundamental behavioural shift – like better information for households and clearer rules on what’s recyclable. The right information is going to be critical to change,” he said.

“Recyclables should also be sorted at collection rather than after, and more recycled material should be included in the production of goods infrastructure and packaging.

“We also recommend that for things that can’t be recycled, waste to energy is considered.”

Department of Agriculture, Water and the Environment director of plastics, packaging and food waste Cameron Colebatch said on a higher level, the government’s role is about supporting the targets.

“Even though they are industry-led, they do have the backing of the

government. The government has dedicated $190 million towards the Recycling Modernisation Funds to improve Australia’s sorting and recycling capacity, which aims to double Australia’s current recycling capabilities,” he said.

“That will get the momentum going for further private equity investments.

So, as we see more demand for recycled content and packaging, it sends the signal to the market to invest more in recycling infrastructure.”

Coca-Cola Amatil group head of CDS development and implementation Jeff Maguire said the company’s role fully aligns with the Monitoring Program.

“The Monitoring Program is linear in progression. If we get the design pieces right, then the collection will facilitate the recycling and the closing of the loop,” he said.

“We’ve got to get the design piece right, what’s going into those pieces, and what’s in the market, so that when we do collect material, we can ensure that it gets recycled.

“It’s a very complex process with a varying number of materials so we have to ensure that it’s not just recycling potential that’s being spoken about but

Behavioural economics Acclaimed inspirational speaker and behavioural economics expert Sonia Friedrich delivered a keynote address, giving insight into the unconscious behaviours that cause shoppers to pick up a product.

She showed how understanding how the brain works and applying this into packaging and design can change behaviour choice.

“Most of us design packaging and content assuming that if we do the right thing, so will everyone else and pick up the right product off the shelves,” she said.

“But there are two problems with that – not everyone can design the best thing and that humans aren’t rational. That’s where the disconnect occurs. So, the more that you and everyone else in the chain that is developing your products and services understand the human dynamic, the better the solutions will be.”

According to Friedrich, businesses now need to think wisely as to how they spend their resources and how to plan for them, as the human behaviour increasingly plays a key role in investments.

“Sometimes a small ‘nudge’ has a ripple effect and may save companies millions of dollars,” she said.

“There’s more than 600 heuristics and biases that determine why humans behave the way that they do.

“So, friction map your journey using what you’ve experienced and data analytics, and find out what your quick wins are and what 36 ProPack.pro December 2020

Sonia Friedrich addresses how understanding how the brain works is crucial in its application into the science of packaging and how the choice of different designs on packaging can change behaviour choice your long-term opportunities are.

From there, have a look to see if there’s something really big that can shift from a quick win to a long-term opportunity, and

make your other frictions disappear.

Behavioural economics provides measured outcomes and should be a consideration of everyone in your business.” www.propack.pro

AIP CONFERENCE FOCUS

material that is actually being recycled.

Ultimately, to underpin investment in a recycling opportunity, there has to be reliable material supply – both in terms of the availability and volume of the material to make the process economic. We need this to drive activity in the market.”

Nestle Oceania head of corporate and external relations Margaret Stuart said the company is “firmly on the journey” to meet the targets for 2025. However, she said there needs to be an overarching view for the entire targets ecosystem.

“The Targets help pull guidelines for brand owners so that across the system, we know what is and isn’t working and what progress needs to happen in other areas as well so that collectively, were all lifting the game so that we can get to the destination we need,” Stuart said.

“The most important action that brands can take is to understand the system. When you understand the players in the system, you know what is driving them and what the limitations are, making you better informed to make right strategic decisions around packaging.

“As global brands, we also need to understand systems in place within each country and try and standardise products in line with them. There are clear challenges, but we need to harmonise our standards around how we package products.”

Creating a circular economy Australian Food & Grocery Council (AFGC) sustainability director Barry Cosier said there are two issues surrounding packaging at the moment – litter from packaging material and the global recycling crisis causing an environmental and economic issue.

“The global estimate of plastics entering the marine environment is 12.2 million tonnes per annum – close to 94 per cent of that is coming from Asia and African river systems. This is driving a bad perception of packaging, even locally in Australia,” he said.

“As for the global recycling crisis, it is mainly a result of China’s national sword policy that is causing environmental and economic issues, and this is where the circular economy solution will sit.

“The solution to this is to move away from a linear, ‘take, make and dispose of” economy into a circular economy.

And to create a circular economy, all stakeholders should be moving in the same direction.”

Cosier also addressed seven actions for brand owners to adopt: • Consider compostable packaging if there’s a high risk of packaging being littered www.propack.pro

• Review packaging designs via the PREP tool and consult the APCO Sustainable Packaging guidelines • Adopt the Australasian recycling logo in your labels • If you have flexible packaging, support REDCycle voluntary product stewardship • Support the APCO recycled content pledge • Contact your packaging supplier for increased recycled content and less complex packaging structures • When redesigning packaging, consider its full lifecycle impact, its impact on food waste and its impact on food or chemical safety Pact Group executive general manager of sales, marketing and innovation Siobhan McCrory said all businesses are at different points in their sustainability journeys but the constant is that the appetite for most companies to make changes in adopting sustainability is growing.

“At Pact, the knowledge about how to build and deliver customer solutions centered around the circular economy is firmly part of our DNA,” she said.

“Pact’s war on waste isn’t solely about being responsible at the end of packaging’s life; it’s about reducing and eradicating waste through the entire supply chain.

“Our 2025 promise is to eliminate all non-recyclable packaging that we produce, have solutions to ‘reduce, reuse and recycle’ all single-use secondary packaging within out reuse business, and offer 30 per cent recycled content across all of our portfolio.”

McCrory added that the industry needs solutions that can solve the end of waste without simply increasing cost and losing value.

“The key to this is through innovation and scale.

“It requires a whole of society approach, with all players involved along the packaging supply chain committed to a solution and ensuring that every opportunity is taken to reduce, reuse and recycle,” she added.

Meeting the targets Tetra Pak Oceania sustainability director Vikas Ahuja said businesses need to think ahead and have a plan in meeting the Global Sustainable Packaging Targets.

According to Ahuja, the modern world is so reliant on safe, nutritious food being available everywhere, but a large part of what enables that need is packaging.

“To achieve the world’s most sustainable food packaging, we need to take many aspects into account, such as carbon emissions, biodiversity, food safety, regulations, recycling systems, sorting systems, and much more.

In other words, we need to consider the full lifecycle of the package,” he said.

As such, Ahuja said packaging needs to address five dimensions to be sustainable: • Raw materials and sourcing • Production and distribution • Food protection and consumption • Recycling • End of life “A package should save more than it costs. Tetra Pak is heavily investing in research and development of carton packages that are made from simplified material structures and increased paper-based content. Besides removing aluminium, we also aim to create a food package with reduced amounts of plastic,” he said.

“That means the world’s most sustainable food package will be made of fully responsibly sourced renewable materials and it will be fully recyclable and carbon neutral.”

Changing the face of packaging worldwide

TerraCycle Australia and New Zealand general manager Jean Baillard said cutting-edge technology and design will take the world from disposability to reusability, and change the face of packaging.

Baillard said TerraCycle launched Loop at the World Economic Forum in 2019 to recycle, reuse and upcycles waste into innovative new materials and products, transforming the way we think of waste.

The company is in the midst of a global rollout for Loop, with a partnership with Woolworths expected in Australia and AEON in Japan by mid-2021.

“In order to make mass consumers move towards and adopt reusable products, design is critically important as people place it above sustainability in terms of credentials. Any one of our Loop solutions needs to be upcycled three to four times to reach a breakeven point in terms of environmental impact,” he said.

“But, we also need to maintain convenience and that is done by making reusable products available to people where they are already shopping for products and at retail outlets that they are used to.

“By giving people disposable options that are convenient, reusability becomes a more widely-accepted and used concept. By making reusability as convenient as disposability, we can eliminate the idea of waste.

“Loop aims to have as many products as possible on this platform for consumers to have a full shopping experience where all their day-to-day products are delivered to them in reusable packaging.”

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UPDATE AUSTRALIAN INSTITUTE OF PACKAGING

Follow the RED Recycled Changes to procurement strategies are key to stimulate further investment in soft plastic recycling and reprocessing

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hen you think of outdoor furniture, roads, bollards, fences, patio decking and even footbridges you might not realise that a growing number of these items are made incorporating ‘soft plastics’ as a way to recycle flexible packaging and materials that have no home at this moment in the current kerbside recycling systems in Australia.

Of the nearly 1.1 million tonnes of plastic packaging placed onto the market in 2017-18, approximately 352,000 tonnes (33 per cent) were soft plastics. However, only 29,000 tonnes or eight per cent of the soft plastic materials was recycled, with around 28,000 tonnes being recycled from Commercial & Industrial (C&I) sources and only 1,000 tonnes from consumers.

This low recycling figure for soft plastic has highlighted the need for industry and government to give added focus to develop a strong national consumer collection program for soft plastics, combined with investment in additional reprocessing facilities, and innovation to include recycled content in flexible materials. Changes to procurement strategies are key to stimulate further investment in soft plastic recycling and reprocessing and to ensure that soft plastics are seen as a valuable resource that can be recycled, rather than disposed of as waste.

What is the meaning of ‘Soft Plastics’?

Soft Plastics are traditionally Polyolefins which is a collective description for plastics types that include (PE) Polyethylene including HDPE (High Density Polyethylene), LDPE (Low Density Polyethylene), LLDPE (Linear Low-Density Polyethylene), PP (Polypropylene) and (BOPP) biaxially-oriented polypropylene. The polyolefins are the most acceptable materials for current soft plastics recycling and reprocessing programs. There are other potential materials used in soft plastics 38 ProPack.pro December 2020

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Nerida Kelton, AIP

1. The REDcycle program has retail drop off points located primarily in Coles and Woolworths supermarkets across Australia

including: (PET) polyethylene terephthalate, (PVC) polyvinyl chloride, (PS) polystyrene, (EVOH) ethylene-vinyl alcohol copolymer, (PLA) polylactic acid, bioplastics, aluminium, nylon and paper. These materials reduce the value of polyolefins and, in some cases are incompatible with the majority of reprocessing systems.

The composition of soft plastic packaging can be broken down into two groups – Mono-layer and Multilayer. Mono-layer packaging refers to the use of one polymer in the development of the material and quite often the material is PE. Multi-layer packaging is composed of two or more materials bonded together through co-extrusion or lamination. The use of different materials types together provides a package with unique barrier and mechanical properties.

Are Soft Plastics recyclable in Australia?

Currently, most Australian kerbside collection of recyclable packaging does not accept soft plastics. This restriction is required as the conventional Material Recovery Facilities (MRF) does not allow for the handling of film and flexible plastics as it gets caught in machinery and causes failures or damage. This restriction has also meant that many consumers are simply not aware that Australia does have recycling and reprocessing facilities available for the recovery of postconsumer soft plastic packaging.

In fact, Australia has a number of companies working to create new innovative solutions that will ultimately minimise the amount of soft plastics that head to landfill or end up in the environment.

How are household Soft Plastics collected in Australia?

The RED Group is a sustainability and resource recovery organisation that developed and implemented the REDcycle Program in 2011. REDcycle is an innovative, recovery model for post-consumer, soft plastic packaging.

The program started with 100 Melbourne supermarkets and today has 1830 retail drop off points located primarily in Coles and Woolworths supermarkets across Australia. At this level of stores and locations provided for consumer drop off of soft plastic packaging, the REDcycle program is classified as ‘Widely Accepted’ recyclability with more than 80 per cent of the population having access to the collection bins.

The REDcycle program is a true product stewardship model where manufacturers, retailers and households share the responsibility to create a sustainable future for as many soft plastics as possible. The cost of collecting and processing the material is covered by many of Australia’s bestknown brand owners and retailers. The REDcycle program accepts clean, dry, uncontaminated flexible packaging materials that meet the REDcycle material thresholds and have been approved through the Australasian Recycling Label (ARL) program.

Packaging such as bread bags, pasta and rice bags, old shopping bags, biscuit and ice cream wrappers, confectionery and frozen food packaging, plastic bags, cereal box liners, fresh produce bags and Australia Post plastic satchels are all accepted via REDcycle. The REDcycle program is recognised through Australian Packaging Covenant Organisation (APCO) and the Australasian Recycling www.propack.pro

AUSTRALIAN INSTITUTE OF PACKAGING UPDATE

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Label (ARL) program and have established ‘Return to Store’, ‘Store Drop Off’ or REDcycle logos on-pack for the consumers. All Brand owners must become a REDcycle partner to be able to use these symbols on-pack and are also required to join APCO. The ‘Return to Store’, ‘Store Drop Off’ or REDcycle logos on-pack communicate to consumers that they can return the packaging to collection points within major retailers across Australia.

Partners within the REDcycle program have access to the Packaging Recyclability Evaluation Portal (PREP) to assess the recyclability of their packaging within Australian recovery systems. Packaging and artwork must also be approved through the ARL program and be able to meet the REDcycle recycling requirements to include the logo on-pack.

What Soft Plastics can and cannot be returned in-store?

Keep an eye out for the ‘Return to Store’, ‘Store Drop Off’ or REDcycle logos that are increasingly being included on packaging as a part of the wider Australasian Recycling Label (ARL) program. If the packaging does not have one of these logos on-pack then it is either not a part of the program, or the materials have not been approved as recyclable under the REDcycle program. These logos are a true indicator of whether the soft plastics can be returned to the store for collection and recycling via the REDcycle program.

Consumers are encouraged to set up a soft plastics bin at home for clean and dry packaging and then return the plastics back to the retail stores that are participating in the REDcycle program.

Usually the REDcycle collection bins www.propack.pro

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2. REDcycle is an innovative, recovery model for postconsumer, soft plastic packaging 3. A low recycling figure for soft plastic has highlighted the need for industry and government to give added focus to develop a strong national consumer collection program for soft plastics

are located at the front of stores near the checkout and may be something that you have never noticed before.

The RED Group website (www. redcycle.net.au) also offers detailed information on what soft plastics are accepted through the REDcycle program and provides a list of all collection points across the country for the consumers.

What happens to the household Soft Plastics after they’re collected?

The RED Group collects, then sorts the recovered soft plastic film packaging and then send it on to its local partners: 1. Replas is Australia’s leading mixed recycled plastic manufacturer which aims to provide a solution for plastic waste by delivering quality cost-effective sustainable products.

Replas blends this mixed plastic with rigid plastics to form a material viable for use in the manufacture of new recycled plastic products.

The company produces a range of over 200 recycled plastic products which includes bollards, signage, outdoor furniture, fitness equipment and Enduroplank/ decking as well as products suitable for traffic control, parks and gardens and the utilities industry.

2. Close the Loop utilise REDcycle material as a component of highperformance recycled asphalt additive for road infrastructure known as Tonerplas. Tonerplas is Close the Loop’s asphalt additive, which enhances the characteristics of asphalt. It produces a high-quality road surface that lasts 65 per cent longer than traditional asphalt and contributes a major solution to the

problematic waste issue of soft plastics. The formulated product is melted into the asphalt mix. A key partner, Downer Group then adds recycled glass and recycled asphalt pavement to the mix to create a superior lower carbon product that results in higher quality roads.

3. Plastic Forests uses REDcycle material as a component of products such as mini wheel stops and air conditioner mounting blocks.

Plastic Forests became the first company globally to commercialise a unique dry-cleaning process to recycle contaminated soft plastics, without using water. Used soft plastics are recycled into resin for use by the plastics industry or may be repurposed by Plastic Forests into a range of sustainable GreenMongrel products.

Getting involved

If you would like to contribute personally, then start by making a ‘soft plastics bin’ at home and at work and arrange to return the packaging to your local collection point on a regular basis. Encourage others to do the same within your workplace and family.

Keep an eye out for products and brands that are advertising the ‘Return to Store’ and REDcycle logos on the packaging and next time you are purchasing products, consider which brands are committed to the 2025 National Packaging Targets and National Waste Strategy.

The next time you need a deck, fence, garden bed or even a patio consider sustainable solutions that are made from soft plastics. Not only are these solutions designed to be low maintenance they are durable and capable of withstanding the harsh Australian climate.

Reach out to your local councils and encourage them to support keeping soft plastics out of landfill by purchasing roads containing Tonerplas and Replas products or reviewing their procurement of outdoor furniture for recreational areas.

I look forward to seeing procurement strategies that actively encourage the purchase of recycled content and more companies taking the lead in purchasing these products to ensure we create a more sustainable world.

Nerida Kelton is the executive director of the Australian Institute of Packaging (AIP) and A/NZ board member of the World Packaging Organisation (WPO).

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UPDATE GREEN CONSUMPTION

Recycling graduates to bec Green Consumption is all about integrity, trust, sustainability, responsibility, as well as accountibility

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ecycling has officially graduated from “Clean up Australia Day” and “Cash for Cans” to becoming part of the mega-trend, Green Consumption. Even heavy weights like Sir David Attenborough, Prince William and Greta Thunberg have all raised awareness on the very broad topics surrounding environmental sustainability. However even without royals, knights, and a teen turned activist turned UN speaker, Green Consumption has been gaining momentum steadily in the last decade with the food industry being a major touchpoint for consumers.

Although food packaging has a definitive purpose for containment, protection, improved shelf-life and conveying information to consumers, the packaging food comes in is now just as important as the food product itself.

If anything, it’s almost a given that the packaging should be recyclable, but consumers still want reassurance that this is true.

Hence when it comes to Green Consumption, both the food/drink component and the packaging component needs to reflect a positive impact on the environment, sustainability and waste-reduction.

It’s all about what is consumed directly (aka food and drink), and indirectly (aka packaging, environmental resources and social impact).

Before we get to the crux of what Green Consumption means for the food and packaging sectors, it’s important to understand why Green Consumption has emerged as a megatrend that is far greater than just recycling and reusable shopping bags.

Short-term trends like paper straws, edible coffee cups, or roof top gardens come and go as they are simply an expression of a mega-trend.

Unlike short-term trends, megatrends highlight a long-term change in consumer behaviours and demands as mega-trends are based on irreversible societal drivers. For example, the heightened sense of social awareness 40 ProPack.pro December 2020

Dr Anneline Padayachee 1. The DORI avatar QR Code used for communicating supply chain transparency and Green Consumption options to consumers

by Foster Farms

and proactive behaviours towards environmental issues like climate change, deforestation, animal extinction, clean energy, landfill control, and preserving the future for the next generations will not be going away. Simultaneously, the rising importance of emerging markets and the impact they are having on the world’s resources is driving a need for more sustainable practices, technological innovations, and equitable distribution.

In 2008, we saw a turning point in the world’s economic history as emerging markets over took the developed world in terms of contribution to the global GDP. Euromonitor International predicts that emerging markets will account for 66 per cent of the global GDP contribution by 2030, with three emerging countries being in the top five largest economies in the world.

It’s not just about money though.

Increasing demands, supply constraints, infrastructure development and manufacturing in emerging countries may create growth and advancement, but it is also putting massive pressure on finite environmental resources.

The rise of emerging markets is forcing collaborations between international agencies, government bodies and businesses to create

environmentally sustainable processes in a way we have never seen before.

The $45 million recycling plant joint venture between Japan’s Asahi Beverages and Australia’s Pact Group Holdings, Cleanaway Waste Management, and the NSW State Government is a prime example of high level cross-collaboration and resource sharing characteristic of the Green Consumption mega-trend.

Increasing Australia’s ability to recycle PET bottles for the creation of new food and beverage packaging rather than send it overseas to be processed before being shipped back to Australia as PET packaging will improve the circular economy within this country, whilst reducing Australia’s reliance on virgin plastic.

Clearly Green Consumption is a mega issue with players from the federal government (and their National Waste Policy Action Plan 2030), to all levels of business and society being involved. Nevertheless, apart from developing large scale recycling processing plants, there are some other more tangible opportunities for food manufacturers to consider in terms of product development and packaging design that fit within this mega-trend.

To begin, Green Consumption is a mega-trend focused on responsibility, accountability and contributing to the greater good. www.propack.pro

GREEN CONSUMPTION UPDATE

ecome Green Consumption 2

3 Consumers

Producers

Retailers

Processors

Distributors

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Hence, transparency at all stages of the product cycle that shows how and why certain ‘green’ processes are being employed is essential (Figure 1).

The food industry is not just manufacturing a product, they also are stewards of the world’s resources (i.e. water, energy, plastics, glass, metals, agricultural practices, pesticides, etc.) relating to food production.

Consumers are not just purchasing a product and meeting a hunger, they are also taking part in the whole value creation albeit sustainable pipeline.

Sharing the story of vertical integration from paddock to retailer via smart packaging technologies is starting to be employed in Australia.

For example, Lillydale shares farmers stories with consumers via a unique labelling system that shows sustainable practices. The transparency also builds trust and rapport in food safety and authenticity between the consumer and manufacturer.

However, Foster Farms in the US has taken this concept to the next level for their poultry products.

In addition to skin packaging, individual portions, cookable trays and employing other shelf-life extension packaging technologies, Foster Farms has developed an avatar-style QR code named DORI (which stands for Deals, Origin, Recipes, Info) (Figure 1).

DORI is a virtual helper that explains www.propack.pro

2. Seven Brothers Brewery breakfast cereal series 3. Green Consumption is built on trust and transparency at all stages of the product lifecycle (Source: A. Padayachee 2020, Used with permission) 4. Cocoa-life launched

by Mondelez Cadbury in partnership with FairTrade in 2016

the story of Foster Farms, how it is involved in sustainable and ethical practices whilst providing consumers with recipes, coupons, and opportunities to contribute to projects like fighting bush fires and supporting Food Banks and homeless shelters.

For some companies, giving consumers the opportunity to demonstrate their Green Consumption motivations by funding social impact projects and holding multi-nationals accountable to ethical practices is the way forward.

ThankYou is a brand that feeds activistic/altrusic motivations, even in the simplest of packaging. Each ThankYou branded product allows consumers to ‘track your impact’ on a social enterprise project.

Similarly, bigger players like Mondelez Cadbury have partnered up with international social activist organisation FairTrade in 2016 to create ‘Cocoa-Life’ recognised by the bright green logo.

This partnership is meant to allow FairTrade to hold Mondelez cocoa farms accountable to fairtrade practices and support development in cocoafarming communities, but may also allow consumers to have guilt-free chocolate (Figure 4).

Taking a different approach, Seven Brothers Brewery have come up with a unique way of taking part in the Green

Consumption mega-trend by collaborating with Kellogg’s breakfast cereals. Seven Brothers Brewery launched their upcycling cereal range in 2018 that are based on Coco Pops, Rice Bubbles and Corn Flakes by-product waste. Consumers are willing to pay a premium to contribute to reducing landfill and decreasing food waste. The use of by-product waste in “upcycling” is highlighted on the packaging (Figure 2).

Green Consumption is all about integrity, trust, sustainability, responsibility and accountability.

Technological advancements in packaging that increases shelf life, decreases waste and is reusuable, all feed into this mega-trend.

However, like all solid relationships, communication and transparency is key. This mega-trend allows food companies the opportunity to take the lead by showing consumers how they are being proactive, rather than reactive, and provide all parties along the product life cycle an opportunity to take a stand for something and/or contribute to the greater good.

Packaging technologies may be one solution in environmental sustainability, but it does not always need to be as there are some amazing opportunities within the overarching Green Consumption mega-trend if food companies choose to be open-minded and creative.

While there are some very real issues like equitable distribution of the world’s natural resources and the global economy, the Green Consumption mega-trend is one that focuses on something more than ourselves.

Contributing to the greater good can be as easy as buying beer made from unusable Coco Pops, a sustainably raised turkey packaged in recyclable plastic film that allows me to provide a meal at a homeless shelter, or Australian bottled water where both the PET bottle and the water have been sourced entirely from Australia.

And everyone, including Greta Thornberg, Prince William or Sir David Attenborough, can do that.

Dr Anneline Padayachee is an awardwinning scientist and published author named as one of Australia’s leading science communicators. Dr Padayachee is an independent consultant in Australia and overseas, and is also an adjunct senior lecturer with the University of Queensland and Associate Academic with /the University of Melbourne.

December 2020 ProPack.pro 41

FOCUS LABELS & PACKAGING

Nekkorb adds automation to labels MPS takes label converters to a new level with connectivity and automation

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utomation in the labels sector continues to accelerate as converters look for an edge.

Frank Brokken, managing director at Nekkorb, said, “The trend is global with technology and connectivity continuing to develop rapidly. Their implementation rates have risen across the business sector and in our industry, integration and automation of inline and offline processes has become a welcome reality.

“It runs across all processes in production, from inspection operations to automated unwinds and rewinds, through to finishing processes such as turret rewinding to slitting, varnishing and cold foiling.

“Management information systems (MIS) enable software integration of the various production stages, enabling smooth workflows for all processes and production stages. It is more than just prepress; it now enables automation for on press and other production stages.”

MPS innovations Nekkorb supplies Multi Print Systems (MPS) label converting equipment that enables label converters to greatly benefit from the latest advancements in the technology.

“MPS listens to its customers and continually improves its technology through innovation,” Brokken said.

“MPS uses research and develops printing technology that results in less loss of valuable production hours and less waste of costly materials.

“The result is the ability to produce greater quantities at lower costs in the same amount of time and without compromising on quality.

“What MPS offers is maximum productivity. The MPS label converting printing presses deliver high quality and efficient production.

“On top of that, MPS develops solutions that collect and analyse data so label converters can increase 42 ProPack.pro December 2020

their efficiency and productivity.”

To operate at their optimal level, workflow systems need accurate data.

All new MPS presses ship with an edge server allowing multidirectional data collection. It can also be retrofitted to the majority of EF presses produced back to 2018.

This technology delivers information such as knowledge about production lines and operation.

Brokken said this enables label companies to integrate these streaming analytics to move from a reactive to a more proactive approach to operations excellence.

“The data stream enables you to know exactly what is happening, in detail, with the press at any given point in time,” he said.

“Using the online dashboard, you no longer have to wait for productivity reports as all the necessary and important information about their production lines is collated on the virtual dashboard.

“These streaming analytics increase agility and responsiveness to what is happening in a label print operation.

“Comparing real-time production data with historical information gives you an up to date perspective on your business. Instead of reacting to old data, you can be proactive and take action by using the streaming analytics.

“It is about real-time processing and decision making.”

The MPS connectivity platform ‘Talk to me’ enables its presses to communicate with software and hardware on the printshop floor, allowing multi-directional data exchange. As a result, press operators and management can gain full control of the printing process and make instant data-driven decisions about each stage.

“One of the big benefits is that it allows you to monitor performance details and use this knowledge to identify bottlenecks and weak points in their production lines,” Brokken said.

Nekkorb supplies Multi Print Systems (MPS) label converting equipment that enables label converters to benefit from the latest advancements in the technology

“Converters using MPS solutions have the opportunity to be faster and more flexible than competitors, gaining extra capacity due to the continuous implementation of the best practices, reductions of errors and downtimes.”

He added that, through the integration of MPS technology and prepress software, converters can significantly raise their production performance. The efficiency boosted by a single entry of data can reduce wastage and errors up to 80 per cent and by automating the processes, the throughput time can be reduced up to 50 per cent.

These kinds of gains present converters with the capability to process over 40 percent more jobs using the same amount of printing presses and operators.

“When you can consistently be more efficient than estimated, this can lead to lower sales prices with the same margin. In a competitive market environment, they can put you ahead of the curve,” he said.

“Besides the machine efficiency, enabling systems to communicate through MPS connectivity introduces label converters to consistency and quality of data used in different departments. This significantly reduces the need for communication between your prepress department, customers, and customer services, which results in savings of time and money.”

For any enquiries, please email frank@nekkorbsolutions.co. www.propack.pro

NEKKORB Solutions provides high quality products and expertise to the print industry

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NEKKORB Solutions Limited T: +64 9 8263441 M: +64 27 7138987 (Frank) +64 21 2346124 (Roy) +64 21 423464 (Natasha) E:

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