Tetra Pak has launched the industry’s first carton made entirely from plant-based, renewable packaging materials.
The new Tetra Rex carton will be the first in the market to have bio-based low-density polyethylene films and bio-based high-density polyethylene caps, both derived from sugar cane, in addition to Forest Stewardship Council-certified paperboard.
Charles Brand, VP Marketing & Product Management at Tetra Pak, says, “Environment excellence is one of Tetra Pak’s strategic priorities and a driver of our product development activities. Together with suppliers, customers and other stakeholders, we are leading the industry towards 100% renewable packaging. We believe that increasing the renewable content of our packages is not only good for the environment, but also offers our customers a competitive advantage in the overall environmental profile of their products.”
Developed in partnership with Braskem, one of the world’s leading biopolymers producers, the new Tetra Rex package will be commercially available in early 2015. Tetra Pak customers using the standard 1 litre Tetra Rex with TwistCap OSO 34 can easily transfer to the new version without the need for any additional investment or modification to their existing filling machines.
Atlantic Zeiser has introduced the world's first integrated system for coding up to 4mm thick booklet labels in an audit-proof process verified by an inspection camera.
Simple and fast job changes ensure economic efficiency even with the shortest print runs and radically different booklet formats. DIGILINE Booklet is dedicated to coding labels that are to be used in clinical drug trials. Regulations and safety requirements increase information contents and hence thickness of booklet label that has reached considerable dimensions already and is likely to grow.
Thermal transfer printers are no longer able to process the peaks and troughs associated with booklet labels, which is a serious problem because printing defects can jeopardise not only market authorisation and substantial investments, but also human lives. Based on contactless drop-on-demand inkjet technology, DIGILINE Booklet achieves supreme print quality and consistency, even with small font sizes, while incurring low operating costs in the absence of ink ribbons and print bars.
DIGILINE Booklet offers maximum process safety at every stage and rules out errors arising from operator intervention. Thanks to a patented, sensor-controlled transport system, the first incoming label of the roll is printed – without any additional splicing of blank ribbon. As a consequence, no blank labels can enter circulation, auxiliary tapes and working time are avoided, and expensive label waste is ruled out.
DIGILINE Booklet maintains excellent print quality in case of machine stops as well – without any impairment or waste. The built-in camera takes care of seamlessly inspecting all of the processed labels. It reliably identifies misprinted, unprinted and missing labels. Both before and after a manual splice, the camera also examines the labels around the spliced area. Furthermore, a side register camera compensates the sidewise print position of each individual label and thus contributes to precise sidewise pint accuracy independent from the inaccurate label position on the ribbon.
Telescoped mother rolls are processed as well – a telling advantage, given that the thick labels, once wound, often form very unstable "slippery" layers. Gentle feed over large guide rollers tailored to the label format prevents accidental detachment of the booklet labels during the production process.
Thanks to a special ultrasound sensor, DIGILINE Booklet can easily process fully or semi-transparent labels as well – unlike most thermal transfer printers. The integral OMEGA inkjet printer with UV-A LED dryer covers a range of print widths from 36 to 210 mm. Suitable label stock includes PE, PET and PVC films, as well as paper.
The benefits of Sidel’s Modulomould swappable mould insert system, along with the company’s packaging design expertise, have both been demonstrated in award-winning bottles from Hariss International, one of Africa’s leading producers of water and soft drinks.
At an awards ceremony at the 2014 East AfriPack Exhibition in Nairobi, Hariss International received the AfriStar Award and medal in recognition of the unique designs of its Riham-branded bottles. The awards, organised by the Africa Packaging Organisation, are the first to cover all African regions, recognising the best in creative design, technology and marketing.
The winning bottles were blown on Hariss International’s Sidel PET bottling lines using Modulomould, a patented technology which allows the production of several bottle shapes from a single mould. Based on removable mould inserts that can be changed in less than thirty seconds with no tools required, Modulomould offers the flexibility to easily adapt bottle designs to meet the needs of different markets. Retaining a constant design for the labelling area and base of the bottles, the inserts allow customisation of the bottle shoulder, body or both.
Also crucial in the design process of the winning bottles was the support given to Hariss International by Sidel’s dedicated packaging design team, part of the company’s Sidel Services business unit. The innovative and engaging bottle designs were tested and validated by Sidel’s packaging experts who have decades of experience in optimising and qualifying PET packaging for a range of supply chains globally. The final moulds were then produced by the Sidel Services line conversions & moulds team, precisely engineered for the most demanding production conditions to protect Hariss International's innovative designs.
Andrews Ruben, Managing Director of Hariss International, says, "We decided to work with Sidel on this project because of their open, transparent and regular communications regarding the project. They passed on their technical knowledge to the Hariss team, so they could understand the solution in-depth."
Hariss International is based in Uganda and produces a range of beverages under the Riham brand on two existing lines supplied by global provider of liquid packaging solutions Sidel. These lines, including the first ever Sidel Combi line in East Africa and another for bottling still water, are soon to be joined by a further two PET bottling lines from Sidel. These will become operational in November 2014 and January 2015, further increasing capacity and brand support for the popular Riham drinks.
Winning the award is the latest demonstration of the close working relationship established between Sidel and Hariss International. In addition to the supply of the original still water line followed by the aseptic PET bottling line in 2013, Sidel has supported Hariss with a range of services. That includes packaging and preform design to help in the creation of unique bottle designs for the company’s brands, and high-quality mould production to efficiently turn the designs into an industrial reality.
Georgios Diakakis, Regional Commercial Manager at Sidel, says, “Sidel has had a long relationship with Hariss International, and we’re delighted to hear that Riham has been awarded an AfriStar. The award reflects our continuous efforts to provide our partners with quality services and innovative solutions. Sidel’s vision has always been to adapt packaging to the goals of the end product and consumer, and the Modulomould method is a perfect example of this. We look forward to continuing our work with Hariss and help them reach new levels of achievement.”
Now, with the installation of the further two PET bottling lines dedicated to producing carbonated soft drinks and juices, Sidel will further help Harris International to remain competitive in what is a growing market. Uganda has recorded an impressive 31% increase in the consumption of soft drinks since 2008, with 2013 seeing 199.6 million litres consumed – a growth of 6.6% on the previous year.
Thanks to improved collection and recycling, the average aluminium closures recycling rate across Europe is now at 45%.
Aluminium recycling saves up to 95% energy use compared to its primary production, with the corresponding savings in greenhouse gas emissions. It can be recycled over and over without any loss of quality.
Aluminium closures are mainly used for wine, spirits, water and olive oil. The advantage of aluminium closures is that they can be collected either together with the mixed packaging fraction or along with the glass collection stream. The aluminium is easily extracted from both material streams so that it can be recycled.
EAFA‘s Executive Director Stefan Glimm says, “Aluminium closures are probably the world’s most recycled closures in the wine and spirits sector. Particularly, European consumers are increasingly aware of the sustainability and convenience benefits of aluminium closures. Nevertheless, the industry will continue supporting national initiatives to enhance the collection and recycling.”
Depending on the instructions to the consumers and the collection and sorting infrastructure in place, recycling rates for closures vary and range from over 85% in Germany to 65% in Italy and 45% in the UK. Encouragingly, countries with smaller alu closure market shares like Spain and France recycle more than one in three aluminium closures.
Although small in size, aluminium closures collected together with the mixed packaging fraction are often separated with eddy-current systems. Similar systems are also used to completely separate the closures in the glass packaging fraction from the glass fraction. This is due to the production requirements in glass recycling. The value of the recycled aluminium supports the economics of the recycling process of both material routes. Once separated, the aluminium closures go into the aluminium recycling stream for re-melting to be used again for other valuable aluminium products.
The recycling rates are calculated on the basis of publicly available national aluminium recycling rates and consumption data from market research companies. This data also shows the considerable extent to which consumption volumes and recycling rates vary from one country to another.
After successfully launching the world’s first Academy of Canmaking and Seaming in March, CMB Engineering is announcing its expansion of its new Academy. The Academy was initially launched with a workshop area where practical lessons could be conducted with some of the most popular machines on the shop floor, such as the CMB5000 Bodymaker and CMB550 Trimmer (CMB 5500 Canmaker). With the recent completion of the Academy’s second development phase, the facility now features three separate classrooms where theory lessons will also take place.
Steve Williams, Academy Training Officer at CMB Engineering, says, “We are very excited with the success the Academy has had since it first launched, and we now look forward to providing more of our customers with enhanced training, supported by our additional facility and resources. Our customers will benefit from a training-friendly environment for both practical and theoretical lessons. We are confident that with the additional resources our training will be even more effective and valuable to the Engineers who attend."
The first customer to take courses at the Academy of Canmaking and Seaming was Carlsberg, the world renowned brewing company who signed up four of its Engineers for a Seamer training course earlier this month. This course, which received exemplary feedback, was taught on the Ferrum ‘F’ Series and included Seam Evaluation as well as Seamer Gold Plan setting.
Jonathan Woolhead, Canmaking Engineer at Carlsberg, says, “It was great to have the opportunity to be trained by our supplier partner at their headquarters. The Academy really served its purpose as a stress free and safe environment to train in, and the course was very useful to help reinforce our canmaking skills and knowledge.”
The Seamer training courses, which are taught by a team of Seaming Engineers with many years of experience in the industry, are supported by a set of SOPs, illustrations and videos, all of which relate to the industry standard BCME manual. Additionally, while CMB Engineering now plans to also add 3400 Necker training to its course portfolio, bookings will continue to be accepted for Seamer and Canmaking courses on the Angelus and Ferrum Seamers and the CMB5500 Canmaker.
Steve Williams says, “The Academy has been very well received by industry professionals and we now have bookings until the end of the year from several high profile customers from the Middle East, Europe and Africa region. Looking forward we want to continue developing the Academy and the courses provided to our global customer base. We are also keen to help meet specific customer needs by producing bespoke training packages and will consider all requests for training on our canmaking equipment.”
Food & Drink International made a huge impact at this year's PPMA Show.
Hosting a seminar on the opening day on lean manufacturing, entitled 'Lean & Learn Together', Food & Drink International's Becky Darnell introduced Craig Mochrie, Bottling Operations & Supply Manager at Morrison Bowmore Distillers and Roy Green of Harford Control who revealed the benefits and results from a comprehensive case study on bottling line operations at Morrison Bowmore's distillery.
Craig Mochrie revealed the overarching reasons behind improved efficiency at their headquarters in Glasgow, where blending, bottling and warehouse operations are carried out. Citing an all-encompassing approach to get everyone at the company involved in streamlining processes and making sure adequate management, traceability and processing operations were adhered to on every level, he told the audience about the levels of success experienced. Although fantastic results have been experienced since work started in 2006 by MBD, Craig explained it had been a real challenge. Making sure of a persistent and consistent approach to quality and transparency meant operational performance was significantly improved.
Roy Green also explained how Harford’s tool kit helped facilitate overall improvements by turning data into accurate real time information for Craig’s team to act upon, but stresses that even the best system is only a system. It still needs disciplined and dedicated teams like Craig’s to take those actions in order to drive performance improvement. MBD have also integrated automation into their existing operations, where appropriate, in order to facilitate their already impressive overhaul of their production operation.
The initial aims set out by MBD were to sustain its high quality standards, whilst improving efficiency and performance and to introduce and train all operational staff in lean methodologies, including total productive maintenance (TPM).
This unified approach made sure everyone involved in the blending, bottling and warehouse processes became an integrated part of the improvement process, given constructive feedback and a chance to voice concerns and suggestions, having an influence on final outcomes. Total Productive Maintenance, or TPM, Craig suggested, can also be short for ‘Today People Matter’, placing people at the heart of performance improvement and sustainability.
Craig said: “You have to understand that no system can deliver the lean manufacturing environment on its own, you have to have that essential buy-in from your team. You also have to be fully committed and up for the challenge.”
Persistence, patience and effort were three key values that Craig believes to be essential in order to effectively make changes of this nature and to recognise that, by definition, Continuous Improvement is never ending.
He adds: “We cannot afford to relax our drive towards Operational Excellence. There is always something more to be done whilst maintaining the substantial gains already made.”
Following a complete process review in 2006, several phases of automation from Harford Control, as well as investment in infrastructure and an emphasis on efficiency and quality improvements, meant that by 2014, huge improvements in both bottling speeds and profits were made. Craig also points to the support, expertise and encouragement which he has had from the parent company Suntory in delivering such impressive results over this period.
Implementing these changes, as well as evolving them with continued support and the latest technology from Harford Control, including adding touch-screen technology and hand-held tablets to the lines and the luxury products areas, meant MBD achieved many benefits.
Again, Craig emphasizes the importance of full operational buy in and teamwork at every stage: “Touch screens and Tablets are great enablers and eliminate most paperwork, whilst giving us good operational discipline and traceability. These devices alone, great as they are, cannot drive the extent of beneficial change we have seen. On the other hand, it would also be inaccurate to trivialise the extent of support and knowledge transfer we have seen from Harford Control.
"We often hear the word partnership used and abused, but Harford have been real partners on our lean journey. Apart from support and training on their fully integrated system, we simply know that if any member of our team hits a snag they can call the Harford team at any time and get the help they need.
"As stated in the presentation it’s the ideal tool kit in driving performance improvement towards manufacturing optimisation."
Benefits to date include:
• A highly efficient and quality-driven bottling operation.
• Specifically-defined operational KPIs, covering quality and cost management
• Management empowerment
• Development and ownership for production operators
• An evolving employee training and development schedule
• A sense of quality in every facet of the business
• An overarching sense of consistent improvement and not resting on achievements made so far.
• A truly supportive partnership with the Harford team, whose support goes far beyond supply, installation and equipment service.
To find out more about the case study, or to discuss similar matters, email Craig Mochrie (firstname.lastname@example.org) or Roy Green (email@example.com)
easyFairs is set to celebrate its tenth anniversary on 25th and 26th February at Birmingham’s NEC.
The flagship packaging event will play host to over 350 exhibitors all showcasing their latest products and developments in the market to thousands of packaging and print designers, retailers, buyers and managers.
Event organiser easyFairs has already unveiled its new three dynamic core brands, Packaging Innovations, Empack and Label&Print, which all areas of the show will fall within. This aligns the full easyFairs packaging portfolio across Europe under the same brand concepts.
Alison Church, Event Director for easyFairs’ UK packaging events, says: “The easyFairs portfolio has become Europe’s fastest growing network of packaging events, so we have taken the opportunity to harmonise our shows across all the markets, simplifying our offer to our exhibitors and the industry as a whole.”
Packaging Innovations – the future of branded and inspirational packaging: The highly successful Packaging Innovations brand will continue to focus on the latest trends and innovations in packaging materials and concepts, with Ecopack and Contract Pack remaining as important components of the show with dedicated floor areas.
Empack – the future of packaging technology: Empack is one of easyFairs’ most established brands across Europe, with a strong presence particularly in the Benelux and Switzerland areas. Its focus is on packaging technology, with core visitors including packaging operations managers, engineers and technologists.
Label&Print – the future of packaging printing, labelling and converting: All aspects of offset printing, converting machinery and labelling equipment will now sit under one major show concept Label&Print. The inclusion of Label&Print as one of the three areas of focus underscores easyFairs’ vision to invest in and expand this aspect of its portfolio.
When the event took place in February 2014 it attracted 6,004 visitors, including packaging buyers from major names such as GlaxoSmithKline, Lush Cosmetics, Heineken, Britvic Soft Drinks, Danone, Asda and Proctor & Gamble; exhibitors were delighted with the buzz and visitor footfall from the moment the doors opened, with 77% of them rebooking onsite for next year’s show.
IBIS Packaging Solutions was just one of the companies exhibiting at the 2014 event. Hayley Mustad, Key Account Manager for IBIS Packaging Solutions, remarks: “The footfall was great, with key decision makers from blue chip companies coming onto the stand. Great show; so much so we have booked for 2015, with a bigger stand!” Next year’s event will feature even more product launches and live demonstrations, making it the ideal shop window through which to showcase products and services in front of thousands of decision makers and influencers with real buying power.
Launching at the show will be four new features – The Drinks Symposium, The Pharmaceutical Symposium, The Retail Symposium and The Beauty Symposium, providing exhibitors and visitors from all spheres of the packaging and print world with a unique programme of valuable and insightful content.
Always popular is the BIG Packaging Debate, which will also be returning to the show, bringing industry experts together to put key issues of the moment under the spotlight. There will be a full learnShops programme addressing hot industry trends and issues; plus the BIG Print Debate and the popular feature Lions’ Lair.
Alison Church concludes: “Next year’s event is going to be a real showstopper. It will be packed with exhibitors specialising in all aspects of packaging and print from materials and design, to machinery, new technologies and equipment. It provides the perfect opportunity to see the latest innovations, touch products and materials, and to discuss your individual business with suppliers face-to-face. It’s going to be a celebrational show!”
The next easyFairs UK packaging events will be Packaging Innovations, Empack and Label&Print, taking place at Birmingham’s NEC on 25th and 26th February in 2015. For anyone interested in exhibiting, more information can be found at www.easyFairs.com/PIUK.
Pringraf roared to victory at this year’s Lions’ Lair competition, which took place at Packaging Innovations and Luxury Packaging London. The company was one of three brave exhibitors who pitched their most innovative product to a panel of fierce packaging experts.
The panel of Lions included Duncan Castle, Technical and Packaging Manager at Tesco, Paul Jenkins, Managing Director at The PackHub, Chris May, Packaging Manager at John Lewis Partnership and Neil Pedliham, Design Manager at Superdrug.
Italian cardboard packaging company Pringraf was the second competitor to enter the Lair, pitching its pioneering product Packly. Packly is aimed at simplifying the lives of packaging designers, brand owners and printing companies, by making it possible to create die-cut templates and order short runs of packaging as well prototypes or mock-ups comparable to the industrial standards, all from a web platform.
Giuseppe Prioriello, CEO and Co-Founder of Packly, says, “We are so happy to have won this year’s Lions’ Lair. It is validation for us that there is a problem in the market, which we can solve. It shows that we are making life easier for the designers, packaging professionals and marketers that need a structural packaging design and have it printed in short run."
The two other companies who took part in the competition were Airpack Systems and Reproflex3. Reproflex3 pitched Packlinc, an app that allows users to scan hidden codes within graphics and then link back to the chosen URL. The app controls the URL destination whilst learning about consumers in real time with Packlinc’s analytics system.
Airpack Systems were last to enter the Lair with its new six and twelve inflatable bottle beer packs, specifically designed to be quick and easy to use, and offering maximum protection during travel and 100% recyclable.
The Lions’ Lair formed part of the highly anticipated showfloor entertainment that took place at this year’s Packaging Innovations and Luxury Packaging London exhibition. The show, once again grew in size, attracting record-breaking numbers of visitors and exhibitors, with major names such as Marks and Spencer, Kimberly-Clark, Tesco, Kingfisher Group and Taylors of Harrogate speaking as part of the learnShops seminar programme.
The next easyFairs UK packaging events will be Packaging Innovations, Empack and Label&Print, taking place at Birmingham’s NEC on 25th and 26th February. For anyone interested in exhibiting, more information can be found at www.easyFairs.com/PIUK.
The RECOUP Plastics Recycling Conference and AGM took place in Peterborough with over 250 delegates in attendance. Leading industry and government speakers shared their knowledge and experiences, with delegates making the most of the chance to network across different sectors and discuss the future for plastics recycling.
Dr Helmut Maurer from the European Commission provided the keynote presentation, putting plastic recycling into the context of circular economy and the EU approach to life cycle thinking. He outlined the recent European Commission proposals and reflected that maybe more attention should be on plastic as specific waste stream. He also questioned whether resources should really be addressed through waste policy, and indicated that a rethink could be needed for the development of separate resource policies. He noted that too much plastic is sent to landfill which could be used and recycled, and concluded that plastic is an ideal material to demonstrate that it is possible and profitable to move towards a circular economy model.
A video address from DEFRA Resource Minister Dan Rogerson confirmed that he is passionate about the challenge and opportunity to deliver a step change in the recycling of plastics, and his support of RECOUP and the plastic supply and recycling chain in its ongoing work. He also confirmed government and public body commitment to work with the plastic industry to achieve recycling targets and realise a genuinely resource efficient economy.
RECOUP’s chief executive Stuart Foster pointed to figures made available by the Environment Agency, suggesting that of the estimated £28 million was received for plastics PRNs in 2013, very little was allocated towards communications despite initiatives such as pledge4plastics being seen as critical to increasing household plastic recycling levels.
He identified that the RECOUP annual survey due out soon is likely to report household plastic packaging collection levels in the region of 475kt for 2013 with further gains in the number of pot and tray collections and modest increases in bottle collections. It was also noted that the design for recyclability guidance would also be updated and re-issued before the end of the year. Other attractions during the day included demonstration 3D printers running with recycled polymer, and the news that RECOUP mascots which had been used very successfully for campaigns over the last 15 years have now been recycled into picnic benches and bin liners by BPI, who were the main sponsors of this year’s conference.
Stuart Foster commented that this conference demonstrated again that ‘RECOUP can help bring together so many relevant organisations together to discuss the present and future of plastics recycling’, and urged more organisations to consider supporting RECOUP.
Kite Packaging will be partnering with Audion Swissvac on a 64 square metre stand for the PPMA Show, the UK packaging supplier as well as showcasing a 3D video experience of the award-winning CMC Cartonwrap machine.
The Cartonwrap is an impressive machine from CMC Machinery, an Italian company who have are most well-known for producing wrapping, mailing and fulfilment machines built to be high-speed and reduce labour costs. The Cartonwrap has been designed using 30 years of innovative thinking from the company, and works by producing a fit for purpose box around a product as it travels through a conveyor. The machine can produce up to 1,000 packs per hour, and has the ability to print and press labels to the packs at the same time – making it ideal for fulfilment operations.
The Cartonwrap picked up the PPMA Show award last year for Most Innovative Processing or Packaging Machine, and has been shortlisted for the Ecommerce Awards and the Postal Technology Awards.
Kite Packaging will be showing a 3D detailed video of the machine at the show, which takes the customer through a cartons journey from product to a fully wrapped and labelled carton, using a fully automated process. Kite’s team of packaging experts will be on hand at stand F90, along with a representative from CMC who will be there to answer customers’ questions and demonstrate the cost and space savings the Cartonwrap has to offer.
Speaking about the partnership a spokesman from Kite Packaging says: “We are really excited to have CMC Machinery on board at our stand this year, along with our offering and Audion Swissvac’s range we will be able to offer all types of customers an automated solution that suits their needs and budgets.”