< Previous20 Food & Drink Internationalwww.fdiforum.netPACKAGING SPOTLIGHTThere surely can’t be a fastermoving sector in the food anddrink industry than packaging.Success is driven by innovation, which isitself driven by the need for products tolook good, give across more informationthan ever before, remain totally securethroughout and also shrink the carbonfootprint as much as possible. Hence, foodpackaging needs to be engineered forincreased strength, using less material,and always taking into account the costelement.This has led to major overhauls of thepackaging process in many companies –and some find this a challenge. As RoyGreen of Harford Control points out,“Many food and drink manufacturers willdoubtless still be recovering from theinvestment costs in satisfying the newlabelling legislation. It is not for us tocomment on whether or not thislegislation is good, bad or indifferent, butwithout doubt it increases the complexityfor the already beleaguered food and drinkmanufacturers. It seems such a pity thatmanufacturers spend all this money to betheoretically compliant and then throughsimple operational or product changeovererrors, do something basic like putting thewrong label on the package.“If this complexity had to be left solelyin the hands of operational personnel,then it would be totally understandablethat from time to time they would get itTheperfectpackageInnovation is driving success throughout the packaging sectorIggesund Paperboardare working via thecrowdsourcing companyCrowdspring to challengethe world’s designers toimprove existingconsumer packaging20-29_Layout 1 24/04/2015 14:05 Page 1Food & Drink International 21www.fdiforum.netPACKAGING SPOTLIGHTwrong. Faced with such complexity, itwould be more a question of ‘when’rather than ‘if’, especially in sites wherethe order of the day is multiplechangeovers, short batch runs, specialoffers and often a consequentially largeproduct portfolio to manage.“For several years now it has beenpossible to completely automate theremote setting up of date coders andbarcode scanners, ensuring the label anddate is correct, and correctly applied, rightfirst time, every time. To virtuallyeliminate the operator risk, such systems,as one might expect, are not cheap, butcompared with the risk of batch rejection,rework, scrap, fines for non-compliance,upset supermarket customers and evenloss of market share, this automationshould be seen as a manufacturingnecessity rather than a ‘nice to have’.”Roy says, “Harford have developed afully integrated system which not onlycopes with coding and labellingverification to satisfy all retailers’ codes ofpractice, but also enables manufacturersto improve performance through increasedvisibility, improved operational discipline,analysis and distribution of such valuableinformation as real time productionefficiency and OEE. Companies who havealready invested in this technology havenot only eliminated coding and labellingerrors, but have improved qualityconsistency generally, while improvingefficiency by at least 10%, and sometimesmore than 30%. Done in this very costeffective manner, the value fromimproved efficiency more than covers theimplementation cost of the whole systemin less than two years. This means thatautomated label verification through theHarford system is financed fromimprovements made and effectivelyrequires no new money.”Events such as Packaging Innovations,which brought thousands of professionalsto Birmingham earlier this year, and theforthcoming PPMA Show illustrate thehuge interest in locating and devising newideas to ensure products stand out on theshelves for all the right reasons. Theintroduction of new machinery has oftenhelped drive development but creativity isequally as important and many of thebiggest successes in packaging in recentyears have come about through a brightidea rather than extensive investment.Indeed, this is emphasised by IggesundPaperboard, who are working via thecrowdsourcing company Crowdspring to23 ÁCorrugated packaging ismaintaining its popularity in the foodindustry as the preferred choice forprotecting and promoting goods,according to a recent survey20-29_Layout 1 24/04/2015 14:05 Page 2Many companies have alreadyimproved efficiency with the Harford Paperless PerformanceImprovement System …… you could do the same oreven betterFind out how onemajor milk bottling site reduced operating costs by more than £2.5million per annum whilst simultaneously improving compliance and quality consistencyFind out how a whisky distiller/bottlerimproved quality consistency, customersatisfaction and bottom line profits bymore than 500%Contact Harford Control Ltd.Tel: +(44) 1225 764461sales@harfordcontrol.comwww.harfordcontrol.com Anyone can achieve similarly stunning results through implementing the proven Harford integrated systems and improvement methodologies.We don’t just write the software and install the hardware, we train and support your people through the change process todo what they do even better and faster than before.Share your objectives with Harford and we’ll guarantee to provide a rapid payback, well in excess of any costs incurred33FROMPHARMACEUTICALSTOPERFUMESFROMMALTWHISKYTOMILKFROMSMOKEDSALMONTOSMOOTHIES20-29_Layout 1 24/04/2015 14:05 Page 3Food & Drink International 23www.fdiforum.netPACKAGING SPOTLIGHTchallenge the world’s designers to improveexisting consumer packaging. StaffanSjöberg, who is in charge of the project atIggesund, says, “Every day we all seeexamples of packaging that could beimproved by a better choice of materialsor a better design. Now we’re givingdesigners all over the world the chance tocontribute their ideas on how to replacepackaging made of glass, plastic or metalwith solutions that use paperboard.”Iggesund is not looking for inexpensiveideas which can be put into commercialuse. Instead, the aim is to get a picture ofhow global designers as a collective groupbelieve they can steer packagingdevelopment in a more sustainabledirection, and Staffan Sjöberg says,“We’re just interested in getting asnapshot of how designers believe theycan improve the packaging they see in theshops they visit on a daily basis. We wantto publish the ideas but we are notinterested in exploiting themcommercially.” The whole idea is toconvince the industry to look closer atwhat’s on offer and identify potentialchanges that can make a difference.The increased consumer choice inrecent years has meant products have tostand out on the shelves, and with brandsand retailers producing more rangevariants, the race for retail shelf-space hascertainly heated up in recent years. AsNeil Farmer, independent consultant andspokesperson for the packaging sector,says, “ To achieve higher shelf spacing isthe challenge facing all producers. This isparticularly so in convenience storeswhere space is even more limited. The useof mixed tray systems therefore has greatmerit, allowing more variety, choice andrange of products. With an assorted rangeof products there’s a greater chance ofseeing something which will catch theeye.”Automation specialist PacepackerServices has helped in this regard with thedevelopment of a new offline, portableMixed Tray Loader pick-and-place systemto quickly generate assorted trays ofproduct. For smaller outlets, these25 ÁPHOTO: SUMITOMO (SHI) DEMAGSumitomo (SHI) Demag – Globally renownedinjection machinery manufacturer - producing qualityplastic packaging components at high volume T:+44 (0)1296 739500 E:sales@dpg.com W:http://uk.sumitomo-shi-demag.eu/Follow us:20-29_Layout 1 24/04/2015 14:05 Page 4Is this the most advanced Print & Apply Labelling system with the lowest cost of ownership?Our customers think so!Contact Industrial Labelling Systems for a complete labelling solution ɻPrint & Apply outer-case barcode labelling ɻPallet labelling ɻSelf-adhesive labels & thermal ribbonsKey features of non-contact labelling ɻLess wear and tear ɻLess changeover times ɻLess setup issues ɻTool free maintenance ɻHealth & safety complianceTel: 0161 655 4846 Email: sales@ilsystems.co.uk Visit our website: www.ilsystems.co.uk@ILS_Print_ApplyIndustrial Labelling Systems Ltd, Unit D4 Brookside Business Park, Greengate, Middleton, Manchester, M24 1GSContact Industrial Labelling Systems for a complete labelling solution ɻPrint & Apply outer-case barcode labelling ɻPallet labelling ɻSelf-adhesive labels & thermal ribbonsKeyfeaturesofnoncontactlabellingKey features of non-contact labelling ɻLess wear and tear ɻLess changeover times ɻLess setup issues ɻTool free maintenance ɻHealth & safety complianceTel: 0161 655 4846 Email: sales@ilsystems.co.uk Visit our website: www.ilsystems.co.uk@ILS_Print_ApplyIndustrial Labelling Systems Ltd, Unit D4 Brookside Business Park, Greengate, Middleton, Manchester, M24 1GSTel: 0161 655 4846 Email: sales@ilsystems.co.uk Visit our website: www.ilsystems.co.uk@ILS_Print_ApplyIndustrial Labelling Systems Ltd, Unit D4 Brookside Business Park, Greengate, Middleton, Manchester, M24 1GS20-29_Layout 1 24/04/2015 14:05 Page 5Food & Drink International 25www.fdiforum.netPACKAGING SPOTLIGHTassorted product trays provide a creativeway for retailers to offer a wider productrange in a smaller space. The productswap unit has already been installed atone UK manufacturer of own-label dips. Pacepacker Business DevelopmentManager Paul Wilkinson says, “Bystocking mixed trays of product, a largersupermarket can hold a wider range ofproduct types, flavours and variants.Equally, a smaller store, which maypreviously have had to drop lines to makeway for other products, can continue tooffer a good variety.” The dip producer clearly sees mixedtrays as being an expanding opportunity.They installed an MTL with a pneumaticCartesian pick-and-place systempositioned over twin lanes of filled trays.The picking heads remove one line ofproduct from the first tray, and places itinto the second. The process is thenreversed to swap items in both trays. Inaddition to offering customers a widerproduct range, using mixed cases andpallets also reduces handling costs andback room stock, so both customers andthe retailers benefit. The system can alsobe configured to other formats, includingflexible packaging. Consumer demand leading to a rise insingle serve packs and smaller size packshas also driven innovation in thepackaging sector and this means there hasbeen a rapid growth in thin walledpackaging, mostly for injection mouldingand thermoforming applicationsNigel Flowers, Managing Director ofSumitomo (SHI) Demag says, “With thinwall thicknesses typically less than 0.6mm,food containers are lighter, cheaper toproduce, easier to transport and store, useless materials and as a result are moresustainable. Manufacturers are also ableto make substantial energy savings, andmany containers, especially those usingin-mould labelling, provide simpleindications of product tampering. Asspecialists in injection moulding machinesand systems, Sumitomo (SHI) Demagprovides injection moulders capable ofthin wall production to a number of foodpackaging clients in plants all overEurope.“Rigid plastics, which is the categorythin walled containers sits in, is forecastto be the fastest growing packagingmaterial up to 2016, with an estimatedannual growth of 4%. Light-weighting andconvenience are important factors in thisexpansion.”A lower moulding weight certainlymeans significant reductions in materialand shipping costs. Stackability ofcontainers is another benefit, while moreproduct can be stacked into transportationvehicles. Thin walling also allows forfaster cycle times compared to thickerwalled plastic parts.Efficient production of thin wall plasticsalso relies on operator skills andexperience, and Sumitomo (SHI) Demagplaces great emphasis on pre-installationtraining and familiarisation, as well as on-going process optimisation. rom amachinery manufacturer point of view,thinner wall containers bring changes inprocessing requirements – higherpressures and speeds, faster cooling times,26 ÁAutomation specialist Pacepacker Services has developed a new offline, portable Mixed Tray Loader pick-and-place system to quickly generate assorted trays of productThere has been a rapid growth in thin walledpackaging, mostly for injection moulding andthermoforming applications, assisted bycompanies such as Sumitomo (SHI) DemagT: +44 (0)1371 811544 • E: sales@pacepackerservices.com • W: www.pacepacker.com Award winning automatedpacking, filling, case loadingand palletising systems 20-29_Layout 1 24/04/2015 14:05 Page 626 Food & Drink Internationalwww.fdiforum.netPACKAGING SPOTLIGHTand modifications to part-ejection and gating arrangements.These process changes have in turn prompted new considerationsin mould, machinery, and part design.There are clearly benefits to be gained from reviewing packagingprocedures, as wastage caused by insufficient or incorrectpackaging is costing companies dearly. Most of the damage isincurred between factory and retailer, and more effective palletwrapping results in both cost savings through reduced productdamage whilst in transit and lower packaging costs, as companiessuch as Aetna Group have illustrated for their clients.The quality of materials also makes a great difference to theeffectiveness of packaging. Corrugated packaging is maintainingits popularity in the food industry as the preferred choice forprotecting and promoting goods, according to a recent surveycommissioned by the Confederation of Paper Industries.This latest survey confirms corrugated packaging’s continuingimportance in supply chains following research by Smithers Pira,which says that demand for the material worldwide is expected toincrease by an average of more than 4% annually over the nextfive years, partially driven by innovative designs. The UKcorrugated industry is making significant investment – almost£500 million in new technology and plant over the last two years– to help brand owners boost sales.Sappi Speciality Papers, meanwhile, has launched atelier, a newconcept in folding box board that broadens their offering in termsof both width and depth of coated virgin fibre carton boards.atelier is a multi-ply board produced on a single-wire boardmachine, a feature that no other paper manufacturer has everachieved. It delivers brightness, purity and gloss with a silk touchand feel and unrivalled bulk and is part of Sappi’s ongoingstrategy to increase its production of speciality products inresponse to growing market demand.The packaging industry moves so fast that many companiesmay find themselves bewildered by the choice that’s on offer –but packaging specialists can certainly help them find the solutionthat’s right for them to ensure they stand out on the shelves andmeet all the demands of their customers.PHOTO: CPI CORRUGATED SECTOR20-29_Layout 1 24/04/2015 14:05 Page 7Food & Drink International 27www.fdiforum.netPACKAGING SPOTLIGHTMore information: www.hbm.com/fdi-fi t7HBM United Kingdom Ltd info@uk.hbm.com Q www.hbm.comFIT for speedTop speed in measurement signal conditioning with up to 180 weighings per minute, FIT7A is guaranteeing speed and effi ciency in your machines.FIT for precisionTop values when it comes to precision, with standard deviations of only 0.1 g for 10 kg and the new accuracy class C4. So your machines can guarantee safety and precision with minimum reject rates.FIT for competitionWith up to 60% cost advantage over other load cells based on electromagnetic force compensation, the FIT7A is competi-tively priced.Your machines can stay competitive and help you open up new, previously unobtained market segments.Make your checkweighers FIT for speed and precisionHBM launchesthe nextgeneration ofload cellHBM – a market leader in the field of test and measurement –presents the new FIT7A Digital Load Cell, specifically designed tomeet the demanding requirements of weighing in modernmanufacturing lines.Suitable for use in a very wide range of production environmentswhich require dynamic weighing, sorting, filling and dosing, therobust FIT7A load cell offers manufacturers high precision andprocessing speed.Based on the very latest HBM strain gauge technology, theinnovative new sensor features class C4 accuracy per OIML R60 anda maximum scale division Y of up to 25,000 and addresses theproblem of bottlenecks, which can often slow down production rates.In comparison to existing sensors which are only able to handle upto 100 weighings per minute, sophisticated new technologyincorporated within the FIT7A means it is now possible to perform180 weighings per minute, therefore dramatically increasingproduction speed and reducing costs.Even with such increased rates, accuracy remains key with theFIT7A. The FIT7A offers increased precision and can performaccurate measurements under temperature fluctuations and in dynamicapplications which means load cells can be installed on multipleproduction machines in a variety of production environments.More economical than existing sensors, which are based onElectromagnetic Force Compensation, the new FIT7A from HBM isexpanding the market for machine manufacturers by enabling them todevelop completely new machine types and new market segments.This is particularly important for sensitive markets with a necessityfor precision and a growing need to achieve the lowest possibleoverfilling in product packaging.Compatible with corresponding HBM software PanelX, whichcombines support for the configuration process with an intuitive userinterface, HBM also provide a downloadable free professionalsoftware package, AEDPanel 32 version 3, to provide diagnosis andanalysis of measurement data, as well as debugging and bug-fixing.For more information, call HBM on+44 (0) 208 515 6000 or visit www.hbm.com20-29_Layout 1 24/04/2015 14:05 Page 8Packaging expertisebuilt on qualityHaving supplied top brandswith quality packagingsolutions for over threedecades, Qualvis is one ofthe UK’s leading print andpackaging companies. Specialising in creating bespoke food packaging for higher valueranges, such as Heston for Waitrose, Marks & Spencer and Tesco’sFinest the company is based at a purpose built 70,000 sq ft facility inLeicester.Qualvis’ growth has largely been achieved from referrals,endorsements and by sticking to the basic principles of business –the customer is king and quality, service and price come in thatorder. According to Managing Director Jason Short, leading brandsstay with Qualvis because they trust the company emphatically:“When it comes to delivery we’re not just a packaging supplier, wecreate partnerships that concentrate on quality and service, which iswhere our name derives from.”Qualvis has helped many brands successfully launch their productsover the last 33 years. For example, Dorset Cereals have benefittedfrom consistent print and design innovation. Qualvis has re-engineered product solutions offering cost savings and ongoingimplementation of improvement strategies in a relationship whichhas endured almost a decade. Qualvis has strength and depth in every department, including aValeTech ink mixing and matching facility and Low Migrationlaboratory for direct food contact. The company holds the ISO 9001quality standard, the BRC Packaging and Packaging MaterialsStandard and is FSC certified. Qualvis is a member of BPIF Cartons, the trade association for theUK carton industry. Jason Short also sits as chairman for BPIFCartons Promotions and Marketing Committee and on the SeniorGeneral Committee.To find out more or to discuss your next project, call 0116 260 2220,email sales@qualvis.co.uk or visit www.qualvis.co.uk.28 Food & Drink Internationalwww.fdiforum.netPACKAGING SPOTLIGHTFlowpack withrevolutionary adjustableinfeed system fromA.M.P-RoseThe X-Pax machine has been designed for single and multi-packwrapping, and combines the flowrapping machine with the verylatest in linear transport systems. The linear transport system XTScombines the benefits of rotary and linear systems.The revolutionary feeding system allows individual product size,number of pieces in the pack, number of product layers, and packlength to all be changed at the touch of a button. Change over partscan therefore be eliminated entirely and downtime reduced to aminimum. This makes the X-Pax suitable for a wide range ofproducts, and in particular for companies that regularly changeproduct or pack sizes for special offers and promotional deals.XTS adapts itself precisely to the customer requirements: thearbitrary number of movers, the modular path guidance, and thecontrollability of each individual mover allows precise configurationto suit the product.Up to 4m/s can be achieved with the feed system, without anyjerking and still with maximum positioning accuracy.Synchronisation, stopping and starting can be accomplished at anyof the stations on the entire path. Added to this is a sensitiveresponse, as jerk-free acceleration profiles even allow the transportof open liquids. The flowrap machine is a medium speed full servo drivenhorizontal wrapping machine suitable for single pack or multipackingwith heat or cold seal wrapping materials. The flowrap is fullysynchronised to the XTS feed system andincorporates a large user friendlyWindows based HMI screen.For more information,call +44 1427 611 969 oremail info@amp-rose.com.20-29_Layout 1 24/04/2015 14:05 Page 9Food & Drink International 29www.fdiforum.netPACKAGING SPOTLIGHTThe importance ofshrink wrappingcontinues to expand.Shrink wrapping is much more cost effective than cartons, usuallysaving between 50-75% on material alone, and saving space withinthe warehouse and distribution process. Shrink wrapping is alsoconsidered to be more environmentally friendly as less packaging isused and what is used is 100% recyclable.Yorkshire Packaging Systems have found the importance of backup and support within the shrink wrapping industry and theavailability of UK held spare parts is often overlooked. As technology continues to improve shrink wrapping machines arebecoming faster. YPS are able to supply a wide variety of high speedside sealers designed to work with high clarity polyolefin shrinkfilms. A mid-range machines YPS can supply has the ability to wrapup to 130 packs per minute. When using machines such as these, reducing downtime is crucialas for every minute the equipment is down there are 130 packs perminute missing from production. Only ten years ago, half this speedwould have been at the top end of the market, but faster machinespeeds have meant the industry has become more reliant on outputspeed. This requires trustworthy, improved speed, reliable machineryand first class back up and support, which YPS make a priority.The high speed side sealers YPS supply are coupled with energyefficient shrink tunnels with infrared technology which reducespower requirements. In keeping with this, YPS also supply highclarity, low shrink temperature shrink films from Bollore in order tokeep the carbon footprint of the machinery at a minimum.For more information,call 01924 441355,email enquiries@yps.co.ukor visit www.yps.co.uk.Shrink wrappingsolutions youcan trustBrisk business for Advanced DynamicsAdvanced Dynamics is a leading supplier of high quality labellingsystems. Its exclusive Pack Leader range of labelling equipment hascaused a real stir in the industry and they have sold six machinesafter their highly successful appearance at Packaging Innovations inMarch.These sales include an ELF-50 desk-top bottle labeller to ane-cigarette manufacturer, while a business in the cosmeticsindustry supplying wet wipes purchased a PL-501 wrap aroundautomatic labelling machine. Another cosmetics company alsoordered two of the flexible and robust PL-501 labellers ondisplay.This follows on from a number of other sales at otherexhibitions, testament to the company’s company philosophy ofproviding the best possible product solutions together with a topclass after sales service. Malcolm Little, Advanced Dynamics’managing director, says, “We’re astonished at how quickly we haveclosed out the orders. One can only assume it’s another sign thatthe UK economy is striding ahead.”Advanced Dynamics’ food equipment is capable of handling awide range of items from fresh produce and soft fruit to cakes andbread. They can supply everything from a single compact labellinghead or a complete bespoke labelling system. The sales team is able to assess food business’ needs and designa solution to improve product packaging standards, businessproductivity and efficiencies. All supplied systems are robust anddesigned in modular concept to integrate with current and futurebusiness requirements. More product details can be found atwww.advanceddynamics.co.uk20-29_Layout 1 24/04/2015 14:05 Page 10Next >