PACK EXPO exhibitors present new containers and materials that combine attention-grabbing appearance and greater functionality with a positive environmental profile.
Today’s brand owners must contend with shrinking margins, globalization and shifts in consumer needs. Remaining profitable requires delivering innovative and value-added products and reducing environmental impact.
Attendees at PACK EXPO International 2010 (October 31-November 3; McCormick Place, Chicago, IL) (www.packexpo.com) will see for themselves how they can use packaging to accomplish their objectives.
And they will be especially interested in The Brand Zone, which debuts in Chicago this year. This special area of the show will feature a variety of innovative containers and materials that brand managers can use to make products stand out on the shelf, enhance convenience and functionality and better satisfy sustainability-related requirements.
Because changes in containers and materials affect equipment, developments are often the result of a collaborative effort. “It makes sense to find a partner with similar goals and attributes,” says Ron Puvak, director business development and marketing at Plastic Technologies, Inc. (PTI) (Holland, OH; Booth # 5030). “We’re very open to collaborative efforts. It not only brings complementary strengths together, but also shares the risk.”
Sustainable Shelf Impact
Some of the newest packaging designs meet demands for both shelf impact and environmental attributes. “Sustainability has to be part of the conversation today,” says Neil Kozarsky, president of T.H.E.M. (Marlton, NJ; Booth # 4330).
The Zipbox™ from T.H.E.M. is a good example. The pouch/folding carton hybrid combines the cube efficiency and stable, upright stance of a folding carton with the easy-open and -reclose and freshness-preserving features of a zippered pouch.
On demo lines at T.H.E.M.’s headquarters, carton converting equipment from Yeaman Machine Technologies, Inc. (Elk Grove Village, IL; Booth # 4443) with zipper/material assembly applicators from Zip-Pak (Manteno, IL; Booth # 1902) seals zippered pouch material to carton blanks at up to 120 per minute today, with higher speeds anticipated on the next machines. Filling on the Yeaman occurs through the bottom of the carton. Its quick-change buckets and rails permit size changeover in less than one hour.
For higher-volume needs, a carton converter, such as Malnove Packaging Systems Group (Jacksonville, FL), would install the Zip-Pak unit right after the folder/gluer.
The process is compatible with a variety of materials including poly-coated paperboard and poly/foil/paperboard laminations for the carton and heat-sealable film with zippers for the pouch portion.
“Phase one targets grocery and convenience store applications in the less than 5-pound range while club store packs of products like pet food or other dry products in the 8-10-pound range appear to be right around the bend,” says Steve Belko, vice president at T.H.E.M., the primary inventor of the hybrid concept.
In addition to standing out on the shelf, Zipbox also offers sustainability benefits. Since its rectangular or square shape fills gaps found between canister or pouch packs, at least 30 percent more product fits on a pallet.
“This means fewer trucks, fewer pallets, less fuel and a smaller carbon footprint,” adds Kozarsky. Although the Zipbox is likely to weigh more than an equivalent size pouch, this heavier tare weight may be offset by reductions in corrugated distribution packaging.
“We’re still collecting data, but with some Zipbox designs it may be possible to reduce or even eliminate corrugated distribution packaging,” he predicts.
Product differentiation is one goal of the oPTI™ bottle foamed polyethylene terephthalate (PET) container from PTI. “Everyone is looking for uniqueness,” notes Puvak. Based on MuCell® microcellular foam injection molding technology, the foamed bottles are made in a few basic steps:
- Nitrogen is injected into the melt through the barrel on a modified preform molding machine to form a single-phase solution of polymer and gas.
- Foam is produced as cavity-fill pressure is dropped below nucleation pressure during the injection cycle.
- Foam cells expand as gas is diffused into bubbles. Processing conditions are used to control cell growth in the finished preform.
Foaming the PET not only results in a unique look and texture, but also imparts stiffness, enabling lightweighting of up to 5 percent without any loss in performance. Container clarity can be specified from almost clear to opaque enough to block up to 50 percent of transmitted light. The foaming process results in a more prominent appearance for details like embossed logos and makes it possible to produce white or silvery colors without additives that can impact the clear PET recycling process. Although capable of producing bottles in a variety of colors, it should be noted that most U.S. recycling programs only recycle clear, blue or green containers.
Likely applications involve foods or beverages, including hot-filled juices. In addition to PET, the foam bottle technology is applicable to other resins such as polylactic acid (PLA) and polyethylene naphthalate.
In-mold label (IML) technology as a package decoration option from Airlite Plastics Co. (Omaha, NE; Booth # 8131) integrates the label into the container and/or lid itself. Printed offset, gravure, flexographically or digitally, IMLs offer graphic quality superior to traditional direct decorating methods like silk screening or dry offset printing.
Since the label is applied as the container is being injection molded, the two fuse together, creating a permanent bond that is resistant to cold, wet environments. There are environmental benefits, as well. Generally, the IML and the injection-molded container consist of the same resin, frequently polypropylene. This mono-material construction simplifies recycling or reuse once the contents of the container have been consumed.
In addition, since the label imparts some structural integrity, container walls often can be downgauged. Combining labeling with container making also eliminates the labeling operation on the packaging line along with related material and transportation costs, as well as waste like pressure-sensitive liner material.
“IML is also compatible with non-round containers, giving designers the opportunity to make alternate shapes to call consumer attention on the shelf,” says Mike Corrigan, vice president sales & marketing at Airlite.
Many brand owners are transitioning from round to non-round containers to meet sustainability objectives and demands for “greener” products from retailers like Wal-Mart Stores, Inc. (Bentonville, AR). “Non-round containers cube better, permitting more product to fit on the pallet and on the store shelf,” explains Jackie Kuehlmann, marketing manager at Inland Label (La Crosse, WI; Booth # 8126), a supplier of several types of labels including two styles of injection IMLs, traditional cut-and-stack and roll-fed. Relatively new to the United States, roll-fed IMLs are cut in place just prior to being positioned in the mold and streamline the IML process. Roll-fed IMLs also possess an enhanced environmental profile because the converting process requires fewer finishing steps and generates less waste.
In some cases, an IML package replaces secondary packaging and results in substantial source reduction. Moving all dietary and product information to IMLs on bowls and lids from Airlite made it possible for Lloyd’s Barbeque Co., a division of Hormel Foods Corp. (Austin, MN), to eliminate the paperboard sleeve that previously carried this information. The conversion saves 973 tons of paper per year.
Greater Functionality
Sometimes product differentiation involves a new silhouette or greater functionality. The E-Z Zip stand-up pouch from Ampac Flexibles (Cincinnati, OH; Booth # 2919) delivers easier opening/reclosing. The E-Z Zip combines tabbed tear strip opening with a dual-track zipper reclosure. Pulling the tab opens the front panel of the pouch. “The tear strip is integral to the zipper material so the outside of the pouch is never compromised until the tab is pulled,” explains Sal Pellingra, innovation and marketing director for Ampac.
On the filling line, the E-Z Zip design eliminates problems with closed zippers as well as product-contaminated zippers. For consumers, there’s no need to use a knife or scissors to open the package, nor are there any uneven tears to remove the header to access the zipper. Leaving the header intact increases the package’s post-opening billboard and presents a more finished looking package through multiple openings and reclosings.
Originally introduced on pre-formed stand-up pouches, the E-Z Zip reclosable zipper now also may be applied on horizontal form-fill-seal (HFFS) equipment through a collaboration with KHS USA, Inc. (Waukesha, WI; Booth # 812). “This fall at PACK EXPO International in Chicago, KHS Bartelt will have a form-fill-seal machine in its booth to show how the tear strip and zipper are attached,” says Pellingra. The retrofittable conversion kit for Bartelt HFFS machines applies the E-Z Zip zipper/tear strip combination and punches out the pull tab. The E-Z Zip zipper/tear strip is compatible with two- and three-layer pouch materials including those with foil or metallized layers. Tab size and shape may be customized. Filling occurs through the top of the pouch.
A cleaner opening also is the goal behind Torayfan TreaTear PP directional-tear sealant films from Toray Plastics (America), Inc. (North Kingstown, RI; Booth # 2935), a supplier of PP and PET films, including metallized structures. Designed as a drop-in replacement for cast polypropylene (CPP) and low-density polyethylene sealant webs, the clear films offer high seal strength and tear straight for neat, spill-resistant opening of retort and non-retort gusseted and non-gusseted pouches. The tear function works so well, there’s no need for laser scoring, perforations or V notches. A simple slit provides the starting point of the tear. Since the films are stiffer than CPP, there’s potential for downgauging and cost reduction.
“Combining precise straight directional tear with seal strength for retort applications is a significant development in the evolution of flexible packaging,” says Matt Brown, operations manager, Toray Plastics (America). “Pouches made with TreaTear film bring value to the consumer by enhancing ease-of-use and reducing spillage. Converters benefit from improved pouch performance, greater production efficiencies, potentially better yields and sustainability advantages.”
The first members of the TreaTear family include TreaTear DR02 film for retort pouches that require 100 percent ink coverage, and TreaTear DR22 film for retort applications that require high strength as well as high clarity to provide product visibility. Available as thin as 30 microns (1.2 mil) TreaTear films offer yield advantages over traditional 60- or 70-micron sealant webs. Additional source reduction may be possible if the TreaTear sealant film also can replace a layer like oriented nylon, which was included in the lamination solely for its directional tear capability. TreaTear DR02 and DR22 sealant films are available in clear and white in gauges from 30 to 100 microns. Applications include seafood, chicken, rice, prepared entrees, Meals Ready-to-Eat military rations and pet food.
Upscale Image
Shaped cans from Silgan Containers (Woodland Hills, CA; Booth # 4043) coupled with a complementary color palette help contemporize metal packaging and the products they contain. “In many cases, shaped cans boost sales through product differentiation and enhanced functionality,” says Carolyn Takata, director of marketing at Silgan Containers. With today’s improved production efficiencies and quality, the cost of shaped cans in either aluminum or steel, competes favorably with traditional metal packaging.
Recent research from IBM Global Business Services (Armonk, NY) indicates growth for consumer packaged goods companies will depend on high volumes or highly differentiated products that appeal to upscale buyers. “The upscale positioning will be driven by strong emotional attachment,” says Takata, adding, “We believe that one way to create that connection is by using shaped cans to evoke emotions triggered by visual cues.”
‘Greener’ Packaging
Eliminating, lightweighting or downgauging packaging material, a practice called source reduction, is a popular way to increase sustainability. That’s why Zip-Pak developed the downsized Slider Advantage zipper. The new design, which is compatible with virtually any form-fill-seal or pre-made pouch/bag holding up to about 2 pounds (1 kilogram), is about 60 percent smaller than the original Slider design, which is still available for larger packages. The Slider Advantage zipper costs less too. “At about 2.5 cents for a 12-inch pouch, the Slider Advantage zipper costs about 50 percent less than its larger predecessor,” says Robert Hogan, director international sales and marketing for Zip-Pak.
With the Slider Advantage zipper, brand owners can add a slider, increase package functionality and meet sustainability requirements at lower costs than previously possible and without any loss of functionality. “Testing shows the smaller clip is not harder for young children or older consumers to manipulate,” reports Hogan. The transition isn’t difficult for the packaging line either. Adopting the Slider Advantage zipper requires a few change parts and a simple on-site retrofit of the zipper application unit.
Sustainable packaging also may consist of materials derived from recycled and/or renewable sources like the EcoLogical Line of Packaging™ from CardPak, Inc. (Solon, OH; Booth # 5939). It consists primarily of fiber-based material, minimizes plastic and can be specified with recycled content or virgin content from managed forests.
“Demand is strong for packaging derived from recycled and/or renewable materials,” reports Tony Petrelli, president of CardPak. “Our EcoLogical Line of Packaging is experiencing a 30 percent annual growth rate in a paperboard packaging market that has been stagnant. In three years, it has grown from zero to one-third of our product mix,” he adds, noting CardPak has embraced sustainability as a corporate objective. “In addition to being ISO 14001 certified, we measure and manage our carbon footprint monthly and have upgraded our lighting systems to reduce energy consumption 66 percent,” says Petrelli.
The EcoLogical Line of Packaging currently includes three primary products, ClubPak™, SustainPak™ and ShelfPak™. The ClubPak products were developed to provide an alternative to polyvinyl chloride (PVC) clamshells. It traps a smaller plastic blister between two pieces of fiber-based materials such as paperboard and/or fluted material to reduce plastic content up to 85 percent in some applications, yet maintains a good billboard for shelf impact. “Most applications also reduce total overall package weight 25 percent to 30 percent,” says Petrelli. Variations include ClubPak 2, which lengthens the flange on the blister to eliminate the need to heat-seal it to the paperboard, thereby minimizing fiber contamination and potential recycling issues; ClubPak 3, which sandwiches a corrugated pad between the paperboard layers for a pillow effect; ClubPak HD 1, a bleached board construction, which replaces the paperboard for the front card with E- or F-Flute corrugated; and ClubPak HD 2, which replaces front and back paperboard layers with corrugated for heavy-duty applications.
The SustainPak concept reproduces the ClubPak in paperboard with 100 percent recycled content and blisters formed from 100 percent recycled PET. One early user of SustainPak packaging is GE Lighting (Cleveland, Ohio) for its Energy Smart brand compact fluorescent light bulbs. Packages, which hold multiple bulbs, feature perforated “doors” to provide access for easy removal of each one.
“We need to be very careful when selecting either virgin or recycled materials for our product applications,” reports Petrelli. “Recycled material is great for promoting the use of post-consumer recycled content but may not function as well structurally for the package attributes necessary for stacking, storing and dispensing. In addition, cost and lead-times may be a consideration as well with a greater demand occurring for recycled content use in the general folding carton market. The use of virgin materials may be necessary for structural considerations and can now be promoted as a renewable resource coming from managed forests and promoting a neutral carbon footprint claim,” he explains.
The newest member of the EcoLogical line, the ShelfPak club-store package, also combines paperboard with a plastic blister, but relies on a footed design so packs stand on their own and eliminate the need for a slotted display tray. The ShelfPak design also can incorporate easy-opening features. Its first commercial user is Beiersdorf Inc. (Wilton, CT) for a Nivea for Men skincare product kit.
Clear Lam Packaging, Inc. (Elk Grove Village, IL; Booth # 213) also advocates use of renewable materials and offers a variety of EarthClear flexible packaging materials created from modified Ingeo PLA from NatureWorks, LLC (Minnetonka, MN). One structure with over 90 percent plant-based content debuted in April 2010 for three flavors of Organic Pretzel Sticks from Snyder’s of Hanover (Hanover, PA).
A year of development effort was needed to optimize the material for pretzel packaging. “It’s important to develop the know-how to create a material with the proper blend of machinability and barrier properties,” says Roman Forowycz, chief marketing officer at Clear Lam. A bright yellow graphic on the upper right of the front panel of the 8-ounce bags helps differentiate the package and directs the consumer to the back panel for more information about the benefits of the renewable packaging.
Another concept from Clear Lam, the PrimaPak, is a flexible, stackable package produced from a single roll of film with a rigid fitment that acts as a reclosable feature. In addition, compared to glass or PET jars or composite cans, the PrimaPak provides enhanced stackability for optimum merchandising and increasing shelf utilization up to 32 percent. “Stand-up pouches are harder to merchandise,” notes Forowycz. The form-fill-seal pack is designed to replace heavier rigid packaging such as glass jars and aluminum cans, which eliminates the issue of transporting empty containers to packers cutting costs for both the manufacturer and the consumer. The PrimaPak is formed, filled and sealed on equipment from Rovema Packaging Machines (Lawrenceville, GA; Booth # 3839). The first commercial application for Clear Lam’s PrimaPak form-fill-seal package is likely to be a private-label product.
In the protective packaging arena, sustainable options also are in demand, and materials derived from renewable sources like wood fiber- and bioplastics are readily available. Other offerings like Astro-Bubble ® Green from Pregis Corp. (Deerfield, IL; Booth # 2823) contain recycled content. In fact levels of recycled content have been increasing steadily. One material, Polyplank ® Renew ™ plank foam contains up to 100 percent recycled content. “Recycled-content products are identical in performance and quality, but are better for the environment,” notes Josephine Fish, director of marketing at Pregis, which recently acquired IntelliPack, a supplier of foam-in-place systems.
The IntelliPack foam-in-place system, scheduled to be formally launched at PACK EXPO International, works in real-time to form a custom protective shell around a product. Ideal for larger, heavier, irregularly shaped objects, the system dispenses two liquid foams into a low-density polyethylene bag or film positioned around the product. When the two liquids come together, a chemical reaction generates rapidly expanding polyurethane foam. A sophisticated software and controls system reads the product’s bar code and adjusts itself to preset parameters to dispense the proper size bag and volume of liquid foam. Eliminating the guesswork about how much material to use not only reduces waste, but also minimizes operator training requirements. The self- diagnostic telemetry system also documents how much material is used and features an ergonomic design that reduces repetitive motion for operators.
StreamTwo, a high-density polyethylene (HDPE) lidstock from Rollprint Packaging Products, Inc. (Addison, IL; Booth # 8118), is designed to seal to HDPE cups and trays to create more easily recycled monomaterial packages. The coextruded or extrusion-coated all-HDPE multilayer material joins StreamOne, an all-polyester lidstock. Rollprint’s Allegro L sealant provides a wide sealing window and smooth peeling performance for easy removal.
Rollprint also plans to showcase its transparent aluminum-oxide-coated ClearFoil X and ClearFoil Z polyester. “We see a growing demand for product visibility,” says Dhuanne Dodrill, president of Rollprint. The clear materials not only provide product visibility, but also exhibit a higher barrier at a thinner gauge than barrier materials relying on aluminum foil laminates. In addition, Dodrill notes, “Foil-free materials don’t interfere with the performance of metal detectors or radio frequency identification tags and readers.”
ClearFoil® Z is said to be the first transparent, non-foil, flexible structure to reach ultra-high oxygen barrier properties of 0.0008 cc/100 in2/24 hours and water vapor barrier properties of 0.0008 g /100in2/24 hrs. ClearFoil® X is designed for less stringent applications with an OTR of 0.004 cc/100in2/24 hrs and a WVTR of 0.004 g/100in2/24 hrs.
To register for PACK EXPO International 2010 or obtain more information, visit www.packexpo.com or contact PMMI’s Show Department: 703.243.8555; fax: 703.243.8556; or e-mail expo@pmmi.org.
About PMMI
PMMI is a trade association of 560 plus member companies that manufacture packaging, processing and related converting machinery in the United States or Canada; machinery components and packaging containers and materials. PMMI’s vision is to be the leading global resource for packaging, and its mission is to improve and promote members' abilities to meet the needs of their customers.
PMMI organizes the PACK EXPO trade shows: PACK EXPO International, PACK EXPO Las Vegas and EXPO PACK México, connecting participants in the packaging and processing supply chaing with their customers around the world. Coming in 2010: EXPO PACK México in Mexico City, June 22–25, and PACK EXPO International, Oct. 31–Nov. 3, at Chicago’s McCormick Place. PACK EXPO Las Vegas returns to the Las Vegas Convention Center Sept. 26–28, 2011.
Learn more about PMMI and the PACK EXPO trade shows at PMMI.org and Packexpo.com.
URL List
Airlite Plastics Co., www.airliteplastics.com
Ampac Flexibles, www.ampaconline.com
CardPak, Inc., www.cardpak.com
Clear Lam Packaging, Inc., www.clearlam.com
Inland Label, www.inlandlabel.com
KHS USA, Inc., www.khs.com/us
Malnove Packaging Systems Group, www.malnove.com
NatureWorks, LLC, www.natureworksllc.com
Plastic Technologies, Inc., www.plastictechnologies.com
Pregis, www.pregis.com
Rollprint Packaging Products, Inc., www.rollprint.com
Rovema Packaging Machines, www.rovema.com
Silgan Containers, www.silgancontainers.com
T.H.E.M., www.them.net
Toray Plastics (America), Inc., www.torayfilms.com
Yeaman Machine Technologies, Inc., www.yeamanmachine.net
Zip-Pak, www.zippak.com