Plastic packaging

Alto innovates for

annah Oakman spoke to New-Zealand based Alto Hto find out more.

Pact recently launched its new project has been about two ‘light block’ bottle, with years in the making. From the Anchor milk in first seed of the idea, through to going on shelves in the new research, prototypes, testing and packaging. implementation - it has been an enormous and collaborative Fonterra, which owns the effort that has spanned eight Anchor milk brand, has long countries, hundreds of people been a customer of Pact - its and innumerable taste tests!” commercial relationship is with Alto Packaging (a Pact Group It began when Fonterra New Eric (left) and Chris (right) in the Inpact Innovation Centre with subsidiary in New Zealand). Zealand approached Alto for a light block bottle solution for the light block bottle Eric Kjestrup, general manager fresh milk based on their current of food packaging, & bottle design. Overseas light sourced some product for a first much to the weight or bulk New Zealand for Alto Packaging block bottles had only ever been round of testing at Fonterra. of the packaging. commented: “We were thrilled used for UHT milk, not fresh. These first prototypes were to see our light block bottle “As we edged closer to generic in style and shape. launched by Fonterra with Fonterra’s research proved that implementation, installing all such a positive response from light - both UV light and visible “Testing at Fonterra on milk the new equipment while still light in supermarkets or fridge consumers and customers. quality, nutrient retention, and maintaining bottle supply to - affected the quality and taste flavour profile was positive the fill lines became the final “We believe this really will of milk. The company wanted to in these early stages and challenge! But we are very proud differentiate Anchor from explore the light block technology encouraged us to keep going. that we were able to implement competitors - with packaging so Alto set out to see what existed We had the next round of without any major disruptions.” that maintains a products’ in the international market and, prototypes made in the Anchor taste profile over its shelf ultimately, to better it. Eric explained that the bottle brand shape and style before life and reduces nutrient prevents light damage, which Chris added: “Our first phase further testing continued.” degradation.” is adaptable for further of research spanned South So what were the main products. “Fonterra will be using Chris Redfern, group technology Africa, Spain, Portugal and Italy. challenges with this innovation? light block technology for its manager at Inpact (Pact Group’s We looked at many different Chris revealed: “Critical Anchor range. innovation arm) added: “This manufacturing platforms and challenges for us were “We also believe it is possible producing a lightweight light that light block could have block bottle based on Anchor’s similar taste, freshness and iconic bottle design - which is nutrient benefits for , unusual, with a large handle so we’ll be keen to explore and a rectangular shape. that. I also think that opaque Also, we needed the ability to packaging might lend itself to manufacture bottles at high some interesting promotional speed to suit Fonterra’s filling opportunities too.” lines. And we needed to be able to do it cost effectively. Alto is always working on new innovations with the team at “Appearance was a big issue and Inpact - a division of Pact Group a big challenge. The light block that supports innovation in bottle has three layers - a black packaging, branding and design. layer in the middle to provide Chris added: “It’s deliberately light resistance, a white inner quite separate to Pact’s and a white outer layer. manufacturing operations, “People expect their milk to be which naturally have a focus on true white so we really needed materials, machinery, logistics to get the colour and appeal of and cost. Suffice it to say the project right and make sure that we have hundreds of our we were able to hide the light own registered designs and The light block bottle in its first day of production barrier layer without adding too trademarks.” © 2013 FoodBev Media Ltd. Reproduced with the permission of FoodBev Media – www.foodbev.com

38 PACKAGING www.foodbev.com/dairy Issue 49 - May · June 2013