Spring 2015

Digital takes off Ultimate Packaging discusses how digital print technology drives consumer engagement

Play it safe: supermarkets and brand- owners lift the on food safety

On the trail: the sustainability push has put paper back on the agenda

Food & beverage | | bio-plastics | contract packaging

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PCI037_Close Brothers.indd 1 13/04/2015 10:14 From the editor

On the web... Keep up with the latest developments Matthew Rogerson across the packaging industry by visiting Editor www.pci-mag.com The rules of engagement

elcome to the spring edition With the technological advancements we of Packaging & Converting are seeing in digital printing, this is becoming W Intelligence. Over the following easier to achieve, and with packaging acting pages, I hope to be able to take you through throughout its life as a consistent medium Packaging & Converting Intelligence the key developments the industry will be for brand messages, even those who are like Spring 2015 seeing in 2015 and provide some insight into me and invariably within arm’s reach of their EDITORIAL where the big opportunities will lie through phone, with all the distractions that brings, Editor Matthew Rogerson the rest of the year. cannot turn off their packaging. Chief sub-editor Gemma Carroll Sub-editors Chris Cox, Miriam Jones In addition to the wide variety of content Packaging that helps busy, unhealthy, Feature writers Chris Godfrey, Oliver Hotham, Greg Noone, Sarah Williams on all manner of end markets, there is also stressed-out, resource-poor customers get the Production manager Dave Stanford the most current research from Canadean, most out of the product with minimal effort Group art director Henrik Williams Designer Marianna Pascariello providing an insight into market movements and offers easy disposal will continue to be a across the global industry. driving force in 2015, while I fully expect to COMMERCIAL Throughout this issue, you will also find see the continued growth in variable data and Client services executive Hannah Fitzgerald Sales manager Nick Smith coverage across the executive dining club personalisation that we saw in 2014. Subscriptions marketing manager Marie Connolly Head of sales Richard Jamieson series, where senior executives gather to One further theme I expect to see growing Publisher William Crocker cover key topics openly and come away with this year will be the trend of ‘occasion’. Given a shared vision for the future; in this edition, our 24/7 connectivity and the need to cram we consider digital print, sustainable more experiences into less free time, memories Packaging & Converting Intelligence is published by packaging and food safety. and a sense of occasion will continue to Global Trade Media, a trading division of Progressive Media Group Limited, a member of the Audit Bureau of Circulation. The year has been phenomenally busy so provide the moments that we treasure. John Carpenter House, John Carpenter Street, far, with multiple product launches, key That five minutes of reflection over a cup London, EC4Y 0AN, UK Tel: +44 20 7936 6400 Fax: +44 20 7411 9800 legislation and a plethora of choice for of coffee, or a gourmet meal cooked in five Email: [email protected] consumers targeting the need to enhance minutes that gives you more time to enjoy Websites: www.globaltrademedia.com www.pci-mag.com their personal space and time without busting time with friends or family through to the ISSN 0968-2996 © 2015 Global Trade Media, a trading division of their wallets. In today’s immediate consumer arrival of a beautiful to the table when Progressive Media Group Limited. Registered in England No. 06276344. environment, when faced with overwhelming you are celebrating – these are the lasting All rights reserved. No part of this publication may be choice, most people will stick to what they memories we will carry with us on our next reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, photocopying or otherwise, know. To gain market share, companies have trip down the shopping aisle and the ones without prior permission of the publisher and copyright owner. While every effort has been made to ensure the accuracy of the to break this habit and really engage with that will keep us returning through nostalgia. information in this publication, the publisher accepts no consumers – from initial marketing to the As always, I welcome any questions or responsibility for errors or omissions. point of purchase and through our homes to comments, and hope you enjoy reading this The products and services advertised are those of individual authors and are not necessarily endorsed by or connected with end of life. edition as much as I enjoyed creating it. the publisher. The opinions expressed in the articles within this publication are those of individual authors and not necessarily those of the publisher. Spring 2015 SUBSCRIPTIONS

Single issue price: UK £28.49 EU €44.49 US $58.99 ROW $58.99 One year: UK £43.49 EU €68.49 US $89.49 ROW $90.49 In this issue Two year: UK £69.49 EU €108.49 US $142.49 ROW $143.99 Digital Page 14: Paper-based packaging is set to profi t from the increasing industry drive towards sustainability. Subscription hotline: +44 845 155 1845 (local rate) takes off Ultimate Packaging discusses Subscription fax: +44 20 8269 7877 how digital print technology drives consumer engagement Page 38: Flexible packaging holds a dominant market Email: [email protected] Packaging & Converting Intelligence Subscriptions, Global Trade position, but how will if be affected by the green push? Media, Progressive House, 2nd floor, 2 Maidstone Road, Sidcup, Page 48: The advent and accessibility of digital printing DA14 5HZ, UK Play it safe: supermarkets and brand- owners lift the lid on food safety means things are starting to get personal. On the paper trail: the sustainability www.getthatmag.com push has put paper back on the agenda

Printed by Stephens & George Print Group | LUXURY | BIO-PLASTICS | CONTRACT PACKAGING Visit www.pci-mag.com

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PCI037_001_Foreword.indd 3 14/04/2015 08:09 Contents In this issue... 14 Cover story

48 Paper and card are back in the packaging frame.

38 Digital printing is set to revolutionise what’s possible with packaging – and this time, it’s personal. How will flexible packaging bend to the market?

boost growth of paper-based Feldmuehle Uetersen held a round- The intelligence packaging’s market share, while table discussion with leading dry- rising raw material costs have goods brand-owners to discuss an 6 All wrapped up moved sustainability to prime innovative packaging material According to Canadean, the global position on every packaging manager’s combining films and packaging market is set to reach agenda. Packaging & Converting paper, HybraPack. Over the course of 1.6 trillion units by 2018, dominated by Intelligence takes a closer look at how the evening, company representatives flexible and rigid plastics, which together sustainability in paper is developing gave details on this new solution and account for more than two thirds of in leaps and bounds. the guest attendees were also able to total production. However, the regional offer their insights as to where this breakdown varies, with the impact of the 17 The secrets of faultless technology could best be applied. strong economic growth of Asia-Pacific high-speed labelling and the expanding Chinese middle class Metsä Board Zanders Food & beverage painting a different picture than the ones seen in the US and Europe. 19 Consumers say sustainable material is future of packaging 28 Protective paper can 10 News Stora Enso Packaging Solutions save your produce The latest industry headlines. Powerflute 21 A lightweight 13 Growing narrow web for the packaging industry 29 Food for thought segment demands International Paper Nearly every FMCG brand-owner top-quality printing and major retailer has a strict MacDermid Printing Solutions 23 Metallised paper makes sustainability programme in place. a strong New materials and innovative Paper & board AR Metallizing packaging developments are playing important roles in these programmes, 14 Reams of progress 24 Hybrid and mighty as are consumers’ perceptions of Consumer demand and tighter With hybrid technology fast becoming value and performance – particularly legislation are just two factors that will of interest to the packaging industry, when it comes to food packaging.

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PCI037_002_Contents.indd 4 14/04/2015 08:10 Contents

31 A lighter packaging approach Ecolean

33 Will bring end to cans? Tetra Pak

34 On the safe side On 9 December 2014, more than 30 delegates representing major food brand-owners and retailers from across Europe gathered at The Ritz London, providing a platform for like-minded executives in the industry to understand how to improve the effectiveness of their food safety in packaging. Matthew Rogerson was on hand 56 to report on proceedings. Packaging & Converting Intelligence reports from HP’s digital-printing-focused dining club event.

47 Invercote responds to Flexible packaging market demands Bio-plastics Iggesund Paperboard 38 A state of flex 62 Green plastic packaging plan Flexible packaging has carved out Smart use of bio-plastics is already a dominant position in the overall Digital printing playing a part in supporting brand- packaging market, and that trend owners’ sustainability targets and of growth seems set to continue 48 Digital distinction shows great potential for an despite the prospect of environmental In today’s hyper-connected, mobile increased role in the future – as legislation that could push companies and social-media-focused world, long as it is used wisely alongside to look for greener alternatives. brands have been exploring ways a number of waste reduction and Industry leaders give Packaging & to drive relevance, engagement and recycled material initiatives. Emma- Converting Intelligence their opinions interaction through packaging – Jane Batey reports. on why flexible packaging is so digital printing is opening up these popular and how its use might opportunities. Matthew Rogerson 64 PLA leads the way change in the years ahead. reports from Ultimate Packaging’s in bio-plastics digital-themed open day. Uhde Inventa-Fischer 43 Maximise brand visibility Esko 51 Print on site and on demand Contract packaging RTI Digital 44 On film: flexible cookware 66 An obligation to excellence DuPont Teijin Films 52 Printing gets personal As manufacturing companies Xeikon continue to need products made to higher specifications with shorter Luxury packaging 55 Pharma pioneers UV ink turnarounds, there has been an Collins Inkjet enormous growth in the need for 45 Deeper luxury contract packaging services. In today’s luxury goods market, a 56 The art of possibility President of the Contract Packaging delicate balance must be struck At the end of 2014, HP hosted a dining Association Chris Nutley offers between fulfilling the need to club that focused on the possibilities further insight into this sector of convey the luxurious look and feel of digital print in packaging, the the industry. the customer expects, while also thrust of which was how the industry meeting the growing requirements is beginning to understand the 69 Shaping the future for sustainability and guarding implications of digital printing and how Belvac against counterfeiters. Absolut’s everyone must work together to realise Anna Schreil and Cartier’s Nawal its full potential – through education, Directory Ait-Hocine explain some of the partnerships, and asking for help from ways this can be achieved. each other and the wider industry. 70 Index

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PCI037_002_Contents.indd 5 14/04/2015 08:10 The intelligence > Market insight

wrappedAll up

According to Canadean, the global packaging market is set to reach 1.6 trillion units by 2018, dominated by fl exible and rigid plastics, which together account for more than two thirds of total production. However, the regional breakdown varies, with the impact of the strong economic growth of Asia-Pacifi c and the expanding Chinese middle class painting a different picture than the ones seen in the US and Europe.

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PCI037_003-005_Trends-Canadean.indd 6 14/04/2015 08:11 The intelligence > Market insight

he Packaging Institute (GPI) China is the world’s largest beer recyclable, easy to handle, tamper-proof valued the US glass market in terms of overall volume and virtually unbreakable, metal finds itself T industry at $5.2 billion in 2014. consumption, and glass are the challenging to compete with other, lighter- Glass faces stiff competition from alternative primary packaging format currently used weight materials. Furthermore, fluctuating packaging materials such as plastics, in this sector. According to Canadean, raw material and energy prices will especially in food and non-alcoholic retail sales of B&C and spirits in Asia- constrain the growth of metal packaging. beverages. Product categories such as Pacific for off-premise channels will However, increased is helping condiments, which have traditionally been increase by more than 12.6 billion litres the metal packaging industry improve its packaged in glass, have seen a gradual between 2014 and 2018, which will environmental credentials with regard to shift towards PET bottles. Despite glass ensure the growth of glass packaging other packaging materials. Increasing the losing ground to other packaging materials, in the region. In light of this increasing recycling rate of cans will be advantageous the benefits of glass packaging – such as demand for alcoholic drinks, major glass to metal packaging as CPG companies, longer , chemical inertness and manufacturers have been accelerating especially beverage manufacturers, will impermeability – will help it sustain market their efforts to consolidate their position increasingly use this material to improve share. Additionally, glass is the preferred through mergers and acquisitions. their own environmental credentials. pack material for premium products due to its exclusiveness and aesthetics. Evian water bottles made of glass are sold Alcoholic drinks are the dominant end- user category of glass packaging worldwide at high-end restaurants in China, indicating due to the inherent characteristics of glass, that glass is still preferred by manufacturers such as its barrier, premium look, chemical inertness and easy recyclability. Outside of for premium products. the alcoholic drinks sector, however, glass packaging is fast losing its share to other For soft drinks, glass packaging is still Metal packaging accounts for the third- packaging materials, especially plastic. The used to underline premium positioning. largest share of the US packaging market European Union’s ban on the use of olive For example, Evian water bottles made by value; the metal packaging industry oil and dipping bowls in foodservice of glass are sold at high-end restaurants was valued at $25.8 billion in 2014. Factors channels across its member states, effective in China, indicating that glass is still driving the demand for aerosols have from the beginning of 2014, meant that all preferred by manufacturers for premium traditionally been product applications foodservice channels, especially restaurants products. In addition, sustained growth such as deodorants, hairspray, shaving and hotels, have had to stock oils in pre- in the packaging industry gel and air fresheners. However, this trend packaged factory bottles with a tamper- will come from the growing momentum in has not been observed in the canned food proof dispensing nozzle and comprehensive the food market, driven by the seasonings, market, which has seen a recent decline. labelling, including details such as origin, dressings and sauces, dairy food, and Campbell, the world’s largest canned- quality, manufacturing and the expiry date. syrups and spreads sectors. soup-maker, has closed two of its This has affected for the Like the rest of the world, glass is manufacturing plants in the US and on-premise channels, as they still stock oils facing increasing competition from introduced new flavours in pouches, but favour glass production for olive oil alternative materials in Asia-Pacific. reflecting a reduction in the use of cans manufacturers, resulting in an increase in Problems such as its heavy weight, the in food packaging. the number of glass bottles, even if there is consequent higher logistics costs, high Despite being the preferred packaging some substitution with plastics. Glass will energy costs in manufacturing and its material for beverages due to its ability to continue to be used widely in the global fragile nature are the main reasons for its keep them colder for longer, the demand for wine industry despite the introduction of decline in demand. To overcome these metal cans is declining as a consequence alternative packaging formats such as PET challenges, the glass packaging industry of growth in alternative packaging options bottles and Tetra Pak . needs to employ new technology to such as rigid plastic variants and pouches. The glass packaging industry in Asia- optimise costs and enhance properties, In Asia-Pacific, the use of metal Pacific is primarily driven by increasing such as lighter-weight packaging. packaging is most widespread in the food demand from the beer and cider (B&C), and beverage markets, which account for and soft drinks markets, in particular the Pedal to the metal approximately 72.5% of the total demand beer and soft (standard) sectors. According The metal packaging industry will continue in the region. China is one of the largest to Canadean, consumers in the Asia-Pacific to see an increase in demand over the next producers and consumers of region purchased 4.8 billion litres of B&C four years, growing at a compound annual in the world. According to the Aluminium and spirits through retail off-premise growth rate (CAGR) of 1.66% between 2014 China Association, China accounts for channels in 2014, 9.5 billion litres more and 2018, lower than the CAGR growth of 40% of global aluminium production, than in 2010. This has been of benefit to 1.69% recorded over the 2010–14 period. and growth will be compounded by high the glass packaging industry. Despite advantages such as being 100% investment in this sector. Alcoa, a leading

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PCI037_003-005_Trends-Canadean.indd 7 14/04/2015 08:12 The intelligence > Market insight

Figure 1. Market share of various Figure 2. Flexible packaging breakdown packaging materials by value, 2014 by end-use market, 2014

Non-food Industrial 3% Paper and board applications 38% 8%

Pharmaceuticals 9%

Metal 17% Market size Glass Consumer Market size $151.0 Billion 3% product $28.5 Billion 10% Others 3%

Food (retail and Retail non-food Rigid plastic institutional) Flexible 12% 20% 58% 19%

Source: Glass Packaging Institute, World Packaging Organization, FPA, Canadean Source: Flexible Packaging Association

aluminium producer, predicts the industry , please products to consumers. In order to will grow at 11% over the next three to The World Packaging Organization (WPO) ameliorate the impact of reduced demand five years in China. valued the US paper packaging industry from tobacco products and the growing The growing middle class, attributable at $57.1 billion in 2014, with a growth adoption of plastics, manufacturers need to rising disposable income, is driving of 4.6% compared with 2013. Per-capita to increase their focus on innovation, the consumption of B&C and soft drinks consumption of paper in the US is 238kg, and extending P&B packaging in new in major Asia-Pacific economies such as which is one of the highest in the world. categories. For example, in the UK, the China and India, which in turn is fuelling Strong global growth of paper and board use of cartons for wine is increasing as demand for beverage cans. According (P&B) packaging is not clearly reflected importers such as Raisin Social begin to to Hindalco, a major aluminium can in the US paper industry, as demand for use Tetra Pak cartons. manufacturer in India, only 5% of the paper-based packaging has shifted to Asia. According to Canadean, P&B is Indian beverage market currently uses Corrugated , primarily used in the second-most-prevalent packaging metal cans, while more than 50% of the transit packaging, are the most popular material after plastics (flexible packaging US beverage market is dominated by the within paper-based packaging. In the US, and rigid plastics), in terms of packs sold same packaging format. The company it is the fastest-growing segment within in the organised retail industry across the expects demand for aluminium cans to paper packaging, driven by food and Asia-Pacific region. reach five billion units in India in 2020, durable goods output. According to Tetra Corrugated packaging is the largest up from the present level of one billion. Pak, liquid cartons will gain popularity constituent of P&B packaging and is mainly The metal packaging industry will see due to greater acceptance by major food used for its cost-effectiveness in transit steady growth in demand over the next manufacturers, and the introduction of packaging. Booming economies, growing three years; however, it will be at a lower cartons in non-traditional food and exports and increasing online purchases rate than that of alternative packaging beverage categories such as wine. are some of the positive factors driving materials such as plastics. Fluctuating In the EU, food, and tobacco and growth of the corrugated packaging prices of raw materials and energy, along tobacco products are the major end industry in Asia-Pacific. The rising cost of with consumer preference for lightweight users of P&B packaging in CPG products. raw materials and high dependence on packaging as it facilitates on-the-go While the growth of online shopping South-East Asia-Pacific markets for raw use, has inhibited the growth of metal and exports act as key demand drivers, materials such as wood and pulp act as packaging in recent years. Aluminium decreasing smoking rates, government threats to the industry. Countries like beverage cans, which primarily serve regulations on smoking and a threat from China, India and Japan are some of the the B&C and soft drinks markets, will plastic packaging limit growth somewhat. major markets that are highly impacted by continue to face competition from Corrugated packaging holds the largest this shortage. alternatives such as PET and glass share of P&B packaging in most of the In the organised retail CPG market, bottles. Therefore, there is an increasing European markets. tobacco and tobacco products, and food need for innovation and technological Increasing preference for shopping are the main end users for P&B packaging. upgrades, backed by investment, to online is helping the growth of industry, as While demand from tobacco and tobacco reduce costs and provide competition for corrugated cartons are primary packaging products is slowing, demand from food, other materials, especially plastics. material for transportation and delivery of especially dairy, is witnessing an increase.

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PCI037_003-005_Trends-Canadean.indd 8 14/04/2015 08:12 The intelligence > Market insight

Companies are investing heavily to at $28.5 billion in 2014. Food packaging is improve their manufacturing capabilities the largest market for flexible packaging, in the Asia-Pacific region in response to the accounting for 67% of consumption, growing demand for corrugated packaging followed by retail non-food, consumer and cartons. For example, anticipating products, pharmaceuticals, industrial further demand for paper packaging in applications and industrial non-food India, leading players such as Tetra Pak (see Figure 2, opposite). have invested heavily in capacity There is a shift towards the use of penetration, expansion and machinery upgrades. lightweight packaging materials, such as and the use In 2014, Tetra Pak inaugurated a new flexible packaging, for products that are of such packs Rs7.0 billion facility near Pune, India, with traditionally packaged in heavier materials is spreading an annual capacity of 8.5 billion packs. like glass, metal and plastics. The key from shampoos, Further enhancing the sustainability advantage of flexible packaging is its toothpaste and credentials, Amcor launched a recycled- low weight, which ensures decreased face cream paper-making machine, named B9 in transportation overheads and reduces to tea, coffee February 2014, which it claimed to be the overall supply chain costs. Though and other Liquid cartons will continue the first of its kind in Australasia. This the flexible packaging industry has hot drinks. to gain acceptance. machine was able to offer a lighter, considerable growth opportunities, it faces The demand for recycled brown paper with the same challenges such as volatile prices of raw packs is expected to benefit flexible qualities and strength as that of traditional material and skilled-labour shortages. packaging manufacturers, as these brown paper. Constant innovation, efforts In terms of the number of plastic CPG products use more packaging to improve raw material production in packs sold in organised retail in Asia- than traditional standard packs. Although Asia-Pacific and the ability to expand Pacific, China and India are the largest recyclability still remains one of the product portfolios to suit new segments markets for plastic packaging. In fact, major challenges, there are sustained of CPG products will be critical for the worldwide, China ranks third in the efforts being made to address the growth of P&B packaging in the region. production of plastics and petrochemicals, environmental concerns that are arising and is the largest consumer of plastics. from plastic waste and to improve the Plastic population The consumption patterns of these recycling of plastics. Plastic is the second-most-dominant countries show that many are shifting In Europe, growing demand from food packaging material in the US and had a from unpackaged to packaged goods. and soft drinks is the primary driver for market value of $30.4 billion in 2014, which This has created huge demand for plastic growth in plastic packaging. The ability translates to 20.0% of the market. The packaging as, compared with other of plastic packaging to provide maximum demand for plastic packaging in the US is materials, it is perceived to be cost- functionality with minimum material expected to grow by 5.3% annually, driven effective and easy to use. weight attracts multiple CPG companies by the increasing popularity of single- Food, soft drinks and household care towards the material. In comparison with serve packaging, and companies shifting are the major markets for flexible and rigid glass and metal, the use of plastics usually from metal and glass to plastic. plastics packaging in China. Constant reduces the weight of the final product, Within rigid plastic packaging, bottles, innovation is helping plastics to enter into thus providing significant savings in trays and tubs represented a share of new segments; for example, energy drinks transportation and storage. approximately 92.0% in 2014, with demand and fruit juices have been introduced to Although it is popular across industries, expected to grow by 3.1% annually for the the Indian market in flexible pouches – a plastic packaging is subject to increasing next three to five years. The fastest growth rare occurrence in global packaging. Some regulation and environmental concerns. is expected in the pharmaceutical and food CPG manufacturers, which traditionally Major retailers such as Tesco, Asda and sectors. Other container types, such as use glass packaging to enhance premium Sainsbury’s have undertaken voluntary cups, are expected to grow due to the credentials, are now shifting to plastics in initiatives to cut down the amount of favourable outlook for food products like order to reduce costs across the life cycle packaging material used for products. yogurts and single-cup coffee. of the pack. CPG manufacturers are also making Even though plastic is a preferred The rising older population and efforts to improve the recyclability of packaging material across industries, number of smaller households has led to plastic packaging; for instance, in Italy, environmental concerns and regulations an increase in demand for single-serve, Levissima has introduced water in a have driven packaging manufacturers convenient, lightweight, portable and bio-, derived from biomass to continue to encourage consumers to – attributes best sources rather than petroleum, in order to take a ‘reduce, recycle and ’ served by plastic packaging formats. increase recyclability and ease consumers’ approach to packaging. Additionally, FMCG manufacturers in environmental concerns. The bio-plastic The Flexible Packaging Association countries such as India are increasingly bottle is made with 30% PET from sugar- valued flexible packaging sales in the US relying on low-priced small for rural cane-derived bioethanol.

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PCI037_003-005_Trends-Canadean.indd 9 14/04/2015 08:12 The intelligence > News

to ensure that product integrity, food safety regulations, and an extensive News list of performance requirements set by beverage producers, distributors Beverage the recycling process will continue to and end users would be met by the Rexam sees Carlsberg rock be a focus for us moving forward.” and its various accessories, including an the can cradle The can was assessed on five integrated pressure-relief valve system. sustainability aspects: material health, At the same time, priority was material reuse, renewable energy and also given to limiting the operational carbon management, water stewardship impact vs the traditional keg by and social fairness. achieving compatibility with existing filling lines and draught equipment. Quadrant CMS and Dispack co-design beer Intelligence bottled keg breakthrough by Diageo and Thin Film Diageo and Thin Film Electronics are aiming to completely change the role of the bottle in the consumer experience with the prototype Johnnie Walker Blue ‘smart bottle’, unveiled at the Mobile World Congress in March. The award was a beverage packaging first. The bottle attempts to enhance Carlsberg has received the first ever the consumer experience by using Cradle-to-Cradle certification for a printed sensor tags featuring Thin beverage can, having been awarded Film’s OpenSense technology, which a bronze-level certification from the can detect the sealed and opened Cradle-to-Cradle Products Innovation state of each bottle. Institute for cans supplied by Rexam The tags and the sensor information into the UK market. the bottles display will allow Diageo The Rexam cans are the first of any to send personalised communications of Carlsberg’s packaging to receive a to consumers who read the tags with certification, and the award marks the their smartphones, allowing targeted first time a beverage package has been and timely marketing messages, such certified by the institute. as promotional offers, cocktail recipes The DOLIUM keg is 100% recyclable. Simon Hoffmeyer Boas, corporate and exclusive content, at retail or communications and corporate social Quadrant Creative Moulding & after purchase. responsbility director at Carlsberg Systems is supporting Dispack Helen Michels, global innovation said: “We are thrilled to celebrate this Projects in creating DOLIUM – a new- director on the futures team at Diageo, collaboration with Rexam, which played generation, one-way PET beer keg said: “We constantly experiment with a key role in helping us secure the with a recyclable valve system as a the latest cutting-edge technology to certification. We will continue to focus cost-effective and easy-to-transport enrich and enhance the experiences on improvement and cooperation with alternative to traditional multitrip delivered by our iconic brands. Rexam as an innovative supplier to stainless steel . “Our collaboration with Thin Film optimise our beverage can packaging Dispack founder Albert Wauters said: allows us to explore all the amazing in the future.” “DOLIUM one-way PET kegs offer new possibilities enabled by smart Rexam’s European sustainability several important advantages; brewers bottles for consumers, retailers and manager, Matthew Rowland Jones, can avoid huge capital investment in our own business, and it sets the bar added: “The bronze certification marks an pools of metal kegs that have a very for technology innovation in the important step in our joint sustainability low yearly rotation, especially in use drinks industry.” journey with Carlsberg. We are thrilled to on long distance. Together with the Thin Film’s CEO, Davor Sutija, be part of a collaboration that sees cans 100% recyclability of the DOLIUM added: “As mobility becomes supplied by Rexam awarded the first one-way kegs, this results in better ubiquitous, consumers want and Cradle-to-Cradle certification of its kind. environmental performance.” expect brands to follow suit and “There is still a way to go towards To offer a cost-effective and deliver custom mobile experiences. encouraging consumers to recycle cans, more environmentally friendly option for “By leveraging OpenSense, Thin so focusing on consumer involvement in the beer industry, the DOLIUM keg had Film is enabling the smart bottles

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PCI037_004_News.indd 10 14/04/2015 08:13 The intelligence > News

which make traditional a standard bio-plastic called polylactic ineffective. All consumers need to do is acid (PLA), developed by Floreon press it together to create an effective Transforming Packaging. and consistent seal that stands the Conventional PLA is produced from test of repeated cycles of opening and sustainable plant feedstock, which reclosing,” she added. means it has a lower carbon footprint The companies are currently seeking and non-renewable energy usage than food-contact approval for the product. any mineral-based thermoplastic. However, until now, it has been renowned for its poor toughness and Pressure-sensitive labels tendency to lose strength on storage in spear an industry first warm conditions. Spear, in conjunction with the Not only does Floreon have improved Association of Postconsumer Plastic toughness, higher strength and Recyclers, has created SpearRC, a durability than PLA, but it is also proprietary technology that creates recyclable, biodegradable and requires a cost-effective, post-recyclable far less energy to process. pressure-sensitive label alternative unique in the industry. Flexible packaging This technology has been developed Eco-packaging proves to allow the 400 billion PET bottles Carrington’s cup of tea used globally every year to take advantage of pressure-sensitive labels Smarter than your average: the bottle’s tags without the recycling contamination allow personalised marketing communication. of traditional materials. to carry digital information that can be While there was an existing accessed via NFC-enabled smartphones. solution, it was cost-prohibitive for Diageo can reap the benefits of the most customers. Now, with the release intelligence gleaned from our smart of SpearRC, there is a cost-effective sensors and create engaging recycling solution including clear, The packaging is sourced from wood pulp. experiences for its customers.” white and metallised-film material Carrington Tea has announced that options. SpearRC first hit the market it will be using bio-based NatureFlex Adhesives in Norway on Carlsberg Group’s oldest packaging films for its Carrington Joint venture wins the and best-selling bottled mineral water, Organics Tea line. Battelle of self-adhesion Farris, in 2014. The flexible packaging material is Battelle and Mondelez have developed derived from wood pulp sourced from an innovative that combines Bio-Plastics managed plantations, is certified to be high self-adhesion and low tack to Patent approved for over 90% bio-based, and home and provide a consistent, easy-to-use- innovative bio-plastic industrial compostable, while also having and-apply adhesive that only sticks high barriers to oxygen and moisture. to itself. Debbie Shandel, executive vice- The adhesive can be pre-applied president and chief marketing officer to packaging film using conventional at Carrington, said: “For our organic tea, printing and technology, we felt that a compostable package followed by curing with ultraviolet would complement our product and energy. It is cost-effective to speak to people who want to make a Floreon is a novel bio-plastic blend. manufacture and apply, and can be positive impact on the environment. easily introduced into existing A leading bio-plastic technology “Functionally, NatureFlex delivers the packaging operations. company has been granted a patent for freshness barrier that our teas require, “Unlike traditional pressure-sensitive Floreon, an novel bio-plastic material. along with excellent receptivity to inks, adhesives, the new low-tack adhesive The unique technology produces a bio- communicating our branding through is not messy, tacky or expensive,” said plastic that is much tougher and easier vibrant print.” Cindy Conner, senior market manager to process than current materials – a The teas are packaged in 20-, in consumer, industrial and medical development that is essential to extend retail-ready ‘soft packs’ that, though products at Battelle. the use of bio-plastics. commonly used throughout Europe “For example, it won’t pick up, Floreon is a novel and biodegradable for economy-sized packaging, are rarely crumbs from crackers or cookies, -based blended with seen in North America.

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PCI037_004_News.indd 11 14/04/2015 08:13 At MacDermid, our experts

are working for you. Standard Ink Coverage We’re not just printing plate experts, we’re package printing experts. Our customers know that they can call on our experienced technical team to help with just about anything in the plateroom or on press, from optimizing their workflow to diagnosing a problem in the print. Our team of product experts at MacDermid has recently introduced Digital MWW, Digital MWW a flexographic printing plate that brings unparalleled print performance to white Ink Coverage ink delivery, providing dramatically reduced mottle and improved opacity - all in one pass on the press. To learn more, contact your MacDermid representative or visit our website.

Our Experts Working for You

+1.404.696.4565 • printing.macdermid.com © 2015 MacDermid, Inc. All rights reserved.

PCI037_MacDermid.indd 1 13/04/2015 10:17 Company insight Growing narrow web segment demands top-quality printing

With the growth of flexo in the tag and label sector, MacDermid Printing Solutions has developed a host of products ideally suited to the narrow web market. Packaging & Converting Intelligence highlights LUX flat-top dot technology.

ccording to PRIMIR’s 2014 ‘Tag and Label LUX flat-top dots combine the best of analogue Printing Trends’ study, print revenue in 2013 for and digital flexo worlds. A the North American tag and label sector was $8.4 billion. Flexo’s piece of this pie is growing – as the quality of flexo print improves, more and more brand managers in food and beverage are moving their work from sheet-fed offset applications to pressure-sensitive labels in the food and beverage categories. Interestingly, increased technical innovation in flexo coincided with the development of roll-fed, pressure-sensitive substrates. Flexo was predominately found in food labels, stickers, promotional labels and tags in the 1970s. Later, in the 1980s, flexo technology expanded into beverage, health and beauty, pharmaceuticals and household cleaners. Today, However, by preventing oxygen from entering the thanks to massive innovation in the past two decades, flexo platemaking process, as the LUX technology does, all dots printing is found in every major end-use sector at quality come up to ‘type high’, meaning they are the same height levels that rival offset and gravure. across the plate. Now the press operator can get the press up to Flexo seems well-suited to the tag and label printing colour quickly without having to guess the right impression. segment for several reasons: first, it can now achieve In 2010, LUX flat-top dot technology was introduced as a high-quality CMYK print; second, it can easily be step in the platemaking process. Platemakers would process a combined in line with other converting technologies; standard digital plate as usual, then, prior to exposure, put the and third, it offers the highest productivity and flexibility. ablated plate through a simple three to five-minute step. This prevents oxygen from interacting with the surface Dot shape does matter of the uncured plate, thus inhibiting the curing process. In a market where high-priced substrates such as self-adhesive The LUX Lamination technology was so successful that, labels, and wrap-around labels are used with in 2014, MacDermid introduced LUX In-the-Plate (ITP), a each and every ever-shortening press run, minimising technology that produces the same LUX flat-top dot but startup waste is crucial. And as the industry consolidates, without any extra steps or equipment. LUX ITP has all the a printer-converter that cannot maintain a high standard of benefits of LUX Lamination but with the convenience of quality for high-end consumer brands that pervade the tag flat-top dots right out of the . and label industry will not last long. LUX features 1:1 mask-to-plate reproduction, eliminating MacDermid’s LUX technology is an ideal solution for the need for applying a bump curve in prepress. On press, tag and label printer- focused on quality and plates with LUX technology provide low dot gain, superb productivity. LUX flat-top dots combine the best of both print quality, exceptional print consistency, outstanding flexo worlds – the consistent, robust print performance of durability and extremely low tack. the analogue dot shape with the efficient workflow and fine LUX Laminators are available in 38in and 62in widths. imaging capability of the digital plate. The LUX ITP 60 plate can be processed in solvents or in In the traditional digital platemaking process, dot MacDermid’s LAVA thermal plate processor. Currently, LUX formation is inhibited by the introduction of oxygen, thus ITP is available as a 60 durometer plate in 0.045in (1.14mm) creating bullet-shaped dots of varying heights, with mid-tone and 0.067in (1.70mm) gauges. dots more elevated from the floor of the plate than finer highlight dots. As a result, press operators often have to adjust and re-adjust the press to find optimal impression. Further information MacDermid Printing Solutions This typically leads to several hundred feet of waste in www.printing.macdermid.com terms of substrate and ink.

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PCI037_Macdermid.indd 13 13/04/2015 14:54 Insight > Paper & board Reams of progress Consumer demand and tighter legislation are just two factors that will boost growth of paper- based packaging’s market share, while rising raw material costs have moved sustainability to prime position on every packaging manager’s agenda. Packaging & Converting Intelligence takes a closer look at how sustainability in paper is developing in leaps and bounds.

very day, more companies In a Confederation of European Paper of a business, typically for us it’s about 5%. decide to invest in eco-friendly Industries (CEPI) study from 2012, more Food waste is high on our agenda. E packaging – like paper. Of the than 80% of European consumers preferred “Packaging is more about protecting recycled packaging materials available, paper-based packaging and labels, the food and [developing] new packaging paper continues to account for the believing paper packaging to be more that is fit for purpose – there are great majority of demand; with 34%, paper and convenient, and that manufacturers and advantages over some materials and board has the second-largest market brand-owners should embrace it more disadvantages over some others. What share in the packaging industry, behind than consumers have seen them doing we see is responsible timber sourcing. You flexible and rigid plastics with 37%. The so far. Almost every news article on can see that in products such as benches, importance of packaging sustainability will sustainability mentions that there is a and I can foresee the day that it might hit continue to grow over the next two years growing awareness of environmental packaging, in which case, the traceability and is expected to become more of a issues among the consumers, although of your sourcing is going to be the big consideration than the cost factor – today’s food safety remains the main concern. important thing.” companies’ number-one challenge. Mark Caul, technical manager for Government regulations that mandate Paper-based packaging offers a versatile packaging at Tesco, says: “When it packaging recycling rates have helped and responsible solution for manufacturers, comes to broad subjects such as plastics, boost the paper market as companies aim retailers and consumers. Since paper is cardboard and paper, aluminium and to increase their resource efficiency by biodegradable and recyclable, it is often steel, they all have a place, so substitution collecting more recycled material. While seen by the final consumer as a preferred is much harder than people think. You companies still invest in developing new packaging material. Improving paper’s really have to be careful when substituting types of , such as barrier properties is seen as a critical step materials based on environmental plant-based plastic, or bio-plastic, the term in increasing its viability as a packaging reasons because there could be ‘biodegradable’ has become tainted since material. To adhere to food-safety unintended consequences. discussions over its definition and real-life regulations, water-based technology is “Environmental, sustainability, green… properties have started. gaining acceptance. Water-based these words are all used, and they need to Large quantities of biodegradable can be formulated to meet the requirements be used properly with consideration. If I packaging end up in landfill where they of a wide range of food packaging. look at the carbon footprint of packaging are deprived of oxygen, decompose and

14 PACKAGING & CONVERTING INTELLIGENCE | www.pci-mag.com

PCI037_006_Paper packaging.indd 14 14/04/2015 08:14 Insight > Paper & board

end up generating methane, the extra- As wealth in developing markets grows, packaging are also incredibly important, potent greenhouse gas. Landfill is the we will see a rise in recycled packaging as Lotte Krekels, packaging manager at third-largest source of man-made methane consumption. Since food packaging Carrefour Belgium, explains: “We have emissions to the atmosphere; if packaging makes up a large chunk of municipal solid our Carrefour Kids line of products, weren’t biodegradable, landfill would be waste, companies may look at recycled which has its own website and product less of a nuisance to the environment. paper packaging as a way to reduce their designs. We are collaborating with a local One way companies are dealing with landfill waste. Belgian children’s book illustrator who has stricter regulations is to decrease packaging illustrated the well-known Danish Cookies size and make packaging more lightweight, Colouring perception tin in a Polish design style after the allowing them to save on transportation Innovation in the food industry has illustrators’ one-year stay in Poznan. We costs and carbon footprint. prompted greater demands for paper hope that consumers will keep the tin The global consumer packaging packaging. Paper packaging is and use it after the cookies are gone.” market is currently valued at approximately increasingly being used as a substitute for €300 billion, of which the paper and carton polystyrene. The paper packaging industry Play your card right industry represents a third. The future has been developing barrier-coated With the European recession expected to promises to be bright for the paper and boards and papers, helping the industry to last until the end of 2017, managing costs carton industry. The sector is expected to close the gap with the plastic packaging is vital for a company’s survival. At a time experience sustained growth of 5% industry, which is also expected to grow. when China’s double-digit growth has annually until 2018. This will result in a In October 2014, Tetra Pak launched the become single-digit, global demand for global market of more than 30 million tons industry’s first carton made entirely from paper pulp is lagging. On top of that, South with an approximate value of €50 billion. plant-based renewable packaging America has become an important pulp The BRICS markets represent roughly a materials. The carton will be the first in and paper-producing continent. Its capacity third of global demand, with the Americas the market to have bio-based low-density expansion is enabled by an increase in accounting for a third and Europe for (LDPE) films and bio-based agricultural productivity; arable land mass approximately the final third. Oceania and high-density polyethylene (HDPE) caps, is being used with short-rotation eucalyptus the African continent account for a minute which are derived from sugar cane, in and shorter-rotation pine, which are amount according to a Forest Stewardship addition to FSC-certified paperboard. unavailable in colder climates. Producers Council (FSC) report. Paper packaging Colours have a significant impact on will put 30 million tons of chemical pulp sales in Europe have only gone up slightly the mood and behaviour of people. For to the global market through to 2020. overall, although France is an exception: it instance, pale yellow will never be seen in Despite increased demand for saw a decline in sales in 2013 due to not hospitals. So it follows that the success of sustainable packaging on the consumer adapting the selling price of final products a product can be significantly affected by side and the fact that over two million tons to the rising costs of raw materials. the choice of colours on its packaging. of paper capacity has been shut down in Europe since 2012, demand on the producer side has fallen. Pulp overcapacity The comeback of cardboard can be explained by is likely to result in lower prices, lowering how consumers and producers have changed their costs and enabling companies to make the perception of plastic and its source ingredient: oil. shift from plastics to the more sustainable paper packaging, and thus possibly stimulating the use of paper and board in China’s middle class of 150 million According to a study by the Johannes the growing packaging industry. people is expected to reach 500 million Gutenberg University in Mainz, France, the This year is the 120th anniversary of within the next ten years, equalling the colour of a package proves to be the most the corrugated box; the first was produced total population of today’s EU. With Asia’s important factor in consumers’ final-second in the US in 1895, and up until then, all steady 7% annual economic growth and its decision-making. In packaging design, shipping was done in wooden . middle-class population growing, brands colour schemes are differentiated according Having been left aside for a long time, are focusing on how to get new consumers to the age, gender, culture and average cardboard is back and is being considered and how to keep them. As long as the income of the respective target group. the material of the future. paper packaging industry hasn’t solved the While sustainability design used to be The comeback of cardboard can be various barrier limitations problems, plastic limited to brown packaging, earthy colours explained by how consumers and will continue to grow on the global market. and textured paper – and all three are still producers have changed their perception For developing countries, rigid plastic very popular – today, brands dare to move of plastic and its source ingredient: oil. materials have rapidly taken a strong away from the clichés. Companies often When oil was abundant, inexpensive, market share as the processing industry remain loyal to their brand colour scheme and easily and peacefully available, plastic for those materials requires significantly to reap the benefits of recognisability. packaging was the obvious choice. This less capital than glass, metal or paper. Demographic targeting and enduring is no longer the case today. Recyclable

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PCI037_006_Paper packaging.indd 15 14/04/2015 08:14 Insight > Paper & board

paper and cardboard have become popular Angelika Christ, secretary-general of The latest report from the European again, all the more so as newly developed the European Federation of Corrugated Recovered Paper Council (ERPC) shows bio-based barrier films can be added. Board Manufacturers says: “Corrugated has that, at more than 81%, paper and board Tech-savvy brand-owners are become an integral part of the discounter is the most recycled packaging in Europe. incorporating new marketing techniques retail business model because it’s great ERPC members are working together such as smartphone apps and QR codes. for display and reducing cost. That’s why closely along the value chain to improve Corrugated converters now work with it is, and will remain, the number-one this rate even further in areas such as digital print specialists, developing choice for discounters.” waste prevention, ecodesign and R&D. technology to meet the demands of these “In Europe, all paper and board has a types of interactive marketing tools. Heavyweights of the industry pedigree: we source from legal, sustainably Digital printing technology has Despite the industry focusing on getting managed forests and have traceability for established a beachhead in corrugated boards lighter while keeping strength the materials used in packaging,” Ringman packaging, but it is clear the output of these similar to their heavier counterparts, points out. “Paper-based packaging is really products is not sufficient to gain the interest there has been the introduction of new a product ‘made in Europe’, with over 80% of mainstream markets. Digital printing is heavyweight products. The majority of of the raw materials coming from the EU. In used by 10% of corrugated cardboard users, lightweight boards are being used in Europe, paper is showing the way for other mostly by the high graphics sector. Digital western Europe, while eastern Europe materials in traceability and recycling. printing may be perceived as an industry has seen an increase in demand for “We also are championing water game-changer, but there are many other heavyweight boards. Primarily targeted recycling where water is reused several options a producer can choose from. at replacing wooden packaging, some of times, having made it possible to reduce The success of corrugated packaging these heavier products are also able to water intake by half in the past two in the retail industry is most tangible in replace double-walled board with an decades. In addition, 93% of water intake is the discount sector: 90% of discounters’ overall lighter-weight single-wall substitute. now returned to the source in good quality. products use shelf-ready packaging The use of a suitably strong corrugated “European paper and board has compared with 40% of non-discounters’. product as a substitute for wooden packs managed to de-couple economic growth The discounters make use of corrugated brings significant weight reduction, from environmental impacts: we have packaging’s eye-catching designs and improving logistics and handling, and dramatically reduced not only our carbon efficiency within the shelf-replenishment providing cushioning for sensitive heavy emissions but our overall environmental process. Supermarket discounters are the products. This creates a more printable impact as well – and performance is still fastest-growing European retail sector. outer surface, and circumvents the improving. Global food wastage amounts German discount pioneers Aldi and regulations concerning pest and insect to as much as 1.3 billion tons, or a third Lidl are the two front-runners across the damage in wooden packs. of food produced worldwide,” he adds. continent, enjoying increasing market In terms of sustainability, Jori Ringman, “Paper packaging can be part of a solution share. The Schwarz Group, owner of Lidl, CEPI’s sustainability director, is clear on to alleviate this serious problem by and the Aldi group are forecasted 5.0% paper’s benefits: “Paper-based packaging minimising waste and food damage along and 3.5% growth a year respectively for the has a good environmental track record the chain.” next five years, compared with mainstream throughout its life cycle, starting from Corrugated packaging has become an retailers at less than 2.0%. At Lidl stores, the fact that wood fibres are renewable integral part of people’s daily life. A recent an entire cross-section of food and and recycled to a high degree. In French study by Ifop showed that 94% household items is displayed in corrugated addition to being renewable and recyclable, of respondents thought cardboard was shelf-ready packaging. it is also biodegradable and compostable.” suitable for packaging and protection, with 90% claiming they regularly buy products packaged in cartons. Most people emphasised the practical aspects of boxes (87%), finding them easy to open (81%), solid (80%) and reusable (69%), and 70 –80% of consumers include the ‘green’ factor of a product in their buying choices. Some consumers are even willing to sacrifice performance for a product that has taken the environmental impact into account, and this increasing concern over the environmental impact of packaging has pushed producers and brand-owners to reduce the amount of material used in Carrefour Belgium teamed up with a local illustrator to give its packaging an enduring, post-life appeal. the production of packaging.

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PCI037_006_Paper packaging.indd 16 14/04/2015 08:14 Company insight > Paper & board The secrets of faultless high-speed labelling Labelling calls for high-level precision and makes tough demands on all the components involved in the process. John Tucker, commercial managing director at Metsä Board Zanders, explains the crucial properties of the perfect label paper.

ottling drinks is one of the final stages in the Bottle labels are exposed to tremendous value-added chain for food production. The filling pressure and friction on the conveyor belt. B systems used here are highly complex, and interlinked production lines must achieve maximum performance. Interruption of the production process will cause delay, resulting in significant financial loss – especially when it comes to luxury and premium products. Bottle labelling, as part of the industrial bottling process, is a high-tech affair. The labels are first placed in a magazine, from where they are picked up at high speed by grippers. Glue is applied to them at the same time, and the label is then attached to the bottle. All parameters must be perfectly aligned to ensure problem-free operation at maximum capacity. The label prevents the labels from floundering during adhesion, so paper is particularly important at this stage, with regard to they can be fixed on the faster and more how it responds on the machine and how efficiently it can efficiently, and be positioned accurately. be applied to the bottle. Tough stuff Paper properties Since vigorous jostling dominates filling lines, labels have No element in the labelling chain is as important as the to be able to withstand these conditions. When bottles paper. Any measures taken here to make savings will not come together on conveyor belts, labels can be exposed pay off in the long run. The technological properties of the to tremendous pressure and friction. Nevertheless, the paper must be optimally balanced to satisfy the strict wet surfaces of the labels must not be damaged. Here, demands of a high-performance process. cast-coated label papers, such as Chromolux, provide According to John Tucker, commercial managing director excellent wet strength. at Metsä Board Zanders, the most important properties for For optimum results, it is important that the natural curl fault-free labelling are flatness, low curl, a rough and optimised of the labelling paper does not impede functionality after back, and optimised expansion and contraction response. gluing. If paper becomes damp, it tends to curl upwards, “Chromolux labels from Metsä Board Zanders are known and labels with excessive curl can no longer be positioned for having high tensile strength, even in wet conditions. accurately on the bottle. Thanks to the rough reverse side, they can be precisely “The curl of a labelling paper is determined by the positioned on containers, and subsequent shifting of the label direction of the paper fibres,” Tucker explains. “This is prevented. The excellent fibre formation of the base paper depends on the direction in which the paper mass passes ensures that labels do not crease or blister,” says Tucker. through the paper machine. During production, the fibres When it comes to adhesion, different paper properties are aligned parallel to the paper path. A curl forms are crucial. If labels have a rough reverse side, they transverse to the direction of the fibres.” require less glue. “This is because only the ‘mountains’ This must be taken into account during printing of the rough surface have to be moistened with glue,” and when cutting the labels. Therefore, with all labels, explains Tucker. Less glue means less water, and the less the direction of the paper fibres must run horizontally in water is used for labelling, the better the adhesion. relation to the upright bottle. Naturally, as well as improving production, this also leads

to reduced costs. Further information In addition, the absorbability of the paper is important Metsa Board Zanders for perfect adhesion, which also depends predominantly www.metsaboard.com www.zanders.de on the properties of the reverse side. High absorbability

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PCI037_Metsa.indd 17 13/04/2015 14:54 Containerboard from Stora Enso Let’s talk about success

We at Stora Enso know that there is only one way to As a 360° solutions provider, we have a holistic view, succeed; by always being one step ahead – identifying your needs and solving problems together with our customers. And we are. regarding runnability, materials, productivity Success to us is making your everyday business bottleneck, etc. The outcome is better grow. To help you achieve that, we’re launching performance, higher profitability and the our 360° solutions provider offer. It derives from optimised application of our world-leading our insight that high quality containerboard products. So let’s not just talk about success. products deserve high quality services. Being our Let us show you how your 360° containerboard customer, you can always benefi t from a unique solutions provider can enhance your business in combination of expertise within both fields. a new and successful way. Today and for the future.

PCI037_StoraLetsTalkAboutSuccess_EN_210x286mm_Veracel_2.indd Enso.indd 1 1 13/04/20152015-03-17 10:1807:19 Company insight > Paper & board Consumers say sustainable material is future of packaging Stora Enso Packaging Solutions has published a report on the future of packaging for millennials. It is estimated that this age group will constitute nearly half of the European workforce by 2025, making it a generation that brand-owners need to be targeting.

than 2.8%. The preference for sustainable fibre-based packaging materials among the next generation of consumers is an important factor for the growth of the industry. The future prospects of corrugated converters are good. Brand-owners will need to make sustainable fibre-based packaging a more central part of their marketing strategies. In turn, the growth of the industry and the opportunities that arise from it will require new capacity and approaches from containerboard providers.

Packaging performance starts with containerboard Stora Enso Packaging Solutions introduces the new 360° solutions provider offer for containerboard. Customers will benefit from a holistic approach to products and services to help them become more successful in their packaging businesses. Fibre-based packaging should be a more central part of marketing strategies. The company has also launched, together with the 360° solutions provider, three new product brands: s it is forecast that millennials will constitute an ■■ Stora Enso AvantFlute increasing proportion of the consumer population ■■ Stora Enso AvantLiner A over the next 15 years, brand-owners need to be ■■ Stora Enso AvantKraft. considering how to appeal to this particular demographic, especially as four out of five young people born between AvantKraft will enter the market in Q4 as Varkaus mill 1980 and 2000 state that packaging has an effect on their (Finland) starts production of kraftliners. AvantFlute and purchase decisions. AvantLiner are already available for delivery from Heinola Fibre-based packaging is, in fact, the preferred choice of mill (Finland) and PM5 (Poland). the next generation of consumers, according to Stora Enso The unique Avant-family of Nordic virgin fibre and Packaging Solutions’ Viewpoint report, entitled Future of recycled fibre products, combined with Stora Enso’s Packaging for the Millennials. Of those surveyed in study, high-quality services such as technical customer service, 88% considered fibre-based packaging materials, such as eFlow, recycling service, rightweighting and rightgrading, containerboard, to be sustainable. will help customers to improve their material selection, With this insight, brand-owners need to be thinking productivity, flow efficiency and recycling. carefully about how they can make their branding and Stora Enso’s long history in the corrugated converting packaging strategies fit with the values and preferences business has given the company exceptional experience of this demanding group. Converters will need to find in creating innovative packaging solutions, as well as new solutions to the increasing demands of brand-owners deep insight into combining design with material expertise. to help them drive sales and reduce total cost and In essence, Stora Enso takes a holistic view on customers’ environmental impact. containerboard product and service needs.

A promising future Containerboard is the largest fibre-based packaging Further information Stora Enso Packaging Solutions market, with an annual volume of more than 150 million www.storaenso.com/360solutionsprovider tons/year and long-term growth expectations of more

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PCI037_Stora Enso adv.indd 19 13/04/2015 14:55 WANT TO TAKE THE WEIGHT OUT OF YOUR PACKAGING? Then the choice is easy

Choose ALASKA PLUS for a packaging board

Alaska Plus, the new GC2 board from International Paper makes it easy for you: it brings together excellent product benefi ts with a signifi cantly lower basis weight and an improved yield. Alaska Plus combines effi ciency with perfect protection in the packaging. It’s the new strength of lightness.

ALASKA PLUS is available in: 190 g/m² 205 g/m² 220 g/m² 235 g/m² 255 g/m² 270 g/m² 280 g/m² 305 g/m² 330 g/m²

High quality packaging for pharmaceutical, cosmetics / hair coloration, chocolates, confectionery and dry food products

www.alaska-plus.com

PCI037_InternationalAZ_210x286+3mm_AlaskaPlus_E.indd Paper.indd 1 1 13/04/201523.03.15 12:3110:17 Company insight > Paper & board A lightweight paperboard for the packaging industry International Paper is a global leader in the paper and packaging industry, with manufacturing operations in North America, Europe, Latin America, Asia and North Africa. Commercial director for coated paperboard and recycled specialities in EMEA, Michael Krüger, discusses the company’s new lightweight GC2 coated paperboard, the Alaska Plus.

veryone knows that the packaging industry is under a With Alaska Plus, International Paper can offer a lot of pressure at the moment, with often contradictory lighter-weight folding boxboard. E demands coming from all sides of the debate. Consumers and regulators want packaging to be environmentally friendly and sustainable, and clients want to keep costs down and bring value to their customers. It was these complex needs that motivated International Paper to develop its new lightweight GC2 coated board, the Alaska Plus, says Michael Krüger, who works as commercial director for coated paperboard and recycled specialities at the company’s sales office in Düsseldorf, Germany.

Alaska Plus combines the benefits Easy switch of our renowned Alaska board Packaging converters and brands will find it easy to switch to with a notably lower weight: Alaska Plus from the standard Alaska product without having to make any performance-related adjustments, says Krüger. A key great stiffness, excellent strength priority has been to allow sufficient time for a smooth transition to and durability, as well as industry- the new Alaska Plus board, and the final switch is planned to be leading quality consistency. completed by the end of June this year. As of July, Alaska Plus will be the only GC2 board produced at the Kwidzyn mill. “We are working closely with our customers and all internal Excellent and effortless stakeholders to ensure a seamless transition to Alaska Plus. Many “The performance of Alaska Plus in printing, converting converters and brand-owners have already transitioned their and packing is as excellent and effortless as our customers business successfully and are enjoying the commercial and would expect from a product with Alaska in the brand environmental benefits of this lightweight folding boxboard.” name,” says Krüger. “Using the latest technology in board The Alaska Plus board comes in nine basis weights: 205, 220, making, we have been able to lower the basis weights by 235, 255, 280, 305 and 330g/m². Two basis weights of 190 and 5–7%, while keeping all other technical parameters stable. It 270g/m² are the latest additions to the the range; 190g/m² replaces combines the benefits of our renowned Alaska board with a the standard Alaska 200g/m², offering the same performance in notably lower weight: the same great stiffness, excellent packaging products with a 5% yield advantage. This basis weight strength and durability, as well as the industry-leading has a unique position on the market, as it is the only high-stiffness quality consistency that brings reliability for high-volume GC2 board product below 200g/m². The 270g/m², or 500µm, is an packaging production and fast packing lines, and it now has additional grade that allows customers to benefit from the tighter- a revolutionary light basis weight.” stacked caliper range of Alaska Plus. Developed as part of the company’s modernisation “With these two new basis weights, we are able to offer a scheme at the Kwidzyn mill in Poland early last year, more comprehensive range of products, making it easier for Alaska Plus is dramatically lighter than its predecessors. our customers to select the right quality for their specific Its lower weight decreases the environmental impact and packaging needs,” says Krüger. cost at every stage of the product’s life cycle. It uses fewer resources during production and creates less waste. Alaska Plus has been designed for pharmaceutical, Further information International Paper healthcare and beauty packaging, as well as chocolate www.alaska-plus.com and dry-food applications.

PACKAGING & CONVERTING INTELLIGENCE | www.pci-mag.com 21

PCI037_International paper.indd 21 13/04/2015 14:53 The packaging solution that suits you

AR Metallizing’s innovative metallized paperboard is sustainable, cost-effi cient and highly functional, matching individual applications’ needs.

AR Metallizing offers packaging materials with a wide variety of barrier properties, protecting products against harmful environmental conditions, such as temperature, radiation and humidity, without making any concessions to design or appearance.

This makes AR Metallizing’s metallized papers the ideal base product for innovative, cost-conscious and environmentally aware consumer goods manufacturers.

www.armetallizing.com

PCI037_AR Metallizing.indd 1 13/04/2015 10:13 Company insight > Paper & board Metallised paper makes a strong case

Making labels and containers for the food and beverage industry, AR Metallizing offers a type of metallised paper that is hard to beat when it comes to strength, protection and retention. And if that wasn’t enough, it also claims to be the most environmentally friendly and cost-efficient packaging solution for the sector.

R Metallizing is the global leader in metallised such as schools, universities or governments, which can, high-end packaging solutions for the beverage, food, at the same time, combine the functionality of metallised A consumer packaged goods and personal care paper with the opportunity to distinguish themselves industries, and counts many of the world’s largest consumer through visually appealing packaging. goods companies among its end users. Every day, millions of consumers in more than 100 countries Thermal qualities have AR Metallizing’s materials pass through their hands, be Moreover, AR Metallizing’s paper has exceptional it in the form of a beer or spirit bottle label, a food or consumer thermal-retention features, adding extensive functionality goods container, or one of many other products. to food and beverage packaging. One of the world’s largest brewers uses AR Metallizing’s paper for its six-packs, the Good-looking protection packaging for which resembles a great-looking cool box. In AR Metallizing’s view, the functions of high-quality Beers also stay cold substantially longer than they do in packaging are twofold. First, packaging should give the conventional packs – in a comparative test, after 1.5 hours packaged goods an attractive appearance, which is a key of being in the sun, the temperature difference was more feature for manufacturers who want to make their products than 4°C. stand out, improve their image and boost sales. Due to its In the same way, AR Metallizing’s paper is used to distinctive ultra-gloss, metallic finish, extensive design prevent chocolates from oxidising (fat blooming), fresh possibilities (including holograms) and printability in nearly food such as fish or meat from perishing, and frozen food all technologies, AR Metallizing’s paper can guarantee from defrosting between the shop and the freezer. It also attractive packaging, which helps premium brands to retain works the other way round: a burger wrapped in AR their position in the market. Metallizing’s paper retains its heat much better than it Secondly, packaging should protect the goods from does in conventional packaging made of harmful environmental conditions, such as temperature, and paper – after an hour, the temperature inside the radiation and humidity. AR Metallizing produces a wide package is almost 5°C higher. range of metallised papers, thanks to the many qualities of To conclude, AR Metallizing’s products have barrier its paper, each one with specific barrier properties. This properties that meet the requirements for a wide variety makes it possible to find a perfect match between the of consumer packaged goods such as beverages, food and converters’ barrier properties requirements and the personal care products. But they also have all the usual characteristics of the used metallised paper, leading to the benefits of AR Metallizing’s paper: the environmental most environmentally friendly and cost-efficient impact is substantially lower than that of conventional packaging solution. alternatives such as foil – the use of aluminium is reduced AR Metallizing’s papers have moisture vapour transmission by a factor of 300, and the product is fully recyclable and rates (MVTR) of between 0.5 and 5.0gsm/m² a day in tropical compostable. In addition, AR Metallizing’s paper can be conditions, making it the perfect packaging for perishable processed at high speeds and printed with nearly all goods that require medium protection against moisture existing technologies. transmission, such as dried fruits or grains, spices, nuts and Together, these qualities make AR Metallizing’s paper chocolates. In addition, it protects against UV radiation and an ideal base product for innovative, cost-conscious and has an oxygen barrier functionality, promoting the environmentally aware consumer goods manufacturers. conservation of the packaged food. As it is greaseproof, protects against condensed steam and has a great wet strength, AR Metallizing’s paper is also Further information AR Metallizing an ideal base material for packaging take-away meals. It www.armetallizing.com can thus be used by quick-serve restaurants or institutions

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PCI037_AR Metallizing.indd 23 13/04/2015 14:47 Insight > Paper & board

Hybrid and mighty With hybrid technology fast becoming of interest to the packaging industry, Feldmuehle Uetersen held a round-table discussion with leading dry-goods brand-owners to discuss an innovative packaging material combining polypropylene films and paper, HybraPack. Over the course of the evening, company representatives gave details on this new solution and the guest attendees were also able to offer their insights as to where this technology could best be applied.

elegates from the dry-goods innovation. Matthew Rogerson existing designs and expectations. We industry gathered at the attended and was able to report on have been working on many different D Gilbert Scott hotel, London, events as they unfolded, providing a projects and ideas. UK, to discuss a new technology, snapshot of an evening that offered For many years, paper has been HybraPack, produced by Feldmuehle insight into commercially viable able to adapt, but it still has some Uetersen and Treofan, which provides developments as well as a positive limitations. That is the beauty of the an innovative combination of sense of direction for the delegates. idea of combining materials to provide materials to create a new type of When everyone had settled into their a new and better product that stand-up pouch material. seats, Feldmuehle’s Eckhard Kallies addresses weaknesses of stand-alone Over the course of the evening, began the discussion. materials by combining them into a attendees discussed the challenges better product. of the industry, consumer knowledge Eckhard Kallies: We think it’s time and regulatory developments, and to test what paper can do to help Marcus Weise: The paper provided invaluable understanding of improve shelf appearance and industry focuses on ‘reduce, reuse what they are looking for in packaging package functionality, and challenge and recycle’ as its mantra. What we

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PCI037_015_Stora Enso.indd 24 14/04/2015 08:31 Insight > Paper & board

were interested in is how to get to the next step of innovation given our Company representatives experience and expertise. nnEckhard Kallies, director of sales and marketing, Feldmuehle Uetersen When we look at packaging nnJeannette Kuhanen, marketing manager, Feldmuehle Uetersen development, there are six nnMarcus Weise, business development director, Feldmuehle Uetersen criteria a new product has to fulfil: nnDr Marco Holst, head of business development for packaging, Treofan attractiveness, convenience, food/ product safety, and it must be economical, ecological and run on Dr Marco Holst: As most of us solution works much better as a existing lines. are aware, there is a lot of attention functional barrier against water and If it can perform these, then it should on mineral oil legislation, being oxygen than a polyethylene-based be relevant to support new product led by Germany, which is currently laminate without aluminium foil. development, and should create a in the third draft of reviewing the Our hybrid has been reduced to usable and beneficial innovation. acceptable amount of chemicals in a metallised two-layer structure, the It looks and feels like you would packaging that can be allowed to barrier properties of which are expect, which is like a standard migrate into food upon contact. comparable to existing multilayer pouch, so why would one wish to Essentially, the focus is to aluminium-foil laminates. change from today’s flexible film reduce this to the lowest amount The obtained barrier properties for pouch into a fibre-based hybrid film acceptable, which means you need this solution are: material such as HybraPack? the best possible functional barrier ■■ oxygen: <20cm3/(m2*d*bar) at 23°C There are some immediate points to protect your product, extend its and 50% relative humidity to consider. We have changed the shelf life and reduce the number of ■■ water vapour: <0.2g/(m²*d) at 38°C paper and not the coating, so you contamination instances. This has and 100% relative humidity. can replace a rigid box without been solved by developing a hybrid sacrificing any of the integrity or solution of paper and a film. Instead of a carton and inner bag, aesthetics. The material runs on Another new prototype is a you can integrate into a pouch the existing pouch lines and reduces metallised hybrid solution with a seal, a spout or a zipper by using a material use by up to 50% against five-layer BOPP film on paper. It is hybrid solution. using boxes. Finally, it is the same a temperature-sealed solid film with This has been demonstrated in size as a carton, so there is no loss 5N/15mm of seal force, but we believe another of our concepts, which of space and it can be taken straight we can increase this to 10N/15mm in concerns ultrasonic sealing the hybrid from the reel to be filled. It’s easy to the not too distant future. material containing 140g paper and 7g fold and put into waste too. With this development, HybraPack BOPP film. As it is a hybrid design, it is neither can be sealed with similar results to For this solution, the seal force is a flexible pouch nor a rigid box; it polyethylene films, so there is no loss 5–8N/15mm and, depending can include a handle and takes less of seal strength or increase of leaks. In on the chosen material, seal strength space through the supply chain. Less addition, the metallised hybrid up to 10–15N/15mm can be achieved. space means less energy – you can transport more and associated costs are reduced. So it takes less to make and goes through the supply chain to the consumer. With regard to lightweighting, the hybrid packaging has all the features of the film with no weight, and all the strengths of the paper. As it is rigid, it is also strong – unlike flexible films – and we believe it can replace flexible films as well as rigid boxes for markets like biscuits, dry goods and cereal. It matches all the criteria mentioned above, including the fact that you can run more reels through transport than you can send boxes, so you can move Delegates were impressed with and showed support for the innovative concept. greater amounts more efficiently.

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PCI037_015_Stora Enso.indd 25 14/04/2015 08:32 Insight > Paper & board

We do this because consumers like than current products to ensure the paper, and it is better than trying to best fit. It’s a good foundation. HybraPack make BOPP film act like paper. We HybraPack is a novelty in the are initially aiming at the dehydrated- Kevin Vyse: It sounds like a fantastic field of modern hybrid packaging food market, like cereals, which you idea and a great development. It’s that serves as an example to will then add water to, so barriers also good to hear that, from your encourage dialogue on new packaging solutions. need to be able to hold liquid without investigations, this will run on HybraPack combines the degradation and also keep dry goods existing pouch lines. I think the characteristics of a firm and stiff moisture-free. difficulty is then transitioning to material with the flexibility of a carton lines, especially given the stand-up pouch. The enhanced display attributes Stuart Blythe: Product protection cost and supply this industry has built of the package offer an entirely is king for us. While cost and fit with over the years; it will be very hard new look and feel to consumers. other products, and sustainability to compete on price and end of life. In addition, hybrid packaging are considerations with any product, The question is where is the allows the combination of paper and plastic to maintain the protection is the number-one factor consumer problem that is being benefits of the materials in a for us. While we would be interested solved? I would encourage you to stand-up pouch to reduce in how this could help promote a take a look at where the packaging material use. product and the materials savings or product could be made better. afforded, it must protect the package If you go into the cartonboard pouches, and this is where HybraPack as its primary purpose. industry, there are going to be many provides a solution. If we can find the cost-efficiency barriers to overcome. right answers for our consumers in Phil Davidson: It’s an interesting For me, the next step is to say we design and give them the right development and well conceived. have this new product, what could aesthetics, we feel this will be a For us, it’s hard to articulate its true we better use it for? successful venture. For example, if application – the focus for McDonald’s we look at cereals, we see HybraPack is recyclability and end-of-life MH: We see the stand-up pouch as a more convenient and efficient scenarios. I would need to know a little as the faster-growing category and packaging type. more about the end-of-life information are concentrating on this. Although for the product and whether it can be cartons may be less expensive, the Antoinette Devine: For us, it’s not more easily recycled of disposed of market is moving from them to just about packaging beer. We have a very diverse African business that handles juice, sachets and various The best of both worlds: hybrid packaging combines the characteristics other non-alcoholic items. There is of stiff materials with the flexibility of a disrupted supply chain and material stand-up pouches. consistency is difficult at high volumes. This could be useful to reduce material dependency and provide more consistent product protection for supply chain in this part of the world.

Richard Gamble: With rigid packs, presentation, branding and graphics are a constant challenge. For example, with the glare we have in store, this seems like something that could provide a strong branding presence as a package type. I think it would add a real benefit for the on-shelf presence, keeping the best of paper’s print and graphic attributes intact.

Peter Singleton: From a product perspective, you have to have one that gets the consumers’ attention. We use

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PCI037_015_Stora Enso.indd 26 14/04/2015 08:32 Insight > Paper & board

Hybrid packaging can be used to hold a multitude of contents, including food and non-food products. Guests  Stuart Blyth – principal scientist for global packaging, Mondelez  Doug Boodrie – global category leader, Associated British Foods  Phil Davidson – sustainability manager, HAVI Global Solutions  Antoinette Devine – global packaging and materials consultant, SAB Miller  Katarzyna Drzazga – packaging buyer, Nairns Oatcakes  Alasdair Ferguson – packaging technologist, Boots UK  Richard Gamble – buyer manager, Reckitt Benckisser  Richard Inns – PEC Partnership  Dr Lars Lundquist – packaging environment sustainability expert, Nestlé Research Centre  Richard Parker – head of the four Ps when we look at a new compliance to child safety and senior- packaging, United Biscuits package type: product, packaging, friendly packaging to be incorporated  Sahab Satsangi – pack change price and prospects. As long as it in all its designs. If you can develop manager, GSK provides something more to each of with these needs in mind, you could  Peter Singleton – principal scientist/engineer, P&G these areas, it will develop into a get our attention.  David Tokin – packaging potentially better product than what development manager, 2 Sisters we are replacing. Also, you have to be David Tokin: Previously, there was  Kevin Vyse – primary food careful with printing and decorating. a pouch product in the market called packaging technologist, Marks & Spencer Little Stars, which did OK, but it Lars Lundquist: End of life is very was eventually withdrawn. This important, and if these materials application would have worked quite Take-home key points provide an 80% reclaimed materials well with it as it would have given The evening had been a lively one and and energy use rate, it would of course that natural feel and texture on the led to a number of key discussion points, be interesting as it would support package that parents are looking for from thoughts on what direction the wider sustainability objectives when they get products for their kids. legislation would take next to debate of the company. about how this product fits into a holistic At the moment, cereal boxes are KV: I think you have come up with approach to packaging and sustainability separated from the inner lining, and some great ideas, and the next step is that is being widely adopted by the that makes it much easier to stream to tie it into consumer insight. These industry. The gains in material reduction and recycle them at end of life. are the questions that need to be asked: were appreciated and delegates had Laminating directly onto the paper, ■ Is the idea driven by real asked for further information on what like this HybraPack does, could cause consumer insight? happens at the end of life regarding an end-of-life issue, making it harder ■ What problem is being solved from recycling or waste streaming. to separate, stream, recycle or reuse the consumers’ perspective? To them, it is just as important to the materials once the consumer is ■ Is it commercially viable or is it reduce the size or weight of the finished with it. just a short-term win? material used to package the product as If there is any material ■ Is it sustainable? it is to be able to dispose of it effectively contamination, it is a big problem. once it has served its purpose. There If there is more waste created, or it These are the dynamics we would was a lot of support in the room, and cannot be reused effectively, then it look for in any innovation. delegates are eagerly looking forward to is counter-productive to change from further developments from Feldmuehle existing products. DT: We would be interested in using Uetersen as it continues to shape As long as you are mindful of these this type of technology, but it’s worth HybraPack for the future. issues, you should be able to develop bearing in mind that the EU way of a successful product putting things into the market is At the time of the dinner, Feldmuehle slightly different to others. In the UK, Uetersen was trading under its previous Sahab Satsangi: GSK needs there is more of a focus on a premium name of Stora Enso Uetersen, which it transparency, traceability, and look and feel. ceased to use in February 2015.

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PCI037_015_Stora Enso.indd 27 14/04/2015 08:33 Company insight > Food & beverage Protective paper can save your produce With healthy eating firmly on the menu and customers more quality-conscious than ever, fruit and vegetables need to arrive in perfect condition, often after travelling thousands of miles. Robert Vænerberg, vice-president of sales and marketing at Powerflute, explains how the firm’s semi-chemical fluting paper provides the strength that reliable corrugated packaging requires.

s consumers go about their weekly grocery shop, the bottom panel is very important. Semi-chem allows boxes selecting the most aesthetic vegetables, they will to maintain their structure for much longer periods of time.” A rarely have a thought for the paper used in the boxes in which the produce arrived. Growers and Right paper, right purpose distributors, meanwhile, are all too aware that such Alongside its world-class strength, Powerflute also has a considerations can mean the difference between success high price tag, as Vænerberg is the first to admit. Its use and failure. Robert Vænerberg, vice-president of sales and must therefore be justified. marketing at Powerflute, explains why the stakes are so high. Most of the mill’s output goes into boxes for transporting fruit “We all know that if customers see a product that looks and vegetables, while the remaining 10–15% is used for more slightly damaged, they will reach for the one behind it,” he traditionally high-value electronic and manufactured goods. For says. “We rarely buy things that don’t look pristine. Millions sturdier products, shorter distances and more lenient conditions, of tons of fruit and vegetables are sent around the world, if recycled paper is often adequate – which is why Vænerberg sees boxes fail, the damage to the product inside and to your the industry’s two tiers as entirely interdependent. business, not to mention the whole ecological system in “We, the virgin fibres industry, would never be able to terms of the amount of food thrown away, is immense.” provide for the world’s needs for corrugated boxes without the recycled paper industry, and the latter would be unable Raw potential to make its paper if we weren’t adding new fibre into the From its Savon Sellu mill in Kuopio, Finland, Powerflute chain all the time. So it’s a complete symbiosis,” he says. produces its eponymous semi-chemical fluting paper. Made “The recycled paper industry, in many ways, gives virgin wholly from birch – which is in plentiful supply in the country fibre its green credentials. Our papers are being recycled at and is known for its stiff fibre – Powerflute is one of three an extremely high rate, and the paper industry is one of the Nordic ’semi-chems’ produced worldwide. Over half of its best recyclers of any industry in the world.” business is in Europe, but it also supplies to corrugators in Asia, The ecological responsibility that does come with virgin Africa, Latin America, North America and the Middle East. paper, Vænerberg emphasises, is ensuring that forestry The pulp in the so-named ‘semi-chemical’ process is practices are sustainable. In that regard, Savon Sellu’s cooked for only 15–30 minutes so as to maintain the location is its greatest asset. Finland’s natural wealth in trees wood’s natural compounds, such as lignin and and water, and its longstanding environmental policy, give hemicellulose. These natural components mean no weight to Vænerberg’s argument that paper milling is an other additives need to be used. agricultural enterprise like any other. The pure raw material and lack of additives mean the “Finland as a country has been a leader,” he says. “We product meets all food packaging standards, but the main have had sustainability enshrined in our legislation since the advantage of the production process is the paper’s ability to late 19th century. Way before people started worrying about withstand humid conditions; while paper is hydroscopic, the sustainability, Finnish legislation specified that if you cut hemicellulose within semi-chemical paper protects the fibre down a tree, you had to plant four new ones.” from the effects of humidity. It’s an ethos at the heart of Savon Sellu’s practices: “In the a case of a box of food that’s being transported for Powerflute uses only PEFC-certified wood, procurement of several weeks in a container, you will quite often have which is certified by the FSC Chain of Custody. This ensures 90–95% relative humidity in the air, and that is gradually that its product is made only from wood harvested from assumed by the paper inside the box,” Vænerberg says. sustainably maintained resources. “If you think about a high stack of fruit trays, if the bottom tray collapses, the whole shipment can be destroyed. Equally, if the bottom of the tray bulges downward from the weight of Further information Powerflute the fruit, it will press on the top fruit in the box below, which www.powerflute.com may render those unsellable. So the strength of the box and of

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PCI037_Powerflute.indd 28 13/04/2015 14:55 Insight > Food & beverage

Nearly every FMCG brand-owner and major retailer has a strict sustainability programme in place. New materials and innovative packaging developments are playing important roles in these programmes, as are consumers’ perceptions of value and performance – particularly when it comes to food packaging.

Customer collaboration At Leading Edge Labels & Packaging, Food an award-winning flexographic label and packaging company based in Kent, UK, working with clients to develop packaging that addresses their sustainability targets is all in a day’s work. Business development for thought and marketing manager Sara Lane regularly meets new and existing clients ast-changing regulations for working with suppliers to cut raw material to explore their packaging needs. food and beverage packaging use and implement smarter packaging. “We offer a broad range of labels and F are matched by the evolving “We’ve got some really exciting, packaging created with sustainability in consumer perception of value, with innovative food packaging ideas that mind,” she explains. “We work a number performance following closely behind. So are working really well,” he explains. of major multiples, FMCG brands and how do brand-owners and major retailers “We have an in-house customer insight various own-label products, and deliver make sure they are doing the right thing for team, direct in-store customer feedback something a little bit different to add business, customers and the environment? and customer panels. One of our newest value, enhance brands and, most ways to listen to the customer is at-home importantly, help drive sales.” Super market? feedback: shoppers give real-time feedback Lane explains how the company is For Shane Monkman, head of packaging on packaging in their own homes by using regularly asked for packaging that uses procurement and supplies at Asda, the their tablets or smartphones and uploading sustainable materials and, in response, goal is to maintain shelf appeal while the videos for us. Leading Edge has developed Bio-Bands, reducing the volume of packaging and “We see the customer talking naturally; an easily recyclable wrap for fruit that raw materials consumed. Responsible they explain how easy packaging is to cuts packaging while retaining shelf for teams in the UK and China, Monkman open, what the portion size is like for a appeal. The company is also looking is committed to the firm’s philosophy of real family, whether or not they need a at a number of different finishes and listening to its customers to gain insight knife to get into the package… We see print technologies that use fewer raw into how products and packaging are it raw, and then use this insight to materials but keep brands visible, such as used, and then basing improvements on develop improved packaging.” specialist inks and holographic printing. this feedback. Asda cut packaging by more than a “We know that the major retailers Monkman’s experience with quarter between 2005 and 2011, and is have their own in-house teams to ensure strategically aligned corporate affairs teams on track to reduce waste by another 3% packaging is as effective and responsible in the UK and China enables him to note across the supply chain by the end of this as possible,” Lane adds, “but we also how the supermarket has “an aggressive year. As part of the Courtauld Commitment, work with smaller brands to deliver that packaging-reduction target” that led to the supermarket is also set to reduce the knowledge and expertise too; we look at increased recycled-waste control and embedded carbon in its packaging and has their production processes, suggesting reduced waste at source, as well as actively already slashed carrier bag use by a third. ways to reduce waste wherever possible.”

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PCI037_011_Food packaging_2.indd 29 14/04/2015 08:21 Insight > Food & beverage

Fishing for new ideas For brand-owners, the understanding that the right packaging choices can heavily influence consumer choices is well known, but striking the right balance between performance and ecological responsibility is also key to profitable growth. Colin Platts, packaging development manager for Young’s Seafood, the UK’s leading fish and seafood processor selling frozen and chilled fish under its own label and as retailer-branded products, understands how good packaging is a juggling act. “Consumers want to eat more fish, as they know the health benefits, but they Young’s is clear that corporate responsibility applies to its packaging just as much as its sh sourcing. also don’t really like touching fish,” he explains. “We also know it’s important fish is taken out, without being seen as a on in any meaningful way by any big to reduce the volume of packaging used separate product with confusion of how to retailers, but I believe that this is the best while making sure that customers get the recycle or dispose. It uses less raw material way to meet their strict sustainability experience they want – the experience as it’s built into the packaging itself. targets and to engage with consumers. of cooking delicious, healthy fish without “We are also currently working on a People don’t have money to waste, either. needing to touch it, or hardly touching it. really exciting product that can be straight- Yes, TTIs or RFID [radio-frequency “We’ve worked hard to create cook-in to-oven and straight-to-microwave – identification, or intelligent barcodes] are packs that are totally functional – there’s again, keeping the cooking experience more expensive than just adding a sticky no need to smell or touch the fish – but that consumers want while being totally label to everything, but when you consider the packaging essentially engages with functional with no waste, and keeping the the huge cost of waste, it is cheap. the consumer to make a pleasurable moisture and freshness in pack.” “What’s really needed is an effective cooking experience.” life-cycle analysis to show how smart Now part of the Findus Group, Young’s View from the association packaging that integrates condition was established in 1805, and its dedication Andrew Manly, communications director monitoring actually would save money to processing and supplying responsibly at the Netherlands-based Active and and increase profits, not to mention sourced fish has been part of its ethos Intelligent Packaging Association, has a giving retailers and brand-owners a new since the beginning. With responsible clear idea of how smart packaging can marketing tool with which to engage sourcing comes responsible packaging, be used for the benefit of suppliers, consumers,” he adds. and Platts is clear the company appreciates retailers and consumers. Clearly, there is a great deal of difference that “doing the right thing now and for “Packaging can be quite a conservative between sustainability in food packaging generations to come” is imperative across sector, with retailers and suppliers and using food packaging to support the whole product life cycle. thinking, ‘If it ain’t broke…’ – but it is sustainable practices. The former is The company’s ten-point ‘Fish for Life’ broke,” he says. “It’s unsustainable to use focused on using innovative biomaterials philosophy includes strict guidelines for ecologically unsound packaging, and the and reducing packaging volume, while ethical trading and social responsibility, volume of waste is also unsustainable. the latter looks at ways to use packaging as well as ensuring its packaging is as People know, or purport to know, about to reduce food waste across the supply effective and sustainable as possible use-by and sell-by labels, for example, chain. Both must work in tandem to through continual improvement. Young’s which play a huge role in the waste issue, deliver the most responsible solution for has been developing a number of chilled- but while the amount of food thrown retailers, suppliers and consumers. pack innovations with additional features away by consumers is well publicised, it’s While it may be cheaper to stick a use- built into the base of the trays to meet nothing compared with the retailers.” by date on products destined to be thrown these targets. Manly’s view is that by implementing away when it passes, this is not a cheap “This needs to be nice to touch,” and integrating smarter packaging, such solution overall. By understanding the says Platt. “It can’t be like the absorbent as time-temperature indicators (TTI), value of how smart packaging can be used cloth you get with meat, for example, as condition monitoring and better tracking, to save money and waste, such as micro- consumers don’t want to touch the fish foods would stay in an optimal state for perforated films to seal-in fish freshness, or smell the liquor. We’ve used surface longer, thereby reducing waste. with careful monitoring of the product life tension to capture the liquor instead, so it He explains: “Smart packaging, or cycle, the true meaning of sustainability stays trapped in the packaging when the intelligent packaging, has yet to be taken through packaging can be realised.

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PCI037_011_Food packaging_2.indd 30 14/04/2015 08:21 Company insight > Food & beverage A lighter packaging approach Ecolean has won a number of awards for its lightweight Lightweighting is a trend that is talked about a lot at the packaging solutions, the most recent being for its reclosing moment, and the brand-owners we work with are reporting device SnapQuick. Packaging & Converting Intelligence speaks improved environmental profiles, brand image and company with Anna Annerås, marketing director. reputation as some of the benefits of using our packs.

Can you provide a brief introduction to Ecolean? Which products might you be launching soon, Anna Annerås: Ecolean was established in 1996 and is a and can you tell us about their development? global packaging company with its head office in Helsingborg, We are launching a reclosing device called SnapQuick for our Sweden. We develop and manufacture packaging material, family-sized packages, which won the 2014 WorldStar packaging packages and filling machines for the liquid-food industry. award. It is important for us to stay true to our lightweight We have two packaging systems: one for refrigerated philosophy. SnapQuick weighs only 0.5g – substantially less than distribution, and an aseptic-packaging system for products that other types of reclosing features, such as screw caps. do not require refrigerated distribution or storage. We are also introducing an aseptic transparent package, Our packages have a unique form that enables our which was presented at the Anuga FoodTech exhibition in customers to differentiate themselves on the store shelves. Cologne in March. We have created a package in our Ecolean format for ambient distribution and storage. We see big What materials does Ecolean use, and what are potential for this package, especially in the juice, nectars and the environmental benefits? still drinks categories. The upgraded EL4+ aseptic filling We use as little raw material as possible. This affects the machine is about to be launched and offers a 33% added whole life cycle of the package, which is no less functional capacity for a maximum of 12,000 packs an hour. The new than that of many of our competitors but weighs half as system has been designed for enhanced user-friendliness, much – our 1L pack weighs only 14g. efficiency and less water consumption.

Further information: Ecolean www.ecolean.com

Clearly light!

Ecolean packaging weighs about half as much as conventional packaging. By using less raw material, combined with consumer convenience, we create unique packages with care for the entire product life cycle. Our size range spans from portion pack to family size, for both ambient and chilled distribution.

Don’t miss our brand new Ecolean Air Aseptic Clear - lets your product do the talking. www.ecolean.com

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PCI037_Ecolean.indd 31 14/04/2015 08:37 MAKES IT EASY TO DO THE RIGHT THING. SMALL CHANGE, BIG DIFFERENCE.

Consumers tell us that they want packages that are easier to recycle. Our new Tetra Top with Separable Top is the perfect solution. Just push in and peel off and the carton sleeve separates from the plastic top. In surveys, over 75% said it would encourage them to recycle more. Tetra Top is a small innovation which can make a big difference. Look out for the Tetra Pak circle. Our promise to protect: tetrapak.com/protection/innovation

Tetra Pak®, and PROTECTS WHAT’S GOOD are trademarks belonging to the Tetra Pak Group. www.tetrapak.com

PCI037_Tetra Pak.indd 1 13/04/2015 10:18

Tetrea re-cycle A4 Diary innov Rev2.indd 1 27/05/2014 16:20 Company insight > Food & beverage Will carton bring end to cans? Tetra Pak hopes to convert the world to its ultra-sustainable, ultra-modern packaging solutions, one tin at a time. Packaging & Converting Intelligence talks to senior company management about the firm’s practical packaging that has been more than 60 years in the making.

n the stark countryside of southern Sweden, a stone’s A space-saving solution throw from the country’s border with Denmark, the “Some retailers have made calculations. If they were to replace I Tetra Pak Recart offices and production facilities, all cans with Tetra Recart, it would be equivalent to actually located on the outskirts of Lund, hum with an optimistic opening about ten more shops for all the space they save. There Scandinavian environmentalism. are two topics that all retailers care about: price and the “It’s been a solid part of our corporate culture for a long environment, so those two fit well with our value proposition.” time,” says the company’s MD, Peter Jhaveri, as we sit down It’s hard to ignore Tetra Recart’s argument: that if ten to chat. “There’s a strong company culture, and in that billion cans were replaced with cartons, there would be culture there’s an element of closeness to the forests – this 150,000 fewer trucks on the road. Designed with thin layers is where we come from. of protective cardboard, plastic and aluminium, it’s also fully The climax of the first media tour of its kind, we’ve spent recyclable and 67% sustainable – for every tree cut down, the morning at the company’s factory. It’s a chance for another is planted. Tetra Pak to share its hard work, crash-test new products, Marketing director of Tetra Recart, Thierry Gihan, argues and make the case for Tetra Pak Recart on home turf. that the company’s focus on sustainability is also part of Released in 2003 as the world’s first retortable carton the value it can offer to customers – using Tetra Pack Recart wrapping, the product is a 100% printable, integrated packaging can help save on logistics in terms of cost and processing and packaging system designed for in-container environmental impact. sterilisation of food. Now the company is keen to show the “It’s the same in the retail chain because of the saving of versatility of the food it can pack, and the tour culminates shelf space, and of fridge space for the consumer,” he says. with a sampling of the more leftfield packaging options, “So sustainability is not only a good thing that we embrace at from hummus to Thai green curry, prepared by the the company, it’s also a value we offer to the rest of the chain.” company’s culinary adviser and resident chef, Kaj Knudsen. Retailers are not convinced by sustainability alone, so Tetra Pak must work to position the carton as a practical and Revolutionary technology economic alternative, offering higher space efficiency and Tetra Pak is on a mission to clean up the planet with its reduced packaging weight. It’s estimated that, in stocking Recart carton technology. The product, made of wood fibre their cartons, retailers can achieve a 30–40% reduction in sourced from forests certified by the Forest Stewardship store space, leading to supply chain savings of 10–40%. They Council, has been available in UK supermarkets since 2005. also weigh 64% less than a tin can, saving energy and It can hold anything that can be found in a tin can, from manpower costs in transportation. tomatoes and vegetables to soups, beans and pet food. As with many things related to food, it often comes down to “We’re particularly focusing on things that are already hearts and minds. Tetra Pak Recart technology is now used by developed or packaged in a retorted package, and trying to more than 140 brands, from Heinz and Knorr to Del Monte. The get that into cartons,” says Jhaveri. dream is to see even more big-name brands on Recart cartons. Tetra Pak calls it the “21st century alternative to canned Figures in Sweden demonstrate what the company has food”, but retailers are used to the traditional ways of doing accomplished through education, hard work and a solid things. Tasked with this hard sell is the company’s marketing campaign. In 2007, only 12% of beans sold in the marketing director, Thierry Gihan, who tells me that the country were packaged in cartons; now, it’s 57%. sometimes daunting ambition of the Tetra Pak mission is If all goes to plan, it won’t be the first time Tetra Pak has what he likes most about his job. revolutionised the packaging game, since it was the first to put “It feels almost like running a start up,” he says. “There’s milk in a carton. The firm’s founder, Ruben Rausing, famously so much market potential. This makes the journey exciting, quipped that “doing something that nobody else has done before pushing for change in such a large industry.” is actually quite hard”. A wry understatement, but his words still Whether cartons will replace cans is, of course, up to ring true, especially when it comes to the Recart product. the consumers. Since 2008 it’s been Gihan’s job to change their minds and he’s developed a three-pronged marketing strategy based on the benefits of cartons, for consumers Further information Tetra Pak and for the environment. “Retailers need the drive to www.campaign.tetrapak.com/tetra-recart/ change,” he says.

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PCI037_AB Tetra Pak.indd 33 13/04/2015 14:46 Insight > Food & beverage On the safe side On 9 December 2014, more than 30 delegates representing major food brand-owners and retailers from across Europe gathered at The Ritz London, providing a platform for like-minded executives in the industry to understand how to improve the effectiveness of their food safety in packaging. Matthew Rogerson was on hand to report on proceedings.

The dinner took place in the plush surroundings of the Ritz Hotel London.

ith some of the best and the evening, commenting that it was rare for the European Regulatory Food brightest in the industry to be in such nice surroundings before Contact Scene’. NIAS stands for W on hand at The Ritz London, moving quickly on to the topic at hand: ‘Non-intentionally added substances’; a panel was convened to discuss issues to emphasise that food contact is a vital all food-contact materials contain of food safety in packaging and pool issue and one that has seen an increased them and all food contains them, and their expertise to identify where the amount of media attention. the legislation requires that food- weak links that could be strengthened He explained that the area has contact materials do not endanger are, and find some positive direction and expanded from plastic contact with food human health. answers to incredibly complex needs. to now include inks, coatings, paper Oldring then went on to explain The panel was moderated by and other materials. Understanding the how different materials contain different Alistair Irvine, the food contact different classes of materials, and how NIAS. Non-fluoropolymers usually have compliance manager of Smithers Pira, they affect food packaging and are around 1,000Da of NIAS, so 1,500Da and and took in four separate presentations covered by legislation is an integral above is considered the basic guideline that provoked a lively back-and-forth part of addressing food safe packaging. to be safe for humans. Oldring then between the delegates and presenters. This led to the introduction of the first stated that ‘flavours, additives and The event began with an overview presentation, from Dr Peter Oldring of food-contact material exposure task’ from Irvine, who welcomed everyone to Valspar, entitled ‘NIAS – the challenge testing – commonly referred to as

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FACET testing – is the gold standard Metsä’s Kantsila and and best approach for measuring NIAS. Nykopp discussed This led to the first exchange of the the company’s traceability initiatives. night, with Irvine suggesting that a major challenge was for analytical science to unequivocally identify all chemicals shown and their toxicology. “That’s right,” Oldring agreed, “in-vitro toxicology testing is not sensitive enough currently. Ideally, we would have an extraction of a sample, followed by a simple ‘pass’ or ‘fail’, but that is not available just yet.” Irvine responded by pointing to testing in other areas of the industry. “There were some successful tools to test in paper, via the Biosafe project,” he said, “which had good methodology but foundered on sensitivity. Could they be contact for board, flexible and corrugated for machinery when processing materials. used to support this?” packaging, and that the legislation was Kantsila explained that lightweighting “Unfortunately,” replied Oldring, “as beginning to tie together. does not impact the integrity of the is the case with commission projects, Minna Kantsila, Metsä Group’s package, just its waste reduction. academia took over and created a tool sustainability manager, and Gunilla Irvine wanted to know if there was a more in line with academic principles Nykopp, sales support manager, took to trade-off between using virgin fibres and than one developed for industry to use, the stage to deliver the presentation. recycled board, as the recycled board but we will get there.” Kantsila began with a short might be cheaper, but is more open to Next to ask a question was Martin overview of Metsä, explaining that for contaminants and migration. Nykopp Kanert, executive director of the sustainability and safety, it is important responded by pointing out that Metsä European Printed Inks Association to know where the raw materials in the was seeing a lot of movement from (EuPIA). He wanted to know how packaging are coming from, something recycled board to virgin board, especially FACET as a testing standard could that Metsä is able to do through its in the area of adding functional barriers help solve problems with NIAS or ownership of the forests, so there is no to the paper, which requires virgin fibre, identify issues that need solving. gap in supply or any unknowns in terms but as this had an additional cost, it is “If you can get exposure low of the paper it can provide. not for all customers. enough, you do not need to identify the substance,” explained Oldring. “You are looking at a combination of Lightweighting is important to reduce the risk assessment, hazard and exposure. weight of the paper and ultimately reduce the FACET provides the exposure; the hazard comes from toxicology,” he said, amount of paper that is wasted, coupled with adding that toxicology is subjective CO2 emission reduction. and it’s hard to find common ground, but it’s the exposure that is most important to industry. In addition, lightweighting is Kantsila added that there is only a important to reduce the weight of the six-month window between cutting Keeping it light: safe and paper and ultimately reduce the amount the tree down and using it for virgin sustainable packaging of paper that is wasted, coupled with fibre, otherwise it must be used for a

Irvine closed the topic to move the CO2 emission reduction. different purpose. discussion forward to the second subject She summed it up by pointing out that In fact, there is a slight issue in of the evening: safe and sustainable a “consistent product is very important”, Finland at the moment in that the trees packaging, presented by Metsä Group. urging suppliers to have consistent paper are growing too fast, with 60% more Irvine pointed out the serendipitous grades so that there are no breaks in the growth than is harvested. This leads to nature of the timing, as the Confederation process, and to ensure that “the same a new problem if the trees grow too fast of European Paper Industries (CEPI) had quality and weight of paper goes into as there is no room for new trees, and announced only the week before that it every product”, in turn meaning that this can lead to oversupply that cannot was in favour of harmonisation on food there is no wasted energy or downtime be used for packaging.

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PCI037_015_Food safety packaging.indd 35 14/04/2015 08:34 Insight > Food & beverage

Kanert from EuPIA wanted to know and compromises that need to be made and testing were also given to if there was a figure of how much in order to best protect the product. the brand-owners. recycled content is used for food This led to the first questions from Delroy was impressed with the packaging. Nykopp said that she didn’t a brand-owner, with Thomas Delroy of openness of Metsä’s process but know off the top of her head but that it Carlsberg wanting to know about virgin pointed out that it was not an industry- mainly depends on the customer – and recycled fibres. wide practice. “This is really good,” he recycled board lines break down more “When you go with recycled fibres, said, “as it’s not the case across paper often than virgin – and it also depends you don’t control the source, so there in general or through the industry.” on what is being packaged; toys, frozen can be a number of contaminants in After this exchange, there was a foods and chocolate biscuits would all the paper that are difficult to track,” final point of discussion regarding the have different figures. he began. company’s R&D centre and its testing, which customers were encouraged to visit and experience for themselves. With virgin fibres, although it is cleaner to make Kantsila explained that this was mainly them, you still have to add some chemicals and in food as some markets, such as cosmetics, do not have the same additives to the paper. How much analysis is being requirements of their paper. put into this paper? What components are present John Bambery, chairman of BPIF and how might they impact the final product? Labels, wanted to know if Metsä was extending this information to other relevant sectors, such as toys or Roland Rex of Procarton interjected “However, with virgin fibres, pharmaceuticals, and Nykopp said it to say his association with recycled although it is cleaner to make them, was looking at multiple segments. cartonboard and virgin board. “This you still have to add some chemicals is the great advantage. You can use and additives to the paper. How much Labelling theory both types – virgin as it’s clean, while analysis is being put into this paper? The next topic was labels, presented recycled provides a further opportunity What components are present and how by representatives from Finnish pulp, to reduce costs and be sustainable. might they impact the final product?” paper and timber manufacturer UPM. “Recycling needs more work. For food Kantsila replied that a lot of testing Jay Betton introduced the subject, packaging, roughly 40% is recycled; its is done across all of Metsä’s mills on explaining that UPM is prevalent in all 50% [recycled] for virgin and 60% for this topic, with Delroy then asking areas but that food is its largest segment board used for food – when recycling, how transparent these findings are by volume of material sold, with 26% you just need to make sure not to and if they are being made available of labels, or 1.5 billion square metres, separate good virgin board.” to brand-owners. Kantsila said they in the market used for food – more Irvine commented that there are were and that there is transparency than double that of retail, the second- a number of advantages of paper. Its regarding all the chemicals used in largest segment, followed by logistics lower weight is good for dry food the process, with Nykopp adding that and then beverages. mainly, but there are lots of trade-offs the laboratory reports from the mills In this area, regulation is very important. With so many diverse materials and substrates, and so many different applications, storage conditions and other variables to consider, it can be very difficult to navigate. Having discussed the two main EU regulations, 1935/2005 and 10/2011, the latter of which is concerned with plastics used at every point in the manufacture of food, Betton explained the need to request a declaration of conformity from suppliers, as this contains detailed information on the materials and substrates being used in packaging. He ended by saying that focus should be on safe and responsible sourcing of materials, echoing the Procarton’s Roland Rex pointed out that recycling remains an issue that the industry needs to address. thoughts of the previous presentation.

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PCI037_015_Food safety packaging.indd 36 14/04/2015 08:34 Insight > Food & beverage

Next to speak from UPM was Oona industry and was astounded that there Koski, who discussed sustainability was no specification for product- efforts in more depth. As it has a contact materials on 42 crown cap complex value chain with different liners, and that she had had to work companies and materials involved, UPM’s backwards up the supply chain in order first step towards sustainability is to to get the information. She finished by know where the material being used saying that brand-owners need to know comes from and how it’s made. what they are getting and what is on One example of this is ecodesign, their product. where UPM quantifies the impact of the Procarton’s Rex agreed and made product, looks for the hot spots of the the further point that with the mineral biggest impact and how these can be oil legislation, converters are now mitigated. She explained the reasoning beginning to volunteer information with reference to raw materials, one of to the association in order to create the areas identified by the company. transparency in the supply chain. “So how do we reduce material?” she BPIF’s Bambery added that the asked. “We can downgauge material big issue was that “in today’s demand- Amanda Jones from Paragon Inks. so that there is less weight, and then based environment, everyone wants you address the hot spot with a practical in the process of packaging due to the everything yesterday, which prevents solution. We can also reduce the expertise it could provide brand-owners taking the time required to properly

environmental impact of labelling or CO2 looking at safe food packaging. check everything.” emissions to improve sustainability.” According to Jones, as a tertiary He said that BPIF had published a UPM found that when you lightweight, supplier to the industry, Paragon feels it’s checklist for labels, but if there was no you actually reduce the impact across vital to understand the brand-owners’ time to go through the list thoroughly, multiple categories. needs in order to ensure it provides then mistakes will be made, adding that Koski then discussed UPM’s RafCycle their customers, the converters, with the as a sector, pharma is good at this, but recycling concept, which looks at end- best possible products. There are many the rest of industry is far behind. of-life scenarios and recycling. She questions that Paragon can provide the Bambery finished by saying the explained that end-of-life questions answer to and also a lot of questions printers, label and carton companies should be part of the thinking right at its customers need to address: what have to segregate into specialist the beginning of the process. print process is being used? What’s the companies rather than operate as “Before deciding on a product or specification? What plates? Is it high general packagers in order to avoid choosing materials, think about what definition? What substrate is it going on? trying to service too many markets and happens at the end of life,” she said. How fast does it need to dry? not being able to do any of them justice. “One solution is in more-sustainable The more the customer can be After an evening of lively, insightful base panelling – RafCycle closes the loop involved in the discussions from the and good-natured discussion, the with liner material, creating new material outset and the more transparency that closing comment went to Carlsberg’s from waste to give the waste a new life.” exists, the quicker solutions can be Delroy, who brought up the circular Sam Hyde from Innocent Drinks found and mistakes avoided. economy and the benefits of avoiding wanted to know what kind of materials Hyde wanted to know how a brand- landfill by reclaiming materials. the waste creates and what their second owner can close the gap to speak with However, he pointed out, this life consists of. Koski responded that it ink producers. Jones said that they are reclamation leads to issues such as depends on the material; if it’s a paper usually an afterthought when it comes migration and potential contamination. liner such as plascene, then it goes to the supply chain as they are so far “What we are trying to do is work back into paper for magazines, while if down it, but when they work directly with suppliers to develop packaging in it’s polypropylene liner, it’s turned into with each other, it can lead to exciting a circular economy so that everything decking for terraces. developments. She quoted the example we design will come back into the of L’Oréal in Africa, which had a number supply chain,” he said. The missing ink of issues with lightfastness on labels, as Wrapping up the panel, Irvine The final presentation was by Amanda well as the impact of humidity and UV identified the take-away message: that Jones, sales director at Paragon Inks. She on its printing and labelling. By working the packaging supply chain is heavily started by explaining that Paragon used closely with each other, they have been dependent on its selection of raw to assume what the customer wanted, able to resolve these issues. materials, and therefore needs to talk but then began to evolve, developing Antoinette Devine of SAB Miller across its length and breadth in order from being a straightforward commodity spoke to say that she spent five years in to ensure that each step is represented supplier to wanting to be more involved pharma before moving to the beverage and carefully considered.

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PCI037_015_Food safety packaging.indd 37 14/04/2015 08:34 Insight > Flexible packaging

A state of flex Flexible packaging has carved out a dominant position in the overall packaging market, and that trend of growth seems set to continue despite the prospect of environmental legislation that could push companies to look for greener alternatives. Industry leaders give Packaging & Converting Intelligence their opinions on why flexible packaging is so popular and how its use might change in the years ahead.

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PCI037_008_Flexible packaging.indd 38 14/04/2015 08:16 Insight > Flexible packaging

he benefits of flexible “From the food side, and I am wrap, stretching and shrinking. packaging are well known and, talking partly from my experience Disposal is also easy. T for a diverse range of products, at Nestlé as well as my current role “Overall, it has many features and it allows companies to innovate and at Carlsberg, the main element in the attributes to enhance convenience keep control of costs. The market is growth of flexible packaging is that in its use,” he continues. “In terms predicted to maintain its current trend it is an efficient material to protect of providing the optimal solutions for of growth and increase its market products,” says Thomas Delory, global customers, the most important factor share, with a faster uptick in its use category manager for secondary and is in improving convenience with compared with every other category tertiary packaging in the procurement easy opening or reclosable packaging, of packaging material. division of Carlsberg Breweries. smaller-sized packaging for single use Market research firm Canadean has “The ease of use is also an and on-the-go facilitation,” he adds. released a study of growth trends in important factor, as are its benefits the packaging market, and its findings for transportation, marketing and That’s a WRAP suggest that between 2013 and 2018, dispensing. It is quite a cheap way to While the cost-efficiency and flexible packaging will be the fastest- achieve the same functionality as other versatility of flexible packaging growing sector of the market, with a materials. Foil is very cost-competitive. continue to drive growth in its use, predicted 4.5% in global volumes for “Now that oil prices are falling, there could be a push in the other that five-year period, which outstrips there are cheaper resins available. At direction from regulators focusing the anticipated 4.2% rise in the use of Carlsberg, we use a range of materials, on issues such as sustainability and rigid plastics and the 3.3% increase from solid board to shrink film, and we waste reduction. expected in the use of glass. find that foil is very cost-effective. For Waste Action and Resources The study suggests that flexible a large FMCG, cost is always a factor,” (WRAP) regulations and the EU packaging will be the most successful Delory adds. directive, for sector, partly because it already From the consumer perspective, instance, address the amount of accounts for more than half of the the visual impact of packaging is a plastics that should be recycled. total market share, and it estimates powerful force in determining Aware of this trend, many businesses that it will account for more than purchasing decisions, as Kristian are looking closely at the amount 55.0% of the total market by 2018, Berings, head of the European of plastics they use, with a view up from 54.3% in 2013. From the packaging department at CSM Bakery to weight reduction or increased manufacturers’ perspective, there are Solutions, explains. recyclability of the materials they use. numerous benefits that derive from using flexible packaging. The first factor to consider is its weight. Due Flexible packaging provides many options for to packaging waste regulations, flexible packaging offers the best differentiation in appearance, such as graphical weight:cost ratio. execution, special effects and transparency, as Then there is the issue of speed. well as in its form and shape. It also has a low Machines can run faster when using flexible packaging rather than other material:product weight ratio. materials and pack formats. Finally, and perhaps most importantly, comes the cost profile. Due to its lightweight “Flexible packaging provides “Regulations hinder and help characteristics and the relative ease of many options for differentiation flexible packaging,” says Berings. conversion, using flexible packaging in appearance, such as graphical “On one hand, there is a ban on using significantly reduces cost per pack. execution, special effects and plastic in shopping and, in some On top of this, there is the increased transparency, as well as in its countries, an environmental tax on functionality that it offers. In catering form and shape. It also has a low plastics. On the other, there are to customers’ changing needs, it is material:product weight ratio,” regulations that aim to improve food essential that product companies he says. safety and limit food waste.” promote convenience, so easy opening “Additionally, it provides many The key for product companies and reclosability are high on the list functional options, such as strength is to keep pace with an evolving of priorities. Other innovative features and barrier properties to extend shelf regulatory landscape while include steam valves for in-the-bag life, and it is a cost-effective option maintaining optimal cost-efficiency. cooking and alternative opening that allows fast production of “We might see some new formats that improve the user interface packaging in many applications, regulations coming in, and there is a with the pack. including bags, form-fill seal, flow lot of discussion in the EU about the

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PCI037_008_Flexible packaging.indd 39 14/04/2015 08:16 Insight > Flexible packaging

circular economy, which is a concept products, because film has a better Some flexible packs are difficult that we have embraced at Carlsberg protective element and the biggest to recycle, as they are laminated with our zero-waste concept,” adds factor in food waste is the disposal and include glues and inks, and it Delory. “What you manufacture can of products that have passed their may also be difficult to sort them get back into the biosphere or be sell-by date. Flexible packaging in the waste stream. Biodegradable reassembled into a new product. extends the sell-by date with materials made from recycled or “There is a very long way to go, relatively low cost. plant-based plastic will, over time, but regulators are discussing how “The LCA is a very complex help to minimise waste, and there is to minimise the impact of packaging analysis to make; there are a lot a noticeable shift towards polyolefins on the environment. However, the of unknowns in terms of the impact derived from natural substances such industries behind flexible packaging of the material, though we do know as sugar cane. – mainly the oil and chemical that flexible packaging cannot be In the future, the push from companies – employ thousands of recycled, so it is either burnt or goes innovative plastics manufacturing people, and regulators don’t want to to landfill. companies and convertors towards destroy those industries.” According to the Canadean research, there is a noticeable transition from The main issue with most flexible packaging glass to rigid plastics and flexible packaging, which have a less positive is that it is made from plastic and therefore is environmental profile. Nevertheless, derived from fossil fuels – but its environmental the study notes that many consumers profile is actually less clear-cut when viewed show little concern for environmental characteristics than for other factors from a long-term perspective. such as cost. “A lot depends on consumer behaviour, and within a population “The environmental impact biodegradable or compostable that is conscious of sustainability, is a problem as the material degrades packaging is certain to continue, you can see a variety of different into micro-particles that could and the focus will be on making behaviours depending on which aisle re-enter the food chain. such innovations as cost-effective as people are in,” Delory believes. “In the “But if food is not packaged possible and ensuring that the product beauty aisle, they may be conscious well enough, it never reaches the performs as well as the materials in of the chemicals that are put into a consumer and is lost in the supply use today. Lightweighting is also sure product, and in the coffee aisle, they chain, so there is a trade-off. The to be a top priority but, in parallel, may choose Fairtrade items. In the supply chain is usually very long, there will be equal emphasis on beer aisle, however, some switch into but flexible packaging would not making sure that convenience for party mode, so they become less necessarily be needed if the supply consumers is constantly improved. conscious of environmental issues. chain were short,” Delory adds. “For 2015, I believe that more “Nevertheless, Carlsberg believes in To improve the environmental convenience features will be built into zero waste, and we believe customers profile of their flexible packaging packaging solutions. There will be new are starting to want sustainable choices, many companies may product launches for us, too, particularly products in the beer aisle now.” decide to move away from laminated in the form of pre-made pouch film and instead employ a surface- packaging,” concludes Berings. Find the balance printed low-density polyethylene film In terms of sustainability, the main that would be recyclable. issue with most flexible packaging is that it is made from plastic and therefore is derived from fossil fuels – but its environmental profile is actually less clear-cut than people might think when viewed from a long-term perspective. “The image of shrink and plastic films has a negative environmental image,” says Delory, “but this is not as bad when you look at the total life- Carlsberg believes customers are starting to consider sustainable cycle assessment [LCA] of these packaging in the beer aisle.

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PCI037_008_Flexible packaging.indd 40 14/04/2015 08:17 PCI037_Cosmo Films.indd 1 13/04/2015 10:15 RESULTS THAT MAKE YOU SMILE

Since we use Esko software, “we only need 60% to 70% of the time we used to take. The number of hours we save not copying fi les back and forth is stunning. Titus Helmke Brand Management International Kärcher Germany

Your deadlines get shorter. Your colors need more consistency. You must supply more value to your customers. Whether you produce packaging, signs, displays or more: you need a trustworthy partner. A partner that supplies the best tools and shares years of expertise. Esko is that partner. Deliver results that make you smile.

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PCI037_ESKO.indd150316_PCI_210x286.indd 1 1 13/04/201516/03/15 14:4210:16 Company insight > Flexible packaging Maximise brand visibility As brands attempt to design the most eye-catching items, Esko supports the design and production management process with integrated solutions that include 3D visualisation technology. The latter helps these firms to raise productivity and reduce time-to-market for their clients’ products.

here are, on average, 35,000–40,000 different products on the supermarket shelves, all vying for T the customers’ attention. In an increasingly competitive marketplace, packaging companies are constantly looking for new ways in which to catch the eye of the shopper and embed their brand in the public consciousness. As a provider of integrated design solutions for clients in the packaging industry, Esko is deploying innovative 3D visualisation tools to optimise the design process, creating efficiencies not only in product placement, but also in A 3D visualisation aids in the designing of packaging. product manufacture and transportation. “For example, what happens to your design if the Finding the right form consumer picks up the item from the shelf, and puts it back Unsurprisingly, success ultimately lies in perfecting the but not at the right angle?” asks de Roeck. “Does your shape of the packaging. “As a consumer, you’re not package still convey the correct brand message? When the necessarily reading what’s on the pack,” says Jan de Roeck, product is contained within self-ready packaging, where Esko’s director of solutions management. “Rather, we read the primary pack is actually left in the shipping package the brands by recognising shape and colour. To that extent, and put on the shelf as such, is the brand still visible? you will recognise a Toblerone package even if the name is Those kinds of questions are best answered by a full, not printed on the box, because you’re not reading the pack, virtual, 3D visualisation of your design.” you’re looking for that triangular shape.” Once consensus is reached over what shape the Size matters product’s packaging will have, the process of brand Esko’s 3D visualisation technology is even allowing clients cultivation can commence. But to get to that point is to apply new efficiencies in product design that contribute easier said than done. More often than not, the period significantly towards reducing transit costs. between devising a basic design concept and putting “Rearranging the product inside the , the finished product on the shelf is fraught with making it an inch or so smaller so that more of these boxes logistical challenges. can fit in the container, makes a tremendous gain for the Esko’s remedy for this problem was to develop Studio brand customer,” says de Roeck. “Having more boxes in Visualiser, a sophisticated 3D design tool that allows any the container simply means fewer containers on the ship, lingering faults in the product that might otherwise delay and therefore a much more environmentally friendly its manufacture to be caught and eliminated. footprint. That kind of access to information as a designer “It’s good to have the feedback in 3D while you’re doing is absolutely crucial.” that, because you may misalign certain design elements, Employing more than 1,300 people and with direct sales such as logos that are placed on different sides of the box, coverage over four continents, Esko is keen to continue if you only work in 2D,” says de Roeck. “If your package is providing optimising solutions at all stages in its clients’ folded, the flaps may be upside down, or they may be supply chain. under a twisted angle. It’s not always easy to see what “Looking forward,” says de Roeck, “it is indeed much your design will really look like unless you see it folded more about creating an efficient supply chain, digitising up in three dimensions. And that’s especially true that supply chain and enabling communication between for design items – such as an image or logo – that cover the different stakeholders, all to the benefit of cost multiple flaps,” he explains. reduction and faster time-to-market for the brands.” As well as expediting the design process, Esko’s Virtual Store software allows the company’s clients to see how its items will fare against competition on the shop shelf Further information Esko without recourse to the time-consuming creation of www.esko.com a physical mock-up.

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PCI037_Esko.indd 43 13/04/2015 14:52 Company insight > Flexible packaging On film: flexible cookware With five decades of experience in ovenproof packaging that aids and enhances the cooking process, DuPont Teijin Films has launched the Mylar range of ovenproof films, which delivers an oven-safe solution for practically any protein and any packing process. As consumers, we expect more for our money and demand the convenience of ‘no-touch’ prepared meals of restaurant-level quality in the comfort of our own home. The most important factor in any meal is how enjoyable it is to eat; cooking with Mylar offers a truly superior Mylar’s ‘no-touch’ cooking helps to ensure food safety. experience, because subtle flavours are retained and Mylar delivers restaurant-quality meals at home without the enhanced during the cooking process. Self-basting occurs concerns of handling potentially dangerous raw food. inside the pack, ensuring that the final product is succulent, The food-safety angle is equally important for food service and Mylar films do not interfere with Maillard reactions and catering, and a number of restaurants and retailers (which give food its appetising golden-brown colour). therefore choose Mylar as their cooking medium. Cooking in Cooking times can be reduced by about 20% in conventional Mylar also helps to lower cost by reducing the frequency of ovens and up to 50% in microwaves, providing fast, quality industrial oven cleaning and by allowing mixed proteins to

food and reducing the CO2 footprint of cooking at home. be cooked together without fear of cross-contamination. Perhaps the greatest advantage of cooking with Mylar is The Mylar range of ovenproof films is designed to work the ‘no-touch’ element and the impact this has on food safety. with practically any packing method and any food stuff; it Food poisoning is a constant concern, and the control of delivers enhanced food safety, convenience and value to Campylobacter is of particular interest to the food industry. food packers, retailers and consumers. ARTWORK DUPONT Mylar Grocer Ad 210 x 148mm PR.pdf 1 21/01/2015 10:35 Further information: DuPont Teijin Films www.europe.dupontteijinfi lms.com

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PCI037_Dupont.indd 44 14/04/2015 08:37 Insight > Luxury packaging Deeper luxury In today’s luxury goods market, a delicate balance must be struck between fulfilling the need to convey the luxurious look and feel the customer expects, while also meeting the growing requirements for sustainability and guarding against counterfeiters. Absolut’s Anna Schreil and Cartier’s Nawal Ait-Hocine explain some of the ways this can be achieved.

ustainability and changing customer brand identity and values, and, at the same time, to perceptions are among the factors now keep evolving and differentiate yourself from the S influencing luxury packaging designers competition in a relevant way. It’s a complex task that and producers. There is a move away from the more doesn’t have any simple solution. decorative, overtly ‘rich’ type of packaging in luxury, “Given the artistic and creative personality of the making instead way for understated, functional Absolut brand, we are often using the bottle, or the and elegant packaging, featuring muted colours and bottle outline, as a canvas for various expressions – improved aesthetics, that customers will want to often together with collaborators. reuse in their home. “Our Unique and Originality products kept This trend is tied into the idea of a unique our premium products without sacrificing product; if there is a slight imperfection, it individuality, craftsmanship and artistic is something that actually adds to the expression,” she continues. “The latest artisan concept rather than being a large-scale examples of spectacular generic, machine-manufactured product. achievements are the Unique and Authenticity is a theme – merging Originality global editions, where we materials and ‘being honest’ with have brought these traits to a completely material selection. If you use wood, for new level. instance, it can be combined with wood “In the case of Unique, we produced finish, matte paper, ply packaging and four million individually designed bottles, so on in order for the whole end product and in the case of Originality, we infused to maintain the material’s message and the glass itself with a streak of colour, provide a more honest, holistic result. again in a quantity of several millions. Well-managed materials brought together “Following decades of globalisation can and will enhance the package. and standardisation, consumers are With the ease of access to information looking for new forms of authenticity on the internet, consumers are now and craftsmanship, and products with much more informed about and a genuine background and history,” interested in their purchases. In the Schreil maintains. “This led to Elyx, luxury market, provenance and honesty which is a single-estate, handcrafted are incredibly important brand-building vodka produced with wheat harvested and packaging tools; where the product and distilled within a 15-mile radius in is from, how it was made, and how it was southern Sweden. The result is a product manufactured or processed sets it apart that has already been strongly endorsed as a luxury item. by third parties; for example, being named By getting answers to these questions, Best Vodka, double gold, at the recent customers can not only feel satisfied San Francisco World Spirits Competition. that they have bought more than just a “Another interesting trend is the brand but that they also own something Spin the bottle: using the product packaging as a evolution of hybrid products. Enhanced that itself is special. If the handbag is canvas is a key part of Absolut’s luxury strategy. by the mixology movement, traditional made on the same assembly line as a Absolutly fabulous category codes are getting blurred as generic version, on the same machine or Anna Schreil, director for PDR and R&D brands from different categories are by the same person, and the difference is at The Absolut Company, agrees: “We are borrowing cues from each other. For simply the name on the tag, this devalues seeing growth in premium, personalised example, in the US we launched one of the brand and will cause customers to products and the rise of craftsmanship. our most innovative products, Absolut look elsewhere. The challenge is to stay true to your Tune, which is a sparkling fusion of

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PCI037_009_Luxury.indd 45 14/04/2015 08:19 Insight > Luxury packaging

Absolut vodka and sauvignon blanc. We also launched Absolut Amber, which is Absolut rested in oak .

Protection in every environment Along with differentiation and maintaining an authentic offering, brand security is also a constant challenge in the premium spirit sector. “We are continuously working to protect our products and prevent illegal copying and refilling,” Schreil says. “This is done through tamper-proof pack material, such as a plastic seal over the top of the The iconic red box has seen a shift towards bottle or non-refillable closures, and with sustainable practices, including using 100% special coding on the bottles. recycled paper and limiting shipping distances. “Digital and ‘Internet of Things’ is also a very interesting area, of course. The For packaging activities, Cartier engaged possible and that it meets our exacting exciting thing here is not only to provide a specialist firm to carry out complete responsibility guidelines.” protection, but also to create clever and life-cycle analyses for two of its iconic To achieve the ‘feel’ of luxury, the engaging solutions that add valuable packaging products: the Cartier red bag packaging that is employed in this content to our consumers, beyond just and the Cartier red gift boxes. Both items sector tends to have multiple layers, being directed to a company web page.” were selected as they are emblematic of such as metallised films and glass, While consumers are becoming more the brand and transcend a single product. and paper, that provide the decorative environmentally aware and continue to be The life-cycle analysis encompassed an effects a consumer can recognise as a better connected to the global market via extensive information-gathering exercise prestige brand. One disadvantage of social media, sustainability is growing as in areas such as raw material use, this approach, an area of focus within the luxury sector. production processes and transportation. however, is that the materials used can Manufacturers are responding with a wide For several years now, 100% of be difficult to recycle. range of materials and processes that are Cartier’s paper product has been made Creating sustainable and recyclable environmentally friendly and aware. with paper from well-managed forests, luxurious packaging that communicates While the FMCG industry has been and Forest Stewardship Council (FSC) or the brand’s excellence is a difficult task, under pressure to reduce the environmental Programme for the Endorsement of but despite the various issues involved, impact of packaging, luxury brands are Forest Certification-certified trees. there has been a move towards now catching up, switching from plastics For packaging such as shopping bags sustainable practices in the luxury to paper, achieving sustainable packaging and boxes, Cartier goes further by using packaging market in recent years. coalition status and addressing a growing certified materials that contains post- Fashion brand Gucci, for example, trend towards ‘responsible luxury’. consumer-waste (PCW) recycled fibres. launched 100% recyclable packaging Responsible luxury is something that Since 2009, the paper used to cover the with FSC-certified paper in 2010. Nawal Ait-Hocine, corporate social red boxes contains 30–50% of PCW However, do customers really care responsibility director at Cartier, is very recycled fibres. This initiative has been about sustainability when purchasing familiar with. One excellent example from rolled out to boxes for watchmaking, luxury packaging? Is this move towards the group comes from the printing and jewellery and eyewear. sustainability for the luxury sector packaging materials for its red gift boxes. “Most of these products will only be genuine or simply a passing fad? To ensure consistency and quality, bought once by a consumer, engagement According to research undertaken Cartier manages the printing of its rings for example, and the packaging has by Greenwise Business, 47% of the 200 product catalogues and similar materials to stand up to the moment in time that is branding and marketing professionals centrally. Printing is carried out in France, associated with its presentation,” says consulted felt that Gucci’s initiative to Switzerland and Italy. To reduce the Ait-Hocine. “Certifications allow us to cut down on excess packaging was a true environmental impact of logistics and to responsibly source the right material, and reflection of the industry’s environmental avoid unnecessary transhipments, as a bring it through the supply chain and into concerns and its future direction. general rule, the printed material is shipped consumers’ hands so that when the As Kering’s François-Henri Pinault directly from the printer to each market, moment arrives and the packaging is states: “If we wait for consumers to insist either by road or by sea, depending on the presented, it accentuates the occasion. upon sustainability as a condition for destination. Furthermore, carton packing is “As that box will then be kept by the purchasing, nothing will happen. It is up optimised to avoid empty space and is consumer for years to come, we need to to us to see to it that the environmental reused when possible. ensure that it is of the highest quality products become the new norm.”

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PCI037_009_Luxury.indd 46 14/04/2015 08:19 Company insight > Luxury packaging Invercote responds to market demands Following Iggesund Paperboard’s announcement that it will upgrade its flagship product, Invercote, the bestselling paperboard in that specific range, Invercote G, will feature a lightly coated reverse side from mid-2015.

Arvid Sundblad says: “The reverse-side coating improves the printing properties but keeps the tactile feeling of roughness.”

ore and more brand-owners want access to continues. “But in making this change we have also preserved high-quality reverse-side printing, for all the other properties that have repeatedly led to Invercote “Mexample to print a colour shade or pattern being ranked by leading brand-owners as the European that improves recognition and reinforces their brand,” comments paperboard market’s strongest brand.” Arvid Sundblad, vice-president of sales and marketing at Iggesund Paperboard. “We are developing Invercote step by step, A more transparent service and always in the direction our customers want.” Concurrently with the introduction of the upgraded Invercote Prior to this latest upgrade, Invercote G has been triple- G, Iggesund has also improved its service offering and made coated on the print side with an uncoated reverse, and available it more transparent under the name Care by Iggesund. The in grammages from 180g/m2 to 380g/m2. Over the years, it has aim is to achieve consistent delivery times, but the offering come to be the quality leader, primarily due to the combination also encompasses everything from a rapid sample service of excellent printing and foil laminating properties, together and the dissemination of knowledge to local technical with high quality and an equally high consistency. One of the support and a transparent supply of raw materials. many reasons for choosing it as a graphic or packaging material “It’s crucial to us that anyone who chooses Invercote will has been the predictability of the end result. not only sleep well at night but will also know that the end Coating the reverse side means the whiteness on the result will be dazzling,” Sundblad concludes. reverse has also been adjusted up. Further improvement has Specifications for the upgraded Invercote G, as well as also been made to the lightfastness, which was already the sample and trial material, were made available from early best on the market, and which is crucial for keeping a February. Deliveries will start on 1 July. package looking fresh over time on the retail shelf. ”This is not a revolution but rather an adaptation to gradually changing customer demands. The reverse-side Further information Iggesund Paperboard coating is very light – it improves the printing properties, but www.iggesund.com still keeps the tactile feeling of roughness,” Sundblad

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PCI037_Iggesund.indd 47 13/04/2015 14:52 Insight > Digital printing

Digital distinction In today’s hyper-connected, mobile and social-media-focused world, brands have been exploring ways to drive relevance, engagement and interaction through packaging – digital printing is opening up these opportunities. Matthew Rogerson reports from Ultimate Packaging’s digital-themed open day.

n March, Ultimate Packaging hosted devoted to presenting the possibilities of well-known advocate of digital print, a brand-focused open day to unveil digital print and addressing some key gave a brief introduction to the Ultimate I the new wide-format HP Indigo questions from brand-owners. Group. “Ultimate Packaging is a high- 20000 digital press and showcase the Ultimate Packaging owner, and sales volume wide-web flexographic business,” 6600 digital press in action. The day was and marketing director, Chris Tonge, a he said, “but I immediately realised the

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PCI037_007_Digital printing.indd 48 14/04/2015 08:15 Insight > Digital printing

potential for digital print. I see it as to match confectionery bags already in artwork, labels and character. Digital complementary technology to flexo at store. Typically, on flexo, minimum print is the only way I can steward all these current speeds. runs of 60,000–80,000 bags are necessary, products in the time frames necessary, “Having spent 20 years selling flexo but digital allows orders of 5,000–10,000, and even without being an expert in print, print to packaging buyers demanding giving the option to test sales before I can operate the system myself, making high-definition quality for the lowest price moving into volume print runs on flexo. changes as I go, and those changes will possible, my engagement now is with Now, M&S can easily test-market 20 be incorporated immediately.” brand-owners and marketing teams varieties before printing to flexo. He explained that management support discussing projects and campaigns that Tonge then gave some examples of – ideally at board level – is essential for enable customer interaction through where digital print had been used by brand the success of digital within a company. packaging on shelf and for home delivery. marketers to interact with consumers, “When it comes to the retail market, it’s “Also, there are many orders just too including Branston Potatoes’ ‘pic on a going through multiple changes,” he said. small for wide-web flexo that can be pack’ trial with a lidding film used on Tesco “[The practice of] consumers going to a printed digitally. Although overall flexo parmentier potatoes. The set up of a simple large supermarket to purchase all their volumes at Ultimate Packaging continue website allowing customers to upload shopping at once is struggling, while to increase each year, average run lengths photos of themselves eating the product the high street discounters are seeing reduce. In 2012, our average was 30,000m; that were then included in subsequent enormous growth. In the case of Iceland, last year, it was 19,000m. As this continues print runs drove engagement and feedback. which has more than 800 stores across and digital print gets faster, this new Walkers Crisps worked with Ultimate the UK, there is no ‘one size fits all’ across technology will become more widely used. Digital via a Facebook campaign allowing product lines; again, without digital, this “Over the next few years, we will be 5,000 of their followers to order unique would be a struggle to manage.” using digital print for small-volume orders, packs featuring names and messages One of the key points of difference but much more to provide innovative and that were then delivered in a presentation raised by Schofield was in the move by exciting ways for brands to interact with box. Once again, a pilot scheme for the retailers from price reduction to value their consumers through packaging. The future, but a great example of a major added, and the ability of digital to expand millennial generation is demanding that UK brand using direct, two-way from package printing to providing the brands engage with them, and digital communication with individuals using in-store merchandising and aisle support, print allows this to happen,” Tonge said. digital print. and to be able to make the same instant There are many benefits of digital over changes and quick turnarounds seen in conventional printing; the most important, Take the plunge that packaging arena. however, is the fact that everything can be The first presentation was from Ian “We used to rebrand every five years; variable – you can rip as many files as you Schofield, Iceland Foods’ own-label and now, this is down to 18 months. What used want to the press and make changes packaging manager, who has first-hand to be complex artwork with associated time instantly. The existing rule book can be experience of the difficulties and benefits delays can now be applied to brands at a ignored and almost everything becomes of moving a company into digital print. single location with 800 variations instantly.” possible, with the revenue stream primarily “I believe the digital vision is worth Other abilities that bolster digital’s coming from brand marketing or supporting, and while to some people it credentials include variety, SKU advertising budgets. seems as if we are going fast and talking proliferation, making last-minute “We are into a new age for packaging about technology before it arrives, it is changes, small runs, fast introduction and where, as well as being functional, it precisely this push that is required to bring turnaround of new lines, rapid marketing facilitates one-way communication with the technology and all its opportunities material support to accompany these new the consumer,” said Tonge. “The impact forward into the market as quickly as introductions, promotions, addressing of digital print on packaging over the next possible,” Schofield said. legislation instantly and reducing write- few years will truly shake up the market.” Iceland has rapidly adopted digital print, offs. On the last point, Schofield focused on Tonge outlined some examples of driven by the fact that it is a ‘difficult the need to ensure that there is no waste, short-run orders and customised trials customer’. “I want everything quickly; I stating that Iceland was very careful to that Ultimate has delivered. Existing flexo don’t want my packaging artwork to look monitor all write-offs and that digital print customers are now using short-run digital like anyone else’s,” he said. “I want to helps by allowing just-in-time deliveries. printing for marketing campaigns and make immediate changes based on Schofield noted that digital technology promotional products. customer feedback, and I want to go into also allows: new, wider presses to carry “When using both side by side, it is new markets as quickly as possible. I don’t out almost any job; the possibility to print important that the packaging looks the want to wait two weeks for artwork to on more substrates than before; lower same on shelf, which we achieve with the come back, as this is a missed opportunity. printing costs, so savings can be passed digital workflows on our HP presses,” said “I do not have a single brand that I look on to consumers; a fixed-price matrix Tonge. The best example for this is the after: I have hundreds of individual SKUs with no hidden costs; the ability to print M&S reverse-print laminate bag produced that all need their individual branding, as and when needed, meaning less waste;

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PCI037_007_Digital printing.indd 49 14/04/2015 08:15 Insight > Digital printing

worldwide suppliers guaranteeing 24-hour not need to be attached to a person an incredibly small price to pay given the printing; and shelf-ready packaging. but can create a unique product that commercial gains provided by the 3–5% is individual or that allows a group of upswing in product sales seen through Clan-destine marketing otherwise unrelated consumers to campaigns such as ‘Share a Coke’. The next to speak was Nancy Janes purchase across a category.” Before lunch, Tonge introduced the of HP, who started by explaining the Irn-Bru also used this format when it 760mm-width HP Indigo 20000 press, the restructuring of HP that will come later printed 52 popular Scottish clan names first in the UK, and took questions from this year, involving a divisional split into and associated tartans on its labels, the audience. He also showed the first Hewlett Packard Enterprise and HP Inc, allowing consumers to purchase their range of products produced off the new with digital residing in the latter. With own heritage label for Burns Night, press: a range of reverse-printed quad the latest technology announcements, leading to a spike in sales and interesting packs for Hider Foods, destined for Shell HP now offers digital presses in sheet, social media activity. service stations as part of the Deli 2 Go web and flatbed configurations to cater She moved on to discuss another range. There were six varieties with a for label, carton, flexible and corrugated inherent benefit of digital – the total print run of 20,000m – perfect for the packaging applications. These new press environmental impact of digital print. With new press. launches are based on the tried & tested the increasing ability to recycle inks and The final speaker of the day was Simon Indigo & Inkjet platforms allowing new the reduction in associated consumables Campbell, Reckitt Benckiser’s head of markets like packaging, to make a step needed to print digitally, on top of the global R&D packaging, who took delegates change advance based on proven core principal of only printing what you on a trip to China to share details of a technology platform. need when you need it, printing digitally project the Sharp Iris team and Reckitt Janes moved on to explain some of becomes very attractive. Benckiser have been working on for the the value of digital print and the reasons Janes’s colleague, Jan van Daele, then past 18 months. Campbell explained that behind its growth against different spoke on the impact of digital print for the Sharp Iris team had been fundamental processes: “There are two main benefits brand-owners and cost vs value. While in the delivery of product personalisation of digital print: added-value printing and digital has a premium cost, this is on a huge scale for Durex. supply chain optimisation. Regarding balanced out by what it can do. He “Sharp Iris has provided creative added value, there are certain things you advised that, as different departments support and set up a print hub in can do with digital that are not possible are involved in the purchase, there Shanghai producing the personalised with conventional printing or, if they are needs to be someone who can find cartons, and the whole project is powered possible, they have prohibitive costs common ground between the budgets. by Smartflow,” he said. “Project One has attached. Variable-data printing – such He then moved on to supply-chain gone live in China, and, already, Reckitt as names, barcodes, track and trace, or cost reductions. While benefits such as Benckiser is exploring further initiatives unique images like watermarks – is a eliminating waste, printing just in time using the benefit of digital printing.” key area. and printing on demand mean price per Digital print has put down firm roots in “In Israel, for example, Coca-Cola unit can be reduced, the percentage of the industry, with its flexibility offering the recently used an HP Indigo-created waste in making the package can also chance to kick-start a creative renaissance algorithm, called Mozaic, that allowed be cut. in packaging and marketing, the initial it to create two million unique Coca-Cola He gave the example of Coke where waves of which are now beginning to labels. Printed on each label is a the per-bottle advertising cost is about break. As Tonge put it, “It’s amazing what unique code to go online and purchase 0.5¢ if you take Coca-Cola’s $3.6-billion happens when you are prepared to invest, associated merchandise if they wish. advertising spend and divide it among step into the unknown and put the correct This shows that personalisation does the 650 billion servings produced. This is team of talented people together.”

The Hider Foods reverse-printed quad packs are the first items to be produced in the UK using the new HP Indigo 20000 press.

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PCI037_007_Digital printing.indd 50 14/04/2015 08:15 Company insight > Digital printing Print on site and on demand With RTI Digital’s Vortex 850R printer, powered by Memjet Waterfall Printhead Technology, you can print full-colour labels on site and on demand with variable data. This allows brewers – and, for that matter, nearly any in-brand producer – to personalise every product at the speed of production, while cutting costs nearly in half. Welcome to a more affordable method of short-run digital printing. For in-plants seeking value-chain improvement with low capital and implementation costs, the Vortex 850R

from RTI Digital offers an elegant solution. Designed to The Vortex 850R can conveniently sit on industrial benchtops. be placed on industrial benchtops, its easy-to-use interface and applicator module allow off-line or in-line full-colour labels with variable data at blazing fast label operations. speeds, which makes on-demand printing and affordable Vortex 850R printers eliminate the need for keeping short runs a reality. large pre-printed label stock and applying variable data How will Vortex 850R and Memjet change the way in a two-step process. When you combine the low total you work? RTI Digital helps printers and in-plants to cost of ownership with the reduced waste and fewer generate new revenue and profit opportunities by process steps, Vortex 850R delivers a value that cannot offering unique digital print solutions. be overlooked. Vortex narrow-format and wide-format printers deliver Vortex 850R printers, with Memjet unique Waterfall the highest combination of quality and productivity at a Printhead Technology, enable businesses to produce low total cost of ownership.

Further information: RTI Digital www.rti-digital.com

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PCI037_RTI.indd 51 14/04/2015 08:38 Company insight > Digital printing Printing gets personal While the demands of brand-owners and print buyers are becoming ever-more elaborate, producers and converters are striving to do things better, faster and on a tighter budget. Xeikon has set up a network of partners that brings together different expertise, allowing it to respond to customer requirements in a personal and cost-efficient way.

Digital printing can produce cheap, personal solutions that fulfil customer requirements.

oday, more than ever, the consumer is in the driver’s An ideal solution seat when it comes to how, when and where marketing Digital printing can help them to do just that. However, integrating T messages are received. For this reason, brands are a digital press in an otherwise traditional workflow is one thing, adapting their marketing programmes to make their packaging aligning all its components so the quality of the finished product more personal and relevant. This can be in the form of matches or exceeds that offered by traditional production methods, messaging targeted at a specific type of consumer, or through and that while improving profit margins, is a different matter. the use of versioning to target a specific demographic or group. Xeikon has long been an innovator in digital printing, and has This change affects marketing messages and brand-owners, been listening closely to its customers from the start. It knows the who are diversifying their products to better target specific regions, ins and outs of digital printing for labels and packaging as no other. seasons, customer groups and events. The result? A growing The company has created a network of industry partners – the volume of short-run labels and packaging that can often be too Aura Partner Network – each with its own expertise in software costly to produce using conventional production methods. or workflow, substrates or consumables, or finishings. Together, That’s where digital printing comes in. Not only can today’s these partners have developed total solutions or suites for the digital presses produce short runs cost-efficiently, they can do production of folding cartons and self-adhesive, heat-transfer so without compromising on quality. and in-mould labels. Each suite is carefully selected and tested on a combination of equipment, technologies and capabilities, Thinking ahead allowing the most cost-efficient production. Forward-thinking converters striving to adapt to new market The centrepiece of each of these solutions is a digital press realities often adopt digital printing, primarily as an alternative that delivers top-notch quality, runs toner that is approved for to conventional methods; it reduces costs and provides use with food, uses the full rotary printing process, and can workflow automation and digital finishing solutions. print on traditional substrates without the need for specific However, to take full advantage of the possibilities created by pre-treatment. The converter or printer can add specific digital printing, converters must look beyond simply reducing software or workflow tools, define the proper finishing, and costs and think about how these technologies can be applied choose the substrates to build and integrate the exact solution to new opportunities and applications: full personalisation, needed to produce the desired applications. just-in-time production and web-to-print offerings, to name a few. Xeikon is a perfect partner to help build a turnkey solution One challenge for the packaging industry is the growing demand for various labels, folding cartons, paper cups and more. for customisation and versioning. Print buyers want more tactile

and eye-catching finishes to boost shelf appeal and generate faster Further information turnaround times. There are also increasing legal requirements and Xeikon www.xeikon.com brand protection issues. In short, producers and converters are www.youtube.com/xeikonnv under pressure to do things better, cheaper and faster.

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PCI037_Xeicon.indd 52 13/04/2015 14:57 THE QUALITY BENCHMARK JUST GOT FASTER

The Xeikon digital presses for labels and packaging excel in productivity and high quality printing. With its top speed of 30 m/min (98 ft/min), the Xeikon Cheetah is the fastest top quality five color digital label press. Furthermore, it offers all the other benefits that make Xeikon label presses unique. With the Xeikon Cheetah, the quality benchmark has just become significantly faster!

Digital press Top quality, true 1200 x 3600 dpi Dry toner electrophotography 30 m/min (98 ft/min) 5 colors Full rotary printing www.xeikon.com

tempengine.inddPCI037_Xeikon.indd 1 1 13/03/201513/04/2015 13:25:07 10:20 PCI037_Collins Inkjet.indd 1 13/04/2015 10:15 Company insight > Digital printing Pharma pioneers UV ink With very specific and critical printing demands in the pharmaceutical industry,Collins Inkjet strives to provide a customised service for different applications. One of its success stories is its UV-LED curable ink, tried and tested by satisfied customer Bell-Mark.

n package printing, consistent, high-resolution print quality is vital. Barcodes, lot numbers, expiration dates I and other variable data must be easily readable, identifiable and scannable. When printed packages contain pharmaceutical items, the coding requirements are amplified because of the associated health and safety risks. The US FDA actually mandates the printed data. An accurate, reliable code can be the difference between success and failure, and this is something with which Bell-Mark has experience. Since 1959, Bell-Mark has been successfully designing, manufacturing and servicing high-performance coding, marking and printing equipment for the industrial marketplace, reaching more than 15,000 companies throughout the world. Pharmaceutical package printing has rigorous demands. A significant portion of Bell-Mark’s business is in the pharmaceutical and medical device industries. the ink will perform as required on Bell-Mark’s substrate,” Like many package printing customers, Bell-Mark’s are he adds. Regarding the customised black, Batesko reports: looking for a printing technology that can meet the rigorous “We have had excellent results. I would certainly demands of packaging environments, print high-resolution recommend Collins’ UV-LED curable black ink. The images quickly and employ a small equipment footprint. company has been excellent to work with and the product has performed as advertised.”

By using UV, we all but eliminate Tailor-made solutions Collins has built its business on formulating and the [problem of] ink drying in a manufacturing industrial inkjet inks that are tailored to nozzle, and this results in less specific applications. The new UV and UV-LED industrial cleaning, flushing and downtime. printing spaces are no different. Unfortunately, there isn’t a ‘one size fits all’ fluid; for those new to digital printing who come from a traditional background, this is a difficult “High-definition inkjet technology is a perfect fit, due to its learning curve. Each situation is different, and in most cases high quality of print, as well as its versatility,” says Bob Batesko, the ink is the afterthought and therefore the variable. director of sales for Bell-Mark. When evaluating the different Similar to Bell-Mark’s case, the ideal solution is digital ink types, Batesko says they decided from the beginning collaborative communication between integrators, to integrate piezoelectric printheads using UV curable inkjet inks. printhead and UV lamp manufacturers, ink and substrate “One of the major problems with inkjet technology is suppliers and customers. This is not always the case, and clogged jets. By using UV, we all but eliminate the it can take a while to reach the desired end. [problem of] ink drying in a nozzle, and this results in less Today, Collins’ customers are pioneering UV curable cleaning, flushing and downtime,” says Batesko. technology in new markets and applications, challenging Bell-Mark approached Collins Inkjet regarding a its capabilities and limitations. This is an exciting time printing installation using a high-speed DOD printhead, where for the digital printing industry, and UV is leading the drying time was an issue. Muslim Contractor, Collins’ lead UV charge. Collins will continue to welcome customers’ chemist, recalls that “the existing ink wasn’t formulated challenges and formulate exceptional UV inks that push specifically for a UV-LED curing lamp, so in order to run, the the into the future of print. production line needed to slow down significantly”. Upon receiving the customer’s stock samples, Muslim formulated a custom black UV-LED curable ink that cured quickly and created a permanent, dark image on Tyvek. Further information Collins Inkjet “Having the ability to jet and cure UV-LED inks through www.collinsinkjet.com our in-house jet testing labs gives us some certainty that

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PCI037_Collins.indd 55 13/04/2015 14:50 Insight > Digital printing

At the end of 2014, HP hosted a dining club that focused on the possibilities of digital print in packaging, the thrust of which was how the industry is beginning to understand the implications of digital printing and how everyone must work together to realise its full potential – through education, partnerships, and asking for help from each other and the wider industry.

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PCI037_013_HP dining V2.indd 56 14/04/2015 08:23 Insight > Digital printing

Opening remarks by Silas Amos, creative director of JKR I have been in the industry for 25 years and expect TIME magazine article on Generation Y, stating that to work for another 20. In this time, digital has been they are narcissists. They like to feel special, and an the biggest game-changer I have encountered. I fully excellent way to make them special is to do something expect the work done by HP and Coca-Cola to change unique, which digital printing allows on packaging. the way we print packaging and improve design, but “Designers used to look two years ahead, but digital this process needs a champion, like HP, that can means that we can now look one month ahead and educate companies about how best to deploy it. deliver, which has huge implications. Design used to “We are hit with 50,000 media messages a day, be like an oil tanker, moving incredibly slowly and taking which we tend to try to dodge; [there are] 500,000 ages to adapt or be on top of a trend, but now we are Facebook posts a minute, and most professionals have in a speedboat and can be more creative. at least 150 emails each day to get through. Therefore, “Digital’s short-run ability means you can be braver consumers are excellent at screening to sift through or more creative in design. Before, with a creative risk, these messages and avoid them where possible. marketing would not want to bet the house, so design “Packaging is the last interruptive media that brands becomes more vanilla so as not to offend anyone, can use to raise value, awareness, sales or educate which dampens the impact of the idea. Now, with consumers. You can turn off your TV or tablet, you can digital short runs, I can produce seven of something turn your phone onto silent, but you cannot turn off your that can be immediately tested and released to see deodorant, can of beans or bottle of whisky. Packaging how they do ahead of big commitments. relays a message to you in your home when you have “Speeding up the beta testing phase, and taking it turned off the other media outlets trying to reach you. out of virtual reality and into pilot schemes, gives us “From the technical side, we are seeing a move real-world data and consumer reaction to work with, from standardisation. Faithful reproduction is being and the ability to make instant changes ahead of a replaced by reproduction that allows infinite variety large launch. in our products and their design. This is fantastic for “In short, we can be more local, timely and on trend, design – high art is about variations on a theme. This but we have to show up – as Woody Allen said, “80% need to change is important, as explained by a recent of success is turning up”.

Nancy Janes: Digitally printed faster time to market and low-risk After 15 years selling flexibles to packaging is very, very new. It’s only test marketing; higher sales results packaging buyers demanding high- in the past 12 months that the new HP and brand recognition through the definition quality for the lowest price Indigo larger-format presses have been clever use of variable data printing, possible, now, with our new digital available to address this market, with of which personalisation is just one capability, my engagement is primarily the quality and colour gamut required possibility; track-and-trace-security with brand-owners and marketing for packaging applications. This printing features; and new relationships teams, discussing projects and technology step change provides new between the brand and its customers campaigns that enable customer opportunities and, as a result, the need via online web-to-print customer interaction through packaging on shelf to drive awareness of what is possible ordering processes. and for home delivery. for brands to take advantage. This is By building networks, partnerships Also, there are many orders just why HP Indigo is investing in events and communities, we can all benefit too small for wide-web flexo that now such as these networking dinners. from these new capabilities. It will take become possible and, although our The ‘Share a Coke’ story is a great time but it will happen. flexo volumes overall increase every conversation opener – it’s hybrid year, our average run length reduces printing in huge volumes, and it gets Chris Tonge: My background is wide- each year; in 2013, it was 30,000m people talking about digital and opens web flexo, but I realised the potential compared with 19,000m in 2014, and the discussion as to the benefits of of digital five to six years ago. I am by the end of 2015, this will probably digitally printed packaging, which seen as a champion for digital within been down to 15,000m. Again this is include: supply chain optimisation for the print industry, but there are many an important factor with digital now the brand and converter, of which there who still cannot see the benefits. I see entering the wide-web market. are opportunities throughout the it as a complementary technology to Once you have done something in product life cycle; environmental and flexo at current print speeds. two days that used to take 20, it’s very sustainability benefits from using less Having developed our digital hard to rationalise moving backwards material, leading to less waste – with business on HP Indigo 6600 narrow when there are such great opportunities no need to hold bulky plates and less press for the past two years with the in the future. ink wasted, the overall energy and installation of the first 20000 press in materials use is lower, and there will be the UK at 760mm width, we now have Paul Earnshaw: We have heard a lot less waste in manufacturing and a more the potential to supply the majority of from design about exciting things from environmentally sound end product; flexible packaging specifications. digital but not much about supply

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PCI037_013_HP dining V2.indd 57 14/04/2015 08:23 Insight > Digital printing

Left to right: Ralph Bates, category manager EMEA, Hewlett-Packard; Paul Earnshaw, packaging manager, Tesco; Louise Gedge, senior packaging engineer, Bacardi; Chris Tonge, sales and marketing director, Ultimate Packaging; Detlef Behrens, managing director, Pfäffle; Matt Bradbury, pack innovation project manager, Mars; Will Holmes, packaging innovation, Taylors of Harrogate; Nancy Janes, WW programmes director, HP Graphics Solutions Business; John Nicholson, packaging development manager, Twinings; Sam Woollett, packaging technologist, Innocent Drinks; Neil Falconer, managing director, Printfuture; Silas Amos, creative director, JKR; Ian Schofield, own-label and packaging manager, Iceland Foods; Arno Melchior, global packaging director, Reckitt Benckiser; Greg Bentley, packaging innovator, Coca-Cola.

chain benefits. Digital has to totally different, we are all using it; was simply the best way to give us support the supply chain to make it we just might not be calling it digital. what we needed. interesting for us – maybe there are Different companies have different It’s given us options; for example, not revolutionary changes needed uses for it, which is why we don’t having lyrics to songs instead of names but certainly the ability to optimise realise that we are all using it in some on bottles – marketing has been able beyond what we currently have. form or another. to do something a little bit different using the same process and supply chain to deliver it. Digital is everywhere – the question isn’t Digital can help unlock creativity, who is using digital, it’s who’s not. Whether it’s but you need the good idea and good a barcode or batch label, or something technology to enable you to realise it. totally different, we are all using it; we just might Neil Falconer: What are the barriers not be calling it digital. to implementation of digital?

GB: It took 18 months to bring Making changes to the supply chain One of the main benefits of digital digital into our labels – with the scale is difficult due to the resistance of is lead times. Flexo might be cheaper, employed in Coca-Cola labels, we printers and users protecting their part but digital is quicker; a flexo run on needed to make sure everything worked of the process. Ultimately, we want to presses is cheaper and longer, but it smoothly ahead of the creation of try to reduce production runs while is not a like-for-like comparison. It almost three billion labels. raising their efficiency. is a tool that needs to support the We did have a benefit in that we ‘big idea’. did not have to change the label, just Greg Bentley: Digital is everywhere – Digital is the tool that allowed us the variations of the name. Unlike a The question isn’t who is using digital, to implement the idea, and the idea or retailer having to amend for a sale or it’s who’s not. Whether it’s a pallet result is what was important to us. We Christmas promotion for example, this barcode or batch label, or something did not set out to implement digital, it does not necessarily speed up the

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PCI037_013_HP dining V2.indd 58 14/04/2015 08:23 Insight > Digital printing

process, but it did make it a little simpler. There were issues; for example, the inks are softer, so we had to adapt the manufacturing process in order to allow these changes. One should bear in mind that flexo and gravure have spent many years getting labels to the point where the price and speed is very attractive – adding digital changes everything, but you need to be willing to make some big changes. The digital supply chain is longer than normal as we have to varnish, slit and then varnish the labels again. It still remains the only way we can use digital – and the best way we have found to do what we needed to do.

Detlef Behrens: In my previous role in pharma, customers were not fans of personalisation as it could lead to errors in packaging, and this was not acceptable and would lead to a lot of waste. Last May, we bought a machine Various examples of successful digital printing campaigns and product runs were given throughout. we used to print packaging for Lindt and moved from offset into digital. We have to make so many little There comes a tipping point HP Indigo means we can go into changes to package printing – for internally. At Iceland, we are now niche markets, and digital is best promotions or in-store sales, or various expanding internationally, with even for a bottom-up approach. A smaller, other needs. Sending artwork out and longer supply chains with smaller 5,000–10,000 run is less profitable in expecting it printed the next day is volumes: 5,000 prawns to South Africa, offset than digital as, with the latter, becoming more common. This is the 6,000 for the Middle East, and a country you can provide a mock-up that is first major benefit. like Angola wants only Portugese on clear and in small quantities to test Digital also has benefits for the label, while Germany wants German with. It’s much more difficult to do diversification. I want to make changes and so on. It would cost a fortune to this with offset printing. Offset is less because I can, and now I can make match these needs going through economical in small runs. those changes instantly. With food, for the normal channels of printing; with instance, gifting is a big thing. You can digital, we can do it – print the 5,000 Sam Woollett: There are definite make lots of changes to the packaging for a market and make any changes – benefits to digital. I can now go into or really make the product stand out. without huge cost or loss. my supply chain director’s office and Ultimately, though, the major benefit let him know we can order 2,000 labels is the speed at which you can react to Lucas Bergmans: Digital volumes – instead of the 10,000 they might customer feedback. For example, this allow you to do something in one, previously have had to commit to – year, we won a best mince pie award – ten or 40 stores, then national roll-out and go into markets that were within one hour, we had it digitally to scale against the existing format. unreachable to us before, quicker printed on the window of the package Previously, we would have to wait for and at a reduced cost. and in all stores by that night. At the lead times to catch up to production, same ceremony, we won best pizza, and but now, we can ramp up quickly Ian Schofield: We are a nightmare that award went on the packaging the when we find a successful design, customer as we never print the same next day. This roll-out is only possible image or promotion. job twice. This presents a massive with digital. challenge, but I was backed by my boss Digital will continue to play a major Louise Gedge: We know it’s great when I asked to be given support to try part no matter what you are doing, but technology, but it needs everyone to digital as a solution. You cannot do it it needs champions and a structure to understand and buy into it. One of the yourself and a lot of support is needed, work in as, if not everyone is on board, major areas I see benefit in is artwork, but it’s worth it. it falls apart. but others might be more interested in

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PCI037_013_HP dining V2.indd 59 14/04/2015 08:24 Insight > Digital printing

The evening generated a lot of interest among the participants.

the lead times. We need to get everyone risk of getting it wrong by doing smaller format digital printer. In the 18 months together to see which needs can be tests. The more people that are included that Greg Bentley has printed his three addressed for each division so that you across units, the better this process billion labels, we have maybe done can use it in more applications. would be. about 2,000, but we have a real need for it. With 2,000 blends of tea and retailers Alex Orchard: This leads back to the Karen Rowe: We see digital as a looking at shorter runs to deliver them classic packaging topic of technology positive. This is a solution that provides to shelves, having digital would allow push and marketing pull – neither one added value and quality, reducing us to print all these variations and get is strong enough to carry out innovation lead times and lowering waste, as well them into the store quicker. We would on its own, so they have to come as providing a great end product. We also be able to provide more limited- together as partners for it to work. could not deliver these waste reduction edition print runs that are currently not The benefits of digital have to be and time efficiencies with litho or as attractive. made clear to both parties in order carton printing. for them to find common ground and One of our main motivators is the Lucas Bergmans: I completely agree; benefits to work from, and resolve any environmental benefit. When you it might take additional cost and you confusion from the outset. If we can have a large and potentially unwieldy need to try to get it right, but labelling have an open door into marketing or supply chain, being able to speed up cost is about the same as a week of the technical/packaging organisation, the process has a lot of potential – TV marketing, has a potentially larger we can adapt digital company-wide especially when it can help reduce impact and is eminently scalable. more readily. waste and provide an environmental It gives you something to think It’s no good just to have an R&D win too. about. Knowing you can do it sparks voice or a marketing director saying off ideas, gives you an opportunity to this is the future; everyone has to come John Nicholson: It would have been really push your creativity and provides together. This is a multidepartmental great to have had these tools a year ago another element to marketing tools. issue, and you need to have that shared as we had a situation where marketing Things I would not consider beforehand, vision to move forward. We have six-to- came to us with a need, but the like changing packaging format every nine-month trends, and if we are going technology ‘tool’ was not available to year or two, I can now bring into to make changes, we need a champion fulfil it and we missed out. We could consideration and know they are to push through testing or reduce the have met this opportunity with a wider- actionable with enormous potential.

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PCI037_013_HP dining V2.indd 60 14/04/2015 08:24 Insight > Digital printing

The participants

Silas Amos Ralph Bates Creative director Category manager EMEA JKR Hewlett-Packard

Detlef Behrens Greg Bentley Director Packaging innovator Pfäffl e Coca-Cola

Lucas Bergmans Paul Earnshaw Marketing manager, carbonates portfolio Packaging manager Britvic Tesco

Louise Gedge Nancy Janes Senior packaging engineer WW graphics solutions business Bacardi programme director Hewlett-Packard

Arno Melchior John Nicholson Global packaging director Packaging development manager Reckitt Benckiser Twinings

Alex Orchard Karen Rowe R&D director, global dairy packaging Print and colour manager Danone Marks & Spencer

Ian Schofi eld Chris Tonge Head of own-label packaging Sales and marketing director Iceland Ultimate Packaging

Sam Woollett Packaging technologist Innocent Drinks

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PCI037_013_HP dining V2.indd 61 14/04/2015 08:25 Insight > Bio-plastics Green plastic packaging plan Smart use of bio-plastics is already playing a part in supporting brand-owners’ sustainability targets and shows great potential for an increased role in the future – as long as it is used wisely alongside a number of waste reduction and recycled material initiatives. Emma-Jane Batey reports.

rand-owners and retailers are the slight grey tint put customers off, which group of plastics that are bio-based or constantly pushing for innovative obviously isn’t what we’re after.” biodegradable/compostable, or both. B ways to reduce their carbon Innocent Drinks is staying open-minded “Being bio-based – using biomass as footprint and meet changing sustainability about using bio-plastic packaging in the feedstock – is the main attribute. The targets – ones they’ve set for themselves future, and is constantly assessing how the benefits here are substitution of fossil and initiatives dictated by various look and feel of sustainable materials resources by renewable feedstock, governments. Currently, the ambitious changes as technology improves. Fox notes increasing resource efficiency and and comprehensive EU Sustainable that the most important thing for the brand reducing the carbon footprint of the Development Strategy for Retail states that is to be “doing what actually works for the material produced at the same time – “retailers in Europe are in an exceptional customer and the environment” rather than provided of course that the biomass is position to promote more sustainable jumping on the latest ‘green’ bandwagon. sourced sustainably; corresponding consumption not only via their daily contact “We use as much recycled plastic as certifications exist on a global level.” with millions of European consumers, but possible and use the labels on our bottles also through their own actions and their to encourage our customers to recycle Bio-plastic fantastic? partnerships with suppliers.” It is with this the bottle, too,” he adds. “We know from It seems clear so far that bio-plastics are message in mind that Packaging & customer feedback that our packaging just one ingredient in a successful recipe Converting Intelligence spoke with key messages are well loved and quite for improving sustainability rather than a players in the retail packaging industry. influential. We’re now using 50% recycled complete solution. As Lange says: “For PET and are involved in getting the UK some products and markets, the additional Looking good recycling infrastructure up to a higher level feature of biodegradability or compostability One well-known brand that is regularly so that the quality of recycled PET is where can be beneficial – mainly in the packaging noted as ‘doing the right thing’ when it we want it to be in terms of clarity.” sector for food or drink solutions, comes to positive brand identity is Innocent This suggestion, that the support compostability can be advantageous. Drinks. The fruit smoothie manufacturer’s, surrounding the recycling industry could “If you have compostable packaging start-up story has been repeated so many make a big difference to the large-scale that you can collect together with bio- times it has become marketing folklore, but take-up of more-sustainable packaging, waste, bio-waste collection volumes will with this incredibly strong brand identity for is reflected in the work carried out by rise, as has been shown in several consumer appeal and ecological awareness the European Association European case studies. This means comes a great responsibility for continuing (EUBA). Kristy-Barbara Lange, its head of diverting bio-waste from landfill and also to walk the walk. communication, says: “Brand-owners that from other mechanical recycling streams For Graham Fox, packaging operations use bio-based plastics help to reduce the where it might mistakenly end up.” manager at Innocent, alternative plastic is impact of their products – and we are Lange’s views about the importance of something that has been trialled without talking from bottles to high-tech sports the right infrastructure in order to allow the great results: “We’re all about being as shirts – on the environment. If they produce use of bio-plastics to flourish, as well as the responsible as possible when it comes to durable products that ideally are recyclable, additional benefits, mirror Fox’s. packaging – and in everything we do,” he they can turn their products into a carbon Lange adds: “For big retailers, of course, a says. “If using bio-plastics is the right thing sink contributing to climate protection. functioning composting infrastructure and to do, we’ll do it; if not, we won’t. We did try “Keeping in mind the ultimate goal to corresponding packaging solutions can also using 100% recycled PET for our smoothie reduce material use and increase resource have cost benefits – fresh products that are bottles, but it had pretty low consumer efficiency in a bio-based circular economy, rotting could just be disposed of together acceptance due to the PET not being bio-plastics can contribute in several key with the packaging. New film solutions for crystal clear. Even though it was perfectly aspects,” she says. “Bio-plastics is quite a fresh produce also offer a range of barrier acceptable in terms of food-contact safety, broad and general term that describes a properties that extend shelf life.”

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PCI037_010_Bioplastic.indd 62 14/04/2015 08:20 Insight > Bio-plastics

Producers of bio-plastics and bio- packaging are keen to support this growing demand for realistic alternatives to traditional packaging materials, and as a leading developer and supplier of eco-friendly food packaging, Biopac is really pushing forward in this sector, as the company’s marketing manager, Karen Randall, explains. “Biopac’s work includes supporting sustainability programmes for fast food retailers, fresh produce manufacturers, airline disposables, outdoor events and retailers. In adopting sustainable packaging solutions, we can show that it pays to prove you’re green – brand values can be enhanced and corporate sustainability targets met with environmentally friendly Stay grounded: compostable bio-plastics offer sustainability benefits – but ethical considerations still remain. packaging solutions. “Biopac’s mission is to establish high- environmental improvement, using its scale currently using bio-plastics in a very performance alternatives to oil-based and to maximise its positive environmental limited area – just one format in one unsustainable materials by researching impact and trialling new technology to be country, for the cap on a Tetra Pak in and developing new materials, finding at the forefront of environmental practice. Sweden – and so far, we are pleased. renewable feedstocks and using novel “McDonald’s recycles 3.7 million litres “But I have to say, we’re reluctant to technology. Innovation is the key objective.” of cooking oil each year, turning it into go gung-ho into plant-based plastics until For McDonald’s, a global brand that biodiesel, which supplies 42% of the fuel the ethics around bio-derived plastics are perhaps has to fight against negative used by the distribution fleet. In addition a lot clearer. Why should land be used to perception in direct opposition to the to cooking oil, we also recycle over 40% of grow plants for plastics if it is better used Innocent reputation, offering responsible our waste, including kitchen food waste, for growing food, for example?” packaging is part of its image makeover. coffee grounds, clean plastic, paper and As O’Driscoll clearly points out, the Press officer Ellen Wright says: tin. The introduction of waterless urinals most important action for brand-owners “At McDonald’s, we recognise our allows McDonald’s to save more than is to meet or indeed exceed sustainability responsibility to protect and preserve the 150 million litres of water every year. targets, however that is achieved. environment for future generations. Our We’ve also had patrols on the streets “My responsibility is to ensure that goal is simple – to continually improve our since 1982, picking up all litter – not just wherever we have the capacity to reduce impact on the environment. All of our McDonald’s packaging.” our carbon footprint, increase the level of activities are centred around the key recycled material, or cut down on waste priorities of reduce, reuse and recycle. Green-top milk or whatever else we can do to be a “Our ambition is to recycle at least As a leading dairy business, Arla Foods is responsible business, we do. 50% of our waste and send none of the active across Europe, with popular brands “Ethical and cost issues around bio- remainder to landfill, diverting the including Anchor, Cravendale and Lurpak. plastics have not yet been resolved remaining waste to a more sustainable Supplying more than 3.3 billion litres of really, so we are watching this issue solution, such as energy. We use as much milk a year in the UK alone, Arla uses a with interest as, if bio-plastics can be recycled material in our packaging as is lot of packaging and, as a cooperative part of our future strategy for responsible safe and practical; for example, all our business owned by the 12,500 farmers it packaging, we want to be involved. Bio- napkins and wraps are made from 100% represents throughout the UK and Europe, plastics are certainly not off the agenda, recycled materials. Our vision for 2020 is it is passionate about maintaining a but my view is: if we can crack the for our packaging to be 100% sustainable, sustainable business. potential of plastic packaging from waste renewable, and recyclable,” she says. Phil O’Driscoll, Arla Foods’ head of material rather than a material that needs While bio-plastics are not yet in the packaging innovation, explains how the to be grown specifically, that’s the right packaging plan for McDonald’s, it is business is keen to embrace sustainable future,” O’Driscoll believes. pleased to incorporate a number of packaging: “We won’t adopt bio-plastics So, rather than bio-plastics being initiatives to support its environmental just for the sake of it; we’re assessing the bright young thing in packaging responsibility. Wright adds: “In recent years, how they can be integrated into our solutions, it is perhaps one of a number McDonald’s has made a number of moves production alongside other ecologically of ways in which brand-owners can meet to meet its goal of continuous sound packaging innovations. We’re their sustainability targets.

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PCI037_010_Bioplastic.indd 63 14/04/2015 08:20 Company insight > Bio-plastics PLA leads the way in bio-plastics Offering numerous economical and ecological advantages over other bio-plastics, polylactic acid, with its highly desirable qualities, is increasingly being used in the manufacture of disposable materials. It is hardly surprising, then, that engineering company Uhde Inventa-Fischer has developed technologies for the complete production chain, as well as the capacity to recycle the plastic.

f all the various types of bio-plastics used in conserve fossil resources and achieve a better CO2 packaging nowadays, polylactic acid (PLA) stands balance during the production process. O out for its high practical value and its excellent As production volumes are lower, bio-plastic is currently ecological and economical properties. The feedstock used somewhat more expensive than comparable . As for its production is either sucrose or glucose, which are the material continues to gain a foothold in the market and primarily extracted from sugar cane, sugar beet, corn or production capacities increase, this price difference will wheat. Agricultural by-products, such as straw, will in decrease over time, and ultimately disappear. future be available as second-generation raw materials. Applications, advantages and Bio-based, biodegradable and recyclable material characteristics PLA offers the following advantages: it is produced from PLA and different blends of the polymer are sold to the renewable raw materials, it is biodegradable, and it can packaging industry as pellets of various grades for the also be fully recycled and returned to the material cycle. production of films, cups, containers and bottles, as well as Being a transparent and biodegradable polyester, it is foamed applications. The material offers great potential, in similar in its characteristics and workability to particular for throw-away packaging films or thermoformed conventional mass-produced thermoplastics, such as products such as cups and yogurt pots, as well as trays for polyethylene terephthalate (PET), polystyrene (PS) or cheese, cold cuts, fruit, vegetables and meat. polypropylene (PP), and therefore products made of As a packaging material, the bio-plastic mainly stands out PLA can be produced on ordinary processing machines for its excellent characteristics. It is transparent, colourless, with only minor modification. highly glossy and very strong. It also has a low water-vapour With these characteristics, PLA will be able to partially barrier and an excellent flavour barrier. Perishable products replace these standard plastics, which will also help to stay fresh longer without losing their flavour. Due to its low surface tension, colouring the packaging, or adding a printed or adhesive colourful design could not be Uhde Inventa-Fischer’s easier. There is a wealth of options for brand-owners to polylactic acid pilot plant, with create or develop the design of their packaging successfully a capacity of 500t/y, is located in Guben, Germany. as part of their brand management. The production of various grades of PLA can already be tailored to the respective application. This is done either directly during production at the plant by adapting the formulations and the reaction processes, or by compounding the PLA with the appropriate additives, blending the PLA with other plastics or copolymerisation. For instance, the softening point of PLA can be significantly increased through targeted optimisation, making the material suitable also for the production of cups used for hot beverages. Furthermore, the compostability can be improved without adversely affecting the performance of the product.

End-of-life options In addition to the development of plants and production processes, plant-engineering specialist Uhde Inventa-Fischer

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PCI037_Uhde.indd 64 13/04/2015 14:56 Company insight > Bio-plastics

has also integrated recycling, as well as end-of-life options for the bio-plastic, into its value chain. The main factors influencing the decision to opt for a particular recycling technology are the type of product application and the local conditions. Chemical recycling of PLA involves breaking it down into the monomer through the process of hydrolysis, and purifying the resultant lactic acid. This can then be fed back into the process as feedstock for repolymerisation to PLA. Other options are mechanical recycling, which involves grinding and melting the PLA so that it can then be reprocessed, industrial composting and industrial incineration, which allows the energy contained in the material to be used.

Uhde Inventa-Fischer is the only plant-engineering The bio-plastic PLA offers great potential, in particular for throw-away packaging films or thermoformed products. company and technology supplier to offer proprietary patented technologies for the complete production chain.

Plant technology Together with its sister company Biotechnology, from the Polymer Division of ThyssenKrupp Industrial Solutions, Uhde Inventa-Fischer is the only plant-engineering company and technology supplier to offer proprietary patented technologies for the complete production chain, from glucose and sucrose through lactic acid and lactide to PLA. At the same time, the individual production steps in the process chain can be built separately or in combination. This has the advantage of giving the customer flexibility with plant configuration and, depending on the business model, Life cycle and end-of-life options. the production of PLA can begin with sucrose/glucose, lactic acid or lactide as the starting material. Some years ago, for development and optimisation of the process, the company commissioned two industrial demonstration plants – one for the production of lactic acid and the other for the production of PLA. These are equipped in the same way as conventional production plants and allow a scale-up of the processes to a production capacity of 100,000t a year. All the usual types of PLA, as well as a variety of modified specialities, have been successfully produced at the plant. During subsequent trials, the various PLA resins were successfully processed into films, thermoformed films, bottles and injection-moulded articles on the industrial machines of cooperation partners, thus confirming the Taghleef Industries (TI), one of the world’s leading producers of BoPP, outstanding quality of the material. CPP and BoPLA films, has processed several metric tons of PLA pellets of various grades from Uhde Inventa-Fischer’s pilot plant into three-layer films within the framework of joint trial runs. The trials were successfully conducted on industrial machines at TI’s site in San Giorgio di Nogaro, Italy. The films produced can be heat-sealed and are renowned for their Further information strength, transparency and low shrinkage. They do not differ in either Uhde Inventa-Fischer quality or characteristics from products already established in the market. www.uhde-inventa-fischer.com

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PCI037_Uhde.indd 65 13/04/2015 14:56 Insight > Contract packaging An obligation to excellence As manufacturing companies continue to need products made to higher specifications with shorter turnarounds, there has been an enormous growth in the need for contract packaging services. President of the Contract Packaging Association Chris Nutley offers further insight into this sector of the industry.

he contract packaging industry A question of materials will continue to respond to the rising serves various functions, Consumer awareness of environmental cost of materials. T furnishing solutions for issues is peaking alongside producer Plastics used for packaging are packaged goods across nearly every demand for economical packaging petroleum by-products, so the price consumer sector. As a result, packaging options. As these forces converge, of petroleum will continue to shape reflects a range of influences, from creative contract packagers will continue packaging decisions. In 2015, package personal consumer preferences to larger to turn to earth-friendly alternatives and redesigns will strive to reduce the total economic forces such as free-market ecologically sound package designs. amount of materials used, resulting in competition and mass-marketing. Packaging materials fall in and out of greater economy and responsible To stay one step ahead of evolving favour over time. This trend has moved packaging ecology. demands, contract packaging companies consumer packaging away from paper Technological advances continue respond to shifting consumer behaviour, and cardboard, and towards streamlined to drive contract packagers towards continually striving to meet the needs of plastic materials. innovative solutions. Consumer demand producers, retailers and end users. In a retrograde shift, paper packages for creative new packages will not let The key to success for contract are sometimes emerging as the most up in 2015, as buyers expect products packagers in 2015 lies in their ability environmentally friendly option, to offer convenience and enhanced to push the envelope on packaging replacing plastics and other materials functionality. Specific contract packaging innovation, while maintaining a strict that aren’t always recyclable. Contract sectors will be affected more than others, focus on economy and sustainability. packagers should once again see growth such as the food packaging industry, Finding the proper balance between in the use of certain materials, which which continues to respond to shoppers’ cost-effectiveness and merchandising may actually lead to a return to more call to reduce food waste. impact remains central to contract traditional options. More than 18 million tons of food packaging success, which now calls for In addition to adopting socially make it to landfill each year in the UK responsible environmental practices and responsible production and packaging alone, so global consciousness continues high levels of package customisation. practices, contract packaging providers to influence packaging decisions, leading

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PCI037_012_Conract packaging.indd 66 14/04/2015 08:22 Insight > Contract packaging

to calls for better shelf life and portion What’s trending? strong driver for the creation of new packaging. Reusable and resealable The Contract Packaging Association packaging concepts and innovative packaging is poised for growth, too, as estimates that the industry has doubled designs with improved cost margins. portability and serving-sized packages in size since 2008. With that scale of With this type of mutually beneficial continue to resonate with consumers growth, and packaging innovators’ arrangement, contract packagers garner on the go. willingness to expand services in 2015, new designs, while manufacturers can Data gleaned from the recent Pack the industry is poised for continued reduce R&D costs. With somewhere Expo 2014 shows growth trends in gains in the new year. between 73 and 85% of consumers’ flexible packaging and using improved Food and beverage, pharmaceutical and purchase decisions made at the point films to replace rigid containers, as well personal care products continue to furnish of sale, packaging designs need to be as security improvements to thwart a large share of contract packagers’ innovative and attractive if a brand hopes tampering and counterfeiting. business, and this won’t shift dramatically to gain the attention of new customers. Child safety is another chief concern in the coming months. In fact, the call In recent years, contract packagers shared by contract packagers and their from these industries will continue to have expanded service offerings to customers, calling for effective child- increase for contract packagers as more include more end-to-end processes, resistant containers. dynamic solutions are required. such as early-stage design capabilities As producers and consumers demand Technology plays an important role through the management of the product greater accountability among packagers, in the future of packaging contractors, throughout its life cycle. With a broader flexibility and package customisation are with serialisation, digital printing and range of services offered by contract also gaining increased attention. advanced robotics leading the way for packagers, manufacturers are able to The trend will not wane in 2015, as cutting-edge providers. Integrating the streamline operations and rely on fewer contract packagers partner with retailers latest technology into the packaging suppliers for the production of goods. to create a unique shelf presence. As process includes streamlining and The following are some of the other part of this trend, contract providers will economising through more efficient notable trends and highlights within use smaller production runs to maximise production methods, but technology also the contract packaging industry: the impact of custom options. finds its way into packages themselves, ■■ some contract packagers have Seasonal specials and promotions, pushing the envelope on materials and gained an edge over competitors for example, will be closely linked to merchandising capabilities. by adopting progressive technology package labels that can be easily altered Contract packaging is a growing such as serialisation concepts, for pinpoint merchandising. business, paving the way for providers robotics and digital printing Increased collaboration between of all sizes to make gains in the coming ■■ serialisation remains at the forefront packaging contractors, and the year. Pharmaceutical packaging alone, of contract packaging processes, manufacturers and producers they serve valued at $50 billion in 2011, will but the regulations are often will streamline packaging costs and help purportedly grow to an industry worth vague and unclear, leaving some to keep the packaging supply chain tight more than $73 billion annually by 2018. packagers unsure of the value of in 2015. By strengthening relationships Sustainability and customisation will offering such services throughout the packaging process – from continue to drive contract packaging ■■ while manufacturers are concerned design through to product management trends in 2015, leading to growth in with sustainbility, many want to be – contract packagers will continue to consumer packaged goods such as more involved in the development expand service offerings and their ability personal care products, food and of sustainable packaging to better to respond quickly to custom requests. beverages. Contract packagers and understand how contract packagers For flexibility and efficiency, packagers their clients share additional forward- are creating it are delaying some parts of the design thinking goals of integrating technology ■■ with consumers becoming process until the final stages of and reducing the amount of packaging increasingly concerned with the production. For example, creating materials used. functionality of a product’s standard labels with customisable packaging, this has become a critical portions for last-minute messages to Better together consideration in the development of consumers enables producers to send With the seemingly endless demand for new packaging. timely, personalised slogans or promotions sustainable packaging and the constant directly to their target audience. efforts by manufacturers to cut costs Due to the industry’s ability to In some cases, shifting printing and increase efficiency, players in the offer innovative and cost-effective responsibilities to packagers, rather contract packaging industry must solutions, the Contract Packaging than relying on printers, is the most continue to provide innovative and Association predicts that the industry cost-effective approach. In practice, the cost-effective solutions. Collaboration will continue to grow as manufacturers adaptable strategy conserves materials and within the supply chain between contract increasingly outsource this stage of the aids warehouse inventory management. packagers and manufacturers has been a supply chain.

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PCI037_012_Conract packaging.indd 67 14/04/2015 08:22 PCI037_Belvac Production Machinery.indd 1 13/04/2015 10:13 Company insight > Contract packaging Shaping the future The safety, storage and ecological benefits of aluminium containers have long been recognised, but what does the future hold for this kind of packaging? Belvac has technology that allows companies to enhance their branding strategies by offering new possibilities in aluminium packaging production.

or decades, global brand managers have been driven to make their products stand out through package design F and point-of-purchase advantage. It is for this reason that brand managers and can makers alike are excited about Belvac’s new shaping technology for aluminium bottles, cans and aerosol containers. Now, Belvac machinery allows distinctive aluminium products to be produced at high speeds and volumes with reasonable container costs using time-proven technology. Belvac Belvac machinery will transform aluminium packaging as we know it. has been the world leader in high-speed, continuous-motion, rotary die-necking technology for more than 30 years. is smaller in size. In some cases this can Shaping and aluminium container light weighting equate to a price that is up to three times higher per ounce. innovations from Belvac Production Machinery are changing the way companies look at aluminium The advantages of aluminium packaging for distinctively shaped bottles and cans. Consumers pay this premium because aluminium packaging Belvac is opening up new opportunities to use aluminium has several advantages in the consumer experience. It can in packaging styles that were previously cost prohibitive. be chilled faster, so that warm beverages from the grocery store will be ready to drink sooner. It also feels colder to the Gone with the glass touch, which can make the drinking experience more Since the bottle was invented, glass has been the material pleasurable in the heat of summer. Aluminium containers are of choice. However, bottles manufactured on Belvac building momentum in many traditional venues while machinery are providing a cost-effective aluminium providing additional benefits to other more niche venues alternative to traditional glass packaging. such as pools, beaches and sporting events, where broken Impact-extruded (IE) aluminium bottles have shown up in glass poses a significant safety hazard. several markets and, for the most part, as promotional Proven customer preferences for aluminium containers products, but the amount of material required to produce a has driven category growth and strongly influenced container has kept the cost high. New technology is customer brand-switching patterns. The new push in the changing that; Belvac machines are using drawn and ironed market for branded, shaped cans and bottles is further (D&I) preforms to produce bottles with nearly 40% less exemplifying this pattern. aluminium than traditional IE methods. A 16oz aluminium bottle produced by IE methods weighs about 50g, but the The green argument 16oz D&I bottles found in supermarkets today weigh only D&I-produced aluminium bottles are a very green technology. Not 31g. This has created a better financial model for branded only does it use much less material than traditional aluminium aluminium containers and is allowing brands to create processes, but aluminium packages in general are almost twice as mainstream offerings for their branded beverages. likely to be recycled. According to the Glass Packaging Institute, in For a bottle, the reduced weight also means reduced 2013, 34% of glass packages were recycled compared with 65% of logistical costs. One weighs about 180g – that aluminium packages, as reported by the Can Manufacturers is equivalent to a six-pack of D&I aluminium cans and Institute. Changing a product’s packaging from glass to aluminium makes a big difference when it comes to shipping costs. can significantly reduce waste, protecting the environment and The breakage costs that are associated with glass are also promoting a green company image. non-existent with aluminium bottles. Belvac is confident that its Shaper and Bottle Can These factors bring the overall life-cycle price of Manufacturing System (BCMS) can deliver the highest-quality aluminium and glass close, but what makes another shaped aluminium cans and bottles at a low cost. difference in the drive to replace glass bottles with aluminium is the premium price that consumers are willing to pay for aluminium bottles. Further information Belvac Consumers in markets ranging from the US to Asia have www.belvac.com shown a willingness to pay premiums, even when the

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PCI037_Belvac.indd 69 13/04/2015 14:48 Directory > Index

Index AR Metallizing...... 22 International Paper...... 20 www.armetallizing.com www.alaska-plus.com

Belvac Production Machinery...... 68 MacDermid Printing Solutions...... 12 www.belvac.com www.printing.macdermid.com

Close Brothers...... IFC Metsä Board Zanders...... 17 www.closeasset.co.uk/rgf www.metsaboard.com

Collins Inkjet...... 54 Powerflute...... 28 www.collinsinkjet.com www.powerflute.com

Cosmo Films...... 41 RTI Digital...... 51 www.cosmofilms.com www.rti-digital.com

DuPont Teijin Films...... 44 Stora Enso...... 18 www.dupontteijinfilms.com www.storaenso.com

Ecolean...... 31 Tetra Pak...... 32 www.ecolean.com www.tetrapak.com

Esko...... 42 Uhde Inventa-Fischer...... IBC www.esko.com www.uhde-inventa-fischer.com

Iggesund Paperboard...... OBC Xeikon...... 53 www.iggesund.com/upgradedg www.xeikon.com

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the sustainability PCI029_Subs Ad 178x124.indd 1 On the paper trail: 13/04/2015 16:05 push has put paper back on the agenda 70 PACKAGING & CONVERTING INTELLIGENCE | www.pci-mag.com

13/04/2015 16:01 PCI037_Index.indd 70 14/04/2015 08:36 Food & beverage | luxury Packaging | bio-Plastics | contract Packaging

PCI037_Cover final.indd 1 Polylactic Acid Uhde Inventa-Fischer has expanded its product portfolio to include the innovative state- of-the-art PLAneo® process. The feedstock for our PLA process is lactic acid, which can be produced from local agricultural products containing starch or sugar. The application range of PLA is similar to that of polymers based on fossil resources as its physical properties can be tailored to meet packaging, textile and other requirements.

Think. Invest. Earn.

Uhde Inventa-Fischer GmbH Holzhauser Strasse 157–159 13509 Berlin Germany Tel. +49 30 43 567 5 Fax +49 30 43 567 699

Uhde Inventa-Fischer AG Via Innovativa 31 7013 Domat/Ems Switzerland Tel. +41 81 632 63 11 Fax +41 81 632 74 03

marketing@uhde-inventa-fi scher.com Uhde Inventa-Fischer www.uhde-inventa-fi scher.com

PCI037_Uhde Inventa-Fischer.indd 1 13/04/2015 10:19 How virgin fibre can add a sweet scent of success

Enjoy both sides of upgraded Invercote G. It performs superbly in countless applications, helping to create a strong shelf appearance and outstanding consumer appeal. Get your own sample at iggesund.com/upgradedG

MADE BY IGGESUND Our care for our customers and their businesses goes far beyond offering two of the world’s leading paperboard brands, Invercote and Incada. We call this Care by Iggesund.

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