PUBLISHED NOVEMBER 2015 BAGS& POUCHES: Diving into the flexible packaging market SPONSORED BY: BAGS&POUCHES: Diving into the flexible packaging market WELCOME TO OUR FIRST eBOOK elcome to Packaging Strategies’ first eBook focusing on the flexible packaging mar- ket. This market is still expanding and growing each year. A report from Trans- W parency Market Research states that the global demand for flexible packaging was valued at USD 73.56 billion in 2012, and is expected to reach USD 99.10 billion in 2019. There is a lot of growth potential here, as the flexible packaging market spreads across several industries—including processing and packaging of pharmaceuticals, personal care products, household items, and food and beverages. Looking back through my years covering the packaging industry, I am amazed at how many more markets have adopted this packaging material, from baby food to laundry soap, motor oil and even body wash. It is an exciting time to be a part of the changes in the packaging industry. Look through this eBook for package inspiration, technical pieces, and articles that show successful product launches. Each article within the eBook focuses on this expanding market. We hope you enjoy reading all about the ever-growing segment of flexible packaging. PS Best, ELISABETH CUNEO Editor-in-Chief [email protected] 2 packagingstrategies.com BAGS&POUCHES: Diving into the flexible packaging market CONTENTS Wilde adopts flow wrapping machinery ..............................5 New and noteworthy .....................................................14 An abundance of pouches ............................................19 Packages of the year pack a punch ...............................28 5 The stand-up pouch success model ..............................34 Flexible packaging expands into more markets ...............38 ‘C’ what was on packagers’ minds at Pouch Forum ..........46 Stand-up pouches step toward acceptance .....................49 Flexible now 25% of all packaging .................................52 Putting the squeeze on applesauce cups .......................55 SPONSORED CONTENT: Stand-up pouches for liquid products ...............8 14 Optimizing pouch seal strength .....................23 Marking and coding ......................................31 Start the journey to outstanding shelf appeal ....44 28 3 packagingstrategies.com 38 RETURNING December 2-3, 2015 IN 2015 Hyatt Regency Orange County The Sequel Garden Grove, CA PRODUCED BY KEYNOTE This December... PRESENTATION SPONSORS Inciting Revolution to Drive FLEXIBLE IS THE FUTURE. Growth and Innovation for Shelf-Stable Stand-up Pouches Due to popular demand, Global Pouch West Joel Henry, Founder, Fig Food Co. After almost two decades in marketing and returns! Join us for networking and educational leadership roles with several major packaged food and beverage companies, Joel Henry sessions at the largest event west of the struck out on his own to found Fig Food Co., a producer of plant-based organic food, Mississippi. Register today at including shelf-stable soups, beans and vegetables. He is outspoken on the need for GlobalPouchWest.com/register. MEDIA PARTNER healthier diets, sustainable agriculture — as well as environmentally friendly packaging. He advocates for changes within the flexible SUPPORTED BY packaging industry to drive growth, and create more opportunities and a more robust supply SEND MORE TEAM REGISTRATION chain for emerging packaged food companies, Send two or more from the same large-cap food companies and grocery retailers. SAVE MORE company and save even more! GLOBALPOUCHWEST.COM BAGS&POUCHES: Diving into the flexible packaging market FLOW WRAPPING WILDE ADOPTS FLOW WRAPPING MACHINERY Meat-based protein bars use art and technology to make a statement. by LIZ CUNEO, Editor in Chief n the world of protein bars, flow wrap is the name of the “At the time, almost all bars were packed with sugar and game. Consumers know and understand this very cus- nuts and there was a lack of anything savory that would de- I tomary packaging. Wilde Snacks of Boulder, CO, wanted liver high amounts of protein but without all the sugar. The to capitalize on this consumer standard, yet give them some- key at Wilde Snacks is that each bar is slow-baked to perfec- thing they had never tasted before or seen in a typical flow tion, allowing the consumer to experience something truly wrap package. When a shopper picks up a Wilde Bar, they are unique,” says Wilde Snack Co-founder/CEO Jason Wright. picking up a meat-based, whole-food savory bar that delivers 10-11 grams of protein, but with very low sugar and sodium, THE WILDE PACKAGE all beautifully wrapped in a standard flow wrap package. Wright wanted to create a whole-food, savory protein bar The idea for Wilde Snacks was born roughly two and a using GAP (Global Animal Partnership)-certified lean meats, half years ago in Boulder. The concept was seemingly simple: ancient grains, super fruits, and veggies, but do it as a bar and combine premium, pasture-raised or grass-fed lean meats not be labeled as “jerky.” The importance of being in the bar from animals raised without growth hormones or antibiotics set instead of the jerky set was a must when Wright set out to with fruits, vegetables, ancient grains, and spices into a bar. create Wilde. 5 packagingstrategies.com BAGS&POUCHES: Diving into the flexible packaging market “We wanted to do it in the bar category because we were tired of the sugary, low-protein snack bar options currently on the shelf. We wanted to give the customer a new savory option but with a familiar feel, so we chose to flow wrap the packag- ing to give them a familiar bar package,” explains Wright. Consumers are used to eating the traditional protein bar or granola bar in a flow wrapped bar package style. Since the consumer is trying something new when choosing Wilde, Wright and his team wanted to make sure they offered it up in a familiar package, on shelves next to the bars they were familiar with. to the CEO. Wright said that the most important thing he “Idea is one part; the execution and developing the inno- learned from his first company was to get the right people on vation is the real work, and the real story,” says Wright. the bus from day one. So who is behind the colorful and eclectic package de- Each package design has its own unique story and uses signs? Wright says one of his biggest accomplishments was bright colors and artistic elements to convey the brand’s inno- convincing JR Crosby to partner with him and Derek Spors vation. Maple Bacon Blueberry is designed to look like a pan- to launch Wilde Snacks. cake with maple syrup, bacon, and blueberries on top. Straw- Jason Wright had the vision to create a new snack bar berry Black Pepper uses both red and black to display a grilled category, but JR Crosby, who owns Ptarmak, an Austin, TX- strawberry topped with black pepper. Chili Lime is meant to based design firm, had the vision for Wilde’s design and have the appearance of an authentic Spanish design one would branding. Derek Spors, who owns Spork & Ladle in Boulder, find on a knitted blanket. Peach BBQ should remind consum- CO, is the genius behind Wilde’s innovative formulas and ers of cooking over an open flame (or a wood fire) and what the flavors. Brendan Synnott is a co-founder and the head coach wood looks like sliced open, exposing the ridges and the grain. 6 packagingstrategies.com BAGS&POUCHES: Diving into the flexible packaging market Wilde Snacks uses the word wild as its base but added the “e” to make it unique to the brand. It is a nod to both the bar’s protein source, and the bar’s innovative concept as a whole. THE EXECUTION Wright knew that Bosch (boschpackaging.com) was known as the leader in flow wrapping, so it was an easy choice when deciding on a machine supplier. In addition to the machine, he had to find a film that was strong enough to contain the bar with a seal strong enough to ensure that ab- solutely no air could get inside. Meat packaging can have no fering low maintenance costs. The Pack 101’s fully adjustable leaks or holes; otherwise, the product can mold. Wright went former and multiple cutting head sizes permit a wide range with Maxim Flex Pac (maximflexpac.com) out of Irvine, CA, of products to be packaged on a single machine, reducing for the film, and Bosch for the flow wrapper to package the the need for future investment and giving manufacturers whole-food, savory protein bars. the agility to quickly adapt to changing market demands. The machine chosen was the Pack 101 horizontal flow Its small footprint and left or right hand execution fits wrapper, which is an entry-level solution that offers a wide most production environments and can easily integrate with size range. The machine is capable of packaging 150 bars per Bosch feeding technology for light automation. minute. Wilde Snacks is currently using this entry-level ma- “We love the consistency of the machine. It produces the chine but has plans to move up as sales increase. perfect seal every time,” says Wright. The Pack 101 comes with an all-servo motor design that Wilde is currently sold at Whole Foods Market locations in enables quick and easy setup and changeovers. It also maxi- Colorado, Utah, and New Mexico. Wright says the plan is to mizes product and film usage during production, while of- expand nationally throughout the natural channel in 2016. PS 7 packagingstrategies.com BAGS&POUCHES: Diving into the flexible packaging market SPONSORED CONTENT STAND-UP POUCHES STAND-UP POUCHES FOR LIQUID PRODUCTS by AMANDA DAHLBY, Marketing Manager, Glenroy Inc. tand-up pouches are one of the fastest- WHY CONVERT FROM RIGID growing packaging formats, with stand- PACKAGING TO POUCHES? Sup pouch usage projected to grow by 7% The benefits of choosing stand-up pouches each year through 2018.