Flexible Packaging STAND AND DELIVER Dennis Calamusa, of Alliedflex™ Technologies Inc, discusses the manifold benefits of stand-up pouch packaging. and technologies from other sectors are now being incorporated in the stand-up pouch package, allowing implementation in the production environment. ZIPPER RECLOSURE In the North American market, consumers were initially exposed to recloseable zipper storage bags which could be used to conveniently package meal leftovers and school lunches, and to repackage food products at home. The market for recloseable zipper bags has grown so Distinctive stand-up pouches rapidly that approximately six billion zipper and slider zipper storage bags are purchased every year in North America alone. Because of this exposure to recloseable products, consumers seem to appreciate it The stand-up pouch format has EASE OF TRANSITION when zipper reclosure is integrated directly successfully separated itself from more Of course, there are sceptics who would into the packaging of the products that they traditional forms of packaging. The pouch prefer to continue using the proven purchase. This is reflected in the growing can be used to replace cartons (bag in packaging methods, even if those formats support and purchase of products that box), canisters (spiral wound or composite), have not changed since the last century. provide quality and purpose, as well as metal cans and rigid plastic containers, However, companies are realising that they convenience to suit busy lifestyles. and presents products in a more elegant can gradually make the transition between The zipper reclosure feature has been one manner. Seldom has a packaging format traditional and modern packaging by of the most important developments to come along that has so successfully ‘partnering’ their existing packaging affect the growth of the flexible packaging crossed over so many product and market methods with innovative flexible packaging. business in decades. Slider zippers are now applications on a worldwide basis. This transitional approach can reduce the risk being used in a variety of markets, including The stand-up pouch format has satisfied a factor involved during the introduction shredded cheese, powdered drinks and multitude of marketing, environmental, phase, and adds value and excitement to baking mixes, as well as on larger bag sizes consumer, and cost improvement needs. The mature packaging methods. As a result, for pet foods and agricultural products. advantages of the pouch are still being companies are stimulating sales, creating Zippers of all types are proving that the realised, as the format is adopted around the new markets and reinventing mature brands. consumer will pay extra for convenience. world for a multitude of applications. The In recent years, designers and converters An astute marketing team will recognise stand-up pouch and its success have provided have added a multitude of features to this fact and implement convenience a wake up call for traditional packagers. the stand-up pouch packaging format features into all future packaging. They will have to consider being more that have enhanced the performance of the The stand-up pouch format is creative if they are going to survive in the package, thereby giving the consumer a particularly conducive to the integration competitive global marketplace. positive experience. Packaging innovation of zipper profiles into pre-made pouches, 98 PACKAGING AND CONVERTING INTELLIGENCE Flexible Packaging and will also complement the current in- between rigid and flexible packaging when it house packaging process that comprises of comes to logistics. This includes the transport horizontal form, fill and seal. of incoming containers, material handling and the warehousing space needed for SPOUTS AND FITMENTS storage. One single truck filled with flexible The ability to incorporate a spout for packages is the equivalent of up to 25 truck- controlled product dispensing and cap loads of rigid packaging. We have become reclosure is revolutionising the use of the accustomed to standard practices that are stand-up pouch package. The pouch can now proving to be very costly. contain a multitude of liquid and semi-viscous products, including a wide variety of RETORT MATERIALS condiments such as tomato ketchup, The ability to post-sterilise flexible mayonnaise, sauces, gravies and beverages. packaging via a retort chamber has The current non-food applications are for created the opportunity to produce a products such as shampoo, lotions, wide variety of prepared and processed detergents, motor oil and paint. The spout foods. These food products have closure may be applied and positioned in the traditionally been packaged in metal cans, top corner, top centre or front panel. A spout pre-formed trays, glass jars and bottles. can even be sealed into the top or bottom Today, the barrier properties required for a gusset of the pouch, depending on the specific application can be custom configured specific design attributes of the application. into laminated material. The package can “ONE TRUCK FILLED WITH FLEXIBLE PACKAGES IS THE EQUIVALENT OF 25 TRUCKLOADS Retort pouches are available in 3–4 OF RIGID PACKAGING” sided styles, or as a stand-up pouch for upright marketing on the traditional retail Spouted pouches have been most then meet the exact shelf life and product shelf. The incorporation of laser scoring as prevalent in Europe and Japan, due to the protection requirements needed to part of the converting process enhances environmental pressures in these regions to accommodate a specific product. The the safety and convenience of opening. reduce packaging bulk, and thus minimise traditional flexible retort material has As retort pouches get larger , it is the amount of waste sent to landfill. In been foil based, to accommodate the expected that zipper features will be used as other parts of the world, the ‘green’ aspect barrier and heat-resistance properties a method of reclosure, particularly for food of packaging does not have the same needed during the retorting process. The service or larger club store sizes. These strict environmental regulations. However, utilisation of silica oxide structures can zippers are specially formulated from higher companies are beginning to realise the now provide comparable barrier properties, temperature resistant polypropylene, as dramatic difference and also allows the retort pouch to opposed to the polyethylene varieties used be heated in a microwave. This further on standard flexible packaging applications. enhances the convenience of both the The ability to capture reverse-printed package and the product. graphics under the surface of the outside lamination on a stand-up Machines can fill and seal pre-made pouches 99 PACKAGING AND CONVERTING INTELLIGENCE Flexible Packaging cost will generally be 10-25 per cent more than if pouches were produced in-house as part of a form, fill and seal process. Ultimately, the cost will depend on the complexity of the pouch design and the volume purchased. However, the capital required to produce packages in-house, (particularly at start up) will be substantial, and in some cases difficult to justify unless there are already established markets to package means that it is no longer necessary with the pre-made approach, as they ensure a rapid return on investment. to label or post-decorate the container as usually use other forms of ‘pre-made’ part of the packaging process. As a result, packaging, including cans, canisters, SPEED IS OF THE ESSENCE packages can go directly from the retort bottles and jars. The pouches only have to The horizontal form, fill and seal method process to case or tray packaging. be filled and sealed at the packaging has always been the most prevalent In due course, we will see more and level. As each specific market improves, process for dry product packaging. more products presented in flexible the packager can gradually move to a However, in recent years liquid retort style packages. The transition from form, fill and seal packaging format, or applications have been implemented in- cans to retort pouches will certainly be choose to stick with pre-made packages line on form, fill and seal machinery. This gradual, due to the fact that the infra- and add a higher level of automation to has especially been the case when pre- structure for can packaging is enormous suit evolving production needs. made pouches are not available within a and highly developed. However the particular region, or when high-volume logistical, marketing and technological FILL, FORM AND SEAL TECHNOLOGY producers have the core skills to operate benefits of retort flexible packaging will A variety of machinery is available to fill more sophisticated machines. Today’s be difficult to ignore. and seal pre-made, stand-up pouches. form, fill and seal systems incorporate a Semi-automatic operation systems are variety of technologies which are able to PRE-MADE POUCHES ideal for pilot plant- or market-testing handle the print and roll variations that Converting stand-up pouches from rolling applications. High-speed continuous have caused difficulties over the past stock and supplying them as ‘pre-mades’ motion systems are also available, and decade. The use of servo technology to to the packager has become a viable can be configured with outputs of isolate and control specific functions has global business for the converting 500 ppm and beyond. The appeal of pre- dramatically simplified the multitude of industry. The option of using pre-made made fill and seal technology is that processes in the horizontal pouch making, stand-up pouches has created an the process is relatively simple. filling and sealing process. A single stand- opportunity for many companies to Pre-made pouches are purchased in the up pouch, horizontal form, fill and seal enter the market, without the need for specific design format required: with system can produce 40–400 packs per expensive capital investment. Pouches zipper or spout, printed or unprinted or minute (depending on the size and fill can be provided in a variety of shapes and ready for filling and sealing.